Barudan troubleshooting

Likely causes: threading missed a guide, too much tension, burred needle or presser foot, needle not centred in the foot, dry needle bars, poor thread

1. Rethread the needle from the cone, checking every guide and the clamp pin, and make sure the thread is seated between the tension discs.
2. Fit a new 75/11 needle with the scarf to the back; replace any needle that breaks thread more than once in a run.
3. Loosen the top tension slightly and sew an 18 mm capital "I" test.
4. Look at the presser foot and throat plate for nicks; polish or replace. Make sure the needle is centred in the foot hole.
5. Clean and oil the needle bars.
6. If one needle only: swap cones between needles to see if the fault follows the thread or stays with the position.
7. If all needles: check the bobbin, bobbin case, throat plate, needle centring and the hook.

Call a technician if: breaks persist on several needles after the steps above.

Link to this fix

Likely causes: dirty or stiff check spring (older machines), thread not wrapped round the rotary detect wheel, upper and lower tensioners out of balance

1. On check-spring machines, clean the spring and post and confirm the spring moves freely; back it off slightly.
2. On wheel machines, make sure the thread wraps fully round the detect wheel; for intermittent faults wrap it twice.
3. Balance the top and bottom tensioners so the wheel turns while sewing.
4. If false D25 stops happen on very short stitches, raise MC1 parameter #04 (T-Break).

Call a technician if: several needles fail to detect breaks.

Link to this fix

Likely causes: unbalanced tension, flagging fabric, hook assembly problem

1. Rethread the top thread and run the "I" test to confirm tension.
2. Hoop tighter and check the gap between the hoop and the sewing arm; a large gap lets the fabric flag.
3. Remove the throat plate and clear all thread from the hook area.
4. Check the positioning finger is not too close to the hook basket and the hook turns freely.

Call a technician if: nesting continues with good tension and tight hooping.

Link to this fix

Likely causes: bad threading, low or empty bobbin, dry hook or needle bars, bent needle, hook timing (last)

1. Rethread and fit a new needle the right way round.
2. Replace a low bobbin.
3. Oil the hook raceway and needle bars.
4. Only then check hook timing: at 25° on the degree wheel (bridge heads) or 23° (arm/single heads) the hook point should sit just behind the needle scarf, above the eye, with about half to one thread width clearance.
5. Sew 20 mm block letters "H O X" to test every pantograph direction.

Call a technician if: you are not comfortable loosening the hook screws; timing usually only shifts after something jams the hook, the needle size changes by more than one size, or thread builds up behind the hook.

Link to this fix

Likely causes: design origin off, hoop too small for the design, wrong frame selected

1. Replace the needle and straighten or replace the presser foot.
2. Check the take-up levers line up at TOP; one low lever means the head is out of sync.
3. Trace the design before sewing.

Call a technician if: problems continue; the needle bar driver may be damaged.

Link to this fix

Likely causes: untrimmed thread holding the slider down, dull blades, worn wave washer, birdnest knocked the trimmer out

1. Break the thread by hand, pull about 50 mm free and let the slider lift it.
2. Clear thread and lint from under the throat plate.
3. Replace the trimmer blades and wave washer and readjust.
4. Clean the slider so it moves smoothly by hand.

Call a technician if: D22 trimmer motor errors keep returning after cleaning.

Link to this fix

Likely causes: stuck thread-keep or jump solenoid, broken take-up lever, side cover rubbing, head out of sync, needle-select board fault

1. Power off and turn the colour-change shaft by hand; never force a bind.
2. On VT machines showing "N00", rotate the manual colour-change shaft behind the tension base with a 4 mm Allen key until a needle number shows, then power cycle.
3. Look for a broken take-up lever or a jammed thread-keep part.
4. Check the needle-select board for a bent sensor plate.

Call a technician if: all levers are not aligned at TOP or the board needs replacing.

Link to this fix

Likely causes: thread wrapped behind the hook, dry machine, mechanical bind

1. Power off, remove the drive pulley cover and turn the degree wheel by hand.
2. Remove the throat plate and pick out thread behind the hook.
3. Oil the machine and try again.

Call a technician if: the shaft still binds.

Link to this fix

Likely causes: design outside soft limits, something jamming the frame, blocked cooling fan

1. Re-centre the design so its trace stays inside the field.
2. Power off and move the pantograph by hand to clear any obstruction.
3. Clean lint from the driver fan and vents.

Call a technician if: soft limits need changing or D29 returns with nothing jammed.

Link to this fix

Likely causes: full memory, damaged stick or card, wrong file type, bad file header, network cable

1. Delete old designs from machine memory (A08, A29).
2. Try a different, freshly formatted USB stick or CF card.
3. Re-save the design from your software as DST or Barudan format and try again (A41).
4. For DFS/LEM network errors, close and reopen the software, reboot both ends, and reroute the cable away from power lines.

Call a technician if: no design will load at all; the internal CF card may need reformatting.

Link to this fix

Likely causes: positioning finger off-centre, bobbin tension wrong

1. Aim for about one third bobbin across the back of a satin column.
2. If the bobbin is off to one side on every needle, remove the throat plate and shift the positioning finger so it is centred on the needle.
3. If width is wrong on every needle, adjust bobbin tension; if it varies needle to needle, adjust top tension instead.

Call a technician if: the finger cannot be centred.

Link to this fix

Likely causes: sewing caps too fast, loose cap hooping, wrong frame setting

1. Keep cap speed at or below 1,000 spm (Barudan's own limit on XL2 and LY machines).
2. Hoop the cap tightly in the Advantage EX or Performance cap frame using Barudan's hooping guide.
3. Sew caps from the centre outward and bottom up in your digitizing.

Call a technician if: the cap drive slips or the frame does not seat.

Link to this fix