I recently purchased a Happy Voyager 1201HCS. I had to assemble out of the box. First the main shaft was jammed, but I did not know that was the problem for two weeks. I corrected that with research. Now I am having continuous thread breaks. I believe the problem to be tension related, but the thread sensors do not make the machine stop when a thread breaks. The arm just flops. I have to turn the machine off to correct and then turn to the C mark on the shaft. My sew outs do not show much bobbin on the back. There is a lot of the color of thread I am using on the back side.
Are there any guides available for proper thread tension? The dealer told me that the thread tension should never be changed. He says only the bobbin tension should be adjusted, but Texmac says differently. They say tension is changed for different fabrics.
I have had some looping as you addressed in a future posting.
I have changed the needles and thread to correct the improper tension problem.
If you have suggestions for this problem other than contacting my dealer I would appreciate it. I have orders to fill and can not do so.

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Hi Patricia,

Consistent thread breaks can also be the result of needles facing the wrong way and improper threading which you already mentioned and am sure you've checked and checked again. Could it also be related to the initial technical problem you had in the two weeks you mentioned?


You can purchase a top thread tension gauge and a bobbin case tension gauge. A gauge is a small device that allows you to have proper and consistent tension. You have to make sure to buy the right size ("M" or "L") bobbin case tension gauge that's right for your machine. They work great and come with instructions and recommended settings/guides.

For the top thread, you can do the "I" test. Basically, embroider a large (and thick) capital "I" for each needle. When embroidered, the backside of the letter should show the middle 1/3 as bobbin thread and the remaining two sides as top thread. If too much bobbin shows, the top thread tension is too tight or the bobbin tension is too loose. If too much top thread shows, then the bobbin tension is too tight or the top thread tension is too loose.

For the bobbin, you can do the yo-yo or drop test.

• Don't put the thread through the pigtail, but make sure the thread is still under the tension spring
• Grab the thread with your thumb and forefinger
• Flick your wrist down

Note: Just in case your bobbin tension is too loose, be sure it lands somewhere safe like on the palm of your other hand etc.

The bobbin case should drop 3 inches. If goes much farther, then the tension is too loose. If it doesn't budge, then it's too tight.

Your bobbin tension is too tight or your top thread is too loose.

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Marc has offered some great advice! In addition to tension issues, the problem could also be caused by small stitches in your design. You may also want to slow down the speed of your machine. I know it will sew faster, but I usually run my machine at around 630 SPM. I have a Voyager, so if you need specific info on how to change your tension or speed, etc. email me and I will try to help.

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