Juki 1541S bobbin case problem

[stickandtin]

Wife was merrily sewing along and all of a sudden bobbin thread started binding and breaking. Took bobbin case out and couldn't pull thread. Took bobbin out and thread was bound up in bobbin. Unwound several feet of thread, put bobbin back in case and put back in machine. Tried sewing a couple of stitches and same thing happens. Thread breaks. Take bobbin case out and can't pull thread off bobbin. Take bobbin out again and thread is bound up on bobbin. Wind new bobbin, put back in machine. Same thing happens. Take bobbin case out, remove bobbin and inspect the case. Inside there is a blue black metal disc looking thing with little arms. Arms look worn and maybe bent up. Take the disc out to inspect, now I can't get it back in. Is this disc damaged? Which way does it go back in? Thanks for any help

 

[stickandtin]

[stickandtin]

Ok, got the disc back in the bobbin case but bobbin turns a little and sticks. Then I can't pull any bobbin thread. I think the holes in the bobbin are catching on those little arms and not allowing the bobbin to turn. Does this make any sense? What's the purpose of that disc anyway?

Edited June 17, 2016 by stickandtin

[RockyAussie]

Just carefully try it without the disk I have a pfaff which I use with a disc like that and 1 without the disk and both work fine. The disc just takes out some of the free play and if it has become bent than it will be no good. Make sure there is no catching on the bobbin without the disc in.Does the bobbin turn anticlockwise when you pull the thread?

[stickandtin]

Took disc out. Inserted bobbin and bobbin still binds and won't turn. I think I may have found the problem. Looks like the needle could have hit the bobbin case and created a little dimple inside the bobbin case and that is what the bobbin is binding on. I'll take a pic of what I'm looking at and post.

[stickandtin]

This is the little dimple I'm seeing. The safety clutch did pop right before all this started happening. Wife was sewing over several layers of a marine vinyl seam.

 

[Uwe]

That'll do it! Time to get out the dremel tool or get a new bobbin basket. 

[stickandtin]

Thanks Uwe. Have any idea what caused the needle to hit the basket like that? 

[stickandtin]

This forum is the greatest sewing forum on the Internet!

[Uwe]

I'm guessing the bobbin case wasn't seated properly inside the hook and came loose. There's a second dimple just above the big one. The needle should never be anywhere those spots. When you insert the bobbin case on a horizontal axis bobbin, make SURE it snaps into place. You have to pull up the little tab to hold the bobbin case (this also hold the bobbin inside the case) then insert the bobbin case into the hook and let go of the tab. You should feel and and hear it "snap" into place.  If the bobbin case comes loose and starts to rotate while you're sewing, all manner of bad, expensive things will happen.