Tajima TMAR-KC: Troubleshooting Skipped Stitches in Multi-Embroidery Designs

1. Incorrect Needle Installation or Size high likelihood

How to tell

Stitches are consistently skipped, especially at the start of a design or after a needle change. The machine may make unusual noises as the needle strikes the bobbin case or needle plate.

Fix

1. Ensure the needle is fully inserted into the needle bar, with the flat side of the needle shank facing away from the rotary hook (typically to the right on Tajima machines). Tighten the needle clamp screw securely.
2. Verify the needle size and type are appropriate for the thread and fabric being used. Consult your machine's manual or thread manufacturer's recommendations. Generally, heavier fabrics/threads require larger needles, and delicate materials require smaller ones.
3. Replace the needle if it is dull, bent, or has a burr. Needles should be changed every 8-10 hours of embroidery or when switching fabric types.

Parts involved: Needles & needle bars →

2. Thread Tension Imbalance high likelihood

How to tell

Stitches appear loose on the top or bottom, or the bobbin thread is visible on the top surface. Skipped stitches may occur erratically or in specific areas of the design.

Fix

1. Adjust the upper thread tension. Turn the tension knob clockwise to tighten or counter-clockwise to loosen. Perform a test sew-out on scrap fabric to achieve a balanced stitch (top and bobbin threads meet in the middle of the fabric).
2. Check bobbin tension. The bobbin thread should unwind smoothly with slight resistance when pulling the thread from the bobbin case. If it's too tight or too loose, adjust the small screw on the bobbin case. Ensure the bobbin is wound evenly.
3. Verify the thread path is clear and free of obstructions. Ensure the thread is correctly seated in all tension discs and guides.

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

3. Poorly Hooped Fabric high likelihood

How to tell

Fabric sags or wrinkles within the hoop, or shifts during embroidery. Skipped stitches are often accompanied by poor registration or puckering.

Fix

1. Ensure the fabric is hooped taut and flat, but not overstretched. The fabric should be drum-tight without distorting the weave.
2. Use the correct size and type of hoop for the design and fabric. For caps or curved items, use specialized cap frames to maintain stability.
3. If fabric shifts during embroidery, pause the machine, re-hoop the fabric, and ensure adequate stabilization is used underneath.

Stabilizer is a consumable, but crucial for proper hooping.

Parts involved: Hoops & frames → Threads & supplies →

4. Damaged or Incorrect Bobbin Case medium likelihood

How to tell

Thread snags or breaks frequently at the bobbin area. Skipped stitches are often accompanied by poor bobbin thread pickup. Visible burrs or nicks on the bobbin case.

Fix

1. Remove the bobbin case and inspect it thoroughly for any nicks, burrs, or rough edges that could snag the thread. Replace the bobbin case if any damage is found.
2. Confirm you are using the correct type of bobbin and bobbin case specified for your Tajima TMAR-KC machine. Incorrect types can lead to tension issues and improper fit.
3. Ensure the bobbin is wound evenly and smoothly. An unevenly wound bobbin can cause inconsistent tension and lead to skipped stitches.

Parts involved: Rotary hooks & bobbin cases →

5. Dirty Machine or Needle Plate medium likelihood

How to tell

Lint, dust, or thread debris is visible in the bobbin area, under the needle plate, or around the rotary hook. Skipped stitches may occur randomly.

Fix

1. Regularly clean the machine, especially the bobbin area, rotary hook, and under the needle plate. Use a small brush, compressed air, or a vacuum to remove lint and thread build-up.
2. Remove the needle plate and inspect it for any nicks or scratches around the needle hole. A damaged needle plate can snag the thread. Replace if damaged.

Needle plate is part of the sewing parts.

Parts involved: Lubrication & maintenance → Presser feet & sewing parts →

6. Incompatible Thread and Fabric Pairing medium likelihood

How to tell

Skipped stitches occur consistently with a specific combination of thread and fabric, even if other settings are correct. Thread may shred or break frequently.

Fix

1. Match the thread weight and type to the fabric. For example, use stronger, thicker threads for dense fabrics like denim, and finer threads for delicate fabrics like silk.
2. Always perform a test sew-out on a scrap piece of the actual fabric with the chosen thread to ensure compatibility before starting the main project.

Parts involved: Threads & supplies →

7. Improper Needle Depth Adjustment low likelihood

How to tell

The needle consistently fails to pick up the bobbin thread, or the loop formation is incorrect. This is more apparent with complex designs or varying fabric thicknesses.

Fix

1. Refer to your Tajima TMAR-KC machine's manual for the recommended needle depth setting. The needle depth determines how far the needle descends into the fabric to interact with the rotary hook.
2. Adjust the needle bar height if necessary, ensuring the needle point is at the correct position relative to the rotary hook tip during its lowest point of travel. This is a precise adjustment; consult the manual for exact measurements and procedures.

Parts involved: Needles & needle bars → Head & mechanical parts →

8. Incorrect Embroidery Speed Settings low likelihood

How to tell

Skipped stitches occur more frequently at higher machine speeds, especially with intricate designs, small details, or thicker fabrics.

Fix

1. Reduce the machine's embroidery speed, particularly for complex designs, delicate fabrics, or when using fine threads. Slower speeds allow for more accurate stitch formation and better thread pickup.
2. Maintain a consistent speed throughout the embroidery process to avoid sudden changes that can affect stitch accuracy.

9. Timing Issues (Needle-to-Hook Synchronization) low likelihood

How to tell

Consistent skipped stitches across all needles, despite correct needle installation, tension, and hooping. The needle and rotary hook are not synchronized, causing the hook to miss the thread loop.

Fix

1. This is a precise mechanical adjustment. If you suspect timing is off, it is best to contact a qualified technician. Attempting to adjust timing without proper knowledge can cause further damage.
2. Refer to the Tajima TMAR-KC service manual for the exact procedure for setting needle-to-hook timing. This typically involves adjusting the rotary hook position relative to the needle at its lowest point.

Parts involved: Rotary hooks & bobbin cases → Shafts, bearings & bushings → Head & mechanical parts →

10. Embroidery Software and Design Issues low likelihood

How to tell

Skipped stitches occur only with specific designs, even when other designs sew out perfectly. The issue may be consistent in the same areas of the problematic design.

Fix

1. Check the embroidery design file for digitization quality. Poorly digitized designs, especially those with very short stitches, tight angles, or excessive density, can cause skipped stitches.
2. If possible, re-digitize the design or use a different, known-good design to test if the issue persists. Ensure the design is optimized for the fabric and machine type.

Refers to the storage medium for the design file.

Parts involved: Floppy, USB & memory →