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Brother XL-6040, Service Manual

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Brother XL-6040 Service Manual Download Page 23

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68. Put the needle bar crank rod onto the needle bar crank shaft and install on the thread take-up crank with the

set screw.  Be careful about the flat surface the screw contacts with.

69. Install the thread take-up lever on the needle bar crank with the left screw.
70. Insert the thread take-up lever support between the thread take-up lever and the thread take-up lever shaft

and install the thread take-up lever shaft with the fastening plate and the screw.

Assembly Points

68. Check that the needle bar crank rod has no axial play.

Check that the needle bar crank rod rotates freely.

68. Fasten with the contact surface (flat surface) of the needle bar crank rod screw at the screw (A) side.

When installing the screw (A), hold the balance wheel by hand so that the upper shaft does not rotate.

69. Hold the balance wheel by hand so that the upper shaft does not rotate ad rotate the driver to the left to

tighten the thread take-up lever left screw.

70. Install so that there is no clearance between the thread take-up lever support right side surface and the

lock ring.  If there is a large clearance, left-right play of the thread take-up lever will generate abnormal
noise (thread take-up lever rattling).  Also, turn the upper shaft by hand and check that rotates freely.

Flat surface

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Summary of Contents for XL-6040

Page 1: ... 6 2001 www promelectroavtomat ru ...

Page 2: ...ng 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 on...

Page 3: ... 1 I 1 MECHANICAL CHART 2 2 POWER TRANSMISSION CHART 3 www promelectroavtomat ru ...

Page 4: ... 2 1 MECHANICAL CHART www promelectroavtomat ru ...

Page 5: ...ake up lever and zigzag movements Thread take up lever Thread take up crank Worm gear Timing pulley Needle bar crank rod Needle bar clamp Needle bar Needle bar block assembly Needle Pattern cam Zigzag connecting rod Z finger Selecting cam Upper shaft www promelectroavtomat ru ...

Page 6: ...ed 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 ...

Page 7: ...atic 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 ...

Page 8: ... 6 II 1 DISASSEMBLING AND REASSEMBLING THE OUTER PARTS AND MAIN PARTS 7 2 LEAD WIRE ARRANGEMENT 27 www promelectroavtomat ru ...

Page 9: ...nt 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...

Page 10: ...ng 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 ...

Page 11: ...justment 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 p...

Page 12: ...ing 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 ...

Page 13: ...H 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 sprin...

Page 14: ... 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 pr...

Page 15: ...evention 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 ...

Page 16: ...ve 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 re...

Page 17: ... 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 W...

Page 18: ... 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...

Page 19: ...aft 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 ...

Page 20: ...otary 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 lowe...

Page 21: ...s the horizontal feed arm shaft through the horizontal feed arm and install the forked connecting rod 61 Install the lock ring on the horizontal feed shaft and fasten with the horizontal feed arm set screw 62 Hang the tension spring for forked connecting rod Assembly Points 59 After installing the horizontal feed shaft assembly push the horizontal feed shaft assembly to the left apply pressure to ...

Page 22: ...l the inner rotary hook rotation prevention bracket with the screw See Adjustment Procedure 10 67 Install the needle plate assembly with the screw and check the feed teeth left right position See Adjustment Procedure 11 Assembly Point 66 Screw the inner rotary hook rotation prevention bracket screw C into screw hole A not B If you screw it into B it will not be possible to install the needle plate...

Page 23: ... needle bar crank rod rotates freely 68 Fasten with the contact surface flat surface of the needle bar crank rod screw at the screw A side When installing the screw A hold the balance wheel by hand so that the upper shaft does not rotate 69 Hold the balance wheel by hand so that the upper shaft does not rotate ad rotate the driver to the left to tighten the thread take up lever left screw 70 Insta...

Page 24: ...sten with the screw XL 6040 series Install the torsion spring on the BH lever installation plate install the BH lever installation plate with the two screws Assembly Points 72 Pass the presser bar through the presser spring and presser bar clamp while compressing the presser spring Be careful that the presser spring does not pop out After installing the presser bar move the presser lifter up and d...

Page 25: ...bar supporter stud holder assembly with the screw 76 Hang the needle bar block assembly tension spring on the arm and needle bar block assembly 77 Install the presser clamp on the presser bar with the screw and install the presser foot 78 Install the needle and tighten the needle set screw Assembly Points 74 If the upper shaft is set to the phase with the needle bar at its lowest point it is easie...

Page 26: ...ecting rod assembly with the two screws Assembly Points 79 Install the feed bracket assembly screws in the order A then B After installing the feed bracket assembly be careful about backlash at the feed bracket assembly gear See Adjustment Procedure 18 80 Hang the feed regulator tension spring with the shorter hook section on the feed bracket assembly 83 Hang the feed regulator tension spring with...

Page 27: ... then hang the driving belt See Adjustment Procedure 3 86 Tighten the cord clamp and install with the screw 87 Install the 3 pin socket holder assembly with the two screws then fasten the lamp cord with the three bundling bands Lamp cord www promelectroavtomat ru ...

Page 28: ...ace plate with the screw 91 Install the flat bed attachment Assembly Points 89 Pass the thread tension assembly and feed bracket assembly dial and Zigzag dial through the hole in the front cover and fit the front cover in place from above At this time make sure that the pattern selected with the selection dial and the pattern displayed on the front cover match Install with the front cover pattern ...

Page 29: ... 27 2 LEAD WIRES ARRANGEMENT www promelectroavtomat ru ...

Page 30: ...GHT POSITION 39 12 FEED DOG HEIGHT 40 13 PRESSER BAR HEIGHT 41 14 THREAD TENSION DIAL TENSION 42 15 SELECTION DIAL OUTER EDGE PLAY 43 16 PATTERN DISPLAY SELECTION POSITIONING 44 17 Z FINGER POSITIONING 45 18 FEED BRACKET INSTALLATION POSITION 46 19 SUPER PATTERN TRIPLE SEWING 47 20 FEED ADJUSTMENT 48 21 BH LEFT NEEDLE DESCENT AND ZIGZAG MAXIMUM LEFT NEEDLE DESCENT ALIGNMENT XL 6060 XL 6050 Series ...

Page 31: ...re 19 Feed adjustment See Adjustment Procedure 20 BHF back feed forward reverse See Adjustment Procedure 22 BH needle descent adjustment See Adjustment Procedure 21 BHF bar tack feed See Adjustment Procedure 23 Z finger position indication gear position adjustment See Adjustment Procedure 17 16 Left baseline adjustment See Adjustment Procedure 6 www promelectroavtomat ru ...

Page 32: ...er shaft horizontal feed cam pulley section and the tension pulley and the lower shaft timing pulley 2 Align the alignment mark for the upper shaft horizontal feed cam pulley and the alignment mark for the lower shaft timing pulley with the front of the sewing machine 3 Hang the timing belt from the upper shaft horizontal feed cam pulley section and tension pulley and lower shaft timing pulley Hor...

Page 33: ... 6 Secure the tension pulley assembly with the screw Adjustment Points Driving belt Unplug the power cord before adjusting the driving belt This is done to avoid the possibility of electrical shock If the driving belt tension is not correctly adjusted the problems below may occur 1 If the driving belt tension is too great the torque may become excessive causing the motor to rotate slower and gener...

Page 34: ...he pattern display to zigzag maximum sewing 2 Loosen the screw securing the eccentric nut B turn the balance wheel lower the needle left and right turn the eccentric nut B with a spanner and tighten the eccentric nut B screw so that the left and right needle descent are symmetric about the center of the steel plate hole Eccentric nut Adjustment range XL 6060 XL 6050 XL 6040 Should be even left and...

Page 35: ...where the distance from the needle plate top surface to the needle tip 14 is 5 6 mm 4 Turn the worm gear or pattern cam to put the Z finger and pattern cam in the state shown in Figure A 5 Tighten the three screws securing the worm gear 6 Turn the balance wheel and check how the needle flows Adjustment Points 5 At this time adjust the meshing of the worm gear and pattern cam gear Adjust the meshin...

Page 36: ...he tip of the needle for left needle descent 4 Turn the selection dial and left straight line sewing 5 Loosen the screw securing the eccentric nut 6 Adjust the eccentric nut so that the tip of the needle comes to the position of the hole drilled in 3 7 Tighten the screw securing the eccentric nut Adjustment Points 6 In left straight line sewing when the eccentric nut is turned to the right the nee...

Page 37: ...ouch the rotary hook assembly point Adjustment Points If there is a difference in the clearances between the rotary hook assembly point and the routing surface of the needle at the left and right needle descent positions loosen the needle bar block shaft A set screw and adjust the needle bar block assembly left right position to eliminate the difference left and right If the clearance is larger at...

Page 38: ...ithin the range 0 8 1 2 mm 5 Tighten the screw securing the needle bar holder Adjustment Points 5 When adjusting the needle bar height the needle bar is turned easily and this can cause obstructions to sewing When adjusting be careful that the front surface of the needle holder After adjusting the needle bar height check the threading hook vertical position Adjustment Procedure 29 If the needle ba...

Page 39: ... the screw securing the inner rotary hook retainer plate L 2 Adjust the vertical position of the inner rotary hook retainer plate L and adjust so that the clearance between the inner rotary hook presser plate L and the rotary hook assembly top surface is 0 4 0 6 mm 3 Tighten the screw securing the inner rotary hook retainer plate L 0 4 0 6 mm Inner rotary hook retainer plate www promelectroavtomat...

Page 40: ...racket 2 Adjust the forward back position of the inner rotary hook rotation prevention bracket so that the hanging difference for the inner rotary hook rotation prevention bracket spring and inner rotary hook projection section is 1 6 1 8 mm Note Adjust so that the inner rotary hook A surface is perpendicular to the feed direction 3 Tighten the screw securing the inner rotary hook rotation prevent...

Page 41: ... distance ADJUSTMENT 1 Turn the feed dial to maximum 2 Turn the selection dial to left straight line sewing 3 Loosen the screw securing the horizontal feed plate 4 Align the feed dog left right position 5 Tighten the screw securing the horizontal feed plate 6 Turn the upper shaft pulley to the feed start position 7 Loosen the screw securing the horizontal feed arm 8 Set the clearance between the f...

Page 42: ...og height is 0 9 1 1 mm at the center of the feed dog 4 Tighten the screw securing the vertical feed finger Adjustment Points If the feed dog height is not correctly adjusted the following problems may occur 1 If the feed dog is too high they may touch the rear of the needle plate and make noise front rear movement may deteriorate the feed distance may become inaccurate and the sewing machine may ...

Page 43: ...adjust so that the distance between the top surface of the needle plate and the bottom surface of the presser foot is 6 0 6 5 mm 4 Tighten the screw securing the presser bar clamp Adjustment Point 3 Check that the side surface of the presser foot and the needle plate feed dog groove are parallel If the presser foot is not parallel the needle may strike the presser foot or the fabric may not feed s...

Page 44: ...3 Pull the thread slowly with the tension gauge in the direction shown in the figure and adjust by turning the thread tension adjustment screw so that the reading on the tension gauge is 0 33 0 38 N 33 38 g f 4 Tighten the screw securing the thread tension nut Adjustment Point 3 Adjust with the thread just passing the thread tension adjustment plates and not passing the upper thread guide plate Fo...

Page 45: ...he screw securing the presser plate 2 Rotate the selection dial bearing to adjust the play 3 Tighten the screw securing the presser plate Adjustment Points 2 Turning the selection dial bearing so that the alignment mark is up reduces play turning it so that it is down increases play Alignment mark www promelectroavtomat ru ...

Page 46: ...at when the selection dial is turned the appropriate pattern display comes to the center of the display window on the front cover Adjustment Point This adjustment is not normally required After installing the front cover if the displayed pattern and the sewn pattern match but the front cover pattern display is not at the center of the window is tilted adjust 1 When adjusting the indication gear be...

Page 47: ...n the selection dial to zigzag maximum sewing then loosen the two screws securing the indication gear 3 Move the selection cam left and right and align the Z finger and the pattern cam center 4 Tighten the two screws securing the indication gear 5 Turn the selection dial and check the position of the Z finger relative to the cam Selection dial Z finger Z finger XL 6060 XL 6050 XL 6040 www promelec...

Page 48: ... C D Adjustment Points 2 If the feed dial gear alignment mark and idle gear alignment mark do not match remove the idle gear lock rating move the gear meshing to lineup the alignment marks then reinstall the lock ring Be careful about backlash between the feed dial gear and idle gear and the feed cam If the backlash is too small the feed dial moves sluggishly If the backlash is too large the inten...

Page 49: ...he feed adjuster nut Adjustment Points 3 Turning the adjustment screw to the right increases the reverse stitch length turning it to the left increases the forward stitch length 4 When fastening the adjustment screw with the nut in order to maintain the position and prevent deviation hold the adjustment screw with the driver while you tighten down the nut When adjusting the SUPER PATTERN check the...

Page 50: ...he adjustment screw nut Adjustment Points 3 Adjust by moving the feed dial gear position left and right so that when normal paper is laid under the presser foot and the balance wheel is rotated by hand 11 rotations 10 pitch in the forward direction the distance that the normal paper is fed is 1 8 2 2 mm If the 19 SUPER PATTERN adjustment is not executed before the FEED ADJUSTMENT the FEED ADJUSTME...

Page 51: ...edle descent 4 Turn the selection dial to button hole 5 Turn the balance wheel and lower the tip of the needle to the paper with left needle descent 6 Loosen the adjustment screw nut 7 Turn the adjustment screw to adjust the needle descent 8 Tighten the adjustment nut Adjustment Points 7 When you turn the adjustment screw to the right the needle descent moves to the right side 8 When fastening the...

Page 52: ...g using a box driver as shown in the figure since the selection dial interferes slightly with the box driver remove the selection dial screw and the selection dial beforehand 4 Turning the adjustment screw to the left makes the left reverse stitches finer turning it to the right makes them larger Also check that the alignment mark for the BH fine adjustment knob is facing straight up 5 When fasten...

Page 53: ...ver remove the selection dial screw and the selection dial beforehand 3 To forward the bar tack turn the adjustment screw to the left To reverse the bar tack turn the adjustment screw to the right 4 When fastening the adjustment screw with the nut in order to maintain the position and prevent deviation hold the adjustment screw with the screwdriver while you tighten down the nut Note that unless t...

Page 54: ... mark 2 on the BH lever 3 Tighten the BH change arm set screw 4 Loosen the screw securing the eccentric nut 5 Turn the eccentric nut and align with 0 5 1 1 N 50 110 gf on the BH lever return side The adjustment should be made within 1 2 rotation of the eccentric nut 6 Tighten the screw securing the eccentric nut Adjust the BH lever changing timing with the BH notch adjustment screw 21 23 mm 20 mm ...

Page 55: ...ve and the thread winding shaft spring position should be aligned 2 If the thread winding thread guide screw is loosened too much the nut will fall into the sewing machine so be careful not to loosen this screw too much 3 When adjusting the bobbin winding for the case shown in B lower the lower thread winding thread guide for the case shown in C raise the lower thread winding thread guide 4 If the...

Page 56: ...ward stitches and reverse stitches Adjustment Point 4 Turning the adjustment screw to the right increases the length for reverse stitches 27 INNER ROTARY HOOK TENSION STANDARD The inner rotary hook tension should be 0 1 N 0 12 N 10 12 gf when 60 polyester thread is pulled slowly with the tension gauge ADJUSTMENT 1 Correctly mount a bobbin with polyester thread 60 green on the inner rotary hook the...

Page 57: ... 8 Needle breaks 57 9 Noise 57 10 Forward and reverse feedings differ 57 11 Improper length of buttonhole legs 57 12 Improper buttonhole size against button size 57 13 Unbalanced patterns 57 14 Needle hits needle plate when pattern selector dial is turned 57 15 Fabric gathers 57 16 The stitch shown in the pattern indication window is different from the one being sewn 58 17 Light is off 58 18 Motor...

Page 58: ...ectly 5 Upper thread breaks during sewing 1 Bent or blunt needle 2 Improper setting of needle 3 Thread tension is too tight 4 Thread is tangled 5 Inferior needle eye 6 Inferior needle slot of needle plate 7 Inferior upper thread path 8 Inferior thread 9 Needle hits needle plate or rotary hook 10 There are scratches on inner rotary hook 1 Change the needle 2 Set the needle correctly 3 Adjust tensio...

Page 59: ...ffer 1 Improper adjustment of reverse sewing lever 1 Refer to P 54 11 Improper length of buttonhole legs 1 Improper adjustment 1 Adjust screw Refer to P 51 12 Improper buttonhole size against button size 1 Improper adjustment of buttonhole length 1 Adjust the length of buttonhole Refer to P 52 13 Unbalanced patterns 1 Stitch length dial is not set at SS 2 Feed dog is worn out 3 Improper height of ...

Page 60: ... indicator plate are not aligned correctly 1 Adjust the release volume Refer to P 34 2 Adjust the pattern indicator Refer to P 44 17 Light is off 1 Inferior light bulb 1 Replace the light bulb 18 Motor does not run 1 Inferior foot controller 2 Inferior motor or inferior brush 1 Replace the foot controller 2 Replace the motor Be sure to turn off the power www promelectroavtomat ru ...

Page 61: ...XL 6060 Series XL 6050 Series XL 6040 Series H1040194 www promelectroavtomat ru ...

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