TL;DR

Needle breakage is usually a bent needle hook, incorrect yarn tension, or worn cam track. Inspect the needle bed and cam tracks at the affected feeder before replacing individual needles.

What you might see

hole or drop stitch in the fabric
needle debris in the fabric structure
clicking or tapping noise from the needle bed
machine stopping with fabric fault alarm

Likely causes

Tap to mark as ruled out

Bent or cracked needle hook from yarn snag or foreign object
Worn cam track allowing needle hooks to collide at the stitch point
Yarn tension too high for the needle gauge, bending hooks on withdrawal
Incorrect needle selection for the yarn count or stitch structure

Required tools

Needle removal and insertion tool
Yarn tension gauge
Replacement needles (same gauge and type)
Magnifying glass or loupe for cam track inspection

Safety first

The rotating needle cylinder has pinch points at every feeder. Keep hands clear of the needle bed while the machine is running.
Broken needle fragments can be propelled from the needle bed. Wear eye protection when inspecting the bed during rotation.

Procedure

7 steps · ~30 min

1
Stop the machine and identify the feeder position where the needle breakage occurred from the fabric defect pattern.
2
Slowly rotate the cylinder by hand at the suspected feeder. Watch each needle hook pass through the cam track and look for a needle that does not rise to full height or that snags.[1]
3
Remove the defective needle using the needle removal tool. Inspect the hook and butt for bending, cracking, or corrosion.
4
Inspect the cam track at the affected feeder for burrs, scoring, or wear marks. A worn cam track will break new needles rapidly.
5
Check the yarn tension at the affected feeder with a yarn tension gauge. Reduce tension if it is above the specification for the yarn count in use.
6
Insert a replacement needle of the same gauge and hook type. Ensure the butt engages the cam track correctly.[1]
7
Restart the machine slowly for 2 to 3 revolutions. Watch the new needle and inspect the fabric for drop stitches.

Sources

Mayer & Cie Mayer Relanit Knitting Machine (Circular / Flat) general technical documentation, Mayer & Cie
Mayer & Cie circular knitting machine general maintenance and needle replacement procedures (general)

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