Barudan, Errors and Solutions

Barudan Embroidery Machine Stops or Won’t Sew: Troubleshooting Guide

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Quick answer: Most Barudan machine stoppages are due to thread path issues, needle problems, or incorrect tension. Begin by checking the upper thread path, bobbin, and needle installation. Clear any error messages on the control panel and restart the machine.

Difficulty: moderateTime: ~30 minTools: Small flathead screwdriver, Small Phillips head screwdriver, Tweezers, Small brush (for lint removal), Compressed air (for cleaning)

When your Barudan embroidery machine stops unexpectedly or refuses to sew, it can halt production. This guide provides practical, step-by-step troubleshooting for common issues, empowering you to diagnose and resolve problems quickly. As a machine operator, understanding these steps will help minimize downtime and maintain optimal machine performance.

Two-minute checks before you open anything

  • Check the control panel for any error messages and note them.
  • Inspect the upper thread path for breaks, tangles, or improper routing.
  • Remove and re-insert the bobbin case, ensuring the bobbin is wound correctly and the thread is seated properly.
  • Verify the needle is correctly installed (flat side facing the correct direction) and not bent or broken.
  • Ensure the embroidery hoop is securely locked in place and the fabric is taut.

1. Thread Breakage or Incorrect Threading high likelihood

How to tell

The machine stops unexpectedly, often displaying a 'Thread Break' error on the control panel. Visual inspection reveals a broken, tangled, or improperly routed upper thread or bobbin thread. Stitches may be skipped or appear loose before stopping.

Fix

  1. Power off the machine.
  2. Remove the upper thread from the needle and all thread guides.
  3. Remove the bobbin case and bobbin.
  4. Inspect the entire thread path (from spool to needle) for any lint, debris, or obstructions. Clean as necessary.
  5. Re-thread the upper thread, ensuring it passes correctly through all guides, tension discs, and the take-up lever. Refer to your Barudan machine's manual for the exact threading path.
  6. Insert a correctly wound bobbin into the bobbin case, ensuring the thread is seated properly in the tension spring. Reinsert the bobbin case.
  7. Use high-quality embroidery thread suitable for your machine and design to minimize breakage.
  8. Verify the needle is installed correctly: flat side facing the direction specified in your Barudan manual (typically to the right or back, depending on the model).

Refer to assembly sections 03 Take up lever, 06 Thread guide, 04 Needle bar, and 01 Head Bed for component locations.

Parts involved: Thread path & tension → Needles & needle bars → Rotary hooks & bobbin cases → Threads & supplies →

2. Needle Issues (Bent, Broken, or Incorrectly Installed) high likelihood

How to tell

The machine stops abruptly, often with a loud 'clunk' or 'snap'. Stitches may be skipped or irregular before the stop. The needle might be visibly bent, broken, or dislodged from the needle clamp. An error message related to the needle or thread break may appear.

Fix

  1. Power off the machine.
  2. Carefully inspect the needle. If it is bent, broken, or dull, replace it immediately.
  3. Ensure the new needle is the correct size and type for your fabric and thread. Refer to your Barudan manual for recommended needle types.
  4. Insert the needle fully into the needle clamp, ensuring the flat side of the needle shank faces the correct direction as specified in your machine's manual (e.g., to the right or back). Tighten the needle clamp screw securely.
  5. Manually turn the handwheel to cycle the needle through a few stitches to confirm free movement and proper installation.

Refer to assembly sections 04A-1 Needle bar A(Z12) or 04B Needle bar B for needle bar components.

Parts involved: Needles & needle bars → Screws, springs & small parts →

Parts you may need for Barudan

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Groz Beckert RG DBXK5 Embroidery Needles Nm 65/9, 70/10, 75/11, 80/12 for Tajima, Barudan, SWFGroz Beckert RG DBXK5 Embroidery Needles Nm 65/9, 70/10, 75/11, 80/...$ 36.29View part →Hirose HSH-7.94ATR(MTQ) KHS12-RYP Rotary Hook for Tajima, Barudan, SWF, Melco, HAPPY, TOYOTA, Feiya, ZGMHirose HSH-7.94ATR(MTQ) KHS12-RYP Rotary Hook for Tajima, Barudan, ...$ 12.09View part →Industrial BC-DBZ(1)-NBL6 Bobbin Case for Barudan TZ1 LE2, Brother ...$ 7.49View part →Koban KHS12-RYP Rotary Hook with Trimmer for Tajima, Barudan, SWF, Toyota, Happy, Melco, FeiyaKoban KHS12-RYP Rotary Hook with Trimmer for Tajima, Barudan, SWF, ...$ 22.29View part →BC-DBZ(1)-NBL6 Bobbin Case for Barudan TZ1, Brother BAS-400, JUKI LZ SeriesBC-DBZ(1)-NBL6 Bobbin Case for Barudan TZ1, Brother BAS-400, JUKI L...$ 7.49View part →Gotek SFRM72-FU Floppy Drive Emulator USB Reader for Tajima, Barudan, Happy Embroidery MachinesGotek SFRM72-FU Floppy Drive Emulator USB Reader for Tajima, Baruda...$ 48.09View part →

All Barudan parts → Thread Path & Tension → Needles & Needle Bars → Rotary Hooks & Bobbin Cases →

3. Bobbin Case or Bobbin Issues medium likelihood

How to tell

The machine stops, often with poor stitch quality (e.g., looping on top, no bobbin thread showing). The bobbin thread may be tangled, or the bobbin case might feel loose or obstructed. Error messages might indicate a thread break or bobbin issue.

Fix

  1. Power off the machine.
  2. Remove the bobbin case from the rotary hook area.
  3. Inspect the bobbin case for any lint, debris, or thread fragments. Use a small brush or compressed air to clean thoroughly.
  4. Check the bobbin itself: ensure it is wound evenly and not overfilled. Replace if damaged.
  5. Verify the bobbin thread is correctly seated in the tension spring of the bobbin case. Pull the thread to feel for smooth, consistent tension.
  6. Inspect the rotary hook area for any lint buildup or damage. Clean carefully.
  7. Reinsert the bobbin case firmly into the rotary hook. Ensure it clicks into place securely.

Refer to assembly sections 01A Head Bed A or 01B Head Bed B for rotary hook and bobbin case access.

Parts involved: Rotary hooks & bobbin cases → Lubrication & maintenance → Threads & supplies →

4. Incorrect Thread Tension medium likelihood

How to tell

The machine stops, often accompanied by poor stitch quality (e.g., puckering, looping, thread breaks). The control panel might display a thread break error if the tension is too high, causing the thread to snap. Stitches may look uneven or unbalanced.

Fix

  1. Power off the machine.
  2. Ensure the machine is correctly threaded, as improper threading can mimic tension issues.
  3. Adjust the upper thread tension dials. Make small adjustments (e.g., half a turn at a time). Refer to your Barudan manual for recommended starting tension settings.
  4. Test the new tension settings on a scrap piece of the same fabric and stabilizer. Aim for balanced stitches where the bobbin thread shows about 1/3 on the underside of the fabric.
  5. If bobbin tension is suspected, consult your Barudan manual for instructions on how to adjust the bobbin case tension screw. Make very small adjustments (e.g., 1/8th turn) as bobbin tension is very sensitive.
  6. Perform regular tension checks when changing fabric types, thread types, or designs.

Upper tension units are typically found in assembly section 06 Thread guide. Bobbin case tension is part of the rotary hook assembly in 01 Head Bed.

Parts involved: Thread path & tension → Rotary hooks & bobbin cases →

5. Hoop Placement or Fabric Issues medium likelihood

How to tell

The machine stops, often with a 'Hoop Error' or 'Frame Obstruction' message. The hoop may be visibly loose, misaligned, or the fabric may be snagging. The needle might hit the hoop or presser foot.

Fix

  1. Power off the machine.
  2. Verify that the embroidery hoop is correctly attached to the pantograph arms and securely locked into place. Ensure all clamps are engaged.
  3. Check that the fabric is taut within the hoop, but not overstretched or distorted. Ensure no excess fabric is hanging down to obstruct movement.
  4. Confirm that the correct hoop size is selected on the control panel for the design being sewn.
  5. Manually move the pantograph (if safe to do so) to check for any physical obstructions in the sewing area.
  6. Ensure the fabric type and stabilizer are appropriate for the design density. Very thick or thin fabrics, or inadequate stabilization, can cause issues.

Refer to assembly section 10 Pantograph drive for pantograph and hoop attachment points.

Parts involved: Hoops & frames → Presser feet & sewing parts → Threads & supplies →

6. Tripped Safety Sensors or Error Messages medium likelihood

How to tell

The machine stops and displays a specific error message on the control panel (e.g., 'Thread Break', 'Needle Error', 'Emergency Stop', 'Door Open'). The machine will not resume operation until the error is cleared.

Fix

  1. Read the error message displayed on the control panel carefully. This message is critical for diagnosing the specific issue.
  2. Address the underlying cause indicated by the error message (e.g., re-thread if 'Thread Break', replace needle if 'Needle Error', close safety cover if 'Door Open').
  3. Once the issue is resolved, clear the error message according to your Barudan machine's operating instructions (often by pressing 'Reset' or 'Stop/Start').
  4. If the error persists after resolving the apparent cause, power off the machine, wait 30 seconds, and restart it to clear any temporary glitches.

Sensors are located throughout the machine, often near the thread path (06 Thread guide), needle bar (04 Needle bar), and rotary hook (01 Head Bed). The control panel is in assembly section 11 Control.

Parts involved: Sensors & switches → Control panels & displays → Circuit boards & electronics →

7. Machine Timing Misalignment low likelihood

How to tell

The machine stops, often with repeated thread breaks, skipped stitches, or needle strikes. Stitches may appear inconsistent or the machine may make unusual noises. This is a more advanced issue.

Fix

  1. Power off the machine.
  2. Manually turn the handwheel slowly and observe the relationship between the needle and the rotary hook. The needle point should pass the hook point at a specific position during its upward stroke, as detailed in your Barudan service manual.
  3. If a misalignment is observed, adjusting the machine's timing is a complex procedure. Refer to the detailed instructions in your Barudan service manual for timing adjustments, or contact a qualified technician.
  4. Do not attempt timing adjustments without proper knowledge and the correct tools, as incorrect adjustments can cause further damage.

Timing adjustments involve components in assembly sections 01 Head Bed (rotary hook), 04 Needle bar, and 08 Drive.

Parts involved: Rotary hooks & bobbin cases → Needles & needle bars → Belts, pulleys & gears → Shafts, bearings & bushings →

8. Power Supply Issues low likelihood

How to tell

The machine stops abruptly, powers off, or fails to start. The control panel may go blank or flicker. This can happen randomly or during power fluctuations.

Fix

  1. Power off the machine.
  2. Ensure the machine's power cord is securely plugged into a stable power outlet.
  3. Inspect the power cord for any visible damage, cuts, or fraying. Replace if damaged.
  4. If using an extension cord or surge protector, ensure it is rated for the machine's power requirements and is in good condition. Try plugging the machine directly into a wall outlet to rule out external power strips.
  5. Check the circuit breaker for the outlet to ensure it hasn't tripped.
  6. If the issue persists, there may be an internal power supply problem requiring a technician.

Internal power connections are typically found in assembly section 11 Control.

Parts involved: Cables & wiring → Circuit boards & electronics →

9. Machine Overheating low likelihood

How to tell

The machine stops after extended periods of continuous operation. It may display a 'Temperature Warning' or 'Overheat' error. The machine's casing may feel warm to the touch.

Fix

  1. Power off the machine and allow it to cool down for at least 30-60 minutes.
  2. Ensure the machine is located in a well-ventilated area, away from direct sunlight or heat sources.
  3. Inspect all cooling vents and fans for obstructions (dust, lint, debris). Use compressed air to clean them thoroughly.
  4. Avoid running the machine continuously for excessively long periods without short breaks.
  5. If overheating persists even after cleaning and allowing cool-down, internal cooling components (fans, sensors) may be faulty, requiring technician service.

Cooling fans and temperature sensors are typically associated with motors and control boards in assembly sections 08 Drive and 11 Control.

Parts involved: Motors & drivers → Sensors & switches → Lubrication & maintenance →

10. Software or System Errors low likelihood

How to tell

The machine freezes, displays generic system errors (e.g., 'System Error', 'Program Error'), or becomes unresponsive. It may refuse to start sewing or stop mid-design without a clear mechanical cause.

Fix

  1. Power off the machine, wait at least 10-15 seconds, and then restart it. This can often clear temporary software glitches.
  2. If the issue persists, perform a factory reset if your Barudan manual provides instructions for this procedure. Be aware that a factory reset will erase custom settings and designs.
  3. Check for any available firmware or software updates for your specific Barudan model on the manufacturer's website. Follow the instructions carefully for installation.
  4. If system errors continue, the main control board or memory may be faulty, requiring a technician.

These issues relate to components in assembly section 11 Control.

Parts involved: Circuit boards & electronics → Control panels & displays → Floppy, USB & memory →

11. Worn or Misaligned Drive Belt low likelihood

How to tell

The machine stops, often with a grinding or slipping noise. The needle bar or pantograph movement may be erratic or completely halted. Visual inspection of the drive belt may show cracks, fraying, or looseness.

Fix

  1. Power off the machine and unplug it.
  2. Locate the drive belt(s) by referring to your Barudan machine's manual for access panel removal. (Note: This may require removing machine casing, proceed with caution).
  3. Inspect the belt(s) for any signs of wear, cracking, fraying, or excessive slack. A worn belt needs replacement.
  4. If the belt appears loose but not damaged, it may need tensioning. Consult your Barudan manual for the correct tensioning procedure and specifications. Do not overtighten.
  5. If the belt is damaged or cannot be properly tensioned, it must be replaced. This is often a job for a qualified technician to ensure correct alignment and tension.

Drive belts are typically found in assembly sections 08 Drive and 10 Pantograph drive.

Parts involved: Belts, pulleys & gears → Motors & drivers → Shafts, bearings & bushings →

12. Lack of Lubrication low likelihood

How to tell

The machine runs sluggishly, makes unusual squeaking or grinding noises, and may eventually stop due to increased friction. Moving parts may feel stiff. This issue develops over time.

Fix

  1. Power off the machine.
  2. Refer to your Barudan machine's maintenance schedule and lubrication points in the manual.
  3. Apply Barudan-approved machine oil to all specified lubrication points, such as the needle bar, rotary hook, and other moving components.
  4. Avoid over-oiling, as excess oil can attract lint and dust, leading to new problems.
  5. Clean any excess oil immediately.
  6. Regularly follow the lubrication schedule to prevent future friction-related stoppages.

Key lubrication points are found in assembly sections 01 Head Bed, 04 Needle bar, 03 Take up lever, and 08 Drive.

Parts involved: Lubrication & maintenance → Needles & needle bars → Rotary hooks & bobbin cases → Shafts, bearings & bushings →

13. Faulty Start/Stop Controls low likelihood

How to tell

The machine does not respond when the Start button is pressed, or it stops unexpectedly without any error message. The button or pedal may feel loose, sticky, or unresponsive.

Fix

  1. Power off the machine.
  2. Inspect the Start/Stop button on the control panel or the foot pedal (if applicable) for any visible physical damage, debris, or sticking.
  3. Gently clean around the button or pedal mechanism.
  4. If possible, test the functionality of the button/pedal by observing its response when pressed. If it feels faulty or does not register input, the component may need replacement.
  5. Replacing control panel buttons or foot pedals often requires technical expertise and specific parts.

These components are part of assembly section 11 Control or 12 Accessories.

Parts involved: Control panels & displays → Sensors & switches → Cables & wiring →

Stop and call a technician if

  • If the machine timing is misaligned and you are not experienced with such adjustments.
  • If persistent system errors or control panel malfunctions occur after basic troubleshooting and resets.
  • If internal power supply issues are suspected (e.g., machine not powering on, flickering displays).
  • If drive belts are damaged or require complex alignment/tensioning.
  • If the machine continues to overheat despite proper cleaning and ventilation.
  • If any internal components appear damaged or require specialized tools for repair.

Prevent it coming back

  • Always use high-quality embroidery thread, needles, and bobbins compatible with your Barudan machine.
  • Follow the manufacturer's recommended cleaning and lubrication schedule diligently.
  • Inspect the thread path and bobbin area for lint and debris before each major project or daily operation.
  • Regularly check needle condition and replace dull, bent, or broken needles promptly.
  • Ensure proper thread tension for both upper and bobbin threads, adjusting as needed for different fabrics and designs.
  • Verify that hoops are securely attached and fabric is properly hooped without excessive tension or slack.
  • Keep machine firmware updated according to Barudan's recommendations.
  • Operate the machine in a clean, well-ventilated environment and avoid continuous, excessively long embroidery sessions.

Frequently asked questions

Why does my Barudan machine keep breaking thread?

Frequent thread breaks are commonly caused by incorrect threading, a dull or bent needle, improper thread tension, lint buildup in the thread path or bobbin area, or using low-quality thread. Systematically check each of these potential causes.

What should I do if my Barudan machine displays an error code?

First, note the exact error code or message. Consult your Barudan machine's operator manual for the meaning of the code and recommended troubleshooting steps. Address the specific issue indicated by the code before attempting to clear it and restart the machine.

How often should I clean and lubricate my Barudan embroidery machine?

Refer to your Barudan machine's operator manual for the recommended cleaning and lubrication schedule. Generally, daily cleaning of the bobbin case and hook area, and weekly or monthly lubrication of key moving parts, is advisable depending on usage.

Can I use any brand of needle in my Barudan machine?

No, it is crucial to use needles specifically designed for industrial embroidery machines and compatible with your Barudan model. Using incorrect needle types or sizes can lead to skipped stitches, thread breaks, and machine damage. Always refer to your manual for recommended needle systems and sizes.

From the Barudan BEVT-Z1501CII parts book

The assemblies involved in this problem, as the manufacturer lists them. Open a section to see every part number, which ones we stock, and get a price on the rest.

Reference book: Barudan BEVT-Z1501CII. Part numbers differ by model - search yours below and we will confirm fit.

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