7 Series

Service- and Maintenance Manual
BERNINA 780
BERNINA 750 QE
BERNINA 710
BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Page 1 von 172
Contents:
Chapter 1 General information ...................................................................................... 6

1.1 Safety Regulations .................................................................................................................................. 6 1.2 Warning: Dangerous voltage levels! ....................................................................................................... 7 1.3 ESD-Related Note: Electrostatic Discharge (ESD) ................................................................................. 8 1.4 Tools and gauges .................................................................................................................................... 9 1.5 Handling Adjustments ........................................................................................................................... 13 1.6 Abbreviations / Names used ................................................................................................................. 13 1.7 Cleaning ................................................................................................................................................ 13 1.8 Technical Details by Model ................................................................................................................... 15
Chapter 2 Electronics and Wiring................................................................................ 16

2.1 PCBA-Base General Information ................................................................................................... 16 2.1.1 PCBA-Base (B780, B750, B710) ................................................................................................... 16 2.2 PCBA-CPU-Module (ARM9) General Information ............................................................................. 17 2.2.1 PCBA-CPU-Module / ARM9 (B780, B750, B710) ......................................................................... 17 2.3 PCBA Front Cover ................................................................................................................................. 18 2.3.1 PCBA Left Front Cover (B710, B750, B780) ...................................................................................... 18 2.3.2 PCBA Right Front Cover (B710, B750, B780) ............................................................................... 19 2.4 PCBA-Power (B710, B750, B780) ........................................................................................................ 20 2.5 PCBA-Threader (B710, B750, B780) .................................................................................................... 21 2.9 PCBA-Dual-Feed Sensor (B710, B750, B780) ..................................................................................... 21 2.11 PCBA-Position (B780, B750, B710) .................................................................................................... 21 2.1.12 PCBA-RET (B780, B750, B710) ...................................................................................................... 22 2.1.13 PCBA Feed-Dog Drop Detection (B780, B750, B710)..................................................................... 22 2.14 PCBA-Lower-Thread Sensor .............................................................................................................. 23 2.15 PCBA-Accessories Connector ............................................................................................................ 23 2.16 PCBA-Presser-Foot Height Sensor ..................................................................................................... 23 2.17 Sensor Support ABC (Presser Foot Recognition) ............................................................................... 24 2.18 Cable Harness ..................................................................................................................................... 25 2.19 BERNINA 780 Block Diagram (B750 / B710)...................................................................................... 26 2.20 Handling of Electronic Components .................................................................................................... 27 2.20.1 Returning Defective Electronic Components. .............................................................................. 27 2.20.2 Repairs of Electronic Components (PCBA's) .............................................................................. 27
Chapter 3 Removal and Refitting of Components ..................................................... 28

3.1 Covers ................................................................................................................................................... 28 3.1.1 Head Cover .................................................................................................................................... 28 3.1.2 Rear Cover ..................................................................................................................................... 28 3.1.3 Front Cover .................................................................................................................................... 29 3.1.4 Free Arm Cover ............................................................................................................................. 30 3.1.5 Free Arm Cover Plate .................................................................................................................... 31 3.1.6 Base-Plate Cover ........................................................................................................................... 32 3.1.7 Belt Cover ...................................................................................................................................... 33 3.2 Electronics and sensors ........................................................................................................................ 34 3.2.1 Front Left and Front Right PCBA-Covers ...................................................................................... 34 3.2.2 Stitch-Length and Stitch-Width Adjusting Knobs ........................................................................... 35 3.2.3 Winder Unit .................................................................................................................................... 35 3.2.4 Winder Motor ................................................................................................................................. 36 3.2.5 LC Display / Touchscreen .............................................................................................................. 37 3.2.6 PCBA-RET / Rubber Key Pad / Ribbon Cable .............................................................................. 38 3.2.7 PCBA-Base .................................................................................................................................... 39 3.2.8 PCBA-CPU-Module ....................................................................................................................... 41 3.2.9 EEPROM (Electrically Erasable Programmable Read-Only Memory) .......................................... 42 3.2.10 Freearm LED Sewing Light .......................................................................................................... 43 3.2.11 PCBA-Power Including PCBA Housing ....................................................................................... 44 3.2.12 PCBA-Power ................................................................................................................................ 45 3.2.13 Head Frame LED Sewing Light ................................................................................................... 46 3.2.14 Presser-Foot Height Sensor ........................................................................................................ 47 3.2.15 PCBA-Threader ........................................................................................................................... 48 3.2.16 Sensor Support ABC (Presser-Foot Recognition Sensor) ........................................................... 48
BERNINA International AG
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3.2.17 PCBA-Dual Feed Sensor ............................................................................................................. 49 3.2.18 PCBA-Accessories-Interface ....................................................................................................... 49 3.2.19 Embroidery Module Interface (BERNINA 780 and 750) .............................................................. 50 3.2.20 PCBA-Lower-Thread-Sensor ....................................................................................................... 51 3.3 Mechanical Components ....................................................................................................................... 52 3.3.1 Hook And Hook Driver ................................................................................................................... 52 3.3.2 Thread-Cutter Unit ......................................................................................................................... 55 3.3.3 Thread-Tension Unit ...................................................................................................................... 56 3.3.4 Clutch Carriage .............................................................................................................................. 57 3.3.5 Threader Head ............................................................................................................................... 59 3.3.7 Needle Bar Support ....................................................................................................................... 60 3.3.8 Needle Bar ..................................................................................................................................... 62 3.3.9 Needle Clamp ................................................................................................................................ 63 3.3.10 Threader Mechanism ................................................................................................................... 64 3.3.11 Main Motor ................................................................................................................................... 65 3.3.12 Dual Feed..................................................................................................................................... 66 3.3.13 Thread Take-Up ........................................................................................................................... 67 3.3.14 Restraint Guided Advance Link Lever ......................................................................................... 68 3.3.15 Stitch-Length Crankshaft ............................................................................................................. 70 3.3.16 Base Shaft ................................................................................................................................... 71 3.3.17 Stitch-Length Stepping Motor ...................................................................................................... 72 3.3.18 Sideways-Motion Stepping Motor (B780) .................................................................................... 73 3.3.19 Presser-Foot Pressure Stepping Motor ....................................................................................... 74 3.3.20 Stitch-Width Stepping Motor ........................................................................................................ 75 3.3.21 Presser-Foot Pressure Toothed Rack Bearing ......................................................................... 76
Chapter 4 Settings ........................................................................................................ 77

4.0 Basics General Information ................................................................................................................ 77 4.1 Belt Tensions ......................................................................................................................................... 78 4.1.1 Upper / base shaft tension ............................................................................................................. 78 4.1.2 Drive Motor..................................................................................................................................... 79 4.2 Head-Frame Plate Position ................................................................................................................... 79 4.2.1 Position of Head-Frame Plate/Stitch Plate in Y Direction .............................................................. 79 4.2.2 Position of Head Frame Plate/Stitch Plate in X-Direction .............................................................. 80 4.3 Presser-Foot Settings ............................................................................................................................ 80 4.3.1 Darning Foot Height ....................................................................................................................... 80 4.3.2 Presser-Foot Fixation ..................................................................................................................... 81 4.4 Needle Adjustment ................................................................................................................................ 82 4.4.1 Distance between Needle Bar and Presser-Foot Bar .................................................................... 82 4.4.2 Needle distribution ......................................................................................................................... 83 4.4.3 Zigzag stitch width limiter ............................................................................................................... 84 4.5 Hook, Needle Drive and Feed-Dog Movement Synchronization .......................................................... 85 4.5.1 Feed-dog lift and advance (synchronization of base shaft and main shaft) .................................. 85 4.5.3 Loop Lift ......................................................................................................................................... 86 4.5.4 Needle / Hook Distance ................................................................................................................. 87 4.5.5 Needle penetration in Y direction ................................................................................................... 87 4.5.6 Needle height ................................................................................................................................. 88 4.6 Feed-Dog Settings ................................................................................................................................ 89 4.6.1 Position of main feed-dog within stitch plate in X direction............................................................ 89 4.6.2 Dual Feed: X-Direction Positioning Against Main Feed-Dog. ........................................................ 90 4.6.3 Main feeding balance mechanical basic setting ......................................................................... 91 4.6.4 Dual Feed Balance Basic Mechanical Setting ............................................................................ 93 4.6.5 Main Feed-Dog Height 0.9-1.0mm ................................................................................................ 94 4.6.6 Feed-dog/Dual Feed Synchronization ........................................................................................... 95 4.7 Clutch Carriage / Thread Cutter ............................................................................................................ 96 4.7.1 Clutch mechanism ......................................................................................................................... 96 4.7.2 Thread Cutter ................................................................................................................................. 97 4.8 Synchrinising Disc ............................................................................................................................. 98 4.8.1 Rough-Adjustment ......................................................................................................................... 98 4.8.2 Fine-Adjustment ............................................................................................................................. 98 4.9 Threader ................................................................................................................................................ 99
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4.10 Basting Device .................................................................................................................................. 100 4.10.1 Needle Bar Guide ...................................................................................................................... 100 4.10.2 Checking the timing of disengagement...................................................................................... 101 4.11 Thread regulator ................................................................................................................................ 102 4.12 Thread Tension ................................................................................................................................. 103 4.12.1 Upper-Thread Tension ............................................................................................................... 103 4.12.2 Lower Thread Tension (Basic Setting) ...................................................................................... 104 4.13 Winder ............................................................................................................................................... 104 4.14 Lower-Thread Sensor Position .......................................................................................................... 105
Chapter 5 Service Program ........................................................................................ 106

Menu 1 Service Information ................................................................................................................... 109 1a Machine Basic Data ......................................................................................................................... 109 1b Machine Soft- and Firmware Data ................................................................................................... 109 1c Machine Operating Time Data ......................................................................................................... 110 1d Machine Stitch Counter Data ........................................................................................................... 110 1e BSR (BERNINA Stitch Regulator) Data ........................................................................................... 110 1f Machine Servicing Data .................................................................................................................... 111 1g Saving / Loading Customer Data ..................................................................................................... 112 1h Customer Data ................................................................................................................................. 112 1i Dealer Data: ...................................................................................................................................... 113 1j Log File:............................................................................................................................................. 113 Menu 2 Display, Buttons and Clock ....................................................................................................... 113 What to test: .......................................................................................................................................... 113 2a Touchscreen Calibration .................................................................................................................. 114 2b LC Display (screen) ......................................................................................................................... 115 2c Blank dark LC Display (screen)........................................................................................................ 115 2d Blank white LCD (screen) ................................................................................................................ 115 2e RGB (Red, Green and Blue) Screen ............................................................................................... 116 2f Keyboard Lights ................................................................................................................................ 116 2h LED's and Brightness....................................................................................................................... 117 Menu 3 Sensors (Mounting Locations in the Machine) .......................................................................... 118 What to test: .......................................................................................................................................... 118 3a Threader Sensor .............................................................................................................................. 118 3b Overlift Presser Food Switch (Presser Foot Height Sensor) ........................................................... 119 3c Lower-Thread Sensor ...................................................................................................................... 120 3d Feed Dog Drop ................................................................................................................................ 121 3e Dual Feed Recognition Sensor ........................................................................................................ 122 3g Winder Microswitch .......................................................................................................................... 123 3h Free Hand System FHS ................................................................................................................... 124 Menu 4 Signals ....................................................................................................................................... 125 What to test: .......................................................................................................................................... 125 4a Stitch width and stitch length knob(s) .............................................................................................. 125 4b Functions of Keys and Buttons on machine .................................................................................... 126 4c Start-/Stop Slide (SSU) .................................................................................................................... 126 4d Foot control ...................................................................................................................................... 127 4f Upper Thread Sensor ....................................................................................................................... 127 4g BERNINA Stitch Regulator (BSR).................................................................................................... 128 4h PCBA-Position ................................................................................................................................. 128 4h Mechanical Fine-Adjustment of Synchronization Disk ..................................................................... 129 4i Speaker ............................................................................................................................................. 130 4j USB Ports.......................................................................................................................................... 130 4k Basting Solenoid .............................................................................................................................. 131 4l Presser-Foot Recognition ................................................................................................................. 132 4m BSR Foot Interface ......................................................................................................................... 134 Menu 5 Stepping Motors (Mounting Locations in the Machine) ............................................................. 135 What to test: .......................................................................................................................................... 135 5a Stitch Width Stepping Motor ............................................................................................................ 135 5b Presser-Foot Pressure Stepping Motor ........................................................................................... 136 5c Upper Thread Tension Stepping Motor ............................................................................................ 136 5e Pinning Positions of All Stepping Motors ......................................................................................... 137
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5f Bobbin Winder Motor ........................................................................................................................ 137 5g Stitch Length Stepping Motor........................................................................................................... 138 5i Sideways Motion Stepping Motor...................................................................................................... 139 Menu 6 Adjustments............................................................................................................................... 140 What to test: .......................................................................................................................................... 140 6a Sewing-Off (customers view) .......................................................................................................... 140 6b Balance ............................................................................................................................................ 141 Rough adjustment ................................................................................................................................. 141 Fine-Adjustment .................................................................................................................................... 142 Fine-Adjustment (Sideways Feed) ........................................................................................................ 144 BDF Balance ......................................................................................................................................... 145 6c Buttonhole Calibration ...................................................................................................................... 147 6d Thread Cutter Clamping Mechanism (Magnet) ................................................................................ 148 6e Thread Cutting Process ................................................................................................................... 148 6f Upper-Thread Tension Reset to Default ........................................................................................... 149 6g Resetting To Factory Settings (Reset All): ....................................................................................... 150 6h Presser-Foot Height And Presser-Foot Pressure ............................................................................ 150 6j Automatic Upper-Thread Tension ..................................................................................................... 151 6l Start-/Stop Unit (SSU) Slide Control Calibration ............................................................................... 152 6m Normal SSU Sewing Speed ............................................................................................................ 152 6n BSR Sewing Mode ........................................................................................................................... 153 Menu 7 Embroidery Module (EMB) ........................................................................................................ 154 What to test: .......................................................................................................................................... 154 Menu 11 Check Out ............................................................................................................................... 155 What to test: .......................................................................................................................................... 155 Important! .............................................................................................................................................. 155 Check-Out Tests: .................................................................................................................................. 155
Chapter 6 Lubrication Diagram ................................................................................. 156 Chapter 7 Firmware Update ....................................................................................... 161
7.1 Update Procedure ............................................................................................................................... 161 7.2 Update Alternative Access ............................................................................................................... 163
Chapter 8 Maintenance Guidelines ........................................................................... 164

8.1 Purpose of the Maintenance Guidelines ............................................................................................. 164 8.2 Explanatory Notes on the Stitch- and Hour Counter ........................................................................... 164 8.2.1 When is a cleaning message displayed? ..................................................................................... 164 8.2.2 When is a maintenance message displayed? ............................................................................. 164 8.2.3 How are the stitches counted? .................................................................................................... 164 8.2.4 Implementation of the Maintenance Intervals .............................................................................. 165 8.3 Maintenance Intervals ......................................................................................................................... 165 8.3.1 Cleaning- and Service-Stitch Reset ............................................................................................. 165 8.4 Wear-and-Tear-Parts Definition .......................................................................................................... 166 8.4.1 Non-Hour-Related Parts .............................................................................................................. 166 8.4.2 Operating-Time-Related Parts ..................................................................................................... 167 8.5 Maintenance Checklist ........................................................................................................................ 168 8.5.1 Measures to be taken before the Maintenance ........................................................................... 168 8.5.2 Measures to be taken after the Service ....................................................................................... 168 8.5.3 Functional Check ......................................................................................................................... 169 8.5.4 Maintenance Checklist BERNINA 780 / 750 / 710....................................................................... 170 8.5.5 Embroidery Module ...................................................................................................................... 171
Document Revision History .......................................................................................... 172
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Chapter 1 General information

1.1 Safety Regulations
Warning! 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. 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 and embroidery 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 Buttonhole foot Presser foot no. 1 Bobbin Other accessories BERNINA stitch length regulator (BSR) foot
The Service Manual and Instructions are protected by copyright laws. It must only be used by authorised dealers. It is prohibited to disclose the service manual to unauthorised 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 http://infogate.bernina.com under 'Service Manual' in the 'Tech. Service' register. If you don't have access to Infogate, contact your local BERNINA importer. They'll be glad to be of assistance. Disclaimer
Masthead: Author: After Sales Service
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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
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1.3 ESD-Related Note: Electrostatic Discharge (ESD)

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. 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. Electrostaticdischarge_ESD 5. To prevent consequential damage or harm, treat faulty PCBs in the same manner as new ones. .
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1.4 Tools and gauges

Commercially available (not available from BERNINA): Vernier caliper, multimeter, TORX screwdriver no. 6, 8, 10 and 10 with 200mm blade length; 15, 20 and 20 with 200mm blade length, 25, and angular TORX nos. 6 and 10, 10mm ring wrench, 6mm flat wrench. Item number Item Use Figure
338109.03.3+
Adjusting needle 130 / 705 H TCN 80 packet of 100 pieces
Needle and hook adjustments
Commercially available
130/705H 100
Needle penetration in Ydirection
030475.50.01
Torx screwdriver T8 (to be ordered, when available) Torx screwdriver T10
Disassembling and reassembling aid
030475.50.00
Disassembling and reassembling aid
734101.50.00
Distance gauge (Schwarz brniert)
Adjusting of threader head height
030883.50.02
Distance gauge 18.98 mm (silver steel)
Adjusting of needle-bar height
730475.51.00
Levelling gauge
Used together with the distance gauge to adjust the needle height
031563.50.00
Eccentric key 2mm
Lateral alignment of head frame and stitch plate
032798.50.00
Synchronisation plate
Home position of walking foot
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734258.50.00
Adjusting gauge
Timing clutch mechanism (Thread cut & embroidery start)
002733.50.00
Pinning tool, long
Pinning positions
001356.50.00
Pinning tool, short
Pinning positions
007937.50.00
Pinning tool, 3mm
Pinning position
734102.70.01
Loop lift gauge
Loop lift gauge for the 7 Series (2.618 mm)
734541.70.00
Centering gauge pentamerous
Aligment of hook driver bearing and und shuttle race ring
398024031+
Feed-dog height gauge
Checking height of feed-dog
398026131+
Darning foot height gauge
Checking of darning foot level
034370.50.00
Bobbin winder gauge
Checking amount of bobbin fill
033958.50.00 (for 1.5) 033958.50.01 (for 2.3) 033958.50.02 (for 3.2)
C-clip holder set 3-teilig, 1.5, 2.3, 3.2 (to order as soon as available!
Assembly C-clips
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398112.03.0+
Spring mounting tool
Spring hooking and unhooking aid
734562.50.00
Auxiliary tool for mounting circlip 1.5
Reassembling aid
034394.50.00
Mounting sleeve
Reassembling aid
001361.70.00
Eccentric key
Various adjustments
006038.50.00
Spring balance gauge
Tension of thread regulator spring
031935.50.00
Plug mounting tool
Mounting aid for plugs and cables Adjusting of belt tension via spherical bearings. 3.5mm distance setting of needle bar clamp.
733019.70.00
Adjusting spanner compl.
032948.50.00
IC extraction tool
Removal of EEPROM
Usual in trade
Multimeter (digital)
Continuity test Ohm measurement Voltage tests
398022030 398111030 Usual in trade
Feeler gauge 0.3mm Feeler gauge 0.15mm Distance measurements Feeler gauge 0.6mm Adjusting tool for feed-dog height at back
007993.50.00
Angular torx 8
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008709.72.00
Upper thread adjusting gauge (set of 5 pieces Thread unwinding weight for 30.6g, 54.4g, 2x 5g, upper thread tension setting 3g) Adjusting gauge for bobbin thread tension Adjusting the tension on the (Set 2 parts: 27.0 gr. & bobbin case 3.0 gr)
033924.70.00
031564.50.01
Tweezers
Plugging and unplugging cables
Commercially available
Watchmaker's magnifier 2.5x (magnification approx. 4x)
Allows for more precise adjustments in the hook-/needle area
652010.20.++
Gauging thread DMC 50 in white
Setting of the upper- and lowerthread tension
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1.5 Handling 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: BDF BSR DC EMB FHS IR LCD LED LMS LTS PCBA RET TFT TT UTS Stands for: BERNINA Dual Feed BERNINA Stitch Regulator Direct Current EMBroidery Free Hand System Infra red Liquid Crystal Display Light Emitting Diode Length Measuring System Lower Thread Sensor Printed Circuit Board Assembled RETurn (PCBA-RET) Thin Film Technic Thread Tension Upper Thread Sensor
1.7 Cleaning
Remove the covers and clean. Electrostatic charging may occur during cleaning.To prevent this, use antistatic office-equipment cleaning agents. We use and recommend BASFs SURFACE CLEAN surface cleaner. It forms a protective film against static electricity, and is suitable for both plastic and metallic surfaces.
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, needle bar holder and needle bar clutch. Main shaft (behind the balance piece), synchronisation disc. Between the upper thread tension discs, and in the total thread passage ways and guides.
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Area of the free arm and base: Bobbin carrier (under the tension spring.) Feed-dog. Hook / hook sensor. Lower thread sensor. Base shaft (feed and lifter cams). Within the thread cutter mechanism. Area of the transmission: Main motor (carbon dust). Toothed belt drive and motor pulley. Hook drive mechanism. Dual and sideways motion feed transmission. Area of electronics: All sensors / light barriers / switches / electronic group of parts.
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1.8 Technical Details by Model

Features Technical Line voltage maximum power input in Watt maximum power output in Watt Eco mode (30% reduction) Total memory space in MB Overall size in mm, L-W-H Weight in kg without accessories Weight of embroidery module in kg Accessories compl., packed Weight in kg, packed Hook system Motor Stitching speed, min./max. Sideways Motion BERNINA Dual Feed (BDF) BERNINA Stitch Regulator (BSR) connector Embroidery module connector Automatic thread cutter Embroidery speed, max. Embroidery file formats Longstitch and basting stitch Knee-operated presser-foot lifter/FreeHand-System FHS Freearm space, diagonal measure in mm Semi-automatic threading device Automatic upper thread tension Automatic presser-foot lifter Presser-foot height in mm, normal Presser-foot height in mm, max. extra lift Presser-foot heightwith FHS in mm Lower- and upper thread sensors Max. stitch length forward in mm Max. stitch length reverse in mm Adjustable increments in mm Max. stitch width in mm Adjustable increments in mm Sewing light (sewing area) Freearm area lighting TFT color display (Thin Film Transistor) Display size in mm (inch) Resolution in pixel Number of colors Display backlight in white User interface USB ports for USB stick or PC Sewing Total number of stitches incl. alphabetfonts Alphabets / Fonts Number of buttonholes types incl. eyelets Button sew-on program Number of utility stitches Number of stitch decorative stitches Embroidery Alphabets Total number of embroidery motifs BERNINA 780 100 - 240 Volt 50-60 Hz 180 145 Yes 128 525 x 205 x 415 14.7 6.2 5.1 18.3 B9 DC / 36 Volt 100 - 1000 SPM Yes Yes Yes Yes Yes 1000 SPM EXP Yes Yes 130 / (285) Yes Yes Yes 7.5 15 10.5 Yes 6 6 0.05 9 0.1 LED LED Yes 17.8 (7) 800 x 480 262144 LED Touch Screen 1/1 1306 8 /798 15 1 32 460 12 130 BERNINA 750 QE 100 - 240 Volt 50-60 Hz 180 145 Yes 128 525 x 205 x 415 14.7 6.2 5.1 18.3 B9 DC / 36 Volt 100 - 1000 SPM No Yes Yes Yes Yes 1000 SPM EXP Yes Yes 130 / (285) Yes Yes Yes 7.5 15 10.5 Yes 6 6 0.05 9 0.1 LED LED Yes 10.9 (4.3) 480 x 272 16777216 LED Touch Screen 1/1 837 6 / 545 11 1 30 250 4 70 BERNINA 710 100 - 240 Volt 50-60 Hz 180 145 No 128 525 x 205 x 415 14.5 5.1 18.1 B9 DC / 36 Volt 100 - 1000SPM No Yes Yes Yes No Yes 130 / (285) Yes Yes Yes 7.5 15 10.5 No/Yes 6 6 0.05 9 0.1 LED LED Yes 10.9 (4.3) 480 x 272 16777216 LED Touch Screen 1/1 680 5 / 439 11 1 29 200 -
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Chapter 2 Electronics and Wiring

Plug diagram and brief descriptions of electronic components
2.1 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 LEDs PCBA-CPU-module interface FHS light barrier 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.
2.1.1 PCBA-Base (B780, B750, B710)

The plugs on the PCBA-Base are listed in the table in accordance with their top left to bottom right arrangement on the PCBA. LED 5 V LED 36 V
X-1701
No. X-1702 X-1701 X-1503 X-1700 X-17 X-3112 X-38 X-3111 X-30 X-2111 X-1 X-42 X-24 X-15 X-40
Color black white white black white black black black black black white blue white white black
Connecting: clutch carriage pull solenoid winder motor and micro switch PCBA-power Main motor PCBA-position thread tension motor various various PCBA-front-cover, right sideways-motion motor PCBA-module stitch-length motor PCBA-detection embroidery module PCBA-lower-thread sensor
X 1702 X-17
X-1503
X-1700
X-3112 X-38 X-3111 X-30 X-2111 X-1
X-42
X-24
X-15
EEPROM
X-40
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2.2 PCBA-CPU-Module (ARM9) General Information

The PCBA-CPU-module contains: Processor (CPU) Memory Data Connectors According to picture .
PCBA-CPU-module sits on PCBA-base. When replacing the PCBA-base, remove the PCBACPU-module from the 'old' PCBA and add to the new.
2.2.1 PCBA-CPU-Module / ARM9 (B780, B750, B710)

X-1 PCBA-Base
X-28 TFT screen
Contacts of PCBA-Base
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2.3 PCBA Front Cover 2.3.1 PCBA Left Front Cover (B710, B750, B780)
The left PCBA front cover contains: Slide potentio meter to control the sewing speed Key-function foil for signal registration Connectors Key-function foil
PCBA Right Front Cover connector
Front side
Back side
Connectors According to picture
Task
S-1
Manual control of sewing speed Registering of signals for: o Needle up/down (S-1) only 780 o Seam securing (S-2) o Pattern end (S-3) o Pattern begin (S-4) only 780 Connecting PCBA left front cover with PCBA-RET and PCBA right front cover.
S-4
S-2
S-3
PCBA-RET connector Sewing speed slide potentiometer
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2.3.2 PCBA Right Front Cover (B710, B750, B780)

The right PCBA front cover contains: Encoder Converter for LCD backlight Key-function foil Connectors Connectors According to picture Task Front side Back side
PCBA Left Front Cover connector
Connecting PCBA-base and PCBA left front cover Registering of signals by stitch-length and stitch-width knobs potentiometers. Registering of signals for left needle position (S-3) and right needle Key-function foil position (S-4). Supply for LCD backlighting Supply for LED freearm lighting
S-3
S-4
Encoder
PCBA-Base connector Touch screen connector LCD backlighting connector
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2.4 PCBA-Power (B710, B750, B780)

The PCBA-power contains: Rectifier Transformer Fuse F1 PCBA-base connector (X-28) Power connector Dipswitch Task 5 V / DC and 36 V / DC for PCBA-base Voltage control, preventing decrease of voltage output
PCBA-Base connector (X-28)
Power connection Power switch Primary fuse F1
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.
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2.5 PCBA-Threader (B710, B750, B780)

The PCBA-threader contains: Microswitch for threading process 2 Connectors Connecting: According to picture Task:
PCBA-Base via harness
Microswitch
Basting Connecting basting solenoid and PCBA-base. Position of hook bar is recognized via microswitch.
2.9 PCBA-Dual-Feed Sensor (B710, B750, B780)

The PCBA-dualfeed sensor contains: Reflection light barrier Connector The PCBA-dual-feed sensor is only available as a complete unit including faceplate Connecting: According to picture Task:
Reflection light barrier
X-38 PCBA-base via harness
The reflection light barrier recognizes whether the dual feed is turned out or in.
2.11 PCBA-Position (B780, B750, B710)

The PCBA-position contains: 3 light barriers Connector Connecting According to picture Task
X17 PCBABase
Light barrier 3 Light barrier 2 A/B Signal
Light barrier 1 receives the initializing signal Light barrier 1 on starting the machine. Light barrier 2 receives the AB signal of the increment disc. This signal is used for the motor control, among others. The hook track signal (light barrier 3) together with the initializing signal defines the moment at which the hook may swing out or in, depending on the position of the needle bar on switching the machine on. This is essential to avoid collision with the needle.
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2.1.12 PCBA-RET (B780, B750, B710)

The PCBA-RET contains 2 LED's Light barrier Ribbon cable connector Key-function foil Connecting According to picture Task
LED 1 (red/green) LED 2 (red/green) Light barrier UTS PCBA left cover Key-function foil
LED 1 Lighting of Start-/Stop button LED 2 Lighting of Start-/Stop button Connecting PCBA left front cover The key-function foil receives the impulses when the rubber keys are pressed.
2.1.13 PCBA Feed-Dog Drop Detection (B780, B750, B710)

The PCBA-detection contains: Light barrier Connector Connecting According to picture Task
Reporting feed-dog status (up/lowered) to CPU via PCBA-base
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2.14 PCBA-Lower-Thread Sensor

The PCBA lower thread sensor contains: Photo transistors IR LED's LED Connecting According to picture Task LED hook area lighting
IR transistors (A/B signal) Sender
Receiver (bobbin
Monitoring of the lower thread amount fill level)
Functions X-40 PCBA-Base The A/B signal measures the rotation of the bobbin to harness using the reflection points on the bobbin for reference. The C signal measures the thread fill on the bobbin via openings in the bobbin that are arranged at different levels.
2.15 PCBA-Accessories Connector

The PCBA-accessories connector contains: BSR connector Spare connector Connecting According to picture Task
Linking element between accessory and machine.
2.16 PCBA-Presser-Foot Height Sensor

The PCBA-presser-foot height contains: Light barrier and Hall sensor Connecting According to picture Task X-3111 PCBA-Base via harness
The upper and lower position of the presser foot bar is recognized via light barriers and the presser foot pressure via the hall sensor and the magnetic strip. Light barrier Hall sensor
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2.17 Sensor Support ABC (Presser Foot Recognition)

The ABC sensors support contains: Infrared (IR) LED's Photo transistors Connecting According to picture Task
X-38 PCBABase via harness
Recognition of presser feet and buttonhole foot signal via sensors.
Sensors
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2.18 Cable Harness

The cable harness includes: 2 cable looms one with 17 and the other with 25 individual wires. One spiral cable holder. Task Note:
The cable harness connects the listed actuators, sensors and PCBA-base.
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.
1 3
17-pin X3111 PCBA-Base 4 6
7 5 8 27-pin X38 PCBA-
# Component 1 Threader sensor 2 Presser-foot height sensor 3 Presser-foot pressure stepping motor 4 Stitch width stepping motor 5 LED sewing light 6 Accessories connector 7 Dual Feed sensor 8 ABC sensor support
Connector color white white black white white white white white
Wire color
Target X3111 / PCBA-Base X3111 / / PCBA-Base X3111 / / PCBA-Base X3111 / / PCBA-Base X 38 / / PCBA-Base X 38 / / PCBA-Base X 38 / / PCBA-Base X 38 / / PCBA-Base
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2.19 BERNINA 780 Block Diagram (B750 / B710)
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2.20 Handling of Electronic Components
Read ESD note (see 1.3) and observe the guidelines.
2.20.1 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. Electrostatic_discharge_ESD
2.20.2 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 oneself are excluded from the repair/replacement process. They will be disposed of. BERNINA International AG reserves the right to charge the original price (of the new component) for electronic components that have been manipulated, repaired by oneself or improperly packaged.
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Chapter 3 Removal and Refitting of Components

3.1 Covers
3.1.1 Head Cover

Disassembly a
Disassembly: Untighten and remove screw a (T20 M4x20). With a slight left turn at the bottom right, raise service cover, pulling it to front to remove. Assembly: Insert service cover into the lugs on top, then push back and down with a slight left turn movement. Refit and retighten screw a (T20 M4x20).
3.1.2 Rear Cover

Disassembly a a
Disassembly: Untighten and remove the 4 screws a (T20 M4x16). Untighten and remove headless screw b (T20 M4x66). Pull cover off, starting to pull top back. Assembly: Position the cover with the cut-out for the power supply plug and main switch flush with the respective openings on the belt cover (see picture bottom right). Carefully push cover against frame, taking care that the latches on the belt cover engage properly. Press cover down into the locks. Refit screw b (T20 M4x66). Refit and retighten the 4 screws a (T20 M4x16). Retighten screw b (T20 M4x66).
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3.1.3 Front Cover

Disassembly
c Disassembly: Remove screws c (T20 M4x16). Carefully tilt cover to front and lift to slide it out of base plate. Carefully unplug ribbon cable d from screen. Carefully unplug ribbon cable e from PCBA-Base. This will release the front cover. Assembly: Replug ribbon cable e on PCBA-Base and ribbon cable d on screen. They must sit centered in the plug. Rehook front cover at top, taking care not to pinch any cables in the duct. Insert cover bottom into base plate, ensuring that the belt cover latches sit properly. Refit and retighten screws c.
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3.1.4 Free Arm Cover Disassembly
Disassembly: Open bobbin door. Remove lower-thread sensor, carefully pulling it off slightly to the right. Disconnect connector. Untighten and remove screw a (T20 M4x16). Untighten and remove 2 screws b (T15). Carefully slide base casing out to the left, taking care not to catch the lower-thread sensor cable. Assembly: Slide casing back under freearm, taking care not to catch the lower-thread sensor cable. Refit screw a (T20 M4x16). Refit and retighten 2 screws b (T15). Retighten screw a (T20 M4x16).
a b
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3.1.5 Free Arm Cover Plate

Disassembly
Disassembly: Remove needle, presser foot, stitch plate, and base casing with bobbin door. Untighten and remove 2 screws a (T20 M4x10). Untighten and remove screw b (T20 M4x10). Untighten and remove 2 screws c (T10 M3x8). Remove freearm cover.
Assembly: Refit freearm cover to freearm. Insert stitch plate. Take care to keep an even clearance between stitch plate and freearm cover when retightening screws a, b and c. Refit base casing and bobbin door.
Warning! Take care not to interfere with the lower-thread sensor wires to avoid damaging them.
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3.1.6 Base-Plate Cover

Disassembly
Disassembly: Untighten and remove screw a (T10 3x10 and u-washer 3.3x7.0.8). Untighten and remove 3 screws b (T10 3x10). Lift base-plate cover out carefully.
Assembly: Slide base-plate cover back in carefully, taking care not to interfere with the lower-thread sensor wires. Refit and slightly retighten screw a (T10 3x10 and uwasher 3.3x7x0.8). Refit and retighten 3 screws b (T10 3x10). Retighten screw a (T10 3x10 and u-washer 3.3x7.0.8).
Warning! Take care not to interfere with the lower-thread sensor wires to avoid damaging them.
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3.1.7 Belt Cover

Disassembly 1
Disassembly: Move needle bar to its top position. Then remove handwheel 1. Turn main shaft by hand in such way that the handwheel retention pin 2 stands upright. Remove the 2 belt cover screws a (T10). Tilt sewing machine to access and remove fastening screw b (T20) on the base plate underside. Remove power plug and main switch from the bracket. Carefully slide off belt cover.
Assembly: Turn main shaft by hand in such way that the handwheel retention pin 2 stands upright. Slide belt cover back into base plate, taking care not to interfere with the PCBA-Base connectors. Slide power plug and main switch back into their respective bracket. Secure belt cover with 2 screws a (T10) on fixing plate. Tilt sewing machine to refit and tighten fastening screw b (T20) on the base plate underside. Refit handwheel 1 to main shaft.
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3.2 Electronics and sensors
3.2.1 Front Left and Front Right PCBA-Covers

Disassembly right Assembly right
/ left
Disassembly: Remove the covers (see 3.1). Unplug front left PCBA-Cover/PCBA-RET ribbon cable. Unplug front left PCBA-Cover/front right PCBACover ribbon cable. Unplug ribbon cable from touchscreen. Remove freearm LED light plug. Unplug front right PCBA-Cover/PCBA-Base ribbon cable. Remove front left PCBA-Cover (T9 4 screws 5 x 10). Remove rubber key pad from under front left PCBA-Cover. Remove front right PCBA-Cover (T9 5 screws 5 x 10). Remove rubber key pad from under front right PCBA-Cover. a Assembly: Refit rubber key pad properly under front right PCBA-Cover. Refit and attach front right PCBA-Cover (T9 5 screws 5 x 10) properly. Note: Take care that the adjusting knobs are in their correct positions. Replug PCBA-Base/front right PCBA-Cover properly. Refit freearm LED light plug. Replug touchscreen ribbon cable properly. Refit rubber key pad properly under front left PCBA-Cover. Refit and attach front left PCBA-Cover (T9 4 screws 5 x 10) properly. Note: Take care not to interfere with the SSU plastic pin. Reconnect front left PCBA-Cover/front right PCBA-Cover ribbon cable properly. Replug PCBA-RET/front left PCBA-Cover properly. Refit the covers (see 3.1). e b d
c 1 2
4 3
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3.2.2 Stitch-Length and Stitch-Width Adjusting Knobs

Disassembly Assembly Disassembly: Remove covers (see 3.1). Remove circlip a, 2 u-washers b (5.6x10x1) and spring c. Slide knob out of cover from front. Assembly: Slide u-washer d (5.6x10x1) onto knob. Insert knob into cover from front. Refit u-washers b, spring c and circlip b. a b c d
3.2.3 Winder Unit
Disassembly: Remove the covers (see 3.1). Disconnect winder plug from PCBA-Base completely and remove winder wire from yellow wire harness. Remove right screw (T20). Slide the winder carrier with the complete winder unit carefully off the threaddistributing pin.
2 Assembly: Use a screwdriver to push down the pressure spring with the u-washer and to 1 slide the u-cut winder carrier under the thread-distributing pin. Then release the pressure spring with the u-washer. Tigthen the right screw (T20) to fasten the winder carrier, taking care that the bobbin pin doesn't touch the cover. Rewind the winder wires around the wire harness. Then reconnect the PCBA-Base plug. Refit the covers (see 3.1).
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3.2.4 Winder Motor
Disassembly: Remove the covers (see 3.1). Remove complete winder unit (see 3.2.3). Cut wire duct strap 1. Remove micro-switch fastening screw (T6). Lift off bobbin pin a. Remove the 2 fastening screws 3 (T8) from the winder motor. Motor including microswitch 002257.70.07 lies free.
1 2
Assembly: Refit winder motor to the cutout provided on the winder carrier and secure with the 2 motor fastening screws. Refit bobbin pin a. Refit microswitch on the lugs and secure with the fastening screw (T6). Refit cable duct strap, taking care that the wires can still be moved. Refit complete winder unit (see 3.2.3). Refit the covers (see 3.1).
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3.2.5 LC Display / Touchscreen

Disassembly Assembly
Disassembly: Remove the covers (see 3.1). Remove front right and front left PCBA-Cover from front cover (see 3.2.1). Sever the self-adhesive copper foil tapes at the top and bottom with a clear cut. Carefully lift the touchscreen from the right bracket by pushing back the retaining clips on the right of the screen. Remove the SL/SW adjusting knobs (see 3.2.2) to replace the touchscreen. Disengage the faceplate with the glued-in touchscreen from the front cover (8 spring locks). Note: Since the touchscreen is glued into the front cover faceplate, it can only be removed complete with faceplate.
a a
2 1 2 1
3 Assembly: Carefully refit faceplate with glued-in touchscreen (8 spring locks). Refit the SL/SW adjusting knobs (see 3.2.2). Slide the screen back into the right bracket. Use the spring mounting tool 398112 030 to pull the retaining clips on the right of the screen back. Then position the screen carefully. Stick self-adhesive copper foil tape over the severed copper foil to bridge the cut. Refit front right and front left PCBA-Cover to front cover (see 3.2.1). Refit the covers (see 3.1).
3 3 3
3 3 3
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3.2.6 PCBA-RET / Rubber Key Pad / Ribbon Cable

Disassembly: Remove back and front covers (see 3.1). Remove ribbon cable from PCBA-RET on front left PCBACover. Carefulla remove the 4 fastening screws (T9) and the bridge (033743.70.00). Remove PCBA-RET. Remove PCBA-RET rubber key pad.
1 1 1 b 1
Assembly: Reposition PCBA-RET rubber key pad into provided place. Guide PCBA-RET ribbon cable through slot in bridge. Reposition PCBA-RET and bridge properly and slightly tighten fastening screw (T9). Bring PCBA-RET and bridge into correct position and tighten fastening screws to secure. Reconnect PCBA-RET ribbon cable to front left PCBACover. Refit the covers (see 3.1).
d c
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3.2.7 PCBA-Base
When replacing the PCBA-Base, remove the EEPROM from the old PCBA and directly fit it on the new PCBA. The EEPROM contains imported machine-related data. For disassembly and assembly (see 3.2.9)
Disassembly: Disconnect all plugs. Remove 3 screws a (T20 M4x10). Slide PCBA-Base out to front. Assembly: Position PCBA-Base on frame and base plate. Note: FHS position plate 2 must be able to freely move within the PCB cut-out. Retighten 3 screws a. Reconnect all plugs (note the color coding, see next page). Note: Ensure that no wires are within the FHS light barrier area 3. Important! Is the EEPROM attached?
a a
a 3 2
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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.
Number Color connects with: X-1702 black clutch carriage pull solenoid X-1701 white winder motor and micro switch X-1503 white PCBA-power X-1700 black Main motor X-17 white PCBA-position X-3112 black thread tension motor X-38 black various* X-3111 black various* X-30 black PCBA-front-cover, right X-2111 black sideways-motion motor X-1 white PCBA-module X-42 blue stitch-length motor X-24 weiss LPB-Detektion X-15 white embroidery module (B780 und B750) X-40 black PCBA-lower-thread sensor X-103 black wireless module * For connector details see 2.18 cable harness
X-1701 X 1702 X-17 X-1503 X-1700
X-3112 X-38 X-3111 X-30 X-2111
X-1
X-42
X-24
X-15
EEPROM
X-40
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3.2.8 PCBA-CPU-Module
Disassembly: Disconnect connecting wire 1. (Pull the plug not the wire!) Remove screw 2. Open locking clips 3 simultaneously in direction of arrows as indicated. PCBA-CPU-Module will disengage on its own by spring-action. Disconnect PCBA-Module. Turn distance bush 4 in direction of arrow as indicated and remove. Assembly: Refit distance bush 4. Reconnect PCBA-CPU-Module (note coding 5!). Press down until locking clips 3 engage. Retighten screw 2. Reconnect connecting wire 1. Warning! The current state of the firmware must be checked after assembly of the new PCBA-CPUmodule. If it is not the latest version, the firmware must be updated (via updating procedure).
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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 Assembly Disassembly: Use IC extractin tool 1 (032948.50.00) to remove EEPROM 2. Assembly: Attach EEPROM 2 to base. Take care to fit EEPROM in the correct position (markings must match) and avoid bending the contacts.
EEPROM fitting position Markings must match.
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3.2.10 Freearm LED Sewing Light

Disassembly: Remove the covers (see 3.1). Disconnect freearm LED sewing light plug from front right PCBA-Cover. Remove freearm LED sewing light from front cover.
Assembly: Slide freearm LED sewing light into front cover. Replug freearm LED sewing light on front right PCBA-Cover. Refit the covers (see 3.1).
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3.2.11 PCBA-Power Including PCBA Housing

Remove power plug to disconnect machine from power supply!
Disassembly: Remove the covers (see 3.1). Unhook the PCB cover 1 and remove it from the air duct 2, taking care not to interfere with the main switch and power supply plug. Remove motor wires from air duct slot. Then unhook air duct from PCBA housing. WARNING! There is a risk of damage to the motor wiring! Disconnect cable 3 from PCBAPower. Remove fastening screws b to remove PCBA-Power and housing.
Assembly: Refit PCBA-Power and housing and secure with fastening screws b. Reconnect cable 3 with PCBA-Power. Rehook air duct onto PCBA housing and slide motor wires through slot. Refit PCBA cover, PCBA housing and air duct, taking care not to interfere with the main switch and power supply plug. Refit the covers (see 3.1).
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3.2.12 PCBA-Power
Disassembly: Remove the covers (see 3.1). Remove PCBA-Power and housing (see 3.2.11). Remove the 3 fastening screws a (T10) from the bottom right guidance 1 to lift PCBA-Power out of machine, taking care not to damage the ESD protective gasket.
a Assembly: Slide PCBA-Power into bottom right guidance 1 of the PCBA housing. Insert ESD protective gasket into slot 1. Tighten the 3 fastening screws a (T10) to secure PCBA-Power in the housing. Refit PCBA-Power and housing (see 3.2.11). Refit the covers (see 3.1).
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3.2.13 Head Frame LED Sewing Light

Warning! Do not pull cables over sharp edges!
Disassembly: Remove the covers (see 3.1). Remove the fastening screw 1.of left LED sewing light on head frame using the small screwdriver (T10) 030475.50.00. Push left LED sewing light out of socket a. Remove the fastening screw 1 of right LED sewing light on head frame using the small screwdriver (T10) 030475.50.00. Unplug presser-foot height stepping motor connection a. Unplug connection b on left LED sewing light. Unplug basting solenoid c and PCBA-Threader d connections. Unlock rubber cable holder e. Remove clip f. Open white cable duct g. Starting with the right LED sewing light h, remove the sewing light cable with greatest care from cable harness.
c f g d e
Assembly: Starting on the left LED sewing light side, refit the sewing light cable into cable harness with greatest care, twisting it a little around the presser-foot height stepping motor cable. Replug presser-foot height stepping motor connection a and slide into head frame. Reconnect sewing light cable b with left LED sewing light. Replug basting solenoid c and PCBA-Threader d connections. Secure rubber cable holder e on head frame. Slide right LED sewing light through cable harness and secure with clip f. Insert sewing light cable into white cable duct g. Close white cable duct. Carefully lay the right end of the sewing light cable. Using the lug as a guide, fit the right LED sewing light h into place and tighten the fastening screw 1 with the small screwdriver (T10) 030475.50.00. Fit the left LED sewing light into the socket a and use small screwdriver (T10) 030475.50.00 to tighten the fastening screw 1. Refit the covers (see 3.1).
h 1
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3.2.14 Presser-Foot Height Sensor

Disassembly:
Remove head cover (see 3.1.1). Remove rear cover (see 3.1.2). Disconnect plug 1. Move actuating lug 2 down. Remove screw 3 (T10 M3x6). Slide presser-foot height sensor 4 out of actuating lug to the right and remove sensor.
Assembly: Place the presser-foot height sensor 4 exactly in the center of the rear lug. Take care that the presserfoot height sensor doesn't touch the lug magnet at the front but has max distance 1.6mm. Retighten screw 3. Reconnect plug 1. Refit covers.
3 max 1.6mm
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3.2.15 PCBA-Threader
Disassembly: Remove covers (see 3.1). Remove screw d (T10 M3x12). Slide PCBA-Threader 6 up and out. Disconnect plugs 4 and 5, remove PCBA-threader 6. Assembly: Reconnect plugs 4 and 5. Important! To avoid that the actuating lug breaks, insert the sensor from left to right, holding it at an angle. Position PCBA-Threader 6 on the pin of the needle bar guide. Retighten screw d. Refit cover 2 with screws a, b and c. Refit covers.
6 5
3.2.16 Sensor Support ABC (Presser-Foot Recognition Sensor)

Disassembly Assembly Disassembly: Remove front cover (see 3.1.3). Use screwdriver to lift sensor support 2 in area 1 over spherical bearing in direction of arrow as indicated. Slide sensor support 2 out of presser foot bar on the right. Disconnect plug 3. Assembly: Reconnect plug 3 on sensor support 2. Slide sensor support 2 over presser foot bar, carefully sliding it down over spherical bearing and taking care to correctly position it in the housing. 3
Caution: Risk of Breakage! Take care that sensor support 2 doesn't catch edges while fitting it.
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3.2.17 PCBA-Dual Feed Sensor

Disassembly Assembly 3 4 5
Disassembly: Remove covers (see 3.1). Lower dual feed 1. Use screwdriver 4 to disengage locking lug 6 of PCBA-Dual-feed-sensor 2 in area 5 in direction of arrow as indicated. Remove PCBA-Dual-feed-sensor 2. Disconnect plug 3.
1 Assembly: Lower dual feed 1. Reconnect plug 3 on PCBA-Dual-feed-sensor. Position PCBA-Dual-feed-sensor 2 and slightly press locking lug 6 engages. Refit covers. 2 until it 3
3.2.18 PCBA-Accessories-Interface
Disassembly: Remove covers (see 3.1). Lower dual feed. Remove 2 screws a (T10 M3x6). Tip: For access to screws see film. Remove PCBA-Accessories-Interface 1. Disconnect plug 2. Assembly: Lower dual feed. Position PCBA-Accessories-Interface 1. Retighten 2 screws a. Refit covers.
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3.2.19 Embroidery Module Interface (BERNINA 780 and 750)
Disassembly: Remove base plate cover (see 3.1.6). Remove PCBA-EMB connector a. Remove the two collar screws 1 (T8) using the angled torx. Disconnect PCBA-EMB plug b. Remove insulation foil c.
Assembly: Place insulation foil c onto PCBA-EMB. Re-insert PCBA-EMB b into base plate. PCBA-EMB to base plate using the angled torx T8. Note:PCBA-EMB is float-mounted. Replug PCBA EMB connector b. Refit base plate cover (see 3.1.6).
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3.2.20 PCBA-Lower-Thread-Sensor
Disassembly: Open bobbin door in base casing fully. Remove lower thread sensor a. Unplug PCBA-Lower-Thread-Sensor connector d.
c b a
Assembly: Replug PCBA-Lower-Thread-Sensor connector d. Insert guiding pin on the left of the lower thread sensor into guiding rail. Click lower thread sensor into place on hook race cover holder pin c. Close bobbin door.
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3.3 Mechanical Components

3.3.1 Hook and Hook Driver
Disassembly Assembly Disassembly: Remove all covers (see 3.1). Remove thread cutter unit (see 3.3.2) Remove bobbin case. Remove hook. Unhook feeddog support spring 3. Remove sideways-motion feed rod 4 on the right side and put it aside Unhook tension spring 5 connector between clutch carriage and belt tensioner. Remove belt tensioner Remove hook driver shaft securing screw 8 (T8). Bring hook driver into its neutral position, then pull out carefully, pushing slightly from the back with a screwdriver (e.g. T8) if required. Note: The hook driver is in its neutral position if the hook driver cams protrude from the hook driver casing the same length. Remove the three securing screws 2 from the hook race ring. Carrfully remove hook race ring. Note: Take care not to lose the spherical washers. 2 2
8 6
Assembly: Carefully insert hook race ring, taking care to position the 3 spherical washers correctly, i.e. flat side up and sitting between hook race ring and aluminium base. Tighten the 3 securing screws only so much that the hook race ring can still be moved in x-axis direction. The hook race ring is firm in all other directions. Insert the setting hook including gauge shaft and fitted pressure spring into hook race ring. Then slide the 5.0mm thick end of gauge shaft through the hook race bearing up
a b
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to stop. Secure gauge end using the quick clamping screw. It must now be possible to compress the gauge shaft to check for smooth running. Align gauge shaft bracing horizontally. Check if hook race ring is properly centred by briefly pressing the gauge shaft. The gauge shaft must be pushed back by the spring automatically. Slightly tighten the 3 screws of the hook race ring 1 => 2 => 3. Then tighten firmly in this sequence: 1 => 2 => 3 The hook race ring is now secured in all directions. Align gauge shaft bracing vertically. Check if hook race ring is properly centred by briefly pressing the gauge shaft. The gauge shaft must be pushed back by the spring automatically Note: 1 If the gauge shaft is pushed back by the spring automatically, the z-axis setting of the hook bearing is fine. Repeat this procedure 3 times. Insert the hook drive to its neutral position in such way that the drive belt can be loaded onto the gearwheel using the spring mounting tool 398112.03.0+ and the hook drive securing screw (T8) sits on the flat side of the hook drive shaft. Tighten the hook drive securing screw so that the hook drive runs smoothly without play or clamping. Check: The hook drive shaft end protrudes ca. 4.5mm from the hook bearing.
~ 4.5mm
Use 3.0mm pin b to lock hook drive in loop lift position. Now turn the handwheel in direction of rotation until the mark on the white plastic belt wheel stands short of the lug mark of the frame. When fitting and setting the belt tensioner, the mark on the white plastic belt wheel must align exactly with the lug mark on the free-arm frame. Rehook tension spring connector between clutch carriage and belt tensioner. Refit sideways-motion feed rod on the right side. Refit and adjust thread cutter unit (see 3.3.2). Insert hook and close hook race cover. Insert bobbin case. Test run the machine. If it runs smoothly and quietly, all the fitting and adjusting work has been carried out properly.
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Note: If the hook makes noise, loosen the 2 hook bearing screws by an eighth rotation, then retighten slightly. Insert the setting hook a including clamping magnet 1 of gauge 734541.70.00 into the hook race ring. Close hook race cover With the motor running, use eccentric spanner to find the position in which the machine runs quietest. Tighten the 2 hook bearing screws slightly 1 => 2. Then tighten firmly 1 => 2
a 1
Note regarding servicing: Use a polishing disk to remove scratch marks on the hook body or slight damages to the hook tips. Replace hook if it is badly scratched or has broken hook tips. For lubrication of hook refer to lubrication diagram (see 6).
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3.3.2 Thread-Cutter Unit

Disassembly Assembly Disassembly 1 1 Remove needle, presser foot and stitch plate. Remove free arm cover (see 3.1.4). Remove free arm cover plate (see 3.1.5). Remove screws 1 of left part of thread catcher/thread cutter unit (3 X T8). Then pull unit to the left to remove. Note: Ensure that the thread catcher lever is in its home position (to the far left). 1
3.3.2a
180 Assembly Refit the left part of the thread catcher/thread cutter unit. Insert it from the left and link it with the right part, ensuring that the thread catcher stands over the metal plate of the right part (pic 3.3.2a). The left part of the thread catcher/thread cutter unit must lie flat on the hook race ring to ensure that the locating pins on the hook race ring mesh correctly and the thread catcher actuating lever sits correctly in the opening provided. Refit and tighten the two screws (3 X T8) to secure the left part of the thread catcher/thread cutter unit.
Disassembly of blade: Remove thread cutter unit (see 3.3.2). Remove blade securing screw (T8). Move the thread catcher slightly to the right and pull the blade up and out. Assembly of blade: Position the new blade under the first layer of metal sheeting. The edge of the blade's fastening lug MUST butt against the recessed bracket edge (pic 3.3.2b). Refit and tighten the blade securing screw 3 (T8). Refit thread cutter unit (see 3.3.2). 3.3.2b
Note regarding servicing: When servicing the machine, the thread cutter must always be removed for cleaning purposes. The blade is a wear part and therefore available as an individual part.
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3.3.3 Thread-Tension Unit

Disassembly Assembly 5
Disassembly: Remove stepping-motor carrier 5 (2 X T20). Remove circlip 6 from pin. Remove clutch gear wheel 7 from pin. Remove u-washer/shim 8. Remove thread-tension nut 9. Remove slotted shim 10. Remove tension spring 11. Remove slotted plastic pressing disc 12. Remove right thread-tension disc 13, tension shim 14 and left thread-tension disc 15.
15
14
13
12
11
10
Assembly: Refit left thread-tension disc 15, tension shim 14 and right thread-tension disc 15, taking care to position them correctly on the thread-tension shaft. Refit slotted plastic pressing disc 12 onto thread-tension shaft. Refit tension spring 11 onto thread-tension shaft. Refit slotted shim 10 onto thread-tension shaft. Screw thread-tension nut 9 onto thread-tension shaft. Refit u-washer 8 onto thread-tension shaft. Refit clutch gear wheel 7 onto thread-tension shaft, taking care that the claws and thread-tension nut mesh correctly. Refit circlip 6. Unload pressure spring as far as to stop against circlip. Refit bracket and stepping motor 5 (2 X T20), taking care that there isn't any play between clutch gear and stepped gear. The clutch gear must still be movable smoothly and without clamping on the shaft. Adjusting is carried out via the Service Program (see 6j). .
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3.3.4 Clutch Carriage

Disassembly: Remove the sideways-motion (see 3.3.18). Remove tension spring 1. Remove the connecting strap between clutch carriage and cutting unit release lever 2 (2 X T10). Remove clamp 3 and unplug pull solenoid plug a. Remove circlip size 2.3 from stop pin, then remove stop pin 4. Remove rounded head stop screw 5 (1 X T20) and eccentric, horizontal guiding pin 6. Remove vertical guiding pin 8 (only loosen 1 X T20 at the bottom 7 but remove 1 X T20 on top 7). Remove clutch carriage, taking care not to tear the pull solenoid cable out. 6 5 7 8 1 Assembly: Refit clutch carriage, taking care to lay in the pull solenoid cable properly. Refit vertical guiding pin 8, sliding 2.3 it down to bottom stop and fasten it by tightening the lower rounded head stop screw 7 (1 X T20). 4 Screw upper second rounded 2 head stop screw 7 (1 X T20) and 2 7 tighten it. Refit horizontal, eccentric guiding a 3 pin 6 and tighten rounded head stop screw 5 only as much that it is still possible to turn the eccentric pin. Then, turn the eccentric pin as needed so that the clutch carriage won't move when tightening the rounded head stop screw 6. Insert stop bolt 4 into clutch carriage and secure with circlip 2.3. Reposition pull solenoid cable properly, replug plug a and refit clamp 3. Refit the connecting strap between clutch carriage and cutting unit release lever 2 (2 X T10)
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Use 3.0mm pinning tool 007937.50.00 to pin the cutting unit. Use 3.0mm pinning tool 007937.50.00 to pin connecting strap between clutch carriage and cutting unit release lever. = Untighten the two screws (T10) on the connecting strap between clutch carriage and cutting unit release lever. = Use the eccentric spanner 001361.70.00 to position the clutch lever in such way that the clutch lever fork won't touch the base shaft in any position and that it can easily be brought into home position by the pressure spring of the pull solenoid. With the lever in this position, retighten the two screws (T10) on the connecting strap between clutch carriage and cutting unit release lever. Rehook tension spring 1. Refit sideways-motion stepping motor carrier (see 3.3.18).
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3.3.5 Threader Head
Disassembly: Set needle bar a to its top position. Remove the needle. Move needle threader holder b a little downwards. Pull threader head c off threader bar.
b a
Assembly: Push threader head c onto threader bar in correct position. Release needle threader holder b. Insert needle. Functional check Adjust threader if necessary (see 4.9).
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3.3.7 Needle Bar Support

Disassembly Assembly Disassembly: Remove covers (see 3.1). Turn handwheel to move thread take-up back. Remove plug 5 from PCBA-Threader. Remove left and right sewing light from head frame 11 (see 3.2.13). Use setting eccentric to remove screw e (T10 M3x6). For access from below use angled torx. Remove angular adjusting piece 10. Unhook tension spring 8. Remove screw f (T10 M3x6) including zigzag support, spring and zigzag segment 9. Unhook two springs 6 and remove them including spring compensator 7. Slide needle bar support 12 to front, then to the left and out of thread take-up crank. Remove seating 13 that sits behind needle bar support. 5
7 6 6
8 13 10 f e 11 12 11
13
13a
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Assembly: Push spring g to the right and retain in this position. Position seating 13 as shown in the picture (is secured by spring g). Note: Fitted position of 13a. The position of the seating must not change during fitting. Rehook two springs 6 in front head plate. Position needle bar support 12 and rehook springs 6 in spring compensator. Note: Rehook right spring 6 to spring compensator, with spring hook going through the opening in the needle bar support. Position angular adjusting piece 10 and use open-end wrench no. 6 to adjust it via eccentric l, ensuring that there is no play or clamping. Retighten screw e. Use pinning tool (003156.50.00) to pin drive gear 16. Position zigzag segment 9 into drive gear 16 and toothed segment 15. Note: Note markings i (zigzag segment 9/drive gear mesh 16) and k (zigzag segment 9/toothed segment mesh 15) Refit zigzag support with screw f and spring 8. Rehook spring 8. Remove pinning tool 14. Adjust needle distribution (see 4.4.2). Refit covers.
14 i 9 15 l
16
i 8 k 9 k
10 15 e
build-in
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3.3.8 Needle Bar
2 Disassembly: Remove needle bar support (see 3.3.7). Unhook spring 1. Untighten setscrew b (T6 M3x4) and remove guide bar. Disengage needle bar 3 by pressing latch 2, then slide it down and out of needle bar support.
Assembly: Insert needle bar 3 into needle bar support from underneath. Insert the needle bar cam into needle bar guide, keeping the latch 2 pressed down Rough-set the needle bar guide and secure the setscrew b (T6 M3x4). Rehook spring 1. Refit needle bar support (see 3.3.7). Adjust threader (see 4.9).
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3.3.9 Needle Clamp

Disassembly Assembly Disassembly: Remove needle clamp screw a. Remove needle positioning pin b. Slide needle clamp 5 down and out of needle bar 7. Remove position plate 6, thread guide 4, guide 2, needle mask 1 and pressure spring 3. Assembly: Refit needle mask 1 and guide 2 on needle bar 7. Refit thread guide 4 including position plate 6 on needle clamp 5. Position spring 3 in guide 2. Use feeler gauge 8 to press spring 3 down, then slide needle clamp 5 over needle bar 7 in direction of arrow as indicated. Retighten needle positioning pin b. Refit needle clamp screw a. 2 1 6 4 5 a b
3 8
a 3
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3.3.10 Threader Mechanism

Assembly Disassembly: Unhook tension spring 9. Unhook tension spring 10. Move needle bar 11 down. Move threader support 12 down. Pinch pressure spring 13. Remove dowel 14 with tweezers. Slide threader bar 15 down and out. a 14
10
13 14
Assembly: Reposition threader support 12 onto needle-bar support. Slide threader bar 15 back on from bottom . Slide pressure spring 13 back onto threader bar, then slide threader bar entirely up. Pinch pressure spring 13. Reposition dowel 8. Reposition dowel 8 so that pressure spring sits in the groove of the dowel (see picture a). Rehook tension spring 10. Rehook tension spring 9.
11
15
12
13 9
10
14
12 11
15
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3.3.11 Main Motor

Disassembly Assembly Disassembly: Remove covers (see 3.1). Remove ventilator fan and drive belt. Remove screws a (T20 M4x12, u-washer 5.3x10x1, serrated washer 5.1x9x0.5). Slide main motor out of motor bracket. Disconnect plugs 1 and 2. Assembly: Reconnect plugs 1 (red positive pole '+') and 2 (black negative pole '-'). Note: The positive pole can be identified by the salient 3. Position motor back into motor bracket. Retighten screw a including u-washer and serrated washer. Refit drive belt and ventilation fan. Adjust belt tension (see 4.1.2). a
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3.3.12 Dual Feed

Disassembly Assembly Disassembly: Remove covers (see 3.1). Remove right LED housing (see 3.2.13). Open cable duct 1 and unplug: ABC sensors board, PCBA-Accessories-connector and PCBA-Dualfeed. Remove all cables from cable duct 1. Remove two screws a (T20 M4x10, u-washer 4.2x9x1) and cable duct 1. Remove PCBA-Dual-feed 2 and PCBA-Accessory-connector 3. Remove circlip 4 and slide link out. Remove two screws b (T10 M3x12) of tongue. Remove screw c (T10 M3x6) of feed regulator support. Loosen screw d. Slide dual feed unit out to the right. Assembly: Position dual feed. Dowel 6 of feed cam 5 mustn't touch the frame. Slightly push dowel 6 to the right until it no longer touches the frame, then retighten screw d. Slightly tighten screw c. Slide link back in and refit circlip 4. Position tongues and retighten screws b. Position cable duct 1 and PCBA-Accessory, then retighten screw a. Remove PCBA-Dual-feed 2 and PCBA-Accessoriesconnector 3. Reconnect all plugs, lay cable in duct and close. Refit right LED housing. Adjust dual feed in X-direction (see 4.6.2). Refit covers.
1 a
d c
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3.3.13 Thread Take-Up Lever

4 Disassembly Assembly Disassembly: Remove covers (see 3.1). Remove needle bar support (see 3.3.7). Remove screw a (T20 M4x10) including bushing support. Untighten setscrew b (T10 M5x5). Slide take-up lever 1 including joint 3 and crank 5 to the left and out of balance piece. Note: Take care not to lose washer 2. a
1 b 5
3 Assembly: Position take-up lever 1, joint 3 including crank 5 and u-washer 2. Refit link shaft 4 with bushing support and screw a. Retighten setscrew b on the surface of crank 5 so that there is no play or clamping. Refit needle bar support, thread tension unit and covers.
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3.3.14 Restraint Guided Advance Link Lever
8 Disassembly: Remove covers (see 3.1). Turn handwheel until the lift-/advance link is in the highest position a. Turn the stitch length cam back to the stop by hand b. Remove the long tension spring 5. Remove the two short tension springs of the guidance 6. Remove slide block 7 from stitch length cam. Turn machine backside to front. Remove connecting strap 8 of sideways-motion stepping motor from feed-dog carrier side and pull away to the left. Untighten the screw 9 (T8) of the bearing pin with clearance grooves, move pin to the far right against stop c, then retighten the screw (T8) slightly. Remove left circlip 10 from bearing pin. Remove u-wahser 11 and plastic ring 12. Carefully slide off joint bearing 13. Loosen screw 9 (T8) of bearing pin, then remove bearing pin. Pull lift-/advance 16 link out, pulling it away from yourself and taking care not to lose the pressure spring. 7 5
a
6 6
16
15
14
13
12
11
10
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Assembly: Refit lift-/advance 16 motion link and reposition pressure spring 15. Refit bearing pin 14, slide to stop c and retighten screw 9 (T8) slightly. Re-insert joint bearing 13 carefully. Loosen bearing pin screw 9 (T8) again, pull bearing pin forward a little, making it easier to refit the plastic ring and u-washer. Retighten bearing pin screw 9 (T8) slightly. d Slide plastic ring 12 and u-washer 11 over bearing pin. Refit circlip 10. Turn machine frontside to front. Refit slide block 7 to stitch length cam properly d. Then position the location pin of the lift-/advance motion link in the slide block. e Refit long tension spring 5. Refit the two short tension springs 6 of the guidance. Check for proper fit. Return machine backside to front. Loosen the bearing pin securing screw 9 (T8) again and position the bearing pin in such way that the securing screw sits in the clearance-groove part e and the long side of the lift-/advance motion control runs parallel to the frame edge of the freearm. . IMPORTANT: Take care to ensure that the pressure spring which excerts pressure onto the back of the lift-/advance motion link can deflect and function properly. Refit the connecting strap of the sideways-motion stepping motor on the feed-dog carrier side, i.e. refit strap, refit pressure spring, then slide u-washer over pin and press down with the auxiliary tool 734562.50.00. Refit circlip 8. Turn handwheel and check for ease of running.
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3.3.15 Stitch-Length Crankshaft
Disassembly: Remove the covers (see 3.1). Remove PCBA-Base (see 3.2.7). Remove restraint-guided thrust link (see 3.3.14). Untighten screw a (T20). Untighten setscrew b (T8) on small belt pulley. Remove 2 screws c (T20) and the spherical bearing clamping jaws. Carefully slide crankshaft to the left and out of rear spherical bearing, clamp and small belt pulley, taking care not to lose the white plastic washer. Assembly: Position the white plastic washer on the crankshaft and to the right of the circlip. From the left, carefully insert crankshaft into small belt pulley (leaving the setscrew accessible), clamp and rear spherical bearing, taking care that the front spherical bearings sit in their proper seats. Retighten the 2 spherical bearing clamping jaw screws c (T20). Refit restraint-guided thrust link (see 3.3.14). Use pinning tool 002733.50.00 to pin crankshaft at front. Use pinning tool 001356.50.00 to pin crankshaft at top. Slightly push small belt pulley and white plastic washer against circlip and retighten setscrew b (T8). Adjust mechanical basic setting (balance) of feed-dog (see 4.6.3 and service program 6b) Refit the covers (see 3.1).
d a b c c e
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3.3.16 Base Shaft
Disassembly: Remove the covers (see 3.1). Remove PCBA-Base (see 3.2.7). Remove restraint-guided thrust link (see 3.3.14). Remove the 3 clamping jaws a along with the 3 screws b (T20). Remove drive belt from belt pulley. Remove base shaft.
Assembly:
Attach loop lift gauge 734571.70.01 (see 4.5.3). Align the mark on the white belt pulley of the clutch carriage at the rear of the sewing machine with the mark on the freearm frame. Use 3.0mm pinning tool 007937.50.00 to pin hook driver at the back. From left, position base shaft into drive belt without securing it yet. Ensure that the spherical bearings are properly positioned. Retighten the 3 screws b (T20) to secure the 3 clamping jaws a. Use 3.0mm pinning tool 007937.5.00 to pin base shaft against lift cam. Slide drive belt over belt pulley. Check belt tension (see 4.1.1). Check loop lift (see 4.5.3).
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3.3.17 Stitch-Length Stepping Motor

Disassembly Assembly Disassembly: Remove covers (see 3.1) and PCBA-Base (see 3.2.7). Note: The stepping motor carrier plate 4 is springmounted on the machine frame. By turning the balance setting cam that lies against the frame, the entire carrier plate is moved via pivot 0. Remove cable locking, then carefully slide cable out of cable duct. Unhook springs 2 and 3. Remove stitch length stepping motor 1. 0 5 2 3
1 4
Assembly: Use pinning tool (001356.50.00) to pin toothed 2 segement 5. Position stepping motor 1 on frame. Slide toothed segment 5 into drive gear provisionally. Rehook springs 2 (Note: see picture for mounting position) and 3. Adjust mechanical basic setting of feed-dog balance (see 4.6.3). Disassembly of stepping motor: Spring 2 mounting position a
a 2 Remove stepping motor 1. Untighten setscrews b (T6 M3x4) and remove drive gear 6. Remove two screws a (T10 M3x6, serrated washer 3.2x6x0.4) and stepping motor 1 from motor bracket. Reassembly of stepping motor: Place stepping motor 1 on motor bracket. Retighten screws a including serrated washers. Slide drive gear pinion 6 over motor axis. Refit PCBA-Base and reconnect plug. Reconnect stepping motor plug P-42 on PCBA-Base. Refit front cover with mounting bracket (032763.70.00). Start pinning position test 5e in Service Program. Place 0.3mm feeler gauge 9 under stop 7 of drive gear pinion 6. Set stop 7 of drive gear pinion 6 against rubber buffer 8 and retighten setscrew b. Remove feeler gauge 9. Refit stepping motor. 7 8
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3.3.18 Sideways-Motion Stepping Motor (B780)

Disassembly Assembly Disassembly: Remove freearm cover (see 3.1.4). Remove screw a (T20 M4x10, u-washer 4.3x9x0.8) including setlug 1 and spring 2. Slide lever 5 up and out of cam 7. Remove two ball bearings 4. Remove screws b (T20 M4x10, u-washer 4.3x9x0.8). Remove entire console 6. Disconnect motor cable plug.
Assembly: 6 Reconnect motor cable plug. Position entire console bracket 6 on frame. Take care to lay cables correctly, then slightly tighten two screws b. Grease the ball bearings 4 a little (Klbersynth UH1 14-100) before positioning them. Position lever 5 in cam 7 on the lower ball bearing 4. Refit screw a including setlug 1, spring 2 and washer. Recheck:Have the balls 4 been placed and are they properly 5 positioned? Adjustment: The pressure of the lever 5 on the cam 7 is adjusted via the height of the setting plate 1 through the eccentric location 8. Slightly loosen screw a. 7 Use eccentric key (001361.70.00) in location 8 to adjust the height of the setting plate 1 until lever 5 sits opposite of guiding 7 without play or pressure. Retighten screw a. Main feed-dog: Adjust position within stitch plate in X direction (see 4.6.1)
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3.3.19 Presser-Foot Pressure Stepping Motor

Disassembly Assembly Disassembly: Remove covers (see 3.1). Remove needle bar support (see 3.3.7). Remove screw a (T10 M3x6, washer 3.2x7x0.5). Loosen screw b (T10 M3x8, washer 3.2x7x0.5). Disconnect motor plug 3. Remove two screws c (T10 M3x6, washer 3.2x6x0.5). Move front head plate 2 as far out to front until stepping motor 1 can be slid out of rear head plate. Assembly: Position stepping motor 1 in rear head plate and insert screws c. Turn stepping motor 1 to mesh drive gear pinion 4 and wheel 5 until there is no play or clamping. Then tighten screws c. Reconnect motor plug 3. Refit front head plate 2 and screws a and b. Refit needle bar support. Refit front cover, start Service Program and carry out (test 6h). c 5 a
b 2
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3.3.20 Stitch-Width Stepping Motor

Disassembly Assembly Disassembly: Remove covers (see 3.1). Loosen setscrew c (T8 M4x4) of drive gear pinion. Use angled torx to remove two screws d (T10 M3x6). Remove screw a (T10 M3x6, washer 3.2x7x0.5). Loosen screw b (T10 M3x8, washer 3.2x7x0.5). Disconnect motor plug 3. Move front head plate 2 as far out to front until stepping motor 1 can be slid out. Assembly: Position stepping motor 1 in front head plate. Slide drive gear pinion over motor shaft. Note: Markings (zigzag segment 4 / drive gear mesh 5) must match! (see 3.3.7 - assembly of needle bar support). Retighten screws d. Reconnect motor plug 3. Retighten screws a and b of front head plate. Use pinning tool 6 (002733.50.00) to pin stepping motor. Start pinning position test 5e in Service Program. Place 0.3mm feeler gauge 7 under stop of drive a gear pinion 8. Retighten setscrew c. Complete test 5e. Remove pinning tool 6 and feeler gauge 7. Adjust needle distribution (see 4.4.2). Refit covers 2 2 b
d 1
c d
5 4 7 c 8
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3.3.21 Presser-Foot Pressure Toothed Rack Bearing

Disassembly Assembly Disassembly: Remove covers (see 3.1). Remove needle bar support (see 3.3.7). Remove circlip 4, washer (4.3x7x0.8), wheel 3 and drive gear pinion 5. Unhook spring 2 and remove. Remove 3 screws a (T10 M3x6). Raise presser-foot bar manually and slide toothed rack bearing 1 entirely out to the front. Assembly: Position entire toothed rack bearing at rear head plate and retighten three screws a. Slide pinion 5 over shaft. Refit wheel 3 including washer and circlip 4. 3 a a 2
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Chapter 4 Settings
4.0 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)! When adjustments are carried out in the correct order, the machine will function flawlessly. Important: Always use a needle size Nm 80 when adjusting and setting the machine, unless otherwise specified. Always check the needle before carrying out adjustments on the machine! The needle must be absolutely straight (130/705 H TCN). For servicing, we recommend that you always use the accessories included with the machine or purchased specifically for it. These are the following: power cable, foot control, buttonhole foot, embroidery module and hoop, BSR foot, and other accessories.
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4.1 Belt Tensions

4.1.1 Upper / base shaft tension
Check: Drive belt 030955.50.03 linking base shaft and belt pulley (picture 4.1.1). Check: When slightly pressed (approx. 100g) in the center of the belt, the belt mustn't move more than 2-3mm. Note: o Too tightly tensioned belts will cause stiff running. o Too slackly tensioned belts may cause slippage. Base shaft/belt pulley drive belt adjustment Basic position of main shaft eccentric spherical bearing The eccentric engagement bore a in the spherical bearing is positioned towards the frame edge c and is horizontal to the centre of the base shaft. Untigthen screw b (T20), then use adjusting spanner # 733019.70.00 to turn the bearing until the specified value has been reached. Retighten screw b. Note: Clockwise turning: belt tension tightens. c a 4.1.1
tension
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4.1.2 Drive Motor

Check Adjustment Check: With a pressure of approx. 500g onto the belt centre a, the belt mustn't move more than 8 +/-1mm. Adjustment: Untighten the 2 screws b (T20 M4x12 and washer 4.2x14x1.5mm) of motor bracing. Slide motor up or down until specification is met. Retighten screws b. a 500gr. 4.1.2
4.2 Head-Frame Plate Position

IMPORTANT! In order to avoid any damage at all, the following settings up to and including (see 4.3.2) shall be carried out without sewing needle!
4.2.1 Position of Head-Frame Plate/Stitch Plate in Y Direction

Check Adjustment Check: 18mm rough setting (picture 4.2.1) between frame and head plate. 4.2.1 Disconnect PCBA-Threader Sensor to clear access to the screw. 18mm
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4.2.2 Position of Head Frame Plate/Stitch Plate in X-Direction

Check Adjustment Check: Attach presser foot 1D. Presser foot is centred in the stitch plate. Use 3/8 inch markings on stitch plate for reference. 4.2.2
Adjustment: Slightly untighten screws a (T20). Apply angled eccentric key 031563.50.00 at eccentric engagement bore b to position head frame plate. Retighten screws a. b
4.3 Presser-Foot Settings

4.3.1 Darning Foot Height
Check Adjustment Check: Attach darning foot 9 or drop-shape foot 26 Pin needle drive balance piece with adjusting stud 030430.51.00. 0.5 +0.2mm Turn wheel a counterclockwise until presser foot is at lowest position. Use darning foot height gauge 398026131+ to check distance (0.5mm +0.2) between stitch plate and sole of drop-shaped presser foot. 4.3.1 Attach darning foot 9 or drop-shape foot 26 Pin needle drive balance piece with adjusting stud 030430.51.00. Turn wheel a counterclockwise until presser foot is at lowest position. Slightly untighten screw b (T8) (picture 3.1). Slide presser foot bar up or down until the distance is 0.5mm +0.2. Ensure that presser foot and stitch plate are parallel. Retighten screw b. b Note: The presser foot height is read by the PCBA-Dual feed sensor and does therefore not require mechnical adjustment as with previous models.
Adjustment:
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4.3.2 Presser-Foot Fixation

Check Adjustment Check: Use a new presser foot 1C to check if the clamping lever a meshes with the clamping bar b by a third to a half. The presser foot sole and the markings on the stitch plate must be parallel. Adjustment: Untighten screw c (T20) (picture 3.2) on clamp d. Adjust clamp height until correct clamping position is reached (1/3 of clamping span). Ensure that presser foot sole and stitch plate are parallel align if required. Use 3/8' markings on stitch plate for reference. Retighten screw c. 4.3.2 c d b
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4.4 Needle Adjustment

4.4.1 Distance between Needle Bar and Presser-Foot Bar
Note: Ensure correct positioning of the head frame plate with respect to the stitch plate in Y-direction (see 4.2.1) Check: Attach presser foot 1C. Attach needle 130/705 Nm 100. Move needle bar down until the tip of the needle is just level with the stitch plate. Turn wheel a counterclockwise to move presser foot bar up. Carefully move the sole of the presser foot up and down until stop in each case. The needle mustn't be touched or bent by the sole when moving the sole this way.
Note: For a better view, use a white paper sheet to rest the tip of the needle.on.
f Adjustment: Loosen lock nut f (10mm). Use screw g (T15) to correct the Retighten lock nut f. g 4.4.1a (Picture 4.4.1a) Needle distribution in Y direction.
position.
0.6 mm
0.4 mm
Important!
The adjusting screw g must only be used for the parallel setting of the needle bar and presser foot bar. It mustn't be used for the setting of the needle/hook distance! Setting of needle/hook distance (see 4.5.4).
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4.4.2 Needle distribution

Note: The machine must be switched on in order to use the Service Program. Refer to the safety instructions please. Adjustment 4.4.2
Check: Use a 130/705H TCN size 80Nm needle. Connect front cover to PCBA-Base. Fit mounting bracket 032763.70.00 Start machine in service program mode. Select test 5e (pinning position of all stepping motors). Use pinning tool 002733.50.00 to pin stitch width stepping motor. Needle must be in the centre of the stitch plate hole in the (picture 4.4.2). 5e Note: If the stitch width stepping motor cannot be pinned, check needle bar support for free movement/smooth running. Adjust the pinning position (see 3.3.20).
Adjustment: Use pinning tool 002733.50.00 to pin stitch width stepping motor. Slightly loosen screw b (T10). Use eccentric key 001361.70.00 in eccentric engagement bore a to centre the needle. Retighten screw b. Test: Attach presser foot 1D. Set to maximum stitch width. Needle mustn't touch the right or left side of the stitch plate.
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4.4.3 Zigzag stitch width limiter

Note: The machine must be switched on in order to use the Service Program. Refer to the safety instructions please. Check Adjustment Check: Start machine in service program mode. Select test 5a. Needle bar support mustn't touch the zigzag stitch width limiter a (picture 4.4.3). Adjustment: Loosen screw b (T10). Position limiter a. Retighten screw b. 5a
4.4.3
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4.5 Hook, Needle Drive and Feed-Dog Movement Synchronization

4.5.1 Feed-dog lift and advance (synchronization of base shaft and main shaft)
Check Check: Turn hand wheel until feed-dog is in operating position. Use new loop lift gauge 734571.70.01 to set loop lift (2.618mm). Pinning tool b 3mm 007937.50.00 need to fit now in pinning positon lifting came/frame.
Adjustment: Untighten second screw d (T10) on main shaft belt pulley in rotating direction. Use new loop lift gauge 734571.70.01 to set loop lift (2.618mm). Untighten first screw d (T10) on belt pulley. Turn belt pulley until base shaft can be pinned against lift cam with the 3.0mm pinning tool 007937.50.00. Retighten first screw d (T10) on belt pulley. Remove gauges. Retighten second screw d (T10) on main shaft belt pulley in rotating direction.
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4.5.3 Loop Lift

Check Adjustment Check: Use pinning tool 002733.50.00 to pin stitch-width stepping motor = center needle position. Use new loop lift gauge to set loop lift (2.618mm) as follows: o Set needle bar to BDC. o Use gauge 734102.70.01 to attach clamp in such way that the machine is blocked in BDC position. o Move gauge to right until the needle bar is risen by 2.618mm and stops. Hook tip must be flush with left needle edge. 4.5.3
Adjustment: Use pinning tool no. 002733.50.00 to pin stitch-width stepping motor = center needle position. Untighten second screw in direction of rotation. Use new loop lift gauge to set loop lift (2.618mm) as follows: o Set needle bar to BDC. o Use gauge 734102.70.01 to attach clamp in such way that the machine is blocked in BDC position. o Move gauge to right until the needle bar is risen by 2.618mm and stops. In rotating direction, the first screw must now be accessible. Untighten. Turn black bevel gear until the hook tip is flush with the left needle edge. Slightly push black bevel gear against white wheel and retighten first screw in rotating direction. The two toothed wheel must run smoothly (no play, no clamping). Use gauge to remove clamp. Retighten second screw in rotating direction. Check again and repeat setting if required.
2.
1.
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4.5.4 Needle / Hook Distance

Check Adjustment Check: Remove stitch plate and presser foot. Use new needle 130/705H Nm 80. Use pinning tool no. 002733.50.00 to pin stitch-width stepping motor = center needle position. Turn handwheel until hook tip is behind the needle. The distance between the needle scarf and the hook tip should be 0.01 0.05mm.
Note: We recommend to use a magnifying glass to ensure accurate setting. Adjustment: Refer to rough-setting (see 4.2.1). Fine-adjustment: Remove plug a from PCBA-Threader. Turn adjusting screw b (T20) clockwise to increase the distance and counterclockwise to reduce it
4.5.5 Needle penetration in Y direction

Check Adjustment Check: Attach presser foot 1d. Presser foot slit is aligned with stitch hole in the stitch plate. Insert needle 130/705H Nm100. It should be in the centre of the stitch hole. Note: The free-arm cover plate must be attached. Setting: Untighten screw a (T6) above catcher tip. Insert stitch plate. Carefully nudge stitch plate in required position with the aid of an angled torx spanner T6. Retighten screw b (T6 screwdriver). Help: A Needle 130/705H Nm 120 should, in position BDC, touch the stitch hole, but must not being pushed aside Note: We recommend to use a magnifying glass to ensure accurate setting. b
= =
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4.5.6 Needle height

Check Adjustment Check: Instead of a needle. Place the silver distance gauge a 030883.50.02 in the needle holder. Note: Don't mix up the gauges the black gauge b 4 3 2 1 0 (734101.50.00) is used for the setting of the height of the threader head. Refit stitch plate. Drop the feed-dog. c Move the needle to centre position. Switch the machine OFF. Place distance plate b 730475.51.00 onto the stitch plate under the distance gauge a. Turn the handwheel to bring the needle to bottom dead centre. Nominal position c of the distance plate b is 2. Adjustment: Note: If the distance plate b deviates from its nominal position c = 2, the needle positioning pin d needs to be replaced. Remove the distance gauge a. Replace the distance gauge with the needle positioning pin d (T6) to set the height. The positioning pins are available in 5 different diameters (see table). Select appropriate needle positioning pin d to make up for the deviation from the specified reference.
Note: The height difference between 2 levels on the distance plate b is equal to the difference from one pin d to the next. Higher setting of gauge required = use smaller diameter. Lower setting of gauge required = use larger diameter
Available size of # 1 2 3 4 5 Art.-No. 032667.50.00 032667.50.01 032667.50.02 032667.50.03 032667.50.04 in mm 1,50 1,85 2,20 2,55 2,90 identification (colour) black (phosphated) galvanised Nicke-plated black (phosphated) galvanised
d 1 2 3 4 5
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4.6 Feed-Dog Settings

4.6.1 Position of main feed-dog within stitch plate in X direction
Check: Use 3mm pinning tool 007937.50.00 to pin console gearwheel a. Turn hand wheel until feed-dog is in operating position. Use pinning tool 002733.50.00 to pin the sideways motion stepping motor (applies only to machines with sideways motion feed). The feed-dog must be evenly distributed in the stitch plate (picture 4.6.1).
4.6.1
Adjustment: With sideways motion feeding (B780)
Turn handwheel until feed-dog is switched on. Use pinning tool b 002733.50.00 to pin sideways motion stepping motor. Untighten screws c (T20). Use eccentric key 001361.70.00 in eccentric engagement bore d to adjust the lateral positioning. Retighten screw c. Remove pinning tool b.
=
b
Withoug sideways motion feeding (B750, B710) d Turn handwheel until feed-dog is switched on. Untighten screws e (T6). Move feed-dog into the specified position. Retighten screws e. e c
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4.6.2 Dual Feed: X-Direction Positioning Against Main Feed-Dog.

With sideways motion: Check Adjustment Without sideways motion:
Check: Switch on dual feed and main feed-dog. Use pinning tool 002733.50.00 to pin the sideways motion stepping motor (applies only to machines with sideways motion feeding). (picture 4.6.2) dual feed unit must be centred against the middle row of teeth of the main feed-dog a. Adjustment: Note: The dual feed mustn't contact the main feed-dog while it is adjusted. Centre out the lateral play of dual feed unit. With sideways motion feeding Use pinning tool b 002733.50.00 to pin sideways motion stepping motor. Untighten screw c (T10). Use eccentric key 001361.70.00 in eccentric engagement bore d to adjust the lateral positioning. Retighten screw c. Remove pinning tool.
4.6.2
Without sideways motion feeding Untighten screw c (T10). Use eccentric key 001361.70.00 in eccentric engagement bore d to adjust the lateral positioning. Retighten screw c. c
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4.6.3 Main feeding balance mechanical basic setting
Check: Remove PCBA-base. Use pinning tool 001356.50.00 to pin bore a = parallel positioning of the toothed segments. Turn drive gear b against stop c = maximum stitch length. The first tooth d of drive gear b must gear into the first gap of the toothed segment e. In stop position c, the stitch length crank f should be pinnable with the pinning tool 002733.50.00.. e
f Correction:Gearing of toothed segment and drive gear. Use pinning tool 001356.50.00 to pin toothed segment a. Untighten screw g (T20). Slide spherical bearing h out to the right and retain it in this position (spring pressure). Slide toothed segment e out of the gearing of drive gear b. Turn drive gear b against stop c = maximum stitch length. Slide toothed segment into gearing. The first tooth d of drive gear b must gear into the first gap of the toothed segment e. Use spring pressure to reposition spherical bearing h to the left into the motor holding plate. g h
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Adjustment: Turn drive gear b against stop c = maximum stitch length. Use pinning tool 002733.50.00 in pinning bore d to pin balance setting cam. Untighten screw g. Use pinning tool 002733.50.00 in pinning bore e to pin stitch length crank. Note:Turn the console driving wheel into pinning position in order to allow access to pinning position e. Retighten screw g to fix drive gear b at stop c. Remove pinning tools. Refit PCBA-base. To fine adjust, refer to Service Program, Test 6b. d
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4.6.4 Dual Feed Balance Basic Mechanical Setting
a Check: Turn feed-dog stitch length crank to maximum stitch length. Crankshaft topo should be pinnable with 4.0mm pinning tool 002733.50.00. Refer to BDF Balance b d
Setting: Turn feed-dog stitch length crank to maximum stitch length. Use 4.0mm pinning tool 002733.50.00 to pin it. Turn adjusting screw a until the distances between the drive belt flange and the adjusting hub are even. Carry out BDF Balance fine adjustment in Service Program 6b
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4.6.5 Main Feed-Dog Height 0.9-1.0mm

Check_front Check_rear Adjustment_front Adjustment_rear Check: Bring feed-dog into operating position. Place feed-dog level gauge 398024.03.1+ on first front row of teeth a. In the feed-dog's highest position, the peaks of the feeddog teeth must be at least 0.05mm higher at the front than at the back (b). Examples: front 0.95 mm, back 0.90 mm front 1.00 mm, back 0.90 mm front 1.00 mm, back 0.95 mm Setting: Main feed-dog height a at the front Move needle bar to TDC. Place feed-dog level gauge 398024.03.1+ on first row of teeth. Slightly untighten screw c (T10), taking care that the setting plate is slightly spring-loaded by pressure spring. Push the feed-dog carrier up to the required height by hand. Retighten screw c and check the height using gauge 398024.03.1+. Repeat adjustment if necessary. b
Main feed-dog height b at the back Move needle bar to TDC. Place feed-dog level gauge 398024.03.1+ on the very back row of teeth. Untighten the 3 screws d (T8) in the lower part of the pusher fork. On the right, move eccentric shaft e into required position with open-end wrench 6. Retighten screw d (T8) and check the height using gauge 398024.03.1+. Repeat adjustment if necessary. Note: Turning clockwise > feed-dog sinks. Turning counterclockwise > feeddog raises. .
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4.6.6 Feed-dog/Dual Feed Synchronization
Check: Remove stitch plate. Switch on main feed-dog and dual feed. Use pinning tool 002733.50.00 to pin the sideways motion stepping motor (applies only to machines with sideways motion feeding). Use new loop lift gauge to set loop lift (2.618mm) as follows: o Set needle bar to BDC. o Use gauge 734102.70.01 to attach clamp in such way that the machine is blocked in BDC position. o Move gauge to right until the needle bar is risen by 2.618mm and stops. Turn feed-dog stitch length crank to maximum stitch length. Use pinning tool 030430.51.00 in pinning bore b to pin main feed-dog stitch length crank. Use pinning tool 030430.51.00 in pinning bore c to pin dual feed stitch length crank. Place Synchroplate f 032798.50.00 on main feed-dog. Use drive wheel d to move presser foot bar manually to lowest position. The dual feed should lie flush against point e at Synchroplate f without play or clamping.
Setting: Loosen screw g (T10). Move dual feed into the specified position. Retighten screw g. Remove Synchroplate and pinning tools.
d c
e g
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4.7 Clutch Carriage / Thread Cutter

4.7.1 Clutch mechanism
Check: The clutch lever fork mustn't touch the base shaft in any position. The pull solenoid pressure spring must be easily able to bring the clutch lever into its home position.
Setting: Use 3.0mm pinning tool 007937.50.00 to pin the cutting unit. Use 3.0mm pinning tool 007937.50.00 to pin connecting strap between clutch mechanism and cutting unit release lever. Untighten the two screws (T10) on the connecting strap between clutch mechanism and cutting unit release lever. Use the eccentric spanner 001361.70.00 to position the clutch lever in such way that the clutch lever fork won't touch the base shaft in any position and that it can easily be brought into home position by the pressure spring of the pull solenoid. With the lever in this position, retighten the two screws (T10) on the connecting strap between clutch mechanism and cutting unit release lever. a
b c
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4.7.2 Thread Cutter

Check: The thread cutting unit should be pinnable with the pinning tool 007937.50.00 when the cutting unit release lever is in its left home position. b e e The positioning pin a a must be exactly in the corner b of the thread guide plate. a Setting: Open the hook race cover and remove the hook. Remove screw c (T8 angled torx) and nut d (open-end or ring wrench 5) from thread guide plate/thread stop. Untighten the two thread guide plate fastening screws e (T8 angled torx). From the left and with the index of your left hand, move the thread guide plate in the opening slightly back diagonally, taking care that the end of the positioning pin sits exactly in the corner b. Retighten the two thread guide plate fastening screws e (T8 angled torx). Refit and rtighten screw c (T8 angled torx) and nut d (open-end or ring wrench 5) on thread guide plate/thread stop. Carry out a manual functioning check.
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4.8 Synchronising Disc

Note:
Check Adjustment Check: Service Program Test 4h. Signal adjustment in loop lift position. The machine must be switched on in order to use the Service Program. Refer to the safety instructions please.
4.8.1 Rough-Adjustment
Loosen screw a (T8) of synchronizing disc b. Use new loop lift gauge 734571.70.01 to set loop lift (2.618mm). Turn synchronizing disc c until screw a lies horizontally pointing to the back (Visible via rear frame opening c when torx screwdriver is inserted). Place synchronizing disc against circlip. Retighten screw a slightly.
4.8.2 Fine-Adjustment
Use new loop lift gauge 734571.70.01 to set loop lift (2.618mm). Service Program Menu 4 (Item 4h). Loosen screw a (T8) of synchronizing disc b. Turn synchronizing disc until signal 1 blanks. Position: between 25 and 27.5. Turning of the synchronizing disc in rotation direction of machine will increase the degree (BDC = 0). Place synchronizing disc against circlip. Retighten screw a slightly. Remove loop lift gauge.
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4.9 Threader
Check: Remove needle and insert threader gauge 734101.50.00. Set needle bar to top dead center. Push threader downward until threader head turns in under the gauge
51 17
Adjustment: Remove basting solenoid housing 51 if there is one. Loosen needle bar guide adjusting screw 17. The threader head can be properly adjusted by moving it up, or down. Retighten needle bar guide adjusting screw 17 (T8). Refit basting solenoid housing.
734101.50.00
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4.10 Basting Device

4.10.1 Needle Bar Guide
Check Check: Set needle bar to bottom dead center (BDC). Disengage needle bar manually via basting magnet clutch 1. Twist needle bar to the left 2 and pull down 3, ensuring that the clutch pin that gears into the needle bar engages smoothly. Set needle bar back to BDC and release again. Check in the same manner by twisting needle bar to the right 2.
Adjustment: Remove basting magnet housing 51. Set needle bar to top dead center (TDC). Remove needle and insert threader gauge 734101.50.00. Push threader 10 downward until threader head turns in under the gauge. Hold threader in this position. Loosen needle bar guide adjusting screw 17. Center needle bar bore within clutch-bolt clearance 4. Retighten needle bar guide adjusting screw 17 (T8). Refit basting solenoid housing.
51 17
734101.50.00 10
=
4
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4.10.2 Checking the timing of disengagement Note: The machine must be switched on in order to use the Service Program.
Refer to the safety instructions please. Check Adjustment Check: Select basting device. Turn cushioner adjusting screw a out by exactly two rotations (counterclockwise), mark if required. In upward motion, the needle bar must disengage approx. 3mm before reaching the top dead centre. Turn cushioner adjusting screw a back by exactly two rotations (clockwise). Adjustment: Turn adjusting screw a (T20) out of cushioner (counterclockwise) until the needle bar doesn't engage anymore. Loosen screw b (T10). Move basting magnet housing up or down as appropriate. Retighten screw b. Adjustment of cushioner position: Start machine and select basting function. Run machine at medium speed while turning adjusting screw a (T20) out (counterclockwise) until needle bar won't engage anymore. Switch off basting function. Run machine at medium speed while turning adjusting screw a slowly (clockwise) b until needle bar engages again. After the engaging of the needle bar turn adjusting screw a in another quarter rotation in maximum in order to ensure centre positioning of clutch pin in clutch hole. Functional check: Attach presser foot 1d (with sensor). Run machine at highest speed to test basting magnet in left and right needle positions Note: If functional test fails in one, some or all needle positions, recheck the setting of the cushioner position and the needle bar guiding and adjust as required.
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4.11 Thread regulator

Check tension: Thread thread regulator with a 30cm long bit of thread. Attach the two thread ends to the BERNINA tension spring scales (006038 50.00). Slowly move the scales up. On moving the regulator spring, the tension value must be 12 15 g. Note: Check if the scale is set to zero (calibrated). Adjustment: Slightly untighten screw 17 (T10). Turning the thumb wheel 16 will tighten or slacken the tension. Retighten screw 17 (T10).
Check position: The thread regulator spring 15 must sit on the regulator spring stop 12. and there must be a distance of 1.6mm (+/-0.3mm) between spring and cover at the same time. Correcting the position: Slightly untighten screw 6 (T10). Adjust regulator spring stop 12 as appropriate until a distance of 1.6mm is 16 reached. Retighten screw 6. 17 6 15 a 1 12
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4.12 Thread Tension

Note: The machine must be switched on in order to use the Service
Program. Refer to the safety instructions please.
4.12.1 Upper-Thread Tension

6j Automatic Upper Thread Tension:
Use a DMC 50 BLANC cotton thread (recommended by BERNINA, also refer to Service Info, Ref-# 18249, in Infogate) to thread the machine.
Step 1: Attach the 30.6-gram gauge to the upper thread (see picture 1). Carefully tilt the machine forward until the gauge hangs freely in the air. (Caution: Don't drop it) Select test 6j for thread tension adjustment. Then select the icon in the screen. A list of selected gauging threads appears. Select DMC 50, 100% Cotton Color BLANC (white) or another 'threaded' gauging thread from the list. The gauge mustn't move down. Turn the stitch width knob to adjust if necessary. Add an additional 5-gram weight (picture 2). The gauge should move down slowly now. Turn the stitch width knob to adjust if necessary. Press to save the setting. You will automatically be brought to step 2. Step 2: Remove the 5gr. weight and replace it with the 54.4 gr. (total 85gr.) see picture 3. The gauge mustnt move down. If required, adjust using the stitch width knob. Add another 10 grams (2 x 5 grams), see picture 4. The gauge should move down very slowly. If required, adjust using the stitch width knob. Touch to save the setting. A 'Successful' message along with the tension settings (in increments) will appear.
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4.12.2 Lower Thread Tension (Basic Setting)

Check: Use white cotton thread DMC 50 BLANC 652010.20.++ for gauging. Use 033924.70.00 gauge to adjust lower thread tension. The bobbin case is inserted into the weight gauge in the same way as into the hook. Hold free end of thread firmly and let the bobbin case and setting weight (without additional weight) hang free. The bobbin case must not move downwards. After attaching an additional 3-gram weight 398142.03.0+ the thread should unwind fast (unwinding speed: 1m/2-4 sec.). Adjustment: Use a small screwdriver to adjust the lower thread tension by turning the bobbin case spring screw as appropriate. Turn screw counterclockwise (to left) to slacken. Turn screw clockwise (to right) to tighten. 398142.03.0
4.13 Winder
Check: The thread should be evenly wound with pre-tension, and the bobbin should be correctly filled.
Check: The thread should be evenly wound with pre-tension, and the bobbin should be correctly filled.
Note: Incorrectly or unevenly filled bobbins can affect the stitch quality and impair the functioning of the lower thread sensor.
a b
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4.14 Lower-Thread Sensor Position
Check: Functioning check in service program menu 3 (item 3c) Correction: The position of the lower thread sensor is given and cannot be adjusted. For removal and fitting refer to chapter 3 (item 3.3.20).
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Chapter 5 Service Program

Entering: Switch machine off ("0"). Keep RET-button pressed, and switch machine on. The machine moves the stepping motors to the home position (brief motor noise). The machine is now in the basic position for servicing - first level. Alternative access: If the touchscreen is calibrated in such way that no selection can be made on the screen, or the basic screen settings are disadjusted in such way that nothing can be seen anymore, an alternative access is provided. Access is achieved by simultaneously pressing the needle position buttons < > and switching the machine on. Select the cross symbols on the touchscreen for calibration. After calibration of the touchscreen, the user sewing program can be directly accessed. Exiting the test program: Switch the machine off. Wait approx 30 seconds before switching the machine on again. The machine can now be used normally. Basic position: Menus 1 to 11 are selected in the service program basic menu. BERNINA 780
1 = Service Info Menu
2 = Screen Menu
3 = Sensors Menu
4 = Signals Menu
5 = Motors Menu
6 = Settings Menu
7 = Embroidery Module (only BERNINA 780/750)
11 = Check-Out
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BERNINA 750
1 = Service-Info
2 = Screen
3 = Sensors
4 = Signals
5 = Motors
6 = Settings
7 = Embroidery Module (only BERNINA 780/750)
11 = Check-Out
BERNINA 710
1 = Service-Info
2 = Screen
3 = Sensors
4 = Signals
5 = Motors
6 = Settings
11 = Check-Out
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Menus: The various tests menus 1 to 11 are selected in the basic service program. Press or to return to basic service program without saving the settings. Tests: The testing level contains the active part of the program. Press or to return to respective menu with saving the settings.
Virtual keyboard The following tests require data entering: 1 2 3 4 Test 1a (purchase date) Test 1f (reset service stitches) Test 1h (customer information) Test 1i (dealer information) touch to delete completely touch to delete individual characters letters, numbers and other characters a: Upper case letters b: Lower case letters c: Numbers, special characters and punctuation marks d: Special marks
Data entry line CLR button () Virtual keyboard including shift key for special characters Selecting a keyboard
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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 = Montht 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.
What to test: Note: Using the virtual keyboard, technical data can be entered in the page. The entered data gives the technician information on already made improvements. Touch the right pointing symbol to go to the next pages. Technical data (1 10).
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1c Machine Operating Time Data
What to test: Total Time Power On Time Standby Time Working Time Sewing Time BSR Time Embroidery
1d Machine Stitch Counter Data
What to test: Total number of stitches Total number of sewing stitches Total number of stitches using BSR Total number of embroidery stitches Stitches since last lubrication Stitches since last service
1e BSR (BERNINA Stitch Regulator) Data
What to test: The BSR foot must be attached and connected. Serial Number Chassis Number Production Date Hardware Revision Boot Loader Version BSR Application Version Sensor Resolution X Sensor Resolution Y
Note: Information will only be displayed if the BSR foot is attached and connected to the machine.
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1f Machine Servicing Data
What to test: Reset lubrication stitches = Stitches sind last service = Reset service stitches = 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.
Stitches since last ubrication = Time for cleaning / lubrication (appears after 500,000 stitches).
Resetting cleaning / lubrication interval to 0 stitches Time for servicing (appears after 3,000,000 stitches) Resetting servicing interval to 0 stitches.
Important: Remember to always reset the counter (cleaning interval) after servicing or repairing.
Service interval
The stitch counter triggers a reminder after 3,000,000 stitches: Please take your machine to a BERNINA dealer for servicing.
Important:
Remember to always reset the counter (cleaning interval) after servicing or repairing.
Touch the leftor right-pointing Entering Service and Repair Data
symbol to go to the previous or next page.
There are 5 entry lines available. The sixth entry will overwrite the first entry. Maintained byon = 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.
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1g Saving / Loading Customer Data
What to test: Before starting to repair or servicing the machine or replacing electronic parts, it is essential to save the customer's data. For this a BERNINA USB memory stick is used. Save the customer settings = Saving of customer data on a BERNINA USB memory stick. Load the Customer settings = Loading of customer data to the machine.
Note: Connect BERNINA USB memory stick and select required button. Remove the stick after saving of data has been confirmed.
1h Customer Data
What to test: 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 restarting the machine. Customer First Name Customer Last Name Customer Telephone Number Customer E-Mail Address
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1i Dealer Data:
What to test: 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. Dealer name Dealer address Dealer telephone number Dealer Internet/E-Mail address
For example: BERNINA Nhmaschinen AG 8266 Steckborn 0521234567 www.bernina.com
1j Log File:
What to test: 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). External saving of internal processes (log book) on a BERNINA USB memory stick. The log file contains processes and configuration data.
Menu 2 Display, Buttons and Clock
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
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2a Touchscreen Calibration
What to test:
Note:
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.
If the touchscreens 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: <
>
Access is achieved by simultaneously pressing the needle position keys and switching the machine on. The touch screen can now be calibrated as per instructions above.
Repair notes: Check touch screen connector cables. Check cables for deformation and or wear and tear. Replace touch screen. Replace PCBA-Front Cover.
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2b LC 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 LC 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 if pixel errors occur.
2d Blank white LCD (screen)
What to test: White blank screen to find dirt or stains. To return to menu 2, touch .
Repair notes: Clean LCD and touchscreen.
Attention! Never use alcohol, petrol, spirits or any corrosive fluids, or abrasive pastes or abrasive cleaners!
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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 colours. 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.
2f Keyboard Lights
What to test: By selecting each individual field, the appropriate button on the machine will light up. The start / stop button will light up green or red respectively. To return to menu 2, touch
Repair notes: Check cables for deformation and/or wear and tear. Replace PCBA-RET if any of the buttons dont light up.
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2h LED's and Brightness
What to test: Select + or -, or alternatively the stitch width knob to alter the brightness. The LEDs will all vary in brightness as the values change. Touch to save and return. Touch to return without saving.
Repair notes: Determine which set of LEDs are not working. Check all connectors. Check cables for deformation and/or wear and tear. Check connectors P-38 and P-3111 on the PCBA-Base. Replace the LEDs. Replace the PCBA-Base.
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Menu 3 Sensors (Mounting Locations in the Machine)
What to test: These sensors can be tested:

a) Threader sensor b) Overlift Presser Food Switch (Presser foot height sensor) c) Lower thread sensor d) Feed Dog Drop e) Dual feed recognition sensor g) Bobbin Winder Switch h) Free Hand System FHS
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 "1" to "0". Press to return to menu 3.
Repair notes:
Check cables for deformation and/or wear and tear. Check correct positioning of PCBA Threader. The PCBA Threader is held in position with a pin and fastening screw 007752.50.34 (T10) in the needle bar support. If the sensor doesn't respond, replace the PCBA Threader Sensor (see 3.2.15).
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3b Overlift Presser Food Switch (Presser Foot Height Sensor)
What to test:
Select test 3b. Three bars will appear. First bar: presser foot up/down recognition. Second bar: presser foot position recognition. Third bar (resolution): sensor type recognition o 0.160mm refers to the resolution of the actually used sensor type. Attach presser foot 1C or 40C. Press the presser-foot button to lower the presser foot. Signal in the first bar changes to "0". Press Start-/Stop button. The presser foot will move into sewing position. Down position will be displayed in the second bar, showing a value of between -0.5mm and 0.2mm. Press the presser-foot lift button. Signal in the first bar changes to "1". The actual presser foot height will be displayed in the second bar: o 9mm standard foot (1C/40C): ca. 10.98mm. 9mm D foot: ca. 10.98 mm. Press to return to menu 3.
Repair notes: Signal doesn't respond: Check cables for deformation and/or wear and tear. Replace PCBA Presser Foot Height Sensor (see 3.2.14). Incorrect reading of presser foot height! "0" will be displayed if the presser foot sits on the stitch plate in most cases. Check the basic setting of the presser foot height in Service program (see 6h).
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3c Lower-Thread Sensor
What to test: Select test 3c. Open the bobbin door. The hook will swing out. Insert a bobbin with only a little quantity of thread. The filling level must be below the 4 holes in the bobbin and the corresponding openings in the bobbin case. Hold the thread and close the bobbin door. Slowly pull the thread. Signals A, B and C must change their color alternately. Press to return to the submenu. Press the "-" magnifier button to close the submenu and return to menu 3.
Repair notes: If signals A, B or C won't change their color as described above, check these points: Check the sensors for dust and stains. Repeat the test using a new bobbin. Check on correct position of PCBA-Lower-Thread-Sensor. (see 3.2.15) Check cables for deformation and/or wear and tear. Replace PCBA-Lower-Thread-Sensor (see 3.2.20).
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3d Feed Dog Drop
What to test: Select test 3d. A feed-dog drop dialog box appears. Press feed-dog drop key below on the belt cover. The color of the box changes to green. Press to return to menu 3.
Repair notes: Signal doesn't respond: Check cables for deformation and/or wear and tear. Replace the PCBA-Detection. Remove the covers (see 3.1). Remove PCBA-Detection fastening screw (T20) on the base plate side in the cutout for the belt cover. Pull PCBA-Detection out a little. Unplug PCBA-Base connector. Replace PCBA-Detection. Replug PCBA-Base connector. Refit PCBA-Detection in required position and retighten fastening screw (T20). Refit the covers (see 3.1).
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3e Dual Feed Recognition Sensor
What to test: Select test 3e. Two bars will appear. Raise the presser foot. Pull the dual feed unit down. The color of the upper bar changes to green. Attach a 9mm D presser foot (e.g. #1D) Press Start-/Stop button on the headframe to lower the presser foot. The presser foot must be positioned on the stitch plate within a range of -0.5mm and 0.2mm. Press the presser-foot lift button. The up position depends on the foot attached - if a 9mm D foot is attached, the up position is at ca. 11.04mm. Attach a 9mm standard foot (1C or 40C). Press Start-/Stop button on the headframe to lower the presser foot. (Down position must be within the range of -0.5mm and 0.2mm). Press the presser-foot lift button. Up position must be at ca. 12.5mm when a 9mm standard foot is attached. Attach an uncoded presser foot or none at all. Press Start-/Stop button on the headframe to lower the presser foot. (Down position must be within the range of -0.5mm and 0.2mm). Press the presser-foot lift button. Up position should be at ca. 10mm. Press to return to menu 3.
Repair notes: Check plugs and cables for deformation and/or wear and tear. Calibrate the presser foot height (Test 6e) If the sensor doesn't respond, replace the PCBA Dual Feed Sensor (see 3.2.17). The support ABC sensor (presser foot recognition) might also be affected (see 3.2.16).
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3g Winder Microswitch
What to test: Pushing the winder actuating lever to left will activate the microswitch. A window appears in the display to set the winding speed. The speed can be adjusted either by turning the SL/SW knobs or directly on the touchscreen by moving a slide bar. Pressing the key will close the window. The color of the bar changes from yellow to green. Press to return to menu 3.
Repair notes: Check cables for deformation and/or wear and tear. Replace winder Replace PCBA-Base (see 3.2.7).
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3h Free Hand System FHS
What to test: After choosing test 3i attach knee lifter on your sewing computer. Move the knee lifter (normal movement). The signal into the corresponding field on screen is changing from 0 to 1. Press Repair notes: Check cables for deformation and/or wear and tear. Check if in the area of the sensor on the PCBA-Base no cables are exposed. Replace the sensor if it doesn't respond. to return to menu 3.
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Menu 4 Signals
What to test: These signals can be selected and tested: a) b) c) d) e) f) g) h) i) j) k) l) m) Stitch width and stitch length knob(s) Functions of keys and buttons on machine Start-/stop slide (SSU) Foot control open Upper thread sensor BERNINA Stitch Regulator (BSR) PCBA-Position Speaker USB ports Basting solenoid Presser foot recognition BSR connector
4a Stitch width and stitch length knob(s)
What to test: Select test 4a. Turn the stitch length or the stitch width knob. The respective bar will fill to reflect the movement. Press to return to menu 4.
Repair notes: Check knobs and PCBA Front Rigth Cover for correct fit and fitting. Replace PCBA Front Rigth Cover (see 3.2.1). Replace PCBA Base (see 3.2.7).
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4b Functions of Keys and Buttons on machine
What to test: Select test 4b. 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 mechanical functioning of the key if the function doesn't light up. Check the rubber contact pad. Check cables for deformation and/or wear and tear. Replace PCBA-RET or PCBA Front Cover (see 3.2.6 or 3.2.1).
4c Start-/Stop Slide (SSU)
What to test: Display of position of the slide on the bar. Select test 4c. Move the Start-/Stop slide from left (0) to right (100): The bar will fill accordingly. Press to return to menu 4.
Repair notes: Check cables for deformation and/or wear and tear. Replace PCBA Left Front Cover (see 3.2.1).
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4d Foot control
What to test: Select test 4d. Slowly press foot control down as far as stop. The bar will fill accordingly. Heelkicking 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. Replace PCBA Base (see 3.2.7).
4f Upper Thread Sensor
What to test: Select test 4f. Remove service cover. Manually move the upper-thread sensor actuating lug from bottom to top. The color of the bar changes to green. Press to return to menu 4.
Repair notes: Check the regulator spring for damage (bent or broken). Check if the regulator is properly hooked and if it actuates the actuating lug. Check if the regulator spring is properly set (see 4.11). Replace PCBA-RET (see 3.2.6).
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4g BERNINA Stitch Regulator (BSR)
What to test: Attach BSR foot. Select test 4g. Lower presser foot. Press the icon to start the test. Place fabric under the presser foot. Move the fabric in different directions. The directions of the movement will be displayed in the screen. The covered distances X and Y will be displayed in mm. Press to return to menu 4.
Repair notes: Check cables for deformation and/or wear and tear. Check BSR foot for dust or stains. Check BSR plug and PCBA Accessories Connector Replace PCBA Accessories Connector (see 3.2.18). Replace BSR foot.
4h PCBA-Position
What to test: Select test 4h. Set needle bar to bottom dead center (= 0). Slowly turn handwheel slowly 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. Handwheel position in degrees: Note: Bottom dead center of needle bar is 0. Upper dead center of needle bar is 180. Loop lift position is reached when signal 1 blanks (26.5). 0 22.5 / 112.5 115 215 277.5 360 (0) X X X X X X X X Signal 1 Signal 2
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Repair notes: If the degrees appear in the correct order but at the wrong time, check the position of the synchronisation 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 the degrees appear in the wrong order or if no signal appears, replace the PCBA-Position.
4h Mechanical Fine-Adjustment of Synchronization Disk
What to test: Pin needle drive balance piece with the adjusting pin 030430.50.00 and set against stop (loop lift). Select test 4h. Signal 1 blanks (26,5) as described above.
What to adjust: Rough adjustment of synchronization disk (see 4.8.1) Loosen screw a (T8) of synchronization disk. Turn synchronizing disk until signal 1 blanks. Position: between 25 and 27,5. Retighten screw a (not too hard).
Attention:
Don't tighten screw a of synchronizing disk too tight.
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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 3.2.7).
4j USB Ports
What to test: Select test 4j. Connect a USB cable from the USB host to a USB client. Recommended: Use a cable with included LED's at the two ends (see photo). If an end-lit cable is used, the LEDs will automatically light up = Host / Client OK If a standard USB cable is used, the icon on the screen must be pressed 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 client and host ports on the machine. Replace PCBA-Base (see 3.2.7).
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4k Basting Solenoid
What to test: Select test 4k. Press the button. The solenoid will click. 'Running' appears. Press the button again to stop the test. 'Successful' appears. Press to return to menu 4.
Repair notes: Check plugs and cables for deformation and/or wear and tear. Replace basting solenoid. Replace PCBA-Base (see 3.2.7).
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4l Presser-Foot Recognition
What to test: The presser foot category is automatically recognised when the presser foot is inserted. See charts below.
Press
to return to menu 4.
Presser feet used (categories)

9mm presser feet 9mm 9mm Sideways motion foot 9mm Darning foot e.g.:Feet 1C, 20C, 40C
For example
Requirements 1
2
5.5mm feet e.g.: Feet 2A, 5, 16, 18
3
Straight stitch foot Darning foot e.g.: Feet 13, 35, 38, 43, 53
4
5.5mm Dual feed foot
NA
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5
9mm Dual feed feet e.g.: Feet 1D, 4D, 20D
6
Straight stitch/dual feed feet e.g.: Feet 8D, 37D, 57D
7
5.5mm feet 5.5mm darning foot Or NO presser foot attached
Presser foot without prismatic reflector
Automatic buttonhole foot Foot 3C Move the carriage of the foot. The signals will alter between 4 states: no signal at all, the two signals together (orange and green), orange only, green only. Repair notes:
If recognition fails, use another presser foot of the same category and repeat the test. Check plugs and cables for deformation and/or wear and tear. If recognition continues to fail, clean or replace the recognition sensor.
The presser feet categories can be viewed in the sewing mode. Press the presser foot indicator (marked in red) at top left. The currently attached presser foot will be displayed in the box top left, along with all other feet on further 6 pages.
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4m BSR Foot Interface
What to test: Select test 4m. Attach the BSR foot and press the button. The color of the bar will change to green and appears. Press to return to menu 4.
Repair notes: Check BSR plug and connector. Check cables for deformation and/or wear and tear. Replace BSR foot. Replace PCBA Accessories Connector (see 3.2.18).
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Menu 5 Stepping Motors (Mounting Locations in the Machine)

What to test: a) SB = Stitch Width b) PFP = Presser-Foot Pressure c) TT = Upper Thread Tension e) Pinning positions of all stepping motors f) Bobbin Winder Motor g) SL = Stitch Length h) SM = Sideways Motion (only B780)
Note: The machine won't synchronize without running main motor. If the main motor isn't running while testing the motors, some stepping motors may not be released.
5a Stitch Width Stepping Motor
What to test: Select test 5a. Press the button to start the test. The stepping motor moves. The needle bar support 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 doesnt move, the fault might be with the motor itself, the wiring or the PCBABase. Check plugs and cables for deformation and/or wear and tear. Swap connectors with the presser-foot pressure stepping motor to check if the fault is with the motor or the PCBA-Base.
Caution! Disconnect from the power supply. Do not disconnect or reconnect when the machine is powered.
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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 doesnt move, the fault might be with the motor itself, the wiring or the PCBABase. Check plugs and cables for deformation and/or wear and tear. Swap connectors with the stitch width stepping motor to check if the fault is with the motor or the PCBA-Base.
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 doesnt move, the fault might be with the motor itself, the wiring or the PCBABase. Check plugs and cables for deformation and/or wear and tear. Swap connectors with the console stepping motor to check if the fault is with the motor or the PCBABase.
Caution! Disconnect from the power supply. Do not disconnect or reconnect when the machine is powered. Do not connect the stepping motor to the stitch length or the dual feed stepping motor, as these two motors work with higher amperage!
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5e Pinning Positions of All Stepping Motors
What to test: Select test 5e. Press the button to start the test. All stepping motors move into their respective home position (pinning position). The bar reads: 'All Stepping Motors in Pinning Position'. To check the settings, use 4mm pinning tool 001356.70.00. To stop the test/stepping motors, press the button again. A 'Successful' message will appear. Press to return to menu 5.
Repair notes: Check pinning positions of motors as per instructions and adjust if needed according the manual. Check plugs and cables for deformation and/or wear and tear. Replace defective stepping motors, if any, as per instructions in the service manual.
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 winder motor (see 3.2.4). Replace PCBA-Base (see 3.2.7).
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5g Stitch Length Stepping Motor
What to test: Select test 5g. Press the button to start the test. The stitch length stepping motor moves back and forth. The word 'Running' appears and the icon changes to turquoise. The feed-dog moves back and forth. 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 doesnt move, the fault might be with the motor itself, the wiring or the PCBABase. Check plugs and cables for deformation and/or wear and tear. Swap connectors with the dual feed stepping motor to check if the fault is with the motor or the PCBA-Base.
Caution! Disconnect machine from the power supply. Do not disconnect or reconnect when the machine is powered.
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5i Sideways Motion Stepping Motor
What to test: Select test 5i. Press the button to start the test. The sideways motion stepping motor moves back and forth. The word 'Running' appears and the icon changes to turquoise. The feed-dog moves from left to right and back again. 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 doesnt move, the fault might be with the motor itself, the wiring or the PCBABase. Check plugs and cables for deformation and/or wear and tear. Swap connectors with the console stepping motor to check if the fault is with the motor or the PCBABase.
Caution! Disconnect machine from the power supply. Do not disconnect or reconnect when the machine is powered.
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Menu 6 Adjustments
What to test: a) Sewing-off b) Balance c) Buttonhole calibration d) Thread Cut- & Claming magnet e) Thread cutting process f) Upper-thread tension reset to default g) Reset to factory settings h) Presser-foot height, preser-foot pressure j) Automatic upper-thread tension l) SSU (Start-/Stop Unit) calibration m) Normal speed control (SSU) n) BSR sewing mode
6a Sewing-Off (customers view)
What to test: Select test 6a. Press the eye icon in the right box to switch the upperthread sensor off. Press the a button to switch to sewing mode. The machine can now be sewn off using various stitch patterns. Press to exit sewing mode and return to service program.
Note: In order to ensure the carrying out of all crucial adjustments and calibrations, follow the check list in menu 11.
Note: Do not run a threaded machine without fabric!
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6b Balance
Note: The following balance adjustments require correct pinning positions (see 4.6.3 and 4.6.4). The two crankshafts, the feeding system mechanism, the lift-and-advance lever must be adjusted so that they move smoothly and without play or jamming. Increased wear of the parts could cause deviations of the default pattern. The machine must reach room temperature prior to adjustments. We recommend to use the slide-on extension table.
Rough adjustment
What to test: Zero feed 1 Attach presser foot no. 1C. Use a double-layered cotton piece for the sewing-off, place it under the presser foot. Don't thread the machine. Feed-dog in the up position (normal sewing). Select zero feed button. While running the machine the fabric should not move. What to adjust: Use the and icons in the display area 1 to set the zero feed to the lowest possible forward and reverse feed. The basic value is 0, the setting ranges from +4 to -4. Press to save the value. Note re feed-direction adjustment: button = forward, button = backward
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Fine-Adjustment
There are 3 different test patterns available for the fine-adjustment of the stitching: 1. Darning program 2. The number 9 (recommended) 3. Leaf pattern What to test: 1. Darning program (stitch counter): Attach presser foot no. 1C. Thread machine and place two-layered sewing-off cotton under the presser foot. Feed-dog in the up position (normal sewing). Press Darning Program button. Sew. The darning pattern must form square with a virtual straight top and bottom line (see picture). What to adjust: Turn balance cam a to adjust until the pattern is stitched properly. a
What to test: 2. The number 9 (preferred) Attach presser foot no. 1C. Thread machine and place two-layered sewing-off cotton under the presser foot. Feed-dog in the up position (normal sewing). Press number 9 button. Sew. The 9 must be stitched without gaps between the stitched lines. What to adjust: Turn balance cam a (T10) to adjust until the 9 is stitched properly. a
Turn CW
OK
Turn CCW
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What to test: 3. Leaf pattern Attach presser foot no. 1C. Thread machine and place two-layered sewing-off cotton under the presser foot. Feed-dog in the up position (normal sewing). Press Leaf button. Sew. The leaf pattern outline must be stitched in such way that the stitching line ends meet exactly.
What to adjust: Turn balance cam a to adjust until the leaf pattern is stitched properly. Note re rotating direction when adjusting: Rotate the balance cam a clockwise = the leaf pattern pulls together Rotate the balance cam a counterclockwise = the leaf pattern pulls apart.
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Fine-Adjustment (Sideways Feed)

What to test: Sideways feed (multidirectional balance): Attach presser foot no. 40C and slide-on table. Thread machine and place two-layered sewing-off cotton under the presser foot. Feed-dog in the up position (normal sewing). Press Pine button. Sew. The stitched pine must be as shown in the center picture below (green tickmark). What to adjust: Turn balance cam a CW or CCW to adjust until the pine is stitched properly. Points 1 and 2 must be flush. End point 2 may however be 1mm above level
Turn CCW
Turn CW
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BDF Balance
What to test: Synchronization of the feed-dog and the dual feed motion (BDF)
Adjustment of the difference in length between the 6 diamond repeats Attach presser foot no. 1D. Thread machine and place two-layered sewing-off cotton under the presser foot. Feed-dog in the up position (normal sewing). Engage dual feed. Select the diamond stitch pattern. Sew the pattern (the machine will automatically stop after 6 repeats). Raise the presser foot and move the fabric approx. 1cm to the right. Make sure that the needle pierces at level with the end point of the last of the 6 diamond repeats. Lower the presser foot. Press the permanent reverse button on the screen. Sew the second set of 6 repeats in reverse. The difference in length between the two stitch rows should not be larger than 12mm.
Difference in length max. 12mm
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What to adjust: Make sure that in the basic position the distances between the drive belt hub and the adjustment hub are regular. Securing screw b holds the drive belt hub in place. Adjusting screw a is used for the mechanical fine-adjustment of the dual feed balance. Turning adjusting screw a clockwise will lengthen the left side of the diamond stitch pattern while the right side of the diamond pattern will be shortened. Turning adjusting screw a counterclockwise will shorten the left side of the diamond stitch pattern while the right side of the diamond pattern will be lengthened.
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6c Buttonhole Calibration
No filter required!
What to test: Attach presser foot no. 3A. Select test 6c. The presser foot is lowered. Press Start-/Stop button. Buttonhole foot calibration starts. The word 'Running' appears and the icon changes to turquoise. The buttonhole foot moves. Signals A and B are recorded. If the calibration was successful, this message will appear: Calibration Successful. If the calibration failed, this message will appear: Calibration Failed. Press to save the test and return to previous window. Press to return without saving.
Customer's view in the Setup menu
Repair notes: Check the ABC sensor board for dust or dirt. Clean if necessary. Check the balance adjustment done previously. Check the mechanical parts of the presser foot (smooth sliding of carriage, motion of the signal-prism). Check foot recognition in test 4l. Replace presser foot. Check plugs and cables for deformation and/or wear and tear. Replace PCBA-ABC Sensor (see 3.2.16). Replace PCBA-Base (see 3.2.7).
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6d Thread Cutter Clamping Mechanism (Magnet)
What to test:
Pressing the key with the respective icon will make the magnet on the clutch carriage move back and
forth. The color of the icon will change to light blue. 'Running' will appear at the bottom of the screen. Pressing the now light blue icon will change it to yellow again. 'Successful' appears at the bottom of the screen. Press Repair notes: Check cables for deformation and/or wear and tear. Replace complete clutch carriage. Replace the PCBA-Base. to return to menu 6.
6e Thread Cutting Process
What to test: Each selection of the thread cutter button (on the head frame) triggers the individual processes (7 steps). See table below:
Message: Lower presser foot, needle upper position. Move to thread catcher position. Move forward to reverse position. Stitch length -2mm. Release tension. Thread catcher position. Return thread catcher. Restore stitch length. Move to intermediate position and cut thread. Move to needle stop position up. Test Done The information 'Test Done' appears. Press to return to menu 6.
Main shaft Position: 220 35 135 142.5 175 185 220 220
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6f Upper-Thread Tension Reset to Default
What to adjust: Select test 6f. The prompting 'To reset tension press OK' appears. To continue, press . 'Do you really want to reset?' appears. If the answer is Yes, press to reset the upperthread tension to default and to return to menu 6. If 'No', press to return to menu 6. The tension values remain unchanged.
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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. IMPORTANT: It is essential to save all the customers data on a BERNINA USB data stick before resetting to factory settings! See data saving in test 1g.
6h Presser-Foot Height And Presser-Foot Pressure
What to test: Presser foot height: Select test 6e. Attach presser foot no. 1C. Press the button to start the test. The color of the button changes to turquoise. The presser foot bar will move a little down, then up, then down entirely. The values will be recorded. 'Successful' appears. Press to save the values. Press to return to menu 6.
Repair notes: Check mechanical smooth running of the presser-foot bar. Check the tension springs for proper positioning.
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6j Automatic Upper-Thread Tension
What to test: (for details see 4.12.1) Select test 6j. Press the button to start the test. The color of the button changes to turquoise. Select the thread used for the thread tension adjustment (DMC 50, Belfil, Mettler or Amann). A 'Successful!' message will appear on successfully completed adjustment. Press to return to menu 6.
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6l Start-/Stop Unit (SSU) Slide Control Calibration
What to test: Select test 6l to calibrate the Start-/Stop Unit slide control. Step 1: Move slider to the left entirely. Press the Start-/Stop button on the head frame. Step 2: Move slider to the right entirely. Press the Start-/Stop button on the head frame. 'Successful' appears. Press to save the test and return to previous window. Press to return without saving.
Repair notes: Check slider for dust or dirt and smooth mechanical running. Check plugs and cables for deformation and/or wear and tear. Replace PCBA Front Cover (see 3.2.1).
6m Normal SSU Sewing Speed
What to test: Select test 6m. Press Start-/Stop button. The driving motor speed (S.P.M.) changes depending on the SSU slide control position. Power consumption is displayed in Watt in the left part of the screen. Driving motor speed is displayed in Stitches Per Minute on the right. Press Start-/Stop button to stop the machine. Press to exit the test. Repair notes: Check slider for dust or dirt and smooth mechanical running. Replace PCBA Front Cover (see 3.2.1). Replace PCBA-Base (see 3.2.7).
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6n BSR Sewing Mode
What to test: Select test 6n. An animated prompt to lower the feed-dog appears. On pressing the red button the prompt to attach the BSR presser foot appears. Attach the BSR presser foot and press the green tick button to confirm. BSR 1 mode appears automatically. To switch to BSR 2 mode, press the respective button. To return to service program, press Repair notes: Check BSR foot for dust or stains. Check BSR plug and PCBA Accessories Connector. Replace PCBA Accessories Connector (see 3.2.18). Replace BSR foot. .
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Menu 7 Embroidery Module (EMB)
What to test: a) EMB interface b) Basic data: Version, date of sale, time c) X-direction sensor d) Y-direction sensor e) X- and Y-direction stepping motors f) X-direction stepping motor g) Y-direction stepping motor h) Hoop reference point i) Embroidering with the embroidery test pattern j) Customer's view of embroidery view k) Hoop recognition l) X-direction motion test m) Y-direction motion test n) Y-direction belt tension o) X-direction belt tension
A detailed description of the embroidery module service program can be found in the Embroidery Module Service- and Maintenance Manual.
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Menu 11 Check Out
What to test: This check-out is designed to give the technician the possibility to check the machine in its main categories, before delivering it to the customer. The first test (or calibration procedure) as listed below will appear automatically on starting menu 11. On successfully completing the test and confirming with , the next test in the order of the list below follows automatically. Important! If a test (or calibration procedure) fails or is cancelled with check-out to service program without saving the settings Check-Out Tests: 1) Touchscreen calibration, menu 2a 2) Lower-thread sensor, menu 3c 3) Upper-thread sensor, menu 4f 4) Balance adjustment, menu 6b 5) Buttonhole calibration, menu 6c 6) Cleaning and servicing intervals, menu 1f After completion and confirmation service menu. of the last test, the check-out program will return to the main
, the program will switch back from
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Chapter 6 Lubrication Diagram

= Klber OY 100 (002779.70.01)
= Velocite 6 (033567.50.01)
= Klbersynth UH1 141600 (002779.72.02)
Head frame
Dual feed
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Threader mechanism / Needle drive
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Toothed-segment needle-bar support
Dual feed crank shaft
Dual feed main shaft lift and advance cam
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Hook shaft / hook race / hook
Feed-dog fork
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Base shaft / feed-dog lift and advance cam
Feed-dog crank shaft
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Chapter 7 Firmware Update
7.1 Update Procedure

Note:
The BERNINA 780, 750 and 710 do not have the same firmware (FW) Update files are available for downloading from Infogate. The update files for BERNINA 780, 750 and 710 can be downloaded to one BERNINA USB stick 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 (> 512 MB). For BERNINA dealers: For BERNINA end users:
http://infogate.bernina.com www.bernina.com/downloads
switch
2. Connect BERNINA USB stick to machine and switch main ON.
3. Select Setup Program, then press the Update button.
4. The Update window opens. Press 'Update'. The updating process starts.
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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 can not be started or in the event of problems occuring while updating, one of the error messages below may appear:
Error message
Possible cause Files not complete or faulty. Update files were not saved to the first level of the USB memory. Defective or incompatible USB stick.
No valid Updates on USB Stick
USB stick not recognized. Restore of customer data failed
Possible solution Save the proper update files to the USB stick (again). Move the update files to the first level of the USB memory (root directory). Use a BERNINA USB stick. Check functioning of USB stick on a pc. Is the USB stick connected? Connect BERNINA USB Stick with updates and customer data to machine, wait for 10 seconds, then try again. Switch the machine with the USB stick connected, off and on again. Check functioning of USB stick on a pc. Repeat update procedure.
Saved settings / personal data missing.
Update failed
Updating of machine with new application failed.
Load the saved settings / personal data again via the service program (1g load the customer settings) 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.
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7.2 Update Alternative Access

Note: If the update can not 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.
Keep the buttons a and b pressed and switch the machine on.
a+b
After the machine has been switched on, the update process will start and check the data on the USB stick. Note: On completion of the manual update procedure, the machine must be started manually. .
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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 service 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; the parts declared in the spare-parts-warranty extension (Bernina warranty provision) are excepted. Compliance with maintenance intervals allows system functioning to be ensured and increases the service life of the sewing and embroidery machines. Should the service and maintenance intervals of these Maintenance Guidelines not be complied with, the guarantee may be limited. The Maintenance Guidelines consist of the wear-and-tear-parts definition. the maintenance check to be carried out during a service.
8.2 Explanatory Notes on the Stitch- and Hour Counter

Every sewing stitch is counted. Owing to the lower 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 3,000,000 stitches a maintenance/servicing reminder appears.
8.2.3 How are the stitches counted?

In sewing mode alone, 3,000,000 stitches are counted. In embroidery mode alone, a 3,000,000 stitch count corresponds to 6,000,000 stitches in real terms. This is due to the lower overall mechanical loading of the system. A combination of sewing and embroidery can be assumed for most machine uses. That means that 4,500,000 stitches have actually been carried out when the stitch counter says 3,000,000. The hours are counted consecutively 1 to 1, not permanently, but always after about 2 minutes (reduction of the write cycles). The hours can only be read out via the Service Program, and are not accessible by the customer.
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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. For example:
Sewing and embroidery hours, total 1'000
Total minutes 60'000
SPM (stiches Total stiches pro min.) 650 39'000'000
8.2.4 Implementation of the Maintenance Intervals

At the 3rd interval (9 million stitches), the service 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 sewing or embroidering speed of about 650 spm is assumed.
Maintenance interval Stitch counter Hour counter 1 3'000000 77 2 6'000000 154 3 9'000000 231 4 12'000000 308 5 15'000000 385 6 18'000000 462 7 21'000000 538 8 24'000'000 615 9 27'000000 692 10 30'000000 769 11 33'000000 846 12 36'000000 923 13 39'000000 1000 14 42'000000 1077 15 45'000000 1154 16 48'000000 1231 17 51'000000 1308 18 54'000000 1385 19 57'000'000 1462 20 60'000000 1538
8.3.1 Cleaning- and Service-Stitch Reset

Service entries must be made by the technician in the Service Program after maintenance or repair work if not, the maintenance stitches will not reset to zero. The same holds true for the cleaning-stitch reset.
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8.4 Wear-and-Tear-Parts Definition

Explanations: The service life of the machine was defined for household 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 sewing and embroidery machine, BERNINA recommends replacing the parts according to the table (9.4.2) once the tenth maintenance interval is reached. The customer has a right to the replaced parts, with the exception of the replaced electronic components, should these be repaired by Bernina. The defined wear-and-tear parts are subject to a charge. The maintenance work to be carried out is listed on the Maintenance Checklist.
8.4.1 Non-Hour-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 / touchscreen Sewing light / back lighting Lower thread and upper 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.) Feed-dog (blunt or worn teeth tips) Covers, casings (cracked/worn threaded holes, tears, scratch marks and signs of wear and tear) Presser feet (scratch marks, wear) Thread cutter Blade of automatic thread cutter Components of automatic/built-in threading process Pressure springs and tension springs Thread take-up crank / needle bar drive Needle bar and needle bar support
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8.4.2 Operating-Time-Related Parts

BERNINA 780 / 750 / 710 Art. # 033734.7X.01 033460.7X.00 033772.5X.00 034393.7X.00 033455.7X.00 033609.7X.00 033468.7X.00 033574.7X.00 030955.5X.02 033514.7X.00 030955.5X.03 031828.5X.00 032104.5X.00 032102.5X.00 032386.7X.00 007903.5X.08 033666.5X.00 002257.7X.07 001635.7X.01 032066.7X.00 032636.7X.00
Article Crankshaft (complete) Crankshaft (complete) Drive belt Hook guidway spare parts set Hook drive Hook (complete) Hook drive ring cover (complete) Clutch carriage (complete) Drive belt Belt pulley (complete) Drive belt Toothed rack Stepped gear Toothed wheel Drive motor Drive belt Link piece Winder motor with sleeve Knee-operated presser foot lever Lever Sideways-motion stepping motor (only B780)
maintenance interval: 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19 10 / 19
Remarks
Dual feed Dual feed
Clutch carriage Arm/base shaft Foot pressure Foot pressure Driving motor
Sideways feed
Embroidery module Art. # 007903.5X.42 007903.5X.41 032456.7X.00 032475.7X.00 007823.5X.03
Article Drive belt Y-direction Drive belt X-direction Flexible gearwheel Y- and X-drive Idler pulleys Spherical bearing
maintenance interval: 13 13 13 13 13
Remarks
Note: The X in the 8th position of the article numbers serves as a placeholder for the modification indicator (a number from 0-9) The counting of the modifications starts at 0.
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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. 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.
Customer data must be saved each time before maintenance or repair work is carried out. Update the machine to the latest firmware. Read out the stitch and hour counter and enter on the Service Report.
Customer data backup in BERNINA 780 Service Program 1g.
Connect BERNINA USB memory stick and select required button. Remove stick after confirmation by the machine. Save the customer settings = Customer data saved onto the storage medium Load the customer settings = Customer data loaded into the sewing and embroidery system.
8.5.2 Measures to be taken after the Service

Loading of the customer data into the sewing and embroidery system = Load the customer settings. 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. .
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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 Visual check: Covers LCD / touch screen Spool pin Feature What to check for specifically Scratch marks and signs of having dropped the machine Tears and cracks Clearance/gap widths Main switch Properly attached Bent Blunt low quality wrong system Damaged insulation Loose contacts / interruptions Squashed cables Connectors Listen for unusual noises and noise level Foot control adjustment
1. 2.
3.
Needle
4.
Power cable Foot control cable
5.
Switch machine on and let it run
6.
Functions to test with machine switched on
7.
Functioning of connectors
8.
(Remove covers) Ribbon cable Single-strand cable
9.
Rough visiual check of settings
10.
Drive motor
11.
Smooth running of the machine mechanical ease of movement
Stepping motors Sewing light Keys and buttons Stitch width and stitch length adjustment Touchscreen Screen / LCD Threading process Embroidery module Foot control / optional wireless foot control USB data stick M/C-PC link Damaged insulation Loose contacts / interruptions Squashed cables Connectors Needle tolerance Needle-/hook distance Feed-dog synchronization (lift and advance timing) Main shaft-/base shaft synchronization Bearing play Mechanical ease of movement (smooth running) Drive belt Shaft and cams play Main and base shaft Thread take-up crank Needle bar support / needle bar Swing bearing Bevel gears Bobbin carrier / hook Drive belt tensions
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8.5.4 Maintenance Checklist BERNINA 780 / 750 / 710

1. Covers to be removed Front and rear cover Base casing Stitch plate Hook Bobbin carrier Recommended parts according to Tear-and-Wear Parts Definition Free-arm area Needle bar / needle bar support Thread take-up crank Upper thread tension disks Complete drive unit including motor Lower thread sensor Sensors / light barriers Thread redirecting guides Thread regulator spring / upper thread indicator actuating lug Needle holder thread guide / thread redirections Hook Bobbin carrier (check for thread remnants under tension spring) Stitch plate Presser feet Feed-dogs of the removed and replaced parts Needle bar / needle bar support Thread take-up crank Spherical bearing Hook drive shaft and hook drive eccentric Hook Shafts / axes Eccentric / cams all drive belts Position of head plate in y- and x-direction Darning foot height Presser foot fixation Distance between and parallel alignment of needle bar and presser foot bar Needle distribution / zigzag stop Hook, feed-dog and needle drive synchronization Loop lift Needle-/hook distance Needle penetration in Y direction Needle height Feed-dogs Mechanical basic settings of balance Automatic thread cutter Synchronizing disk Threader mechanism Basting solenoid Thread tensions Winder Covers (ensure correct placement of cables and connectors) Electronic balance Buttonhole calibration (only use presser foot 3A that has come with the machine). Cleaning- and maintenance-counters reset Enter service/maintenance date etc. According to Sewing-Off Guideline SI 47-050 Covers Does the machine run, are the accessories complete? Check using Service Program (see 6.11)
2.
Parts that must be removed
3.
These areas must be cleaned
4.
Check these parts for scratch marks, deformations, exceptional wear and/or oxidation and polish or replace if required
5.
Assembly:
6.
Oiling / lubrication according to lubrication diagram in Service Manual
7.
Check / adjust settings according to Service Manual (Use a new needle 130/705H 80 TCN)
8.
Fitting
9.
Check /calibrate tests in Service Program
10. 11. 12.
Sewing-off Cleaning Final check
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8.5.5 Embroidery Module

1. Covers to be removed Upper y-arm cover Upper x-cover
Recommended parts according to Tear-and-Wear Parts Definition 2. Parts that must be removed
3.
These areas must be cleaned
X- and y-axes idler pulleys X-axis Y-guiding rail Covers Sensors / light barriers Connector plug Flex wheels Idler pulleys Ball bearing X-axis Actuator (hoop recognition) Drive belt of the removed and replaced parts Y-arm guide rolls (Klber OY 100) Belt pulley axes (Klbersynth UH1 14-1600) Gear wheel axes (Klbersynth UH1 14-1600) X-axis (Klber OY 100) Gear wheels (Klbersynth UH1 14-1600) Y-/X-drive belts Hoop holder on y-profile
4.
Check these parts for deformations, exceptional wear and/or oxidation and polish or replace if required
5. 6.
Assembly:
Oiling/lubrication
7. 8. 9.
Check/adjust settings according to Service and Maintenance Manual of Embroidery Module Fitting Check /calibrate tests in Service Program
Covers (ensure correct placement of cables and connectors) Calibration using the blue template and the reference point is essential and must be carried out. For X/Y test pattern assessment refer to Service and Maintenance Manual of Embroidery Module.
10. 11. 12.
Sewing-off Cleaning Final check
Covers Is the set of accessories complete?
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Document Revision History

Date May 2012 Version 1.1 Description First release in German Author Dieter Uhmeier
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Service- and Maintenance Manual

Chapter 1 General information ...................................................................................... 6

Chapter 2 Electronics and Wiring................................................................................ 16

Chapter 3 Removal and Refitting of Components ..................................................... 28

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Chapter 4 Settings ........................................................................................................ 77

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Chapter 5 Service Program ........................................................................................ 106

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Chapter 8 Maintenance Guidelines ........................................................................... 164

Document Revision History .......................................................................................... 172

Page 5 von 172

Chapter 1 General information

Masthead: Author: After Sales Service

Page 6 von 172

1.2 Warning: Dangerous voltage levels!

Caution! High voltage

Page 7 von 172

1.3 ESD-Related Note: Electrostatic Discharge (ESD)

Page 8 von 172

1.4 Tools and gauges

Adjusting needle 130 / 705 H TCN 80 packet of 100 pieces

Needle and hook adjustments

Needle penetration in Ydirection

Torx screwdriver T8 (to be ordered, when available) Torx screwdriver T10

Disassembling and reassembling aid

Disassembling and reassembling aid

Distance gauge (Schwarz brniert)

Adjusting of threader head height

Distance gauge 18.98 mm (silver steel)

Adjusting of needle-bar height

Eccentric key 2mm

Lateral alignment of head frame and stitch plate

Home position of walking foot

Page 9 von 172

Timing clutch mechanism (Thread cut & embroidery start)

Pinning tool, long

Pinning tool, short

Pinning tool, 3mm

Loop lift gauge

Loop lift gauge for the 7 Series (2.618 mm)

Centering gauge pentamerous

Aligment of hook driver bearing and und shuttle race ring

Feed-dog height gauge

Checking height of feed-dog

Darning foot height gauge

Checking of darning foot level

Bobbin winder gauge

Checking amount of bobbin fill

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

Page 10 von 172

Spring mounting tool

Spring hooking and unhooking aid

Auxiliary tool for mounting circlip 1.5

Spring balance gauge

Tension of thread regulator spring

Plug mounting tool

Adjusting spanner compl.

Continuity test Ohm measurement Voltage tests

398022030 398111030 Usual in trade

Page 11 von 172

Plugging and unplugging cables

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