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Brother embroidery machine problems and how to fix them

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5/8 in seam allowance

Short answer

Most Brother embroidery machine problems come from threading, the needle, the bobbin or stabilizer, not a fault in the machine. Rethread the top with the presser foot up, put in a new 75/11 embroidery needle, use embroidery bobbin thread inserted correctly, and hoop with the right stabilizer. For on-screen messages, read the exact wording and follow the manual's error list for your model.

Machines for this job

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Brother's PE and SE embroidery and combo machines, such as the PE800, PE900, SE700, SE1900 and SE2000, are among the most popular home embroidery machines in the US. Like any embroidery machine, they can break thread, nest under the hoop, show bobbin thread on top or stop with a message on the screen. This guide groups the common problems by symptom and gives the fix in the order to try it. Error wording and steps vary by model and software version, so use your manual's error and troubleshooting pages alongside this guide.

Problems by symptom

  • Top thread breaks or shreds

    Most likely causes
    Old needle, threading, thread quality
    First fixes
    New embroidery needle, rethread with foot up, check spool cap

  • Bird nest under the hoop

    Most likely causes
    Top thread missed tension discs
    First fixes
    Rethread with the presser foot up

  • Bobbin thread shows on top

    Most likely causes
    Top tension too tight or bobbin issue
    First fixes
    Rethread, check bobbin type and insertion, then tension

  • Puckering around the design

    Most likely causes
    Stabilizer or hooping
    First fixes
    Firmer stabilizer, hoop fabric taut but not stretched

  • Outlines do not line up

    Most likely causes
    Fabric shifting in the hoop
    First fixes
    Better stabilizer, tighter hooping, smaller hoop

  • Needle breaks

    Most likely causes
    Bent needle, hoop not attached, thick seams
    First fixes
    New needle, reattach hoop, avoid thick seams under the design

  • Machine will not start embroidering

    Most likely causes
    Presser foot up, hoop not attached, message on screen
    First fixes
    Read the message, lower the foot, reseat the hoop

  • Design too large message

    Most likely causes
    Design bigger than the hoop or field
    First fixes
    Choose a larger hoop if supported, or resize the design
Start with the first fix in each row

Thread breaking, shredding and nesting

Thread problems are the most common complaint, and they are usually fixed by rethreading and a new needle. Always thread the top with the presser foot raised so the thread seats in the tension discs. Use the correct spool cap for the spool size, and make sure the thread is not catching on the spool's notch.

Use a 75/11 embroidery needle for most work and replace it often; embroidery wears needles fast. Use 40 weight embroidery thread and the bobbin thread recommended for your machine. A bird nest under the fabric almost always means the top thread is not under tension. Our guides to embroidery machine bird nesting and embroidery thread shredding and breaking go deeper.

Note.If the needle strikes the hoop or presser foot, turn the machine off, check the hoop is attached and the design fits, and replace the needle before continuing.

Tension problems on Brother embroidery machines

The usual sign of a tension problem is bobbin thread showing on top of the design, or loops of top thread on top. Before changing any tension setting, rethread the top and check the bobbin: correct bobbin thread, wound evenly, inserted the right direction and pulled through the tension spring.

Many Brother embroidery models let you adjust embroidery thread tension in a settings screen. Small changes are best, and test on scrap fabric with the same stabilizer. The bobbin case tension is set at the factory, and some Brother models use a separate bobbin case for embroidery; avoid turning the bobbin case screw unless your manual describes it. Our embroidery machine tension settings guide explains the I-test for checking balance.

Error messages and on-screen warnings

Brother embroidery machines show messages on the LCD when something needs attention. The exact wording differs between models and software versions, so look up the message in your manual. Common types of messages include:

  • Presser foot messages: lower or raise the presser foot before starting or moving.
  • Upper thread messages: the machine detected the top thread broke or ran out.
  • Bobbin messages: the bobbin thread is low or ran out, on models with a bobbin sensor.
  • Embroidery unit or carriage messages: the arm needs to move to its start position; keep the area clear.
  • Hoop or frame messages: the hoop is not attached, or the design is larger than the selected hoop.
  • Safety device messages: the machine stopped because something blocked the needle or motor.

Hoop and design size problems

If the machine refuses a design or reports it is too large, compare the design's size in millimeters with your hoop's stitch field. A 5x7 machine cannot stitch a 6x10 design without splitting or resizing it. Our embroidery machine hoop size chart lists standard fields, and the hoop size guide checks a design against them.

If the machine does not read a design from USB, check that the file format is one your machine supports, usually PES on Brother machines, and that the file is not in too many nested folders. See Brother embroidery machine file formats. If problems seem software-related, check whether your machine has a firmware update; see how to update a Brother embroidery machine.

Embroidery fields of 4x4, 5x7, 6x10 and 8x12 hoops drawn to scale, sharing one corner8x126x105x74x44x4 hoop100 x 100 mm3.9 x 3.9 in5x7 hoop130 x 180 mm5.1 x 7.1 in6x10 hoop160 x 260 mm6.3 x 10.2 in8x12 hoop200 x 300 mm7.9 x 11.8 in2 in (50.8 mm) at this scale
Stitch fields, not outer hoop sizes. Exact fields vary a little by brand and model, so check your machine's manual.

When to call for service

Most problems are fixed by threading, needles, bobbins and stabilizer. Call Brother support or an authorized service center if the machine makes grinding or knocking sounds, if the embroidery arm does not move smoothly, if the needle repeatedly strikes the plate with a new needle and correct hoop, or if the machine shows an error that persists after following the manual.

Regular cleaning of the bobbin area prevents many issues. If you are considering an upgrade for larger designs or more speed, our best Brother embroidery machines and best embroidery machines for beginners guides compare current models.

Compare Brother embroidery machines →

Frequently asked questions

Why does my Brother embroidery machine keep breaking thread? The most common causes are an old needle, threading with the presser foot down, the wrong spool cap, or poor quality thread. Replace the needle and rethread first.

Why is the bobbin thread showing on top? The top tension may be too tight relative to the bobbin, or the bobbin may be inserted wrong or use the wrong thread. Rethread and check the bobbin before adjusting tension.

Why will my Brother embroidery machine not start? Check the screen for a message. Common reasons are the presser foot being up, the hoop not attached, or the design being too large for the hoop.

Should I adjust the bobbin case tension? Generally no. It is set at the factory. Adjust top tension in small steps first and contact service if the bobbin case seems wrong.

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