Osman Bayrak


  1. Needle Depth and Hook Timing should be checked first. Refer to Operation Manual for instructions how, and the specific settings to use.
  2. Replace the needles if they have not been changed recently. Constant use will dull the needle tips and needle eyes have been known to form burrs. It is a good practice to change them on a regular basis.
  3. The thread may also be a cause of thread breaks. If the thread is to old due to Shelf Life it could be dry or brittle which would cause thread breaks. If you must use the thread, try spraying the cone with a pure silicone spray to help remove the dry and brittleness of the thread cone. The operator must make the choice to change the thread cone if the breaks continue. Storing thread in a plastic bag in the freezer can further the shelf life of thread also.
  4. Check the Thread Path for proper threading. Refer to the Operation Manual for instructions on how to thread the machine.
  5. Check all thread guides for burrs or scratches. Take a piece of thread and insert the thread into each thread guide and use the dental floss method to check for burrs. If some are found, try using emery cloth to smooth them out. If the burrs are to deep to smooth out then change the guide.
  6. Check the Hook Assembly for burrs which could cause a thread break. If possible smooth them out or replace the Hook Assembly. A part of checking the hook is making sure it is set correctly, check Hook Timing. Refer to the Operation Manual.
  7. Check the UTC Retaining Finger for damage and proper, setting refer to the Operation or Technical Manual for instructions.
  8. Inspect the Hook Assembly for cleanliness and oil the Hook Assembly every 4 operating hours. Refer to Operation Manual.
  9. Thread Tension that is too tight can be a cause for thread breaks. Observe the Tensioner Thread Wheel for uneven motion while the thread is being pulled through the wheel. This would indicate that the tension is to tight. Check the Felt Pads that are on the top and bottom of the wheel for oil and wear. Replace as needed. Once a year is a good idea.
  10. Check the Presser Foot Height, the bottom of the Presser Foot should not be hitting the needle plate while sewing. The height of the Presser Foot is determined by the Needle Case Damper, a Shim and a Felt Pad. Refer to the Technical Manual for an illustrated view of these parts. If one or any of these three part are missing, they can be ordered through your distributor.
  11. Check the Needle Plate hole for burrs both on the top and underside. Make sure the needle is not hitting any part of the Needle Plate, and centered in the needle plate hole. Use the Head Timing Menu to bring needle down to check this setting. The Operations Manual shows how to bring the needle bar to needle depth to be able to check Needle Plate Hole Centering.
  12. Check the Take Up Lever for excess movement. Take the Pick Up Lever that is engaged and try to move it up and down, if it moves over 1/4 of an inch, there may be teeth missing off of the Take Up Lever Drive Gear or the individual take up lever itself, or they may just be worn.
  13. The meshing of these two gears is another possible cause. If either wear or not meshing of the gears is detected call your distributor.
  14. Incorrect Needle Depth and Hook Timing can cause thread breaks. Hitting a Hoop or getting Bird Nesting or even breaking a needle could change the Needle Depth and Hook Timing, so make sure they are correct.
  15. The design may be a cause due to the density. This may happen on small letters in sizes .50 inch down to .25 inch. The default setting in EDS is 4.2 which is 60 stitches per inch. This density will produce 3 needle strikes in the same needle hole which can cause thread breaks. Even a large design if it is to dense in stitch count could be a problem. The most apparent is the reduction of a design by the operator.
  16. If an Expanded Design is used, the stitch density can not be reduced. Refer to your EDS Manual for information about Design Density. Sew the design at a slower speed trying 500 to 550 SPM.
  17. The eye size of the needle can make a difference. If the thread is breaking to often try using a larger eyed needle. If a 70/10 size needle is being used, switch to a 75/11 or 80/12 to allow for the thread thickness and the density of the design.
  18. Make sure the thread is correctly threaded, refer to the Operation Manual page 2-4 for instruction. Check the thread tension it may be too tight. Refer to the Operation Manual page 2-7 for instruction on how to adjust the bobbin and the upper Tensioners. If bobbin tension keep varying after setting, change the bobbin case, as it could be a cause for poor sew quality and thread breaks.
  19. Use adequate backing. An inadequate amount of backing may allow part of the garment to be pulled down into the needle plate hole, thus causing a threads break. One piece of Tear Away backing may not be good enough for a sweat shirt. The purpose of backing is the help support and stabilize the material during the sew out.