Needle breaks galore

[sewsew7]

Hi everyone. Hoping someone can help me with a problem I just can't seem to diagnose myself. I have been having a pile of needle breaks all weekend on one machine. I am attempting to put names on the sides of caps with a micro clamp. Has always worked for me before, and the settings started out the same. This time, it sews about five stitches, then I hear a clunk and the machine stops, always with a broken needle. I have used the brush and canned air to make sure there is no little piece of needle that is getting caught in the rotary hook, uped the thickness of my fabric, set the acti feed setting to 4. I turned the machine off yesterday because of this problem, and thought maybe if I turned it back on today, it would miraculously have fixed itself. No such luck. It has been an incredibly long, LONG weekend, and my brain is fried. If someone could offer some advice, I would be most appreciative. [img]smile.gif[/img]

[Juli in Kona]

I the bobbin in correctly? As you hold the bobbin case and are putting the bobbin in, the thread should be coming off the top (From left to right, so when pulled it turns clockwise). If it is in backwards, it won't work right.

Is the retaining finger in correctly and gapped right? Is you needle in backwards?

Check those and let us know if it helps.

Juli in Kona

[sewsew7]

Hi Juli. Yup checked all that. but it all was right. I checked some older postd and someone suggested to check the manual for hook timing adjustment. I am currently attempting to do this for the first time, and am feeling lost. I checked the hook point for the correct position, and all seems fine. Looks the same on the other machine too. I am still at a loss, as to what could be causing these needle breaks. Any other suggestions you can think of? Thanks for your help. It's good to have this as a resourse for when one is feeling LOST!!

[The Embroidery Authority - OLD]

Dear SewSew7 (No first name?),
I doubt your problem is related to hook timing unless you know you jammed something in the rotary hook. Save this for your last option.
If your needles are breaking, then we need to look at what the needles are hitting to begin troubleshooting your problem.
First we need to know if your needle is hitting the needle plate. And if so, how far off is it from center of the machine? It's either that your needleplate is slightly off center or your needlecase is not centering itself correctly. This proceedure will differ depending on what model machine you have.
If the needle is clearing the needle plate going through the center of the needle plate hole, then the next area we would suspect would be the bobbin case or bobbin basket. The pig tail spring on the front side of the bobbin case must always be at 12 o'clock when installed in the machine. If the bobbin case is allowed to rotate too far away from this position, you will break needles and possibly throw your machine out of time. This can happen if your retaining finger is not doing what it's supposed to. this would be the little silver arm that is attached to the left side of the sewing arm and extends out in front of the sewing arm just above the bobbin case. It's function is to hold the bobbin basket in the correct position.

With a new needle in any of your needle bars, hit the emergency stop button (kills power) and manually rotate the Z shaft (silver rod under the center of the top portion of the machine) counter clockwise and try to determine which of the above is your problem. Try not to continue breaking needles if you can help it because it will only create a more expensive problem to fix.
ie: one customer told me he was able to finish sewing the garment after breaking about 20 needles from start to finish. You never know when one broken needle will "break the camel's back".
Good Luck,
Ed Orantes
Melco Tech & Trainer
504-258-6260

[Rod or Sharon]

Tom, ole buddy...is it time to fly me back to New Jersey.....for a visit.... ??

Have you checked the operation of the knife and selector? It may be possible that the needles are impacting one of these if the pushrod has come loose or is broken to either one of them...

Rod Springer
Amaya Tech & Trainer

[Rod or Sharon]

Whoops,

Thought I was addressing Mr Sew and Sew....but sewsew7...need to check the knife and selector ops anyway....

Rod Springer
Amaya Tech & Trainer

[Mr. Sew & Sew]

Sir Rod - tis not me.

I get the occasional needle break, but I just figure it's God's way of telling me it's time to change that needle.

Have you noticed that Ed posted his picture on the boards now every time he puts a post on there. He doesn't look Southern at all.

Tom

[sewsew7]

Thanks for jumping in guys. Lots of things to consider. The machine I am having trouble with is an XT.sugsted by Rod, and both cables are still attatched and in good working order. I have had this happen once, so I knew to look there, but alas, tis not the problem. I checked my pig tail as suggested by Ed and it is in the 12 o'clock position with the normal amount of wiggle. Have checked the gap as well, but am sure this is not the ticket either. It is possible however that my needle plate is not centered as suggested. With fresher eyes this morning, it appears that my needle is oriented closer to the back of the needle plate hole than the front. It seems to be okay side to side. Worth a try anyway. Could you please post a reminder on the steps to take to correct this, as brain still feels exhausted, the phone is ringing off the hook, and I am attempting to get five kids out the door on time to meet the bus for school. Man, sometimes, when it rains, it pours, which honestly it looks like it could do any minute now. Thanks for everyones help. Hope to be happily sewing away soon. [img]smile.gif[/img]

[Hugo Torbidoni]

Is there a chance that your feeder gear is broken?
Go to the stepper menu and click on feed forward 200. Measure how much thread feeds out(If any). Do this several times and see if the amount of thread being fed is consistant.

Hugo Torbidoni
Melco Tech
301-471-3157

[sewsew7]

No the feeder gear is working properly. I phoned Melco and their suggestion is to use two layers of the cap backing and some adhesive spray. I am going downstairs to try this now, but am a little skeptical. I just don't want to cause any major trouble with the machine while I'm testing these suggestions. Fingers crossed.

[The Embroidery Authority - OLD]

SewSew7,
If your needle is hitting the backside of the needlecase, then, either your needle is bent backwards or the upper portion of your needlecase is too far forward. This would require a service call as your needlecase would need a throurough going over.
Usually one can tell where the needles have been breaking by all the strike marks in that area.
Also, if you are using two layers of the cap backing, definitely be sure you are using a sharp and larger needle as it can be tough for a needle to penetrate the cap and backing and still make it straight through without any deflection.
Also, (again), I wasn't aware you were sewing on caps. Is it possible that you are sewing too close to the bill and then the presserfoot is being shoved forward by the bill into the path of the needle and then the needle deflects forward until it hits something and then breaks. I've seen this many times before. Make sure you aren't sewing any closer than 1/4inch from the edge of the silver strap that goes across the top of the cap against the bill.
Best of luck,
Ed Orantes
Melco Tech & Trainer
504-258-6260

[The Embroidery Authority - OLD]

Tom, (Alf)
I've always been referred to as an "ED-ucated little monkey". Therefore the picture is appropriate. Besides, I got tired of being called "Mr. Incredible". I still have to hear that from the wife.
What's your story on the alien???

Ed

[sewsew7]

I am sewing on hats, but on the sides of them, so the bill is turned to the side and out of the way. The extra layer of backing and the adhesive spray made no difference what so ever, as I feared. I am using a micro clamp to do this, and am well within my hoop limits. I have just got myself in the habit of tracing everything that goes on the machine. I switched the needle I was sewing with, just to see if it was needle specific, and the only difference is that the needle didn't snap in half this time, only bent backwards. Now that I am more awake and alert I have been trying to set the needle plate properly, as I am almost positive it must be hitting this. There are a few new scrapes on top of the needle plate. I can't for the life of me seem to get the needle to stay in this spot when sewing. Everything looks good, go to sew and again, broken needle. I am going to go and switch the jobs the machines are sewing and see if this will help, even just for today. I have one machine sewing flats and the other is suppose to be sewing these hat sides. Am hoping to get up and running at some point today. Thanks to everyone who has offered their advice. I will keep telling myself that I will get through this, I will get through this, and if that doesn't work, well, Ed's picture should be enough to keep me smiling.

[Judy]

Are you using a 12 needle? Somewhere buried in my stash of supplies I even have some 14's. There are days I would use a railroad spike if I could find one to fit the Amaya!

[Hugo Torbidoni]

Have you tried removing the micro clamp and sewing with a regular flat hoop? if so what are the results?

Hugo Torbidoni
Melco Tech