Barudan Embroidery Machine Bird’s Nesting Troubleshooting

1. Improper Threading high likelihood

How to tell

The upper thread path appears incorrect, the thread is not fully seated in the tension discs, or there are visible twists or tangles in the thread path from the cone to the needle.

Fix

1. Completely unthread the machine from the thread cone to the needle.
2. Carefully re-thread the machine, ensuring the thread passes through every guide, the pre-tensioner, the main tension discs, and the take-up lever.
3. Verify the thread is securely seated within the main tension discs. A common mistake is not pulling the thread firmly enough into the discs.
4. Ensure there are no twists, knots, or tangles in the thread path.

Refer to the '06 Thread guide' and '03 Take up lever' sections of your Barudan parts manual for correct thread path diagrams.

Parts involved: Thread path & tension →

2. Incorrect Thread Tension high likelihood

How to tell

If the upper thread tension is too loose, loops of thread will appear on the underside of the fabric. If the bobbin thread tension is too loose, the upper thread will pull the bobbin thread to the top. If either is too tight, the thread may break or pull excessively.

Fix

1. Upper Thread Tension: Perform a tension test stitch. If the upper thread is too loose, turn the upper tension dial clockwise in small increments (e.g., 1/4 turn) and re-test until the stitch quality improves. The upper thread should pull the bobbin thread slightly to the underside, creating a balanced stitch.
2. Bobbin Thread Tension: Remove the bobbin case. Hold the bobbin case by the thread tail and gently jerk it. The bobbin case should slowly unspool a few inches of thread. If it unspools freely, the tension is too loose; tighten the small screw on the bobbin case. If it doesn't unspool, it's too tight; loosen the screw. Refer to your Barudan machine manual for specific bobbin tension calibration procedures and recommended settings.

The upper tension unit is typically found in the '06 Thread guide' assembly. The bobbin case is part of the 'rotary-hooks-bobbin-cases' system.

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

3. Bobbin Case Issues medium likelihood

How to tell

Inconsistent thread feed from the bobbin, visible damage or burrs on the bobbin case, or the bobbin case not seating correctly in the rotary hook. The bobbin itself might be wound unevenly or be the wrong size.

Fix

1. Remove the bobbin case and inspect it thoroughly for any burrs, nicks, or damage, especially around the tension spring and thread exit point. Replace if damaged.
2. Ensure the bobbin is wound evenly and is the correct size for your Barudan machine. Insert the bobbin into the case, making sure it spins freely.
3. Thread the bobbin case, pulling the thread under the tension spring. Confirm the thread exits smoothly.
4. Re-insert the bobbin case into the rotary hook, ensuring it clicks firmly into place and is seated correctly. Rotate the handwheel slowly to confirm the hook engages the bobbin case properly.

The bobbin case is a critical component of the 'rotary-hooks-bobbin-cases' assembly. Refer to the '01A Head Bed A' or '01B Head Bed B' sections for rotary hook components.

Parts involved: Rotary hooks & bobbin cases → Screws, springs & small parts →

4. Incorrect Needle Installation or Damage medium likelihood

How to tell

The needle may be bent, dull, burred, or inserted incorrectly. This can lead to skipped stitches, thread shredding, or improper loop formation, causing nesting.

Fix

1. Turn off the machine. Loosen the needle clamp screw.
2. Remove the current needle and inspect it for any bends, burrs, or dullness. Replace if any damage is found.
3. Insert a new, correct size needle (appropriate for your fabric and thread) all the way up into the needle bar, ensuring the flat side of the needle shank faces the correct direction (typically away from the operator or as specified in your Barudan manual).
4. Tighten the needle clamp screw securely. Do not overtighten.
5. Perform a test stitch to confirm proper stitch formation.

Needles are part of the 'needles-needle-bars' system. Refer to '04A-1 Needle bar A(Z12)' or '04B Needle bar B' sections for needle bar components.

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

5. Poor Fabric Stabilization medium likelihood

How to tell

The fabric shifts or puckers during embroidery, or the design appears distorted. This movement can cause the needle to pull excess thread to the underside.

Fix

1. Ensure you are using the correct type and weight of stabilizer for your fabric and design density. Heavier fabrics or dense designs require firmer stabilization.
2. Hoop the fabric and stabilizer together tightly, ensuring there are no wrinkles or slack. The fabric should be taut like a drum.
3. If necessary, use a temporary adhesive spray between the fabric and stabilizer to prevent shifting within the hoop.
4. For very delicate or stretchy fabrics, consider using a 'floating' stabilizer underneath the hooped fabric, or a double layer of stabilizer.

Parts involved: Hoops & frames → Threads & supplies →

6. Thread Quality Issues low likelihood

How to tell

Thread frequently breaks, frays, or sheds excessive lint. Old or low-quality thread can be inconsistent in thickness or strength, leading to poor stitch formation.

Fix

1. Use only high-quality, machine-compatible embroidery thread from reputable brands.
2. Avoid using old, brittle, or improperly stored thread. Store thread in a clean, dry environment away from direct sunlight.
3. If a specific cone of thread consistently causes issues, try a different cone of the same type or a different brand to rule out thread quality as the cause.

Parts involved: Threads & supplies →

7. Dirty or Worn Machine Parts low likelihood

How to tell

Visible lint, dust, or thread fragments in the thread path, tension discs, bobbin area, or rotary hook. Grinding noises or stiffness in moving parts. This can impede smooth thread flow.

Fix

1. Regularly clean the entire thread path, including all guides, pre-tensioners, and main tension discs, using a small brush or compressed air.
2. Remove the needle plate and bobbin case. Thoroughly clean the rotary hook area, removing all lint, dust, and thread snippets. Use a small brush and vacuum.
3. Inspect the rotary hook for any nicks or burrs that could snag the thread. If found, a technician may need to polish or replace the hook.
4. Lubricate the machine according to your Barudan machine's maintenance schedule and lubrication points specified in the manual. Use only recommended embroidery machine oil.

Focus on cleaning the '01A Head Bed A', '01B Head Bed B', '02 A Thread cut A', and '06 Thread guide' assemblies.

Parts involved: Lubrication & maintenance → Thread path & tension → Rotary hooks & bobbin cases → Head & mechanical parts →

8. Incorrect Machine Speed low likelihood

How to tell

Bird's nesting occurs primarily on complex designs, small details, or when using delicate threads, especially at high speeds.

Fix

1. Reduce the machine's embroidery speed, especially for intricate designs, small lettering, or when using delicate threads (e.g., metallic, fine rayon).
2. Adjust the speed based on the fabric type. Thicker fabrics or multiple layers may require a slower speed to allow the needle to penetrate properly and form stitches cleanly.

Parts involved: Control panels & displays →