The way the picker works, is every time the machine starts to sew after a trim has occurred, is on the first few stitches it moves into the bobbin area and the 2 prongs of the picker align the bobbin thread so that it is straight, so that when the upper thread gets picked up by the rotary hook that it meets the bobbin precisely to get a good tie in for the first few stitches during the inching mode. The picker is that forked component just outside the bobbin area of your machine. The next possibility is the picker not working correctly. Remember whenever you turn the tension knobs always provide a good balance by turning both the small and the larger tension knobs to reach the desired look.
If the bobbin drop test looks good then tighten up the top tension. Make sure that you have an inch to an inch and a half drop to the bobbin. For instance, if on the back of the design you see little bobbin thread showing, then either your bobbin is too tight or the top tension is too loose. Look at the back of the design and you can determine this by the ratio of upper thread and bobbin thread showing in the back of the design.
The most common reason for thread pull outs on embroidery machines is improper tension. Diagnosing Thread Pull Out's on your Embroidery Machine
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