Thread Break Diagnostic

This tool can help diagnose a thread break issue. It does assume that your machine has been properly maintained, greased, and oiled. It also assumes that you have already inspected the following

If the above items have been address, please begin answering the questions below to lead you to a possible solution for your thread break troubles.

Thread Break Diagnostic Tool

No	Question/Heading	Answers
1	What type of thread break is it?	False Break (AOS flags a break, but no thread is broken) Real Thread Break (Thread is actually broken)
2	What type of false thread break is it?	False Bobbin Break False Top Thread Break Mistrim Bird nest (mass of thread under the needle plate)
3	What type of true thread break is it?	Real Bobbin Break Real Top Thread Break Mistrim Misstart Bird nest (mass of thread under the needle plate)
4	Answer from above: False Bobbin Break	Check your Acti-feed settings. Check your presser foot adjustment. If the above items did not work, contact Melco Technical Support.
5	Answer from above: False Top Thread Break	Check your Acti-feed settings. Check your presser foot adjustment. Check your bobbin tension. Check for thread buildup under the needle plate. If the above items did not work, contact Melco Technical Support.
6	Answer from above: Mistrim	Check the tie stitches of the design. Check your Acti-feed settings. Clean underneath the needle plate and ensure that it is centered. If the above items did not work, contact Melco Technical Support.
7	Answer from above: Bird Nest	Make sure the thread is lined up under the pinch roller. Clean and grease the pinch rollers. Check the rotary hook support. Clean underneath the needle plate and ensure that it is centered. If the above items did not work, contact Melco Technical Support.
8	Answer from above: Misstarts	Check the needle orientation. Check the tie stitches of the design. Check the acti-feed settings. Check the bobbin tension and tail length. If the above items did not work, contact Melco Technical Support.
9	Answer from above: Bobbin Breaks	Check the bobbin tension. Clean the bobbin case. Check the bobbin case for damage. Use continuous filament polyester bobbin thread. Check for an over-wound bobbin. If the above items did not work, contact Melco Technical Support.
10	Do the thread breaks happen on just this design?	Thread breaks on this design only. Thread breaks on all designs.
11	Contact Melco Technical Support	By phone at 1-800-799-8313 By e-mail at service@melco.com
12	Does the break happen on just this material/garment?	Thread breaks on this material/garment only. Thread breaks on all materials/garments.
13	Do the thread breaks happen on just one needle?	Thread breaks on one needle only. Thread breaks on all needles.
14	Where in the design do the thread breaks most often occur?	Thread breaks on the start or end of elements. Thread breaks mostly on the lettering. Thread breaks mostly in the corners. Thread breaks all over the design.
15	Answer from above: Thread breaks on this design and material/garment only.	Check for application specific issues like specialty thread or needle type. If the application information does not help, contact Melco Technical Support.
16	Answer from above: Thread breaks mostly at the start or end of elements.	Check the tie stitches of the design. Check the bobbin tension and tail length. If the items above do not help, contact Melco Technical Support.
17	Answer from above: Thread breaks mostly on the lettering.	Avoid doubling tie stitches. Make sure the stitches are long enough to sew well. Check the density settings. Lettering that is too dense will not sew smoothly. If the items above do not help, contact Melco Technical Support.
18	Answer from above: Thread breaks mostly on the corners of elements.	Try capping or mitering the troublesome corners. If that does not help, contact Melco Technical Support.
19	Answer from above: Thread breaks all over the design.	Check for stitches that are too small to sew well. Check the density settings. Designs that are too dense will not sew smoothly. Has the design been scaled too far? Check for too many needle penetrations in a concentrated area. Check for application specific issues like specialty thread or needle type. If the items above do not help, contact Melco Technical Support.
20	Answer from above: Thread breaks mostly on one needle.	Change the needle. Check the needle orientation. Change the cone of thread. Some cones can become damaged and prevent smooth sewing. Check for application specific issues like specialty thread or needle type. If the items above do not help, contact Melco Technical Support.
21	Answer from above: Thread breaks on all needles.	Check the presser foot adjustment. Check the actifeed settings. Check the bobbin tension. Check for application specific issues like specialty thread or needle type. Clean under and center the needle plate. Check the rotary hook support. Reset the machine. If the items above do not help, contact Melco Technical Support.