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Knowledge Base

Needle & Needle Bar Issues

October 03, 2026

Needle problems are among the most frequently reported issues — from bent needles caused by shipping, to wrong needle types, to pile height gear misconfigurations. Always confirm your machine model and current mode (cut pile vs. loop pile) before diagnosing.

Issue Reference Table

Symptom Likely Cause Fix / Action
Needle tip is bent Impact during shipping or hitting the frame while tufting Replace needle. Watch the 'Needle Replacement' video in the Vimeo showcase.
Needle not sticking out / no yarn placement Pile height gear at position 15+ or even-numbered hole used incorrectly Adjust pile height to position 13–14. See Pile Height section below.
Needle tip broke off the bar Impact or stress fracture; shipping damage Replace needle completely. Do not attempt to re-attach.
Needle bar slightly bent Shipping stress or impact Carefully use a mallet to gently straighten. Re-test.
Yarn not passing through needle eye (thick yarn) Shutter strip blocking the eye opening Adjust shutter strip — see Yarn Feed & Tension.
Wrong needle type installed Incorrect needle sent or picked from spare parts bag Identify correct type (cut pile vs. loop pile). Request correct replacement.
Needle re-seated but still misaligned Set screw not tightened after replacement Re-seat per Needle Replacement video. Confirm set screw is tight.

Needle Replacement Procedure

  1. Turn OFF and UNPLUG the machine.
  2. Open the 'Needle Replacement' video in the Vimeo showcase for a visual guide.
  3. Loosen the set screw holding the needle just enough to slide it out.
  4. Remove the bent or broken needle carefully.
  5. Insert the correct replacement needle for your machine type (cut pile or loop pile).
  6. Re-tighten the set screw firmly — a loose screw causes recurring needle issues.
  7. Manually cycle the machine by rotating the white gear by hand before powering on.
  8. Test with a small piece of cloth before resuming full use.
Needle bar set screws — upper and lower screws secure the needle and shutter strip
Needle bar set screws — upper and lower screws secure the needle and shutter strip

Pile Height Gear & Needle Position

  • Recommended pile height positions: 13 or 14
  • Position 15 or higher: needle does not protrude far enough; yarn won't be placed correctly
  • Even-numbered gear holes should NOT be used unless the top bar is also adjusted accordingly — using even holes without the bar adjustment causes misalignment
  • If the machine is "running but not tufting," check the pile height gear position first — this is one of the most common setup errors
Pile height gear — white gear with bolt seated in adjustment hole
Pile height gear — white gear with bolt seated in adjustment hole

Slightly Bent Needle Tip: Try Straightening First

If your needle gets dented or bent, for example from the machine falling, you can often fix it yourself. With the machine off and unplugged, use needle-nose pliers to gently bend the needle back as straight as you can. This usually works, and we rarely end up replacing needles. If straightening doesn't work, replacement needles are available from us. Just contact support.

Cloth Pusher Bolt Snapped or Cloth Pusher Slipping

The cloth pusher is held down by a thin bolt. If the cloth pusher slides back, it has usually been moved too far forward and come out of its seat. Overtightening the nut can snap this bolt.

To replace the bolt:

  1. Turn OFF and UNPLUG the machine.
  2. Follow the 'Low pile cloth pusher replacement' video in the Vimeo showcase. It was made for an earlier model, but the steps are practically the same.
  3. Remove the front of the machine, take off the lower bearing, and remove the scissors. This gives you access to the bolt.
  4. Replace it with the spare bolt in your spare parts bag. It is small and black, with a flat part.
  5. Tighten gently. Do not overtighten.

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