Problem with big red...

[Medusa]

I have constant thread breaks on my machine. I think it is the sensor bar, but I don't run on auto. Is there a tech who can help? Arizna...west valley

[Rod or Sharon]

You have not given enough information. The list of why you are getting the thread breaks is very long.

The threadbreak sensor would not be at the top of the list as to why....

How long have you operated this machine?
When was the last time a "COMPLETE" lubrication was done?
How many stitches or Z rotations does this machine have?
Why are you running in Standard?
Which leads to the question, what software version are you running?
Caps, flats or both?
Poly thread or rayon?
Machine speed?
What color are the inner threadfeed rollers ( not the red pinch rollers )? And when was the last time they were replaced?
Hook timing? Have you attempted to adjust it?
Proper gap on the rotary hook support finger?
Needles in backwards?
Is the problem on all needles or just one?
Where is your presser foot height set at?

When was the last time a tech looked your machine over?

And the list goes on and on>>>>>>>>>>

We have to know what you have done or have not done.

Rod Springer
Amaya Tech & Trainer

[Medusa]

Issues...

All excellent questions! I am not able to answer many of them however. I have had the machine since its birth in 2005. I did a complete maintenance cycle yesterday.

I am running in standard because I have never had good luck with auto. I have never had a tech look at it. I am running AOS 6.8. Old software...

Caps and flats both running at 750 (again, not much luck running at higher speeds). Poly thread.

The inner rollers are from yellow to bronze to brown. I have never replaced them. I don't know how to do the hook timing. Proper gap?

This happens on all needles. presser foot height adjusted the way I was taught at Melco...turn it down to touch and one click up. All needles have been replaced. I am out of the 75s, so I replaced all with 80s.

I would love a tech to come look at it...I have not had much success yet with Hassan...the AZ guy.

I tried reinstalling the software...had issues with AOS opening.

I called tech support this morning...they fixed the AOS problem (via me deleting a file in the system folder). They suggested I run the machine at 9000 at a minimum and on auto. I am now doing this and successfully sewed a shirt, but I feel like I am limping along.

I only had one working set of LEDs...now I have none as the one set blew during maintenance.

I still get the thread breaks on the straight stitching. Zig-zag and column appears to be OK, but when it outlines or starts a new element with a straight line...it breaks. I am able to mitigate this by stopping the machine at that point and restarting...the slower speed appears to help it limp along in those areas.

Thank you for any help you can give. Tech support suggested I check the x-cable tension and sent me instructions. Of course, I have to buy a gauge first...

You have not given enough information. The list of why you are getting the thread breaks is very long.

The threadbreak sensor would not be at the top of the list as to why....

How long have you operated this machine?
When was the last time a "COMPLETE" lubrication was done?
How many stitches or Z rotations does this machine have?
Why are you running in Standard?
Which leads to the question, what software version are you running?
Caps, flats or both?
Poly thread or rayon?
Machine speed?
What color are the inner threadfeed rollers ( not the red pinch rollers )? And when was the last time they were replaced?
Hook timing? Have you attempted to adjust it?
Proper gap on the rotary hook support finger?
Needles in backwards?
Is the problem on all needles or just one?
Where is your presser foot height set at?

When was the last time a tech looked your machine over?

And the list goes on and on>>>>>>>>>>

We have to know what you have done or have not done.

Rod Springer
Amaya Tech & Trainer

[Rod or Sharon]

Quote: presser foot height adjusted the way I was taught at Melco...turn it down to touch and one click up.

A rule of thumb....run the presser foot as low as you can as long as it is not damaging the fabric or leaving a foot print on the material. Just touching the material and raising it one click can leave it too loose and flagging will result. With the Reds, which I still have one, the majority of sewing on flats is done with the presserfoot all the way down..T's, polo's, towels, etc.........

Quote: All needles have been replaced. I am out of the 75s, so I replaced all with 80s.

A possible clue here is that the straight stitches and outline walk stitching are "too short" and the 80 size needles are poking too big of a hole , which for lack of a better description, is causing missed stitches and thread breaks. You did not say whether these were "real" thread breaks or "false" thread breaks. This is also where the hook timing is a very critical part of the equation. As the stitches get shorter and/or the columns get narrower the loop that is created on the backside of the needle for the rotary hook point to pick up becomes smaller. If the hoop point misses the loop for any reason, missed stiches and thread breaks will occur.

Quote: The inner rollers are from yellow to bronze to brown. I have never replaced them. I don't know how to do the hook timing. Proper gap?

You need to "closely inspect these to determine if they have grooves worn in them from the thread. This applies to the red pinch rollers as well. If they have grooves, they need to be replaced as they are no loner feeding the thread without some slippage which also leads to the thread break issue.

Quote: Tech support suggested I check the x-cable tension and sent me instructions. Of course, I have to buy a gauge first...

Adjusting the X cable tension on the Reds is different than on the XT series. It is more difficult and the possibility of breaking the cable is a concern. But, yes this is something that needs to be checked and/or adjusted.

Quote: I would love a tech to come look at it...I have not had much success yet with Hassan...the AZ guy.

If you have never had a tech look at the machine, does your quote mean you have not been successful in being able to get an appointment with him?

Here is another option for you...unless of course you would like me to come to AZ to give the Big Red some TLC... :-)

Robert Wood
Farmington, NM
(505) 326-1652 or (505) 486-4696
[email protected]
Melco Certified Tech: Bravo, Amaya, XT, XTS
Cert Trainer for: DS Lite, DesignShop, DesignShop Pro, DesignShop Pro+, Embroidery Consultant, Digitizing Services
On Site Or Web Based Training

Rod Springer
Amaya Tech & Trainer
Star, ID

[Medusa]

Well...

I have a lot to look at here. I was able to get a hold of the local tech, after I check some things out, he may come. Unless you are going to be coming through AZ anytime soon!

I will keep you posted. Thank you so much for your guidance.

Quote: presser foot height adjusted the way I was taught at Melco...turn it down to touch and one click up.

A rule of thumb....run the presser foot as low as you can as long as it is not damaging the fabric or leaving a foot print on the material. Just touching the material and raising it one click can leave it too loose and flagging will result. With the Reds, which I still have one, the majority of sewing on flats is done with the presserfoot all the way down..T's, polo's, towels, etc.........

Quote: All needles have been replaced. I am out of the 75s, so I replaced all with 80s.

A possible clue here is that the straight stitches and outline walk stitching are "too short" and the 80 size needles are poking too big of a hole , which for lack of a better description, is causing missed stitches and thread breaks. You did not say whether these were "real" thread breaks or "false" thread breaks. This is also where the hook timing is a very critical part of the equation. As the stitches get shorter and/or the columns get narrower the loop that is created on the backside of the needle for the rotary hook point to pick up becomes smaller. If the hoop point misses the loop for any reason, missed stiches and thread breaks will occur.

Quote: The inner rollers are from yellow to bronze to brown. I have never replaced them. I don't know how to do the hook timing. Proper gap?

You need to "closely inspect these to determine if they have grooves worn in them from the thread. This applies to the red pinch rollers as well. If they have grooves, they need to be replaced as they are no loner feeding the thread without some slippage which also leads to the thread break issue.

Quote: Tech support suggested I check the x-cable tension and sent me instructions. Of course, I have to buy a gauge first...

Adjusting the X cable tension on the Reds is different than on the XT series. It is more difficult and the possibility of breaking the cable is a concern. But, yes this is something that needs to be checked and/or adjusted.

Quote: I would love a tech to come look at it...I have not had much success yet with Hassan...the AZ guy.

If you have never had a tech look at the machine, does your quote mean you have not been successful in being able to get an appointment with him?

Here is another option for you...unless of course you would like me to come to AZ to give the Big Red some TLC... :-)

Robert Wood
Farmington, NM
(505) 326-1652 or (505) 486-4696
[email protected]
Melco Certified Tech: Bravo, Amaya, XT, XTS
Cert Trainer for: DS Lite, DesignShop, DesignShop Pro, DesignShop Pro+, Embroidery Consultant, Digitizing Services
On Site Or Web Based Training

Rod Springer
Amaya Tech & Trainer
Star, ID