Brother XL-6060 User manual





6. 2001.
www.promelectroavtomat.ru


This service manual has been compiled for explaining repair procedures of the MODEL XL-6060, XL6050, XL-
6040.
This was produced based on up-to-date product specifications at the time of issue, but there may have been
changes of specifications for the purpose of improvements.
Contact manufacturer or local sales company for information concerning such changes.
Brother Industries, Ltd.
Nagoya, Japan

I.PRINCIPAL MECHANISMS..................................................................................1
II.DISASSEMBLING AND REASSEMBLING THE SEWING MACHINE................6
III.MECHANICAL ADJUSTMENT STANDARDS AND ADJUSTMENT
PROCEDURES...................................................................................................28
IV.TROUBLESHOOTING PROCEDURES..............................................................55

1. Use the operation procedure given in this document.
2. Always disconnect the power cord from the socket before starting to install or remove any parts.
3. Always replace only with genuine Brother parts.
4. Do not alter this sewing machine.
*Doing so can cause fire, electrical shock, injury, etc.
www.promelectroavtomat.ru

-1-
I. 
1.MECHANICAL CHART....................................................................................2
2.POWER TRANSMISSION CHART..................................................................3
www.promelectroavtomat.ru

-2-
1. MECHANICAL CHART
www.promelectroavtomat.ru

-3-
2. POWER TRANSMISSION CHART
(A) Generating mechanism of needle bar, thread take-up lever and zigzag movements
Thread take-
up lever Thread take- up crank Worm gear Timing pulley
Needle bar
crank rod
Needle ba
r
clamp
Needle bar Needle bar
block assembly
Needle
Pattern cam
Zigzag connecting
rod Z finger Selecting cam
Upper shaft
www.promelectroavtomat.ru

-4-
(B) Mechanism of feed dog and rotary hook movement
Lower shaft
gear
Rotary hoo
k
assembly
Feed dog
Feed carriage
Vertical feed
cam
Horizontal
feed plate
Feed pattern
cam
Feed finger
Feed regulator
Horizontal
feed shaft
Horizontal feed cam
pulley
Forked
connecting rod
Horizontal
feed arm
Lower shaft
Timing belt
Lower shaft
timing belt
Worm gear Timing pulley
Driving belt
Motor
www.promelectroavtomat.ru

-5-
(C) Automatic 1-step BH mechanism (XL-6060, XL-6050 Series only)
BH change
shaft BH change arm BH stopper BH cam BHF finger assembly
BH Iever
BH foot
Feed control
cam (BH) BHF finger assembly
2-(A)
2-(B)
www.promelectroavtomat.ru

-6-
II. 

1.DISASSEMBLING AND REASSEMBLING
THE OUTER PARTS AND MAIN PARTS........................................................7
2.LEAD WIRE ARRANGEMENT.......................................................................27
www.promelectroavtomat.ru

-7-
1. DISASSEMBLING AND REASSEMBLING THE OUTER PARTS AND MAIN
PARTS
Disassembly procedure
1. Remove the screws holding the face plate, then remove the face plate to the left.
2. Remove the flat bed attachment by sliding it to the left.
3. Remove the six screws holding the front cover (three on the rear, two on the bottom, one of the left), then lift
up the front cover from the bottom side, open it forward, and remove it.
4. Lower the presser lifter, remove the four screws holding the rear cover (two on front, one on rear, and one
on bottom), and then remove the rear cover. Remove the handle too.
www.promelectroavtomat.ru

-8-
5. Remove the two screws holding the 3-pin socket folder assembly on the rear of the sewing machine,
remove the 3-pin socket folder, and then remove the three wiring harness bands for the lamp cord.
6. Remove the screws holding the cord clamp.
7. Remove the two screws holding the motor holder, then remove the motor. The driving belt can be removed
too.
Lamp cord
www.promelectroavtomat.ru

-9-
8. Remove the two screws holding the thread tension assembly, then remove the thread tension assembly.
9. Remove the two screws, the lock ring, and the feed rod tension spring, remove the tightening screw for the
Zigzag adjustment nut for the Zigzag connecting rod, then remove the Zigzag connecting rod assembly.
10. Remove the lock ring, and the screw, then remove reverse sewing lever A.
11. Remove the tension spring for reverse sewing lever B, then remove reverse sewing lever B.
12. Remove the feed regulator tension spring.
13. Remove the two screws holding the feed bracket assembly, then remove the feed bracket assembly.
www.promelectroavtomat.ru

-10-
14. Loosen the setscrew for the needle, then remove the needle.
15. Remove the screws holding the presser holder, then remove the presser holder and the presser foot.
16. Remove the tension spring from the needle bar block assembly.
17. Remove the screws holding the needle bar supporter stud holder assembly, then remove the needle bar
supporter stud holder assembly.
18. Remove the needle bar block assembly, then remove the setscrew and lock nut.
Disassembly Point
18. Turn the needle bar block assembly slightly to the left side, then pull it forward to remove it.
www.promelectroavtomat.ru

-11-
19. (XL-6060, XL-6050 Series)
Loosen the BH change arm screw, remove the BH change shaft, remove the two screws holding the BH
lever installation plate, and then remove the BH lever installation plate assembly. At the same time, remove
the torsion spring.
(XL-6040 Series)
Remove the two screws holding the BH lever installation plate, and then remove the BH lever installation
plate. At the same time, remove the torsion spring.
20. Loosen the presser bar clamp screw, take out the presser bar, and then remove the presser bar clamp and
presser spring.
21. Take the presser lifting shaft from the arm, then remove the presser lifter.
Disassembly Point
21. Lifting up the presser lifter makes it easier to remove the presser bar. Be careful not to let the presser
spring pop out when removing the presser bar.
These parts are not used
for XL-6040 series
BH lever is not used for
XL-6040 series
www.promelectroavtomat.ru

-12-
22. Remove the screw holding the thread take-up lever shaft fastening plate, then remove the thread take-up
lever shaft.
23. Remove the left thread take-up lever screw, then remove the thread take-up lever.
24. Loosen the thread take-up crank set screw, then remove the needle bar crank and the needle bar crank rod.
Disassembly Point
23. Remove the left thread take-up lever screw by holding the balance wheel by hand so that the upper shaft
does not turn and turning the screwdriver to the right.
24. Loosen the thread take-up crank set screw by holding the balance wheel by hand so that the upper shaft
does not turn.
www.promelectroavtomat.ru

-13-
25. Remove the two needle plate screws, then remove the needle plate assembly and the inner rotary hook.
26. Remove the screw holding the inner rotary hook rotation prevention bracket, then remove the inner rotary
hook rotation prevention bracket.
27. Remove the screw holding the inner rotary hook left retainer plate, then remove the inner rotary hook left
retainer plate.
28. Remove the two screws holding the camber prevention plate, then remove the camber prevention plate.
29. Remove the feed base tension spring.
www.promelectroavtomat.ru

-14-
30. Remove the lock ring for the horizontal feed arm shaft, loosen the horizontal feed arm set screw, then
remove the horizontal feed arm shaft.
31. Remove the screws holding the horizontal feed assembly center right and the horizontal feed assembly
center left, remove the horizontal feed assembly center right and the horizontal feed assembly center left,
then remove the horizontal feed shaft assembly.
32. Remove the forked connecting rod.
33. Loosen the rotary hook shaft set screw, then remove the rotary hook assembly, rotary hook shaft, and three
washers.
34. Remove the screw holding the tension pulley assembly, then remove the tension pulley assembly.
35. Remove the screw holding the eccentric metal presser and the screw holding the lower shaft metal presser,
then remove the lower shaft assembly.
Disassembly Point
31. Be careful not to lose the pressure spring (A) in the horizontal feed assembly center left.
www.promelectroavtomat.ru

-15-
36. Remove the total of two screws securing the left and right metal pressers and remove the upper shaft
assembly.
37. Remove the screw securing the fastening plate, then remove the feed regulator and feed regulator shaft.
38. (XL-6060, XL-6050 series only)
Remove the two screws securing the BH stopper assembly, then remove the BH stopper assembly and
spring.
39. Remove the three screws securing the selection unit, then remove the selection unit.
40. Remove the M4 hex screw.
41. Remove the screw securing the presser plate, then remove the selection dial assembly.
42. Remove the CS lock ring, then remove the torsion spring and the thread slack plate C.
43. Remove the three bottom leg rubber pads.
44. Remove the leg adjustment screws.
Disassembly Point
37. When removing the feed regulator, be careful not to lose the plastic washer (A).
These parts are not
used for XL-6040
series
www.promelectroavtomat.ru

-16-
Assembly Procedure
45. Install the leg adjustment screws.
46. Install the three bottom leg rubber pads.
47. Pass the thread slack plate C and torsion spring onto the arm press-fit shaft, hang the torsion spring, then
install with the CS lock ring.
48. Install the selection dial assembly with the presser plate and screws.
49. Install the M4 hex screw.
50. Align the selection unit with installation reference hole on the arm rear surface and install with the three
screws.
51. (XL-6060, XL-6050 series only)
Install the BH stopper assembly and spring with the two screws.
52. Pass the feed regulator onto the feed regulator shaft and plastic washer (A), then secure with the fastening
plate and screws.
Assembly Points
47. After installing the thread slack plate C, rotate it and check that the force of the torsion spring returns it to
its original position.
48. Align the selection dial shaft bearing alignment mark (G) with 20° below the front. (See Adjustment
Procedure 15.)
50. Install the selection unit screws in the order (B), (C), then (D).
50. Watch out for backlash between the selection cam gear section and the selection dial assembly gear
section. (See Adjustment Procedure 15.)
51. After installing the feed regulator and feed regulator shaft, check that the feed regulator has no axial play
and that the feed regulator rotates freely.
52. Insert the plastic washer (A) between the feed regulator and arm.
These parts are not
used for XL-6040
series
www.promelectroavtomat.ru

-17-
53. Pass the upper shaft through the timing belt and install with the two metal pressers and two screws.
Assembly Point
53. After installing the upper shaft, rotate the balance wheel by hand and check that it rotates freely.
www.promelectroavtomat.ru

-18-
54. Pass the lower shaft section through the timing belt and secure with the eccentric metal presser (left side),
the lower shaft metal presser (right side), and install with the two screws. Align the timing of the upper shaft
and lower shaft. (See Adjustment Procedure 2.)
55. Secure the tension pulley assembly with the screw and install while adjusting the tension of the timing belt.
(See Adjustment Procedure 3.)
56. Pass the spacer U, rotary hook assembly, spacer, and flat washer (thin) onto the rotary hook shaft in that
order and secure with the screw.
Assembly Points
54. When installing the lower shaft, check that the lower shaft rotates freely, then align the timing of the upper
and lower shafts and hang the timing belt on the upper shaft and lower shaft pulleys. (See Adjustment
Procedure 2.)
55. When adjusting the tension of the timing belt with the timing pulleys, check the upper shaft and lower shaft
timing. (See Adjustment Procedure 2.)
56. Install the spacer under the rotary hook assembly passed onto the rotary hook shaft with the thicker side
facing up. After the rotary hook assembly is installed, check that the rotary hook assembly has no vertical
play.
www.promelectroavtomat.ru