Tajima TMAR-KC: Troubleshooting and Fixing Bird’s Nesting

1. Incorrect Thread Tension (Upper or Bobbin) high likelihood

How to tell

If the upper thread tension is too loose, you will see loops or a tangled mess (bird's nest) on the underside of the fabric. If the bobbin tension is incorrect, stitches may appear uneven, fabric may pucker, or the upper thread may not pull the bobbin thread correctly to the fabric's underside.

Fix

1. Ensure the upper thread is correctly routed through all tension discs and guides. The thread should have a slight resistance when pulled.
2. Adjust the upper thread tension dial. Turn clockwise to tighten, counter-clockwise to loosen. Make small adjustments and test.
3. Remove the bobbin case. Hold it by the latch with the bobbin inside and pull the thread. The bobbin case should slowly descend a few inches, then stop. If it drops quickly, it's too loose; if it doesn't move, it's too tight.
4. Adjust the small screw on the bobbin case to fine-tune bobbin tension. Turn clockwise to tighten, counter-clockwise to loosen. Make very small adjustments (e.g., 1/8th turn) and re-test with the drop test or a bobbin tension gauge.

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

2. Improper Upper Threading high likelihood

How to tell

Visually inspect the entire upper thread path from the spool to the needle. Look for the thread missing a guide, slipping out of tension discs, or not being fully seated in the take-up lever eyelet. The thread may appear slack in sections.

Fix

1. Completely remove the upper thread from the machine.
2. Re-thread the machine carefully, ensuring the thread passes through every guide, tension disc, and the take-up lever eyelet. Pay close attention to the pre-tensioner and main tension discs.
3. Ensure the thread is seated correctly in the needle eye.
4. Use high-quality embroidery thread that is less prone to fraying or breaking.

Parts involved: Thread path & tension → Threads & supplies →

3. Incorrect Bobbin Case Setup high likelihood

How to tell

The bobbin thread may not feed smoothly, leading to bunching. The bobbin case might feel loose or wobble when installed, or the thread unwinds in the wrong direction.

Fix

1. Remove the bobbin case from the rotary hook.
2. Ensure the bobbin is inserted so that the thread unwinds in a counter-clockwise direction when viewed from the top of the bobbin case.
3. Check that the bobbin case is clean and free of lint.
4. Re-insert the bobbin case into the rotary hook, ensuring it clicks securely into place and is properly aligned. Gently tug the bobbin thread to confirm smooth feeding.

Parts involved: Rotary hooks & bobbin cases →

4. Damaged or Incorrectly Installed Needle medium likelihood

How to tell

The needle may appear bent, dull, or have a burr. Stitches may be skipped, fabric may be damaged, or the thread may break frequently. If installed incorrectly, the needle may not pick up the bobbin thread reliably.

Fix

1. Inspect the needle for any signs of bending, dullness, or burrs. Replace if any damage is found.
2. Ensure the correct needle size and type are used for the fabric and thread combination (refer to your machine manual for recommendations).
3. Loosen the needle clamp screw and remove the old needle. Insert the new needle fully into the needle bar, ensuring the flat side of the needle shank faces directly to the back of the machine.
4. Tighten the needle clamp screw securely.

Parts involved: Needles & needle bars →

5. Lint Build-Up and Lack of Maintenance medium likelihood

How to tell

Visible lint, dust, or thread fragments in the bobbin area, under the needle plate, or within the tension discs. Thread movement may feel restricted or gritty.

Fix

1. Turn off the machine and remove the needle plate.
2. Use a small brush or compressed air to thoroughly clean the bobbin case area, rotary hook, feed dogs, and under the needle plate. Remove all lint and thread debris.
3. Clean the upper thread path, including the tension discs and thread guides, with a soft brush or a piece of thread flossed through the discs.
4. Apply lubrication to designated oiling points as per your Tajima TMAR-KC machine manual. Do not over-oil.

Parts involved: Lubrication & maintenance → Rotary hooks & bobbin cases → Thread path & tension → Screws, springs & small parts →

6. Improper Fabric Hooping or Stabilizer Use medium likelihood

How to tell

The fabric shifts or puckers during embroidery. Stitches may be misaligned, or the fabric appears loose within the hoop. Bird's nesting occurs more frequently with certain fabric types or designs.

Fix

1. Ensure the fabric is hooped tightly and evenly, without wrinkles or slack. The fabric should be taut like a drum.
2. Select the appropriate stabilizer type (cut-away, tear-away, water-soluble) and weight for your fabric and design density. Use multiple layers or a heavier stabilizer for dense designs or unstable fabrics.
3. Ensure the hoop is securely attached to the machine's pantograph arms and does not wobble.

Parts involved: Hoops & frames → Threads & supplies →

7. Excessive Embroidery Speed low likelihood

How to tell

Bird's nesting occurs primarily during high-speed operation, especially with dense designs or challenging materials. The machine may sound strained.

Fix

1. Reduce the embroidery speed on the machine's control panel, especially for complex designs, dense stitch counts, or delicate fabrics.
2. Monitor the machine's performance at lower speeds to find the optimal balance between production and stitch quality.

8. Incorrect Presser Foot Height low likelihood

How to tell

Fabric may lift excessively with the needle, shift during stitching, or be held down too tightly, causing drag. Bird's nesting may occur due to fabric movement.

Fix

1. Consult your Tajima TMAR-KC manual for the correct presser foot height adjustment procedure.
2. For thin or slippery fabrics, slightly lower the presser foot to minimize fabric movement.
3. For thicker materials (e.g., caps, heavy garments), ensure the presser foot is high enough to allow the fabric to move freely without excessive drag.
4. If your machine has a digitally controlled presser foot, verify its calibration and settings for the current fabric and design.

Parts involved: Presser feet & sewing parts →