horizontal break in stitching caps

I am using Hatch 2 and had very good success in flat embroidery on a Tajima TMEX901 but am not enjoying caps. The cap is hooped correctly and the driver is adjusted but I continue to have strange satin stitch capital letters. There is a horizontal break in the lettering and the satin fill is offset or poor around curves. I am sure it is simple fix. I have tried other capital letterings and had the same result- never had problems with the machine. tensions are correct. I did contact my service people and they said if tension/bobbin/needle are okay it looked like a digitizing issue. No problems with images. Please see pictures (so embarrassed,.,,,) thank you in advance- Christine

This looks like several issues. If you will create a support ticket and attach your design, I'll be happy to look at it. But from looking at the images:
The satin stitch (white) is too wide and your machine will not stitch that wide.
It does not appear to have any underlay
The satin stitches are all going in one direction and they are falling in some of the groves of the hat.
You should use a topping with this much texture in the hat so the stitches have a smooth surface to stitch on.
Looks to be a digitizing issue.
It also could be your thread type used.

One thing you can do is that you should always test the design on a flat surface as a test piece to make sure the design itself stitches okay before you put on a hat or anything else.
Again, open a support ticket and attach the design and images.

Kim thank you! I am not concerned with the white- just the yellow lettering.... I will switch out the cap driver and run it again to see if that is the issue- will report back. I also cannot figure out how to remove my duplicate post. thank you for responding!

Kim thank you! I am not concerned with the white- just the yellow lettering.... I will switch out the cap driver and run it again to see if that is the issue- will report back. I also cannot figure out how to remove my duplicate post. thank you for responding!

Kim I am betting this IS mechanical or I am missing something in the setup of the image- here is the flat version. Other than the vertical of the L it seems great. Thoughts?

BBBWAAAHAHAHAHA I forgot to install two screws.... Kim thanks for the support