Common Reasons for Sewing & Embroidery Machines to Malfunction

Needle Breaks
  1. Needle is inserted incorrectly
  2. Needle clamp screw is loose
  3. Bent needle being used
  4. Upper or lower threading is not correct
  5. Upper thread tension is set too tight/high
  6. Needle and/or thread for fabric being sewn is not correct
  7. Material pulled and/or moved excessively during sewing
  8. Incorrect spool cap
  9. Wrong combination Needle/Thread/Material used
  10. Wrong presser foot being used for application
  11. Bobbin Case (Inner Rotary Hook) not inserted correctly
Loops on top or bottom of fabric during sewing
  1. Upper or lower thread tension not set correctly
  2. Upper or lower threading is not correct
  3. Incorrect bobbin being used
  4. Bobbin is not inserted properly
  5. Threading is out of tension
  6. Missed take up lever when threading
Upper thread breaks
  1. Upper threading is not correct
  2. Upper thread tension is set too high/tight
  3. Upper thread is too large for the needle eye
  4. Needle is inserted incorrectly
  5. Incorrect spool cap
  6. Shuttle Hook/Inner Rotary is not installed correctly
  7. Incorrect bobbin being used
Lower thread breaks
  1. Lower thread could be entangled in shuttle
  2. Lower thread tension is set to high/tight
  3. Lower threading is not correct
  4. Shuttle Hook/Inner Rotary is not installed correctly
  5. Incorrect bobbin being used
  6. Burns on the needle plate
Skips stitches
  1. Needle is not sharp and/or straight
  2. Needle is inserted incorrectly
  3. Needle and/or thread for fabric being sewn is not correct
  4. Upper or lower threading is not correct
Machine runs slow and/or noisy
  1. Machine may require cleaning or lubrication
  2. Lint and/or debris may be caught in shuttle and/or feed dog assemblies.
  3. Upper or lower threading is not correct
  4. Shuttle Hook/Inner Rotary Hook is not installed correctly
  5. Belt is too tight or too loose
Material tends to Pucker during Sewing/ Embroidering
  1. Upper or lower thread tension is set too high/tight. (Tight tensions, Adjust for garment and thread type. Polyester thread will stretch during sewing especially if tensions are too tight. After the stitching is complete, the thread returns to its original length puckering the garment.)
  2. Upper threading is not correct
  3. Thread may be caught or is catching on something
  4. Lower thread is unevenly wound on bobbin
  5. Incorrect bobbin being used
  6. Improper hooping tensions. (Hoop sturdy, woven fabrics tightly: Loose hooping will cause the fabric to bunch up under the stitching. Hoop soft knits tautly using a stable backing: over stretching will cause it to look puckered when the hoop is removed.)
  7. Design densities are too heavy. (Too many stitches in an area pull fabric causing it to look puckered. Decrease the design slightly (5%-10%)
  8. Dull needle. (Dull needles push the fabric down instead of pushing between or piercing the weave. Replace needle.)
  9. Column stitches are too long. (Re-digitize as fill stitching or multiple rows of column stitching.
Design Out Of Register
  1. Loose hooping. (Re-hoop being careful not to pull stetch fabric out of shape in an attempt to hoop tightly)
  2. Unstable fabric. (Use more or heavier backing. For more stability use an adhesive spray to fix backing to garment.)
  3. Design digitized incorrectly. (The design may need more pull compensation or underlay to accommodate stretchy or high – napped fabrics.)
Needle Cuts or Holes in Garments
  1. Dull Needle. (Replace needle. Dull needles have a difficult time getting through the garment causing some fabrics to tear.)
  2. Wrong needle point type. (Sharp and round point needles can cut some knits. Use ball point.
  3. Delicate fabric. (The simple penetration of the needle will cut some delicate fabrics. Soften the impact by using topping.)
Thread Breaks
  1. Improper threading. (Re-thread machine assuring thread goes through all guides order.
  2. Too much or incorrect adhesive spray. (Use only adhesives designed for embroidery applications. Excessive adhesive build-up on needles causes them to drag and break thread. Replace needle after using adhesive spray.
  3. Stitch length too short. (Slowing down machine helps. Increase stitch length)
  4. Stitching over stitching. (Reduce density in the overlay. Avoid more than 2 layer of thread)
  5. Old dry thread, (Replace thread. Thread becomes brittle with age and prolonged exposure to light, air, and heat. Store thread in cool dark place.
  6. Excessive Friction (Increased friction between the needle and thick or abrasive fabrics or backing with excessive chemical coatings. Reduce machine speed.)
Error Codes or Warnings-
  1. Refer to your Operation Manual