EMC 10-12T Technical Manual Model Num 008410-01 Serial Num 10100xx

• A Complete Illustrated Parts Manual

Illustrated Parts Manualfor the EMC 10/12embroidery peripheral

110237-01, Revision A

1575 West 124th AvenueDenver, Colorado 80234United States of America

Internet Address: [email protected]

Copyright © Melco Embroidery Systems, 1994, 1995.

ALL RIGHTS RESERVED No part of this publication may be reproduced, stored in a retrieval system, ortransmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise)without prior written approval of Melco Embroidery Systems. Melco reserves the right to revise this publicationand to make changes in it at any time without obligation of Melco to notify any person or organization of suchrevisions or changes.

All precautions have been taken to avoid errors or misrepresentations of facts, equipment, or products.However, Melco Embroidery Systems does not assume any liability to any party for loss or damage caused byerrors or omissions.

Printed in the United States of America

Revision A November, 1995

Monitor A

D C

G

Table of Contents (Pictorial)

E F

B

i-i

EMC 10/12 Embroidery Peripheral Melco Embroidery Systems

A Logic Control Box Assemblies See Pages 38-1 and 39-1

B Z-Drive Motor Assemblies See Pages 32-1 to 36-1

C Y-Drive Motor Assemblies See Pages 27-1 to 31-1

D Motor Drive Box Assemblies See Pages 40-1 and 41-1

E Power Distribution Box Assemblies See Pages 42-1 to 44-1

F X-Drive Motor Assemblies See Pages 23-1 to 26-1

G Color Change/Grabber Assemblies See Pages 11-1 to 13-1

Table of Contents (Pictorial)Item Item Ltr. Description Comments

i-ii

110237-01, Rev. A Illustrated Parts Manual

Table of Contents

Covers (Heads 1-4) 1-1



Covers (Z-Drive) 4-1

Table Top Assembly 5-1

Drop Table Assembly (1 of 2) 6-1

Drop Table Assembly (2 of 2) 7-1

Machine Parts (Lighting) 8-1

Machine Parts (Chassis) 9-1

Sewing Head Assemblies 10-1

Color Change/Grabber Assembly (1 of 3) 11-1



Thread Tree Assembly 14-1

Needle Case Assembly (1 of 2) 15-1

Needle Case Assembly (2 of 2) 16-1

Thread Tensioner Assembly 17-1

Sewing Head Components (1 of 3) 18-1



Bobbin Idler Assembly 21-1

Take-Up Drive Lever Assembly 22-1

X-Drive Motor Assembly (1 of 3) 23-1



X-Drive Roller Blind Assembly 26-1

Y-Drive Motor Assembly (1 of 5) 27-1

Page Description Number

i-iii






Z-Drive Motor Assembly (1 of 5) 32-1





Gearbox Assembly 37-1

Logic Control Box Assembly (1 of 2) 38-1

Logic Control Box Assembly (2 of 2) 39-1

Motor Drive Box Assembly (1 of 2) 40-1

Motor Drive Box Assembly (2 of 2) 41-1

Power Distribution Box Assembly (1 of 3) 42-1



Trimmers, Head Level (1 of 2) 45-1

Trimmers, Head Level (2 of 2) 46-1

Cam Box Assembly 47-1

Cap Frame Mount Assembly 48-1

User Station Assembly (1 of 2) 49-1

User Station Assembly (2 of 2) 50-1

Harness Assembly (Power Distribution Box) 51-1

Harness Assembly (Logic Control Box) 52-1

Harness Assembly (Heads 1-12) 53-1

Harness Assembly (Motor Power & Lighting) 54-1

Sash Hoop Assemblies (1 of 2) 55-1


i-iv


Sash Hoop Assemblies (2 of 2) 56-1

Sash Frame Assembly 57-1

OPTIONS

Melco Cap Frame Assembly 58-1

Cap Frame Drive Assembly 59-1

Melco Cap Gauge Assembly 60-1

Tubular Hoop Assemblies 61-1

Tube Frame Assembly 62-1


i-v


INTRODUCTION

Model and Serial Numbers

There is only one model version of the Melco EMC 10/12T Sewing Peripheral. This modelis operated on 220 Volts only. The EMC 10/12T is identified as model part number008410-01.

Determine the model number of your machine before you use this manual to orderparts. The machine MODEL number is located on the label that is placed on the front ofthe frame, under the table and to right side of the machine.

Remember, although many parts are identical between the various embroideryperipheral models, this manual should only be used for identifying and ordering parts forthe machine(s) described above.

The Serial Number for the EMC 10/12T Embroidery machine is located at the rear of theunit, behind the User Station area.It is easily visible when you stand behind the #1 Sewing Head and look just under theMonitor Shelf at the large vertical beam supporting the Logic Control Box.

How To Use This Manual

The manual is divided into several sections, each containing a set of parts most commonto each other, or to a function of the machine.

FIGURES

Accompanying each section is a figure showing the general area of the machine that isrepresented in that section. Parts are identified with letters and numbers in these figures.Letters contained in circles generally are used to refer the user to a different figure orsection of the manual that identifies the assembly with more detail. Part numbers and partidentifications of the numbers inside circles are found on the pages adjacent to the figure.

i-vii


ITEM NUMBERS

All the numbers in circles on a diagram are listed in the first column of the parts listingaccompanying that figure. Each item number in each figure is identified independentlyin hopes to help prevent any confusion that may occur by trying to "cross-reference"part numbers.

PART NUMBERS

The Melco part number is found in the second column of the parts list, directly in linewith each item number from the first column.

PART DESCRIPTIONS

Each part listed has a descriptive name in the third column of the parts listing. Hardware(such as screws, washers, etc.) are described by size in order to help the user to identifycommon hardware items that can be obtained by local sources if desired.

CAUTION: When purchasing hardware from a sourceother than Melco, it is the user’s responsibility toensure that such hardware is of sufficient quality andgrade to meet or exceed Melco’s original equipmenthardware. Melco assumes no liability for the use ofinadequate hardware that was purchased by and/orinstalled by other than an authorized Melco factoryrepresentative.

i-viii


Special Parts Handling

If care is not taken in handling certain parts of the sewing head, there is a goodprobability the sewing head will not function properly or the parts will fail prematurely.

These parts are to have special handling considerations from the vendor, through qualitycontrol inspection, into spare parts inventories, then on to packaging for shipping, andfinally to installation.

Handling of these parts (and for that matter all parts), is not limited to the considerationsbelow. Please use common sense, good judgment, and accepted handling practices inhandling all parts. If you have any questions or concerns, please call your area servicedepartment.

General Considerations

* Painted surfaces need to be protected from dirt, other foreign matter, nicks, andscratches.

* Non-painted surfaces must not be touched by the human hand, to preventcorrosive body oils, dirt, and other foreign matter from contaminating thesurfaces.

* Protect all bearings, bushings, cams, rails, gears, rollers, needle bars, pins, studs,connecting rods, guide shafts, and other surface finishes from dirt, other foreignmatter, marring, scratches, and nicks, etc.

* Bearing surfaces and shaft bore surfaces need to be thoroughly cleaned andmating parts oiled before assembly.

Printed Circuit Boards

Printed circuit boards are packaged and shipped in anti static bags. The components ofthe printed circuit boards are sensitive to static electrical discharges. The use of standardanti static precautions is recommended.

Special Packaging

Some parts are packaged in specially sealed packages. These packages keep lubricanton the parts and protect them from contamination during shipment. To install theseparts, clean your hands and place a small amount of sewing machine oil on your fingersto keep the integrity of the part intact.

i-ix


Covers (Heads 1-4)

Figure 1

1-1


Covers (Heads 1-4) Reference Figure 1

Item Part ItemNo. Number Description Comments

1 003509-06 Screw, Button Head Cap, M4 x 0.7 x 6 Lg 2 008105-01 Cover, Spacer, Tensioner Bracket, Start/Stop 3 008083-01 Cover, Spacer, Tensioner Bracket 4 008084-01 Cover, Spacer, Tensioner Bracket, E-Stop 5 008262-01 Cover, End, Tensioner Bracket 6 008065-01 Cover, Rear, Tensioner Bracket 7 008281-01 Cover, Spacer, Keypad 8 008024-01 Switch, E-Stop, Assembly 9 008026-01 Switch, Stop, Assembly10 008125-01 Cover, Spacer, Lower11 006802-01 Damper, Spacer Cover12 008129-16 Standoff, Hex, M/F, M4 x 0.7 x 16 Lg13 008121-02 Cover, Tensioner Bracket, Right14 006452-01 PCB, Remote Keypad, Assembly15 008025-01 Switch, Start, Assembly16 008495-01 Miniature Insulating Bushing

1-2


Covers (Heads 5-8)

Figure 2

2-1




1 003509-06 Screw, Button Head Cap, M4 x 0.7 x 6 Lg 2 008105-01 Cover, Spacer, Tensioner Bracket, Start/Stop 3 008083-01 Cover, Spacer, Tensioner Bracket 4 008084-01 Cover, Spacer, Tensioner Bracket, E-Stop 5 008065-01 Cover, Rear, Tensioner Bracket 6 008024-01 Switch, E-Stop, Assembly 7 008026-01 Switch, Stop, Assembly 8 008125-01 Cover, Spacer, Lower 9 006802-01 Damper, Spacer Cover10 008129-16 Standoff, Hex, M/F, M4 x 0.7 x 16 Lg11 008025-01 Switch, Start, Assembly12 008495-01 Miniature Insulating Bushing

2-2


Covers (Heads 9-12)

Figure 3

3-1




1 003509-06 Screw, Button Head Cap, M4 x 0.7 x 6 Lg 2 008105-01 Cover, Spacer, Tensioner Bracket, Start/Stop 3 008084-01 Cover, Spacer, Tensioner Bracket, E-Stop 4 008262-01 Cover, End, Tensioner Bracket 5 008083-01 Cover, Spacer, Tensioner Bracket 6 008065-01 Cover, Rear, Tensioner Bracket 7 008024-01 Switch, E-Stop, Assembly 8 008026-01 Switch, Stop, Assembly 9 008122-01 Cover, Tensioner Bracket, Left10 008125-01 Cover, Spacer, Lower11 006802-01 Damper, Spacer Cover12 008129-16 Standoff, Hex, M/F, M4 x 0.7 x 16 Lg13 008025-01 Switch, Start, Assembly14 008495-01 Miniature Insulating Bushing

3-2


Covers (Z-Drive)

Figure 4

4-1


Covers (Z-Drive) Reference Figure 4


1 007700-01 Plate, Back, Z-Cover, Right Hand 2 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg 3 690427-04 Washer, Lock, Split, M4 4 690439-04 Washer, Flat, M4 5 007699-01 Plate, Back, Z-Cover 6 007702-01 Plate, Clamp, Z-Cover 7 007703-01 Plate, Clamp, Z-Cover 8 006676-03 Cover, Z-Shaft, #1 9 006676-02 Cover, Z-Shaft, #210 007701-01 Plate, Back, Z-Cover, Left Hand

4-2


Table Top Assembly

Figure 5

5-1


Table Top Assembly Reference Figure 5


1 008156-01 Table Top, #9 2 007727-13 Screw, Sheet Metal, Pan Head Phillips, M4 x 13 Lg 3 008325-01 Cover, Table, Trimmer 4 008136-01 Angle, Support, Table 5 008138-01 Angle, Support, Drop Table 6 008155-01 Table Top, #6, #8 7 008146-01 Angle, Support, Table 8 008139-01 Angle, Support, Drop Table 9 008154-01 Table Top, #5, #710 007727-16 Screw, Sheet Metal, Pan Head Phillips, M4 x 16 Lg11 008165-01 Cover, X & Y Drive, Top12 008153-01 Table Top, #413 008152-01 Table Top, #314 008145-01 Angle, Support, Drop Table15 008340-01 Clip, Table Top16 671910-12 Screw, Pan Head Phillips, Self-Tapping, #10 x 3/4"17 007719-40 Screw, Flat Head, M6 x 1.00 x 40 Lg18 008151-01 Table Top, #219 008312-01 Angle, Support, Table20 008317-01 Table Top, #1A21 008314-01 Angle, Support, Table22 008149-01 Angle, Support, Table23 008150-01 Table Top, #124 008313-01 Angle, Support, Table25 008159-01 Table Top, #1326 008147-01 Angle, Support, Drop Table27 008158-01 Table Top, #11, #1228 008134-01 Frame, Main29 008140-01 Frame, Drop, Table, Assembly30 001963-09 Nut, Hex, M831 690427-08 Washer, Lock, Split, M832 690439-08 Washer, Flat, M833 008148-01 Angle, Support, Drop Table34 008157-01 Table Top, #1035 008137-01 Angle, Support, Table36 008376-01 Table Top, #9B

5-2


Drop Table Assembly (1 of 2)

Figure 6

6-1


Drop Table Assembly (1 of 2) Reference Figure 6


1 671910-12 Screw, Self-Tapping, Pan Head Phillips, #10 x 3/4" 2 001963-09 Nut, Hex, M8 3 690439-08 Washer, Flat, M8 4 008200-01 Runners, Plastic 5 007719-10 Screw, Flat Head Phillips, M6 x 1.0 x 10 Lg 6 008199-01 Plate, Extension Support 7 690439-06 Washer, Flat, M6 8 690427-06 Washer, Lock, Split, M6 9 671686-10 Screw, Socket Head Cap, M6 x 1.0 x 10 Lg10 008240-01 Pillar, Ext. Plate11 671686-12 Screw, Socket Head Cap, M6 x 1.0 x 12 Lg12 008141-01 Locator13 003379-01 Nut, Hex, M514 671852-25 Screw, Socket Head Cap, M5 x 0.8 x 25 Lg15 690427-08 Washer, Lock, Split, M816 671852-60 Screw, Socket Head Cap, M5 x 0.8 x 60 Lg17 690439-05 Washer, Flat, M518 008144-01 Movotec Lift System, Assembly19 671852-12 Screw, Socket Head Cap, M5 x 0.8 x 12 Lg20 690427-05 Washer, Lock, Split, M521 008140-01 Assembly, Frame, Drop Table22 008342-01 Locator, Hook23 008341-01 Locator, Side

6-2


Drop Table Assembly (2 of 2)

Figure 7

7-1


Drop Table Assembly (2 of 2) Reference Figure 7


1 008200-01 Runners, Plastic 2 007719-10 Screw, Flat Head Phillips, M6 x 1.0 x 10 Lg 3 008199-01 Plate, Extension Support 4 690439-06 Washer, Flat, M6 5 690427-06 Washer, Lock, Split, M6 6 671686-10 Screw, Socket Head Cap, M6 x 1.0 x 10 Lg 7 671910-12 Screw, Self-Tapping, Pan Head Phillips, #10 x 3/4" 8 008240-01 Pillar, Ext. Plate 9 001963-09 Nut, Hex, M810 690439-08 Washer, Flat, M811 690427-08 Washer, Lock, Split, M812 690439-05 Washer, Flat, M513 671852-60 Screw, Socket Head Cap, M5 x 0.8 x 60 Lg14 008144-01 Movotec Lift System, Assembly15 671852-25 Screw, Socket Head Cap, M5 x 0.8 x 25 Lg16 003379-01 Nut, Hex, M517 008141-01 Locator18 671686-12 Screw, Socket Head Cap, M6 x 1.0 x 12 Lg19 671852-12 Screw, Socket Head Cap, M5 x 0.8 x 12 Lg20 690427-05 Washer, Lock, Split, M521 008140-01 Assembly, Frame, Drop Table

7-2


Machine Parts (Lighting)

Figure 8

8-1


Machine Parts (Lighting) Reference Figure 8


1 690427-06 Washer, Lock, Split, M6 2 342500-16 Nut, Hex, M6 3 690439-06 Washer, Flat, M6 4 008343-01 Left Hand Shield, Fluorescent 5 008344-01 Right Hand Shield, Fluorescent 6 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg 7 008034-01 4 Foot Single Fluorescent Lamp 8 008371-01 Plate, Fluorescent Support, Left Hand 9 008372-01 Plate, Fluorescent Support, Right Hand10 690439-04 Washer, Flat, M4

8-2


Machine Parts (Chassis)

Figure 9

9-1


Machine Parts (Chassis) Reference Figure 9


1 008162-01 Pads, Jack Screw 2 008161-01 Screw, Jack 3 008163-05 Way, Cable, 61.02" Lg 4 008163-04 Way, Cable, 78.74" Lg 5 008143-01 Bracket, Cylinder End 6 690439-08 Washer, Flat, M8 7 690427-08 Washer, Lock, Split, M8 8 671687-40 Screw, Socket Head Cap, M8 x 1.25 x 40 Lg 9 008160-01 Leg Weldment, Center Support10 008142-01 Bracket, Cylinder Center11 690439-10 Washer, Flat, M1012 690427-10 Washer, Lock, Split, M1013 003183-01 Screw, Socket Head Cap, M10 x 1.5 x 100 Lg14 007726-16 Screw, Pan Head Phillips, Self-Tapping, #12 x 1.0"15 008329-01 Shelf, Storage, Right Hand16 008225-01 Shelf, Storage, Left Hand17 672018-12 Screw, Socket Head Cap, M4 x 0.7 x 12 Lg18 690439-04 Washer, Flat, M419 008217-01 Bracket, Table Support, Right20 671686-16 Screw, Socket Head Cap, M6 x 1.00 x 16 Lg21 690427-06 Washer, Lock, Split, M622 008216-01 Bracket, Table Support, Left

9-2


Sewing Head Assemblies

Figure 10

10-1


Sewing Head Assemblies Reference Figure 10


A -------------- Needle Case Assemblies See Pages 15-1 and 16-1 B -------------- Thread Tensioner Assembly See Page 17-1 C -------------- Thread Tree Assembly See Page 14-1 D -------------- Sewing Head Components See Pages 18-1 to 20-1 1 003136-06 Screw, Button Head Socket, M3 x 0.5 x 6 Lg 2 006529-01 Set, Cover, Rotary Hook 3 006034-21 Cover, Bed, Rear 4 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg 5 008241-01 Pillar, Head Support 6 001963-09 Nut, Hex, M8 7 008332-01 Washer, Head 8 690439-08 Washer, Flat, M8 9 007526-01 Cover, Bed, Front10 005704-01 Tubing, .125" ID x .187" OD x 2 Feet Long11 005702-01 Guide, Thread, Thread Tree12 672018-12 Screw, Socket Head Cap, M4 x 0.7 x 12 Lg13 690427-04 Washer, Lock, Split, M414 690439-04 Washer, Flat, M4 15 005707-01 Clip, Tubing16 008054-01 Clamp, Color Change Linkage17 001922-10 Screw, Socket Head Cap, M3 x 0.5 x 10 Lg18 008126-01 Cover, Head, Rear19 005284-01 Nut, Lock, M620 008055-01 Shaft, Color Change Link21 008067-01 Thread Break, Support Bracket22 008068-01 Bracket, Detect, Thread Break23 001922-08 Screw, Socket Head Cap, M3 x 0.5 x 8 Lg24 008069-01 Brush, Contact, Thread Break25 690811-34 Washer, Internal Star, #4 26 690439-03 Washer, Flat, M3 27 005028-01 Magnet, Needle Case Cover28 008129-30 Standoff, Hex, M/F, M4 x 0.7 x 30 Lg

10-2


Color Change/Grabber Assembly (1 of 3)

Figure 11

11-1


Color Change/Grabber Assembly (1 of 3) Reference Figure 11


1 007705-01 Cover, Color Change 2 008111-01 Plate, Front, Housing, Color Change 3 001922-12 Screw, Socket Head Cap, M3 x 0.5 x 12 Lg 4 008054-01 Clamp, Color Change Linkage 5 008055-02 Shaft, Color Change Link 6 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg 7a 008448-01 Cover, End, Housing, Color Change, Left (see *NOTE below) 7b 008112-01 Cover, End, Housing, Color Change, Left (see *NOTE below) 8a 008449-01 Plate, Bottom, Housing, Color Change (see *NOTE below) 8b 008113-01 Plate, Bottom, Housing, Color Change (see *NOTE below) 9 008057-01 Blade, Sensor, Interrupt10a 008456-01 Bar, Color Change Drive (see *NOTE below)10b 008058-01 Bar, Color Change Drive (see *NOTE below)11 008049-01 Bearing, Linear, Slide12 001963-05 Nut, Hex, M413 690427-04 Washer, Lock, Split, M414 690439-04 Washer, Flat, M415 005526-01 PCB, Color Change Encoder, Assembly16 007720-01 Standoff, Hex, M/F, M4 x 0.7 x 6 Lg17 008345-01 Fixing, Embroidery Stitch18 008346-01 Spring, Embroidery Stitch19 008268-01 Embroidery SP Indicator20 003136-06 Screw, Button Head Socket, M3 x 0.5 x 6 Lg21 007548-01 Cover, LED

*NOTE: Items 7a, 8a and 10a are used on machines from Serial Numbers1010001 through 1010028 except on Serial Numbers 1010012, 1010013 and 1010020

Items 7b, 8b, and 10b are used on machines with Serial Numbers1010012, 1010013, 1010020 and on Serial Numbers 1010029 to current.

11-2



Figure 12

12-1




1 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg 2a 008448-01 Cover, End, Housing, Color Change, Left (see *NOTE below) 2b 008112-01 Cover, End, Housing, Color Change, Left (see *NOTE below) 3 008062-01 Clamp, Split-Hub, 8mm ID 4 007574-01 Washer, Thrust, 1mm 5 008061-01 Bearing, Thrust, .315" ID 6 007544-01 Motor, Color Change 7 008014-01 Harness, Color Change 8 008064-01 Shaft, Cam, Color Change 9 008056-01 Cam, Color Change10a 008449-01 Plate, Bottom, Housing, Color Change (see *NOTE below)10b 008113-01 Plate, Bottom, Housing, Color Change (see *NOTE below)11a 008452-01 Plate, Support, Cam, Color Change (see *NOTE below)11b 008116-01 Plate, Support, Cam, Color Change (see *NOTE below)12a 008451-01 Plate, Mounting, Motor, Color Change (see *NOTE below)12b 008115-01 Plate, Mounting, Motor, Color Change (see *NOTE below)13 690034-36 Washer, Flat, #6 14 690033-36 Washer, Lock, Split, #615 670174-08 Screw, Pan Head Phillips, 6-32 x 1/2"16 008059-01 Pulley, 1/5P, 12 Groove, Modified17 003504-01 Belt, Timing, 39T, 1/5P18 008060-01 Pulley, 1/5P, 16 Groove, Modified19 007554-01 Bracket, Mounting, Disk Drive20a 008450-01 Cover, End, Housing, Color Change, Right (see *NOTE below)20b 008114-01 Cover, End, Housing, Color Change, Right (see *NOTE below)21 007717-06 Screw, Set, Cup Point, M5 x 0.8 x 6 Lg

*NOTE: Items 2a, 10a, 11a, 12a and 20a are used on machines from Serial Numbers 1010001 through 1010028 except on Serial Numbers 1010012, 1010013 and 1010020

Items 2b, 10b, 11b, 12b and 20b are used on machines with Serial Numbers 1010012, 1010013, 1010020 and on Serial Numbers 1010029 to current.

12-2



Figure 13

13-1




1 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg 2 008117-01 Cover, Housing, Grabber 3 008079-01 Pulley, Timing, 32 Groove, 1/5P, 2.017" OD, Modified 4 008110-01 Belt, Timing, 59T, 1/5P 5 008078-01 Disk, Grabber Home 6 008062-01 Clamp, Split-Hub, 8mm ID 7 008123-01 Bracket, Grabber Drive 8 001922-06 Screw, Socket Head Cap, M3 x 0.5 x 6 Lg 9 005850-01 Thread Holder Optical Switch, Assembly10a 008449-01 Plate, Bottom, Housing, Color Change (see *NOTE below)10b 008113-01 Plate, Bottom, Housing, Color Change (see *NOTE below)11 008059-01 Pulley, 1/5P, 12 Groove, Modified12 670174-08 Screw, Pan Head Phillips, 6-32 x 1/2"13 690033-36 Washer, Lock, Split, #614 690034-36 Washer, Flat, #6 15a 008452-01 Plate, Support, Cam, Color Change (see *NOTE below)15b 008116-01 Plate, Support, Cam, Color Change (see *NOTE below)16a 008451-01 Plate, Mounting, Motor, Color Change (see *NOTE below)16b 008115-01 Plate, Mounting, Motor, Color Change (see *NOTE below)17 007698-01 Motor, Driver, Grabber18 008007-01 Harness, Grabber/Color Motors19 005034-01 Screw, Set, Socket, Cup Point, M4 x 0.7 x 6 Lg20 008120-01 Shaft, Stub, Grabber Drive

*NOTE: Items 10a, 15a and 16a are used on machines from Serial Numbers1010001 through 1010028 except on Serial Numbers 1010012,1010013 and 1010020

Items 10b, 15b and 16b are used on machines with Serial Numbers1010012, 1010013 and 1010020 and on Serial Numbers 1010029 to current.

13-2


Thread Tree Assembly

Figure 14

14-1


Thread Tree Assembly Reference Figure 14


1 671852-12 Screw, Socket Head Cap, M5 x 0.8 x 12 Lg 2 690427-05 Washer, Lock, Split, M5 3 690439-05 Washer, Flat, M5 4 690439-04 Washer, Flat, M4 5 672018-12 Screw, Socket Head Cap, M4 x 0.7 x 12 Lg 6 008047-01 Bracket, Support, Thread Tree 7 008048-01 Plate, Spool 8 005702-01 Guide, Thread, Thread Tree 9 005703-01 Tube, Guide, Thread, Thread Tree10 005701-01 Seat, Cone, Thread Tree11 008089-01 Foam Padding

14-2


Needle Case Assembly (1 of 2)

Figure 15

15-1


Needle Case Assembly (1 of 2) Reference Figure 15


1 007511-01 Cover, Needle Case, Lower 2 003509-06 Screw, Button Head Cap, M4 x 0.7 x 6 Lg 3 007510-01 Cover, Needle Case, Upper 4 003509-10 Screw, Button Head Cap, M4 x 0.7 x 10 Lg 5 008483-01 Assembly, Guide, Thread, Lower 6 007519-01 Spring, Lower Thread Guide 7 007503-01 Plate, Guide, Needle Bar 8 001924-06 Screw, Slotted Cheese Head, M4 x 0.7 x 6 Lg 9 001935-06 Screw, Flat Head Phillips, M3 x 0.5 x 6 Lg10 008482-01 Assembly, Guide, Thread, Middle11 007528-01 Support, Tensioner Bracket12 007527-01 Magnet, Thread Retaining13 672018-16 Screw, Socket Head Cap, M4 x 0.7 x 16 Lg

15-2


Needle Case Assembly (2 of 2)

Figure 16

16-1


Needle Case Assembly (2 of 2) Reference Figure 16


1 001828-01 Screw, Set, Needle Clamp 2 001528-01 Clamp, Needle 3 007591-01 Damper, Needle Clamp 4 007924-01 Foot, Presser, Assembly 5 001535-01 Spring, Presser Foot 6 001922-08 Screw, Socket Head Cap, M3 x 0.5 x 8 Lg 7 001922-10 Screw, Socket Head Cap, M3 x 0.5 x 10 Lg 8 001840-01 Clamp, Stop, Needle Bar 9 005577-01 Damper, Needle Case10 007408-01 Stud, Connecting, Needle Bar11 007505-01 Shim, Needle Case12 007506-01 Felt, Needle Case13 005009-01 Washer, Flat, .260" ID x .420" OD x .03" Thick14 001537-01 Spring, Holding, Needle Bar15 001532-01 Bar, Needle16 002637-08 Screw, Socket Head Cap, Low Head, M5 x 0.8 x 8 Lg17a 702876-05 Spacer, Precision, .313" ID x .010" Thick (Use as Required)17b 702876-08 Spacer, Precision, .313" ID x .016" Thick (Use as Required)18 008484-01 Lever, Take-Up, Assembly19 007502-01 Rail, Guide, Lower20 007504-01 Shaft, Take-Up Lever21 007501-01 Case, 10 Needle22* 008474-01 Bracket, Grabber23 002884-01 Spacer, Support, Velcro24 672018-20 Screw, Socket Head Cap, M4 x 0.7 x 20 Lg25 671855-08 Screw, Pan Head Slotted, M3 x 0.5 x 8 Lg26* 008472-01 Bar, Grabber27 007518-01 Spacer, Shaft, Take-Up Lever28 671855-06 Screw, Pan Head Slotted, M3 x 0.5 x 6 Lg29a 700837-01 Spacer, Shaft, 1/4" ID x .002" Thick (Use as Required)29b 700837-02 Spacer, Shaft, 1/4" ID x .004" Thick (Use as Required)29c 700837-03 Spacer, Shaft, 1/4" ID x .006" Thick (Use as Required)30 662744-08 Pin, Dowel, .25" OD x .50" Lg31* 008471-01 Velcro, Wiper, Pile32 001960-06 Screw, Set, Flat Point, M4 x 0.7 x 6 Lg

*NOTE: Items 26 and 31 could be replaced as a factory built assembly:008470-01 Grabber Bar Assembly

Items 22 and 31 could be replaced as a factory built assembly:008473-01 Grabber Bracket Assembly

16-2


Thread Tensioner Assembly

Figure 17

17-1


Thread Tensioner Assembly Reference Figure 17


1 007080-01 Knob, Adjust, Pretensioner, Plastic 2 003654-01 Spring, Pretensioner 3 005137-01 Disk, Pretensioner 4 007531-01 Post, Pretensioner 5 007524-01 Pretensioner Bracket 6 007523-01 Bracket, Tensioner 7 005531-01 PCB, Thread Break, Assembly 8 001924-06 Screw, Cheese Head, Slotted, M4 x 0.7 x 6 Lg 9 672018-16 Screw, Socket Head Cap, M4 x 0.7 x 16 Lg10* 005196-01 Base, Tensioner11* 004854-01 Spring, Tensioner, Thread12* 005422-01 Cap, Spring13* 005197-01 Knob, Tensioner, Black, Assembly14 003560-01 Tab, Tensioner15* 005198-02 Pad, Felt, .095" Thick16* 005198-01 Pad, Felt, .065" Thick17* 006474-01 Disk, Tensioner, Thread, Assembly18* 004908-01 Disk, Plastic19* 004897-01 Post, Tensioner20* 007559-01 Spring, Check21 007529-01 Collar, Tensioner Assembly22 001922-10 Screw, Socket Head Cap, M3 x 0.5 x 10 Lg23 007548-01 Cover, LED24 008481-01 Assembly, Guide, Thread, Upper25 003509-06 Screw, Button Head Cap, M4 x 0.7 x 6 Lg26 002897-01 Post, Guide (Quantity 4)27 007659-02 Standoff, M-F, 3/16" Round28 008468-01 Pigtail (Quantity 11)29 008496-04 Screw, Self-Tapping, #4 x .25"

*NOTE: Items 10-13 and 15-20 should be replaced as a factory built assembly:007547-01 Tensioner, Thread, Main, Black, Assembly

17-2


Sewing Head Components (1 of 3)

Figure 18

18-1


Sewing Head Components (1 of 3) Reference Figure 18


A 004504-01S Bobbin Idler Assembly See Page 21-1 1 003539-01 Counterweight, Phase II 2 003535-01 Shaft, Bobbin, Phase II 3 005601-01 Bracket, Needle Plate 4 001522-01 Pulley, Drive, Bobbin, Bottom, 16T, 1/5P 5 003545-01 Cam, Drive, Take-Up Lever 6 003546-01 Screw, Set, Cam 7 002698-01 Rod, Crank, 90 Deg 8 003532-01 Shaft, Arm 9 001523-01 Pulley, Drive, Bobbin, Top, 32T, 1/5P10 002809-01 Belt, Timing, 1/5P, 104 Groove, 3/8" Wide 11 001939-01 Rod, Connecting12 003531-01 Plate, Retainer, Bearing, Arm Shaft13 004261-01 Collar, Shaft, Headup14 008395-01 Solenoid, Jump Stitch14a ------------- Nut, Panel Included in Item #1415 006561-01 Bracket, Jump Stitch Solenoid16* 001955-14 Ring, Retaining, External17 008490-01 Case, Bobbin, Small18 009000-01 Hook, Rotary, Small Bobbin18a ------------- Screw, Rotary Hook Included in Item #1819 006520-01 Plate, Needle, UTC20 004643-01 Screw, Needle Plate21 007353-01 Sensor, Under Thread Control, Assembly22 003533-05 Ring, Retainer, External, Arm Shaft23 002697-09 Washer, Wave, 35mm OD24 002696-15 Bearing, Ball, Radial, 15mm ID25 001926-12 Screw, Flat Head Socket, M4 x 0.7 x 12 Lg26 003534-10 Ring, Retaining, External, Bobbin Shaft27 002696-08 Bearing, Ball, Radial, 8mm ID28 002697-03 Washer, Wave, 22mm OD29 671855-06 Screw, Pan Head Slotted, M3 x 0.5 x 6 Lg30 008499-01 Spool, Bobbin, Aluminum31 002610-14 Pin, Spring, 3mm OD x 14mm Lg32 672018-16 Screw, Socket Head Cap, M4 x 0.7 x 12 Lg33 001971-06 Screw, Set, Flat Point, M6 UNF x 6 Lg34 002637-10 Screw, Socket Head Cap, Low Head, M5 x 0.8 x 10 Lg35 001926-12 Screw, Flat Socket, M4 x 0.7 x 12 Lg36 702946-30 Spacer, Shaft, .187" ID x .312" OD x .03" Thick37* 006560-01 Bracket, Latch38 672018-12 Screw, Socket Head Cap, M4 x 0.7 x 12 Lg

18-2


Sewing Head Components (1 of 3) (cont) Reference Figure 18


39 002668-01 Collar, Support, Gear40 670038-10 Screw, Socket Head Cap, 10-32 x 5/8"41 003622-21 Cover, Solenoid42 006526-01 Bracket, Picker43 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg44 007257-01 Cam, Trimmer45 001927-10 Screw, Set, Flat Point, M5 x 0.8 x 10 Lg46 007272-10 Screw, Set, Cone Point, M5 x 0.8 x 10 Lg47 001922-20 Screw, Socket Head Cap, M3 x 0.5 x 20 Lg48* 006559-01 Pin, Latch49* 002876-21 Latch, Jump Stitch50 690427-04 Washer, Lock, Split, M451 006549-03 O-Ring, .187" ID x .06" Thick

*NOTE: Items 16, 37, 48 and 49 should be replaced as a factory built assembly:007340-01 Bracket, Latch, Jump Stitch, Assembly

18-3


This page intentionally left blank

18-4



Figure 19

19-1




1* 001845-01 Bushing, Spring Cradle 2* 001864-01 Spring, Jump, Reciprocator 3* 001865-01 Bushing, Shaft, Needle Bar 4* 002807-01 Stud, Connector, Reciprocator 5* 001842-01 Bracket, Stopper, Steel 6* 004676-01 Bracket, Stopper, Delrin 7* 004878-01 Reciprocator 8* 671855-06 Screw, Pan Head Slotted, M3 x 0.5 x 6 Lg 9* 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg10 001858-01 Shaft, Guide, Needle Bar11 001875-01 Bearing, Shaft, Guide12 001955-18 Ring, Retainer, External, 5/16" ID13 004264-08 Screw, Set, Cone Point, M4 x 0.7 x 8 Lg14 002821-01 Pad, Resevoir, Felt

*NOTE: Items 1-9 should be replaced as a factory built assembly: 001990-01S Assembly, Reciprocator

19-2



Figure 20

20-1




1 672018-16 Screw, Socket Head Cap, M4 x 0.7 x 16 Lg 2 -------------- Needle Case Assemblies See Pages 15-1 & 16-1 3* 007515-01 Plate, Bearing, Retainer 4* 007516-01 Stud, Bearing, Retainer 5 007517-01 Bearing, Radial, 4mm ID x 9mm OD 6 007562-06 Ring, Retaining 7 007520-01 V-Rail, Needle Case 8 672018-12 Screw, Socket Head Cap, M4 x 0.7 x 12 Lg 9 672018-06 Screw, Socket Head Cap, M4 x 0.7 x 6 Lg10 007546-01 Bracket, Support, Take-Up Lever Guide11 007507-01 Guide, Take-Up Lever12 671855-06 Screw, Pan Head Slotted, M3 x 0.5 x 6 Lg13 007473-01 Cover, Front, Arm, Right14 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg15 007514-01 Cover, Front, Arm, Left16 007521-01 V-Rail, Arm17 002610-14 Pin, Spring, 3mm18 007522-01 Bearing, Cross-Roller19 001942-01 Plate, Position, Machined20 002821-01 Pad, Resevoir, Felt

*NOTE: Items 3 and 4 should be replaced as a factory built assembly:007558-01 Plate, Retainer, Bearing, Assembly

20-2


Bobbin Idler Assembly

Figure 21

21-1


Bobbin Idler Assembly Reference Figure 21


1 003593-01 Roller, Idler 2 002817-01 Bar, Idler, Assembly 3 002816-06 Spring, Idler 4 003668-01 Cover, Rear 5 003188-01 Screw, Shoulder, M5 x 7mm OD x 0.8 Lg 6 660278-01 Stud, Press, 1/4" OD x 1/2" Lg 7 003543-05 Nut, Jam, Hex, M5 8 672036-10 Screw, Button Head Cap, M5 x 0.8 x 10 Lg 9 690713-04 Washer, Lock, External Star, 1/4" 10 702876-08 Spacer, Shaft, 5/16" ID x .016" Thick11 001955-18 Ring, Retainer, External, 5/16" ID

21-2


Take-Up Drive Lever Assembly

Figure 22

22-1


Take-Up Drive Lever Assembly Reference Figure 22


1* 003567-01 Base, Drive, Lever, Take-Up, PHS II 2* 001947-01 Bushing, Base, Drive, Lever, Take-Up 3* 004821-01 Lever, Drive, Lever, Take-Up 4 001983-01 Follower, Assembly 5* 004820-01 Shaft, Drive, Lever, Take-Up 6 001893-01 Case, Gear, Drive, Lever, Take-Up 7 001894-01 Gear, Drive, Lever, Take-Up 8* 660830-10 Pin, Groove, 1/8" OD x 5/8" Lg 9 003543-05 Nut, Jam, Hex, M510 672018-14 Screw, Socket Head Cap, M4 x 0.7 x 14 Lg11 690427-04 Washer, Lock, Split, M412 690439-04 Washer, Flat, M413 671855-06 Screw, Pan Head Slotted, M3 x 0.5 x 6 Lg14 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg

*NOTE: Items 1 and 2 should be replaced as a factory built assembly:005362-01 Assembly, Bushing, Take-Up Lever

Items 3, 5, and 8 should be replaced as a factory built assembly:004768-01 Lever, Drive, Lever, Take-up, Assembly

22-2


X-Drive Motor Assembly (1 of 3)

Figure 23

23-1


X-Drive Motor Assembly (1 of 3) Reference Figure 23


1 690439-06 Washer, Flat, M6 2 671686-16 Screw, Socket Head Cap, M6 x 1.0 x 16 Lg 3 702875-10 Spacer, Shaft, .18" ID x .063" Thick 4 005535-01 PCB, Home/Limit Assembly 5 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg 6 008053-01 Cover, X-Y Home 7 008167-01 Cover, X-Drive 8 004262-08 Screw, Pan Head Phillips, M4 x 0.7 x 8 Lg 9 008062-01 Clamp, Split-Hub, 8mm ID10 008051-01 Flag, X-Y Limits11 001955-18 Ring, Retaining, External, 5/16"12 008088-01 Pulley, Timing, 80 Groove, 2.03mm Pitch13 008087-01 Belt, Timing, .375" Wide, 175 Groove, .080" Pitch14 008085-01 Pulley, Timing, Flanged, 21 Groove, 2.03mm Pitch15 007721-40 Pin, 6mm OD x 40mm Lg16 008232-01 Belt, Timing, Continuous, 32mm Wide17 007718-06 Screw, Set, Cup Point, M6 x 1.0 x 6 Lg18 008081-01 Pulley, Timing, Flanged, .625" Bore19 007722-16 Screw, Socket Head Cap, 3/8-16 x 1.0" Lg20 690033-06 Washer, Spring Lock, 3/8"21 008179-01 Mount, Plate, X-Y Drive22 008397-01 Motor, X-Y Drive23 671687-25 Screw, Socket Head Cap, M8 x 1.25 x 25 Lg24 690427-08 Washer, Lock, Split, M825 690439-08 Washer, Flat, M8 26 008205-02 Coupling, Connecting, 20mm27 008230-01 Bearing, Ball28 008183-01 Channel, X-Drive29 008184-01 Shaft, Drive30 005034-01 Screw, Set, Cup Point, M4 x 0.7 x 6 Lg31 006525-01 Key, 6mm32 008082-01 Pulley, Timing, 40mm Wide33 008050-01 Shaft, Drive, Home Switch34 008052-01 Plate, Base, X-Y Home35 007852-01 Bushing Strain Relief36 007728-12 Screw, Set, Flat Point, M8 x 1.25 x 12 Lg37 672018-20 Screw, Socket Head Cap, M4 x 0.7 x 20 Lg38 671686-30 Screw, Socket Head Cap, M6 x 1.0 x 30 Lg39 008388-01 Block, Tensioner

23-2



Figure 24

24-1




1 007717-06 Screw, Set, Cup Point, M5 x 0.8 x 6 Lg 2 672018-30 Screw, Socket Head Cap, M4 x 0.7 x 30 Lg 3 008196-01 Dowel, Trolley 4 007723-06 Screw, Set, Brass Tip, M5 x 0.8 x 6 Lg 5 008191-01 Trolley, Rear, Assembly 6 671686-25 Screw, Socket Head Cap, M6 x 1.0 x 25 Lg 7 008193-01 Shaft, Rail, Guide, X-Axis 8 008229-01 Block, Support, Rail 9 001962-06 Screw, Set, M3 x 0.5 x 6 Lg10 008181-01 Clamp, Plate, Belt, X-Y Drive11 671687-30 Screw, Socket Head Cap, M8 x 1.25 x 30 Lg12 005034-01 Screw, Set, Cup Point, M4 x 0.7 x 6 Lg13 008183-01 Channel, X-Drive14 008187-01 Bearing, Needle15 008182-01 Idler, Roller16 008188-01 Bearing, Plain17 008195-01 Shaft, Idler18 008189-01 Belt, Timing, Poly, 50mm19 008190-01 Trolley, Front, Assembly20 008194-01 Drive, Plate, X-Axis21 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg22 008209-01 Plate, Sash Bearing23 008324-01 Bracket, Bearing Rear24 672018-20 Screw, Socket Head Cap, M4 x 0.7 x 20 Lg25 008323-01 Bearing, Block26 008231-01 Bearing, Ball27 008215-01 Bearing, Spigot28 672018-12 Screw, Socket Head Cap, M4 x 0.7 x 12 Lg29 690439-04 Washer, Flat, M430 671853-10 Screw, Button Head Socket, M4 x 0.7 x 10 Lg31 008210-01 Plate, Bearing32 008192-01 Plain Bearing33 690427-04 Washer, Lock, Split, M434 007725-70 Screw, Hex Head, M10 x 1.5 x 70 Lg35 008453-01 Shim, X-Y Axis, 1mm (Use as Required)36 008453-02 Shim, X-Y Axis, 1.5mm (Use as Required)37 008453-03 Shim, X-Y Axis, 2mm (Use as Required)

24-2



Figure 25

25-1




1 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg 2 008194-01 Drive, Plate, X-Axis 3 007717-06 Screw, Set, Cup Point, M5 x 0.8 x 6 Lg 4 672018-30 Screw, Socket Head Cap, M4 x 0.7 x 30 Lg 5 008190-01 Trolley, Front, Assembly 6 008196-01 Dowel, Trolley 7 007723-06 Screw, Set, Brass Tip, M5 x 0.8 x 6 Lg 8 008191-01 Trolley, Rear, Assembly 9 008193-01 Shaft, Rail, Guide, X-Axis10 671686-25 Screw, Socket Head Cap, M6 x 1.0 x 25 Lg11 008229-01 Block, Support, Rail12 001962-06 Screw, Set, M3 x 0.5 x 6 Lg13 008181-01 Clamp, Plate, Belt, X-Y Drive14 671687-30 Screw, Socket Head Cap, M8 x 1.25 x 30 Lg15 008185-01 Shaft, Drive16 008205-02 Coupling, Connecting, 20mm17 008230-01 Bearing, Ball18 008183-01 Channel, X-Drive19 008187-01 Bearing, Needle20 008195-01 Shaft, Idler21 008188-01 Bearing, Plain22 008182-01 Idler, Roller23 005034-01 Screw, Set, Cup Point, M4 x 0.7 x 6 Lg24 008189-01 Belt, Timing, Poly, 50mm25 008209-01 Plate, Sash Bearing26 008324-01 Bracket, Bearing Rear27 672018-20 Screw, Socket Head Cap, M4 x 0.7 x 20 Lg 28 008323-01 Bearing, Block 29 008231-01 Bearing, Ball30 008215-01 Bearing, Spigot31 672018-12 Screw, Socket Head Cap, M4 x 0.7 x 12 Lg32 690439-04 Washer, Flat, M433 671853-10 Screw, Button Head Socket, M4 x 0.7 x 10 Lg34 008210-01 Plate, Bearing35 008192-01 Plain Bearing36 690427-04 Washer, Lock, Split, M437 007725-70 Screw, Hex Head, M10 x 1.5 x 70 Lg38 008453-01 Shim, X-Y Axis, 1mm (Use as Required)39 008453-02 Shim, X-Y Axis, 1.5mm (Use as Required)40 008453-03 Shim, X-Y Axis, 2mm (Use as Required)

25-2


X-Drive Roller Blind Assembly

Figure 26

26-1


X-Drive Roller Blind Assembly Reference Figure 26


1 690034-03 Washer, Flat, #10 2 671910-12 Screw, Pan Head Phillips, Self-Tapping, #10 x 3/4" 3 008378-01 Bracket, Roller Blind 4 008335-01 Cover, Roller Blind 5 008336-01 Roller, Blind, X-Drive 6 690439-04 Washer, Flat, M4 7 671853-10 Screw, Button Head Socket, M4 x 0.7 x 10 Lg 8 008324-01 Bracket, Bearing Rear 9 008375-01 Strap, Fixing, Blind, X-Drive10 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg

26-2


Y-Drive Motor Assembly (1 of 5)

Figure 27

27-1


Y-Drive Motor Assembly (1 of 5) Reference Figure 27


1 008231-01 Bearing, Ball 2 008215-01 Bearing, Spigot 3 672018-16 Screw, Socket Head Cap, M4 x 0.7 x 16 Lg 4 690439-04 Washer, Flat, M4 5 672018-12 Screw, Socket Head Cap, M4 x 0.7 x 12 Lg 6 007723-06 Screw, Set, Brass Tip, M5 x 0.8 x 6 Lg 7 007717-06 Screw, Set, Cup Point, M5 x 0.8 x 6 Lg 8 671686-25 Screw, Socket Head Cap, M6 x 1.0 x 25 Lg 9 001962-06 Screw, Set, M3 x 0.5 x 6 Lg10 008229-01 Block, Support, Rail11 008198-01 Shaft, Rail, Guide, Y-Axis12 007725-70 Screw, Hex Head, M10 x 1.5 x 70 Lg 13 008191-01 Trolley, Rear, Assembly14 672018-30 Screw, Socket Head Cap, M4 x 0.7 x 30 Lg15 008181-01 Plate, Clamp, Belt, X-Y Drive16 008196-01 Dowel, Trolley 17 008190-01 Trolley, Front Assembly 18 008201-01 Arm, Drive, Y-Axis19 672018-08 Screw, Socket Head Cap, M4 x 0.7 x 8 Lg20 008203-01 Plate, Guide, Y-Axis21 008202-01 Extension, Driver, Y-Axis22 008331-01 Bearing, Ball23 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg24 008209-01 Bearing, Plate, Sash25 008210-01 Bearing, Plate26 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg27 008303-01 Plate, Roller Mounting, Front28 008323-01 Bearing, Block29 671853-10 Screw, Button Head Socket, M4 x 0.7 x 10 Lg30 008302-01 Plate, Roller Mounting, Rear31 008192-01 Plain Bearing32 690427-04 Washer, Lock, Split, M4

27-2



Figure 28

28-1




1 008318-01 Cover, Y-Drive, #1 2 008185-01 Shaft, Drive, Pulley 3 005034-01 Screw, Set, Cup Point, M4 x 0.7 x 6 Lg 4 007721-40 Pin, 6mm OD x 40mm Lg 5 008230-01 Bearing, Ball 6 004262-08 Screw, Pan Head Phillips, M4 x 0.7 x 8 Lg 7 008166-01 Cover, X-Drive 8 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg 9 008053-01 Cover, X-Y Home10 008050-01 Shaft, Drive, Home Switch11 008085-01 Pulley, Timing, Flanged, 21 Groove, 2.03mm Pitch12 008087-01 Belt, Timing, .375" Wide, 175 Groove, .080" Pitch13 008086-01 Pulley, Timing, 60 Groove, 2.03mm Pitch14 001955-18 Ring, Retaining, External, 5/16"15 008051-01 Flag, X & Y Limits16 008062-01 Clamp, Split-Hub, 8mm ID17 008052-01 Plate, Base, X-Y Home18 005535-01 PCB, Home/Limit, Assembly19 702875-10 Spacer, Shaft, .18" ID x .063" Thick20 671686-16 Screw, Socket Head Cap, M6 x 1.0 x 16 Lg21 690439-06 Washer, Flat, M622 008187-01 Bearing, Needle23 008182-01 Idler Roller24 008188-01 Bearing, Plain25 008195-01 Shaft, Idler26 008205-02 Coupling, Connecting27 008234-01 Shaft, Connecting, 1-228 671686-25 Screw, Socket Head Cap, M6 x 1.0 x 25 Lg29 008186-01 Belt, Timing, Poly, 50mm Wide30 008453-01 Shim, X-Y Axis, 1mm (Use as Required)31 008453-02 Shim, X-Y Axis, 1.5mm (Use as Required)32 008453-03 Shim, X-Y Axis, 2mm (Use as Required)

28-2



Figure 29

29-1




1 671687-30 Screw, Socket Head Cap, M8 x 1.25 x 30 Lg 2 006525-01 Key, 6mm 3 008204-01 Shaft, Pulley, Drive 4 004262-08 Screw, Pan Head Phillips, M4 x 0.7 x 8 Lg 5 008168-01 Cover, Y-Drive, Bottom 6 008197-01 Channel, Y-Drive 7 008230-01 Bearing, Ball 8 008205-02 Coupling, Connecting, 20mm 9 008234-01 Shaft, Y-Drive, #110 008179-01 Mount, Plate, X-Y Drive11 008397-01 Motor, Y-Drive12 690033-06 Washer, Spring Lock, 3/8"13 007722-16 Screw, Socket Head Cap, 3/8-16 x 1.0" Lg14 342596-19 Screw, Set, Cup Point, M6 x 1.0 x 6 Lg15 008081-01 Pulley, Timing, Flanged, .625" Bore16 008182-01 Idler Roller17 008188-01 Bearing, Plain18 008195-01 Shaft, Idler19 008187-01 Bearing, Needle20 008186-01 Belt, Timing, Poly, 50mm Wide21 005034-01 Screw, Set, M4 x 0.7 x 6 Lg22 008082-01 Pulley, Timing, 40mm Wide23 008232-01 Belt, Timing, Continuous, 32mm Wide24 008236-01 Shaft, #3, Y-Drive25 008319-01 Cover, Y-Drive, #226 671687-25 Screw, Socket Head Cap, M8 x 1.25 x 25 Lg27 690427-08 Washer, Lock, Split, M828 690439-08 Washer, Flat, M829 672018-20 Screw, Socket Head Cap, M4 x 0.7 x 20 Lg30 671686-30 Screw, Socket Head Cap, M6 x 1.0 x 30 Lg31 008388-01 Block, Tensioner32 007728-12 Screw, Set, Flat Point, M8 x 1.25 x 12 Lg33 008453-01 Shim, X-Y Axis, 1mm (Use as Required)34 008453-02 Shim, X-Y Axis, 1.5mm (Use as Required)35 008453-03 Shim, X-Y Axis, 2mm (Use as Required)36 008396-01 Harness, Motor

29-2



Figure 30

30-1




1 671687-30 Screw, Socket Head Cap, M8 x 1.25 x 30 Lg 2 008204-01 Shaft, Pulley, Drive 3 008197-01 Channel, Y-Drive 4 008230-01 Bearing, Ball 5 008205-01 Coupling, Connecting, 15mm 6 008236-01 Shaft, #3, Y-Drive 7 008182-01 Idler Roller 8 008188-01 Bearing, Plain 9 008195-01 Shaft, Idler10 008187-01 Bearing, Needle11 008186-01 Belt, Timing, Poly, 50mm Wide12 005034-01 Screw, Set, M4 x 0.7 x 6 Lg13 004262-08 Screw, Pan Head Phillips, M4 x 0.7 x 8 Lg14 008320-01 Cover, #3, Y-Drive15 008453-01 Shim, X-Y Axis, 1mm (Use as Required)16 008453-02 Shim, X-Y Axis, 1.5mm (Use as Required)17 008453-03 Shim, X-Y Axis, 2mm (Use as Required)

30-2



Figure 31

31-1




1 671687-30 Screw, Socket Head Cap, M8 x 1.25 x 30 Lg 2 008185-01 Shaft, Pulley, Drive 3 008197-01 Channel, Y-Drive 4 008230-01 Bearing, Ball 5 008236-01 Shaft, Connecting, 3-4 6 008205-01 Coupling, Connecting, 15mm 7 005034-01 Screw, Set, M4 x 0.7 x 6 Lg 8 008182-01 Idler Roller 9 008188-01 Bearing, Plain10 008195-01 Shaft, Idler11 008187-01 Bearing, Needle12 008186-01 Belt, Timing, Poly, 50mm Wide13 008453-01 Shim, X-Y Axis, 1mm (Use as Required)14 008453-02 Shim, X-Y Axis, 1.5mm (Use as Required)15 008453-03 Shim, X-Y Axis, 2mm (Use as Required)

31-2


Z-Drive Motor Assembly (1 of 5)

Figure 32

32-1


Z-Drive Motor Assembly (1 of 5) Reference Figure 32


1 690439-08 Washer, Flat, M8 2 690427-08 Washer, Lock, Split, M8 3 671687-25 Screw, Socket Head Cap, M8 x 1.25 x 25 Lg 4 008399-01 Motor, Z-Drive 5 008252-01 Plate, Z-Motor 6 690033-06 Washer, Spring Lock, 3/8" 7 007722-16 Screw, Socket Head Cap, 3/8-16 x 1.0" Lg 8 007717-06 Screw, Set, Cup Point, M5 x 0.8 x 6 Lg 9 008243-01 Connector, Motor10 008135-01 Frame, Dummy Head11 007724-01 Key, .188" Square12 008237-01 Shaft, Z-Drive, #113 007728-12 Screw, Set, Flat Point, M8 x 1.25 x 12 Lg14 008396-01 Harness, Motor

32-2



Figure 33

33-1




1 008238-01 Shaft, Z-Drive, #2 2 670018-16 Screw, Socket Head Cap, M4 x 0.7 x 16 Lg 3 004263-21 Cover, Gearbox 4 006043-21 Gear, Case, Assembly, Grey 5 008237-01 Shaft, Z-Drive, #1 6* 008292-01 Bearing, Thrust, Z-Shaft 7 008293-01 Collar, 15mm ID, Gearbox 8 342630-01 Collar, Shaft, 15mm ID 9 008243-01 Connector, Motor10 002668-01 Collar, Support, Gear11 670038-10 Screw, Socket Head Cap, 10-32 x 5/8" Lg12 008205-01 Coupling, Connecting, 15mm ID13 001971-06 Screw, Set, Flat Point, M6 x 1.00 x 6 Lg14 003195-01S Assembly, Gears, Bevel15 007724-01 Key, .188" Square16 007717-06 Screw, Set, Cup Point, M5 x 0.8 x 6 Lg

*NOTE: Parts with asterisk in the item bubble have a smaller ID

33-2



Figure 34

34-1




1 008370-01 Shaft, Z-Drive, #4 2 670018-16 Screw, Socket Head Cap, M4 x 0.7 x 16 Lg 3 004263-21 Cover, Gearbox 4 006043-21 Gear, Case, Assembly, Grey 5 008238-01 Shaft, Z-Drive, #2 6 002668-01 Collar, Support, Gear 7 670038-10 Screw, Socket Head Cap, 10-32 x 5/8" Lg 8* 008292-01 Bearing, Thrust, Z-Shaft 9 008293-01 Collar, 15mm ID, Gearbox10 342630-01 Collar, Shaft, 15mm ID11 008205-01 Coupling, Connecting, 15mm ID12 001971-06 Screw, Set, Flat Point, M6 x 6 Lg13 003195-01S Assembly, Gears, Bevel


34-2



Figure 35

35-1




1 008239-01 Shaft, Z-Drive, #3 2 672018-16 Screw, Socket Head Cap, M4 x 0.7 x 16 Lg 3 004263-21 Cover, Gearbox 4 006043-21 Gear, Case, Assembly, Grey 5 002668-01 Collar, Support, Gear 6 670038-10 Screw, Socket Head Cap, 10-32 x 5/8" Lg 7 008370-01 Shaft, Z-Drive, #4 8 008205-01 Coupling, Connecting, 15mm ID

35-2



Figure 36

36-1




1 671687-60 Screw, Socket Head Cap, M8 x 1.25 x 60 Lg 2 690439-08 Washer, Flat, M8 3 693155-15 Washer, Thrust, 15mm ID 4 008098-01 Bar, Idler 5 008104-01 Belt, 5mm HTD 6 008103-01 Pulley, Z, 25T, 5mm HTD 7 671686-25 Screw, Socket Head Cap, M6 x 1.0 x 25 Lg 8 690439-06 Washer, Flat, M6 9 008351-01 Bearing, Z-Drive Shaft10 008350-01 Spacer, Bearing, Z-Shaft11 008349-01 Block, Bearing, Z-Shaft12 008352-01 Cover, Drive, Trimmer13 671686-08 Screw, Socket Head Cap, M6 x 1.0 x 8 Lg14 690427-06 Washer, Lock, Split, M615 008239-01 Shaft, Z-Drive, #316 008354-01 Cover, Bearing Housing17 008259-01 Rod, Trimmer, Guide, 6mm18 007727-13 Screw, Sheet Metal, Pan Head Phillips, M4 x 0.7 x 13 Lg19 008325-01 Cover, Table, Trimmer20 001963-09 Nut, Hex, M821 671687-25 Screw, Socket Head Cap, M8 x 1.25 x 25 Lg22 008090-01 Support, Trim Cam23 690439-04 Washer, Flat, M4 24 690427-04 Washer, Lock, Split, M425 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg26 007718-20 Screw, Set, Cup Point, M6 x 1.00 x 20 Lg27 008118-01 Pulley, Cam, 25T, 5mm HTD28 003221-01 Hub, Adjustable, 1/2" ID29 001955-14 Ring, Retainer30 007572-37 Ring, Retainer31 008096-01 ATH Bar Driver32 008039-01 Pivot, Trimmer Drive33 008100-01 Shaft, Idler Pivot34 008077-01 Bearing, Needle Roller, 15mm ID35 008099-01 Pulley, Idler36 008094-01 Pin, Clevis37 008097-01 Clevis, Double, Trimmer Drive38 008095-01 Pin, Clevis, .187"39 008224-01 Cover, Trimmer Housing40 672018-12 Screw, Socket Head Cap, M4 x 0.7 x 12 Lg41 008260-01 Coupling, Rod, 6mm42 008442-01 Spacer, Z-Shaft, Trim Cam Box43 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg

36-2


Gearbox Assembly

Figure 37

37-1


Gearbox Assembly Reference Figure 37


1 006043-21 Assembly, Gearbox 2 003195-01S Assembly, Gears, Bevel 3 002668-01 Collar, Support, Gear 4* 008292-01 Bearing, Thrust, Z-Shaft (See Note) 4a* 008292-01 Bearing, Thrust, Z-Shaft (See Note) 5 670038-10 Screw, Socket Head Cap, 10-32 x 5/8" 6 672018-16 Screw, Socket Head Cap, M4 x 0.7 x 16 Lg 7* 342630-01 Collar, Shaft, 15mm ID 8 001971-06 Screw, Set, Flat Point, M6 x 1.00 x 6 Lg 9* 008293-01 Collar, 15mm ID, Gearbox10 004263-21 Cover, Gearbox11 004258-12 Pin, Dowel, .1875" OD x .75" Lg


Items 4a and 9 are used on Head 1 only

Items 4 and 7 are used on Heads 1, 3 and 7 only

37-2


Logic Control Box Assembly (1 of 2)

Figure 38

38-1


Logic Control Box Assembly (1 of 2) Reference Figure 38


1 007805-01 Speaker Assembly 2 008019-01 Cable, Connector Interface, 30 Pin (See Figure 39) 3 005538-01 PCB, Connector Interface 4 671855-06 Screw, Pan Head Slotted, M3 x 0.5 x 6 Lg 5 007806-01 Cable, Low Voltage Interface (See Figure 39) 6 007662-01 Harness, DC Power, Control (See Figure 39) 7 008018-01 Cable, Connector Interface, 26 Pin (See Figure 39) 8 008020-01 Cable, Connector Interface, 40 Pin (See Figure 39) 9 690439-04 Washer, Flat, M410 690427-04 Washer, Lock, Split, M411 672018-08 Screw, Socket Head Cap, M4 x 0.7 x 8 Lg12 341673-01 Clamp, Cable, Flat, 1" x 1"13 008021-01 Cable, Connector Interface, 20 Pin (See Figure 39)14 005546-01 PCB, Low Voltage Driver15 008263-01 Holder, Control Board Support16 671855-12 Screw, Pan Head Slotted, M3 x 0.5 x 12 Lg17 001960-16 Screw, Socket Head Cap, M4 x 0.7 x 16 Lg18 690713-38 Washer, Lock, External Star, #8 19 690439-04 Washer, Flat, M420 671855-08 Screw, Pan Head Slotted, M3 x 0.5 x 8 Lg21 007660-01 PCB, PCMCIA Interface22 702875-12 Spacer, Shaft, 3/16" ID x 1/8" Thick23 006433-01 Hard Disk Drive, 85 Mb24 001960-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg25 690439-04 Washer, Flat, M426 003176-01 Bumper, Motor Stop27 008264-01 Plate, Mount, Hard Drive28 690439-03 Washer, Flat, M3 29 690427-03 Washer, Lock, Split, M330 680430-03 Nut, Hex, M331 008128-01 Base, Control Box32 008265-01 Angle, Cable Support33 008359-01 Mount, PCB, Jump Stitch, Solenoid34 007868-01 PCB, Jump Stitch Interface, Assembly35 001922-06 Screw, Socket Head Cap, M3 x 0.5 x 6 Lg

38-2


Logic Control Box Assembly (2 of 2)

Figure 39

39-1


Logic Control Box Assembly (2 of 2) Reference Figure 39


1 007662-01 Harness, DC Power, Control (See Figure 38) 2 008019-01 Cable, Connector Interface, 30 Pin (See Figure 38) 3 007601-01 Cable, Connector Interface, 30 Pin 4 671855-06 Screw, Pan Head Slotted, M3 x 0.5 x 6 Lg 5 005518-01 PCB, CPU188 6 005523-01 PCB, Control Interface 7 008018-01 Cable, Connector Interface, 26 Pin (See Figure 38) 8 008020-01 Cable, Connector Interface, 40 Pin (See Figure 38) 9 005386-01 PCB, Video Contoller10 005448-01 Dongle11 007807-01 Cable, Starlan Network Interface12 345068-11 Cable, Data, 5 Cond. w/ Drain13 008021-01 Cable, Connector Interface, 20 Pin (See Figure 38)14 005091-01 PCB, Network Security15 007806-01 Cable, Low Voltage Interface (See Figure 38)16 004244-01 PCB, Disk Drive Controller17 671855-16 Screw, Pan Head Slotted, M3 x 0.5 x 16 Lg18 672018-16 Screw, Socket Head Cap, M4 x 0.7 x 16 Lg19 690439-04 Washer, Flat, M420 690713-38 Washer, Lock, External Star, #8 21 000434-02 Coupler, Inline22 000434-01 Coupler, Inline23 702875-16 Spacer, Shaft, 3/16" ID x .500" Thick24 008128-01 Base, Control Box25 006435-01 PCB, CPU386

39-2


Motor Drive Box Assembly (1 of 2)

Figure 40

40-1


Motor Drive Box Assembly (1 of 2) Reference Figure 40


1 007687-01 Cap, Electrolytic, 2000 uF, 200V 2 007688-01 Cap, Electrolytic, Mount, 2" Diameter 3 690439-04 Washer, Flat, M4 4 690427-04 Washer, Lock, Split, M4 5 001963-05 Nut, Hex, M4 6 690439-06 Washer, Flat, M6 7 690427-06 Washer, Lock, Split, M6 8 671686-12 Screw, Socket Head Cap, M6 x 0.8 x 12 Lg 9 007566-01 Cover, Rear, Box, Motor Drive10 672018-06 Screw, Socket Head Cap, M4 x 0.7 x 6 Lg11 672018-08 Screw, Socket Head Cap, M4 x 0.7 x 8 Lg12 007691-01 Harness, DC Power 1, +160V13 007692-01 Harness, DC Power 2, GND14 007696-01 Harness, DC Power 6, GND15 007695-01 Harness, DC Power 5, +160V16 007694-01 Harness, DC Power 4, GND17 007693-01 Harness, DC Power 3, +160V

40- 2


Motor Drive Box Assembly (2 of 2)

Figure 41

41-1


Motor Drive Box Assembly (2 of 2) Reference Figure 41


1 007697-01 Harness, Motor Power 2 007690-01 Harness, Motor Drive Commands 3 007566-01 Sheetmetal, Motor Drive Box 4 672018-06 Screw, Socket Head Cap, M4 x 0.7 x 6 Lg 5 007918-01 Jackscrew, D-Connector, w/Hardware 6 007689-01 Harness, Motor Drive Power 7 672018-14 Screw, Socket Head Cap, M4 x 0.7 x 14 Lg 8 690427-04 Washer, Lock, Split, M4 9 690439-04 Washer, Flat, M410 007686-01 Diode, Bridge Rectifier, 200V, 25A11 672018-16 Screw, Socket Head Cap, M4 x 0.7 x 16 Lg12 007671-01 Motor Drive, Brushless, 160V, 13/6.5/3.2513 007567-01 Heatsink, Motor Drive Box

41-2


Power Distribution Box Assembly (1 of 3)

Figure 42

42-1


Power Distribution Box Assembly (1 of 3) Reference Figure 42


1 007902-01 Base, Power Distribution Box 2 007810-01 Circuit Breaker, Weber 15A 3 182499-01 Fuse Holder 4 007813-01 Transformer, 3KVA, 240/120 5 690713-03 Washer, Lock, External Star, #10 6 670880-08 Screw, Hex Head, 10-32 x 1/2" 7 672018-08 Screw, Socket Head Cap, M4 x 0.7 x 8 Lg 8 690427-04 Washer, Lock, Split, M4 9 690439-04 Washer, Flat, M410 007834-01 Assembly, 24V Transformer11 671852-12 Screw, Socket Head Cap, M5 x 0.8 x 12 Lg12 690427-05 Washer, Lock, Split, M513 690439-05 Washer, Flat, M5

42-2



Figure 43

43-1




1 007902-01 Base, Power Distribution Box 2 670174-06 Screw, Pan Head Phillips, 6-32 x 3/8" 3 007816-01 Assembly, AC Outlets 4 690713-38 Washer, Lock, External Star, #4 5 690034-34 Washer, Flat, #4 6 192298-06 Block, Terminal 7 007708-01 Plate, Mount, Relay, Power Box 8 700134-01 Spacer, Nylon, .140" ID x .250" OD x .18" Lg 9 672018-12 Screw, Socket Head Cap, M4 x 0.7 x 12 Lg10 690427-04 Washer, Lock, Split, M411 690439-04 Washer, Flat, M412 007843-01 Relay, Solid State13 001963-05 Nut, Hex, M414 007686-01 Rectifier, Bridge15 672018-06 Screw, Socket Head Cap, M4 x 0.7 x 6 Lg16 672018-08 Screw, Socket Head Cap, M4 x 0.7 x 8 Lg17 001922-12 Screw, Socket Head Cap, M3 x 0.5 x 12 Lg18 690427-03 Washer, Lock, Split, M319 690439-03 Washer, Flat, M320 007803-01 PCB, E-Stop Control21 007901-01 Lid, Power Distribution Box22 007833-01 Cap, 20,000uF, 50V, 2 inch23 007688-01 Mount, Cap, 2.0"24 007853-01 Power Supply, +5/+12/-12 VDC25 702875-13 Spacer, Shaft, 3/16" ID x .188" Thick26 007838-01 Assembly, Resistor, 24V Bleeder27 190662-01 Jumper, Barrier, Terminal Strip

43-2



Figure 44

44-1




1 007902-01 Base, Power Distribution Box 2 007827-01 Assembly, Fan, 115 VAC, 120 CFM 3 680043-36 Nut, Nylock, #6 4 680430-03 Nut, Hex, M3 5 690427-03 Washer, Lock, Split, M3 6 690439-03 Washer, Flat, M3 7 007846-01 Harness, Power Output (Reference Only) 8 001922-12 Screw, Socket Head Cap, M3 x 0.5 x 12 Lg 9 342763-01 Assembly, Filter, Fan10 670405-32 Screw, Flat Head Socket, 6-32 x 2"11 007852-02 Bushing Strain Relief

44-2


Trimmers, Head Level (1 of 2)

Figure 45

45-1


Trimmers, Head Level (1 of 2) Reference Figure 45


1 008258-01 Link, Connecting, Trimmer 2 008109-01 Assembly, Drive, Arm Short, Trimmer 3 671852-16 Screw, Socket Head Cap, M5 x 0.8 x 16 Lg 4 672018-20 Screw, Socket Head Cap, M4 x 0.7 x 20 Lg 5 008261-01 Link, Connecting, Picker 6 006526-01 Bracket, Picker 7 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg 8 001935-06 Screw, Flathead Phillips, M3 x 0.5 x 6 Lg 9 001962-06 Screw, Set, Flat Point, M3 x 0.5 x 6 Lg10 003511-01 Mount, Picker11 001955-08 Ring, Retainer, External, .125"12 003141-01 Base, Picker13 005615-01 Picker14 003136-06 Screw, Button Head Socket, M3 x 0.5 x 6 Lg15 003131-01 Pin, Swivel, Front16 003123-03 Screw, Set, Cup Point, M3 x 0.5 x 3 Lg17 006305-01 Screw, Pan Head, M2 x 0.4 x 3 Lg18 003685-01 Clip, Fixing, Drive Arm19 005601-01 Bracket, Needle Plate20 005602-01 Arm, Drive, Movable Knife21 005617-01 Knife, Movable22 005600-01 Knife, Spring, Fixed 23 003136-04 Screw, Button Head Socket, M3 x 0.5 x 4 Lg 24 006671-01 Presser, Thread, Under25 008075-01 Base, Arm26 006387-01 Bracket, Bed, Cable27 004550-01 Mount, Cable Tie28 001926-10 Screw, Flat Head Socket, M4 x 0.7 x 10 Lg29 008040-01 Bushing, Trimmer Pivot30 008076-01 Spacer, Pivot, Trimmer31 008041-01 Plate, Nut, Long Arm32 005034-01 Screw, Set, Cup Point, M4 x 0.7 x 6 Lg33 008039-01 Pivot, Trimmer Drive34 672018-12 Screw, Socket Head Cap, M4 x 0.7 x 12 Lg35 690427-04 Washer, Lock, Split, M436 008038-01 Arm, Linkage, Long37 008259-01 Rod, Trimmer, Drive, 6mm38 003452-01 Solenoid, Picker, Assembly39 003126-01 Bracket, Solenoid40 690439-03 Washer, Flat, M341 004642-01 Washer, Lock, Split, 5-4042 680430-03 Nut, Hex, M3

45-2


43 003130-01 Arm, Solenoid 44 672018-08 Screw, Socket Head Cap, M4 x 0.7 x 8 Lg45 003155-01 Swivel, Wire46 008467-01 Collar47 008466-01 Spring48 008465-01 Spring Mount Bracket49 006525-01 Key, Shaft, 6mm x 6mm x 32mm50 006524-01 Block, Mount, Cap Frame51 671852-08 Screw, Socket Head Cap, M5 x 0.8 x 8 Lg52 006538-01 Knob, Knurled, M5, Black

Trimmers, Head Level (1 of 2) (Cont) Reference Figure 45


45-3



45-4


Trimmers, Head Level (2 of 2)

Figure 46

46-1


Trimmers, Head Level (2 of 2) Reference Figure 46


1 002892-01 Mount, Conduit, Front 2 008063-01 Guide, Blade 3 690439-04 Washer, Flat, M4 4 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg 5 003509-08 Screw, Button Head Socket, M4 x 0.7 x 10 Lg 6 008066-01 Housing, Drive, Grabber, Left 7 003136-06 Screw, Button Head Socket, M3 x 0.5 x 6 Lg 8 008043-01 Blade, Grabber 9 007590-01 Sprocket, Drive, Grabber10 008496-08 Screw, Self-Tapping, #4 x .50"11 008127-01 Housing, Drive, Grabber, Right12 008106-01 Shaft, End, Grabber, Drive13 005034-01 Screw, Set, Cup Point, M4 x 0.7 x 6 Lg14 007549-01 Coupler, Shaft, Grabber15 008101-01 Shaft, Grabber, Drive

46-2


Cam Box Assembly

Figure 47

47-1


Cam Box Assembly Reference Figure 47


1 003215-01 Follower, Cam 2 004499-01 Bearing, Shaft, Flanged w/Hub 3 003202-01 Bearing, Shaft, Lever 4 007552-01 Wall, Side Drive, Cam, Right 5 004500-01 Cam, Trimmer 6 007599-01 Shaft, Cam, Trimmer 7 008118-01 Pulley, Cam, 5mm Pitch 8 004875-01 Lever, Cam 9 003213-01 Shaft, Lower, Cam10 003234-01 Spring, Cam Follower11 003220-01 Plate, Mounting, Solenoid12 003210-01 Wall, Mounting, Bearing13 007550-01 Shaft, Linkage Bar14 007553-01 Pin, Drive, Linkage15 003221-01 Hub, Adjustable, 1/2" ID16 008095-01 Pin, Clevis, .187" OD17 008097-01 Clevis, Double, Trimmer Drive18 003245-01 Pad, Solenoid19 007621-01 Solenoid, Cutter, Assembly20 001955-16 Ring, Retainer, External, .188"21 690034-03 Washer, Flat, #1022 690033-03 Washer, Lock, Split, #1023 670038-12 Screw, Socket Head Cap, 10-32 x 3/4"24 003219-01 Screw, Set, 1/2 Dog Point, 1/4-20 x 1/2"25 670872-08 Screw, Set, Knurled Cup, 1/4-20 x 1/2"26 342872-08 Collar, Shaft, 1/2" ID27 670147-08 Screw, Button Head Cap, 10-32 x 1/2"28 003214-01 Washer, Fender, #1029 680104-03 Nut, Hex, 10-3230 003218-12 O-Ring, 1/2" ID x 3/32" Thick31 003236-08 Spacer, Shaft, 1/2" ID x 1/16" Thick32 670038-08 Screw, Socket Head Cap, 10-32 x 1/2"33 680043-03 Nut, Lock, 10-3234 007572-37 Ring, Retainer, External, .352" 35 008093-01 Pin, Clevis, .3745" OD36 003218-10 O-Ring, 3/8" ID x 3/32" Thick37 003235-08 Spacer, Shaft, .38" ID x .010" Thick38 001955-19 Ring, Retainer, External, 3/8"39 003231-11 O-Ring, 5/16" ID x 1/16" Thick40 665162-06 Collar, Set Screw, Precision41 001955-22 Ring, Retainer, External, 1/2"42 007555-01 Wall, Side Drive, Cam, Left

47-2


43 008096-01 Bar Driver Trimmer44 008092-01 Bracket, PCB Mounting45 001922-06 Screw, Socket Head Cap, M3 x 0.5 x 6 Lg46 690427-03 Washer, Lock, Split, M347 003136-06 Screw, Button Head Socket, M4 x 0.7 x 6 Lg48 690427-04 Washer, Lock, Split, M449 690439-04 Washer, Flat, M450 005850-01 Thread Holder Optical Switch, Assembly51 008102-01 Interruptor, Sensor, Trimmer Cam52 671852-10 Screw, Socket Head Cap, M5 x 0.8 x 10 Lg53 690439-03 Washer, Flat, M354 008091-01 Shaft, Guide, Trimmer55 344370-06 Bearing, Split Sleeve, Self-Lube

Cam Box Assembly (Cont) Reference Figure 47


47-3



47-4


Cap Frame Mount Assembly

Figure 48

48-1


Cap Frame Mount Assembly Reference Figure 48


1 006526-01 Bracket, Picker 2 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg 3 006523-01 Mount, Dove Tail, Cap Frame 4 001926-12 Screw, Flat Head Socket, M4 x 0.7 x 12 Lg 5 672018-20 Screw, Socket Head Cap, M4 x 0.7 x 20 Lg 6 008464-01 Block, Mount, Cap Frame 7 006525-01 Key, Shaft, 6mm x 6mm x 32mm 8 007575-01 Spacer, Insulating 9 006527-01 Clip, Contact, Cap Frame10 007571-02 Screw, Pan Head Phillips, Nylon, M3 x 0.5 x 5 Lg11* 671852-08 Screw, Socket Head Cap, M5 x 0.8 x 8 Lg12* 006538-01 Knob, Knurled, M5, Black13 006537-01 Tab, Quick Disconnect, .020" x .190"14 001922-08 Screw, Socket Head Cap, M3 x 0.5 x 8 Lg15 008465-01 Spring Mount Bracket16 001922-06 Screw, Socket Head Cap, M3 x 0.5 x 6 Lg17 690427-03 Washer, Lock, Split, M318 690811-34 Washer, Internal Star, #4

*NOTE: Items 11 and 12 should be replaced as a factory built assembly:006714-01 Screw, Thumb, 8mm Lg

48-2


User Station Assembly (1 of 2)

Figure 49

49-1


User Station Assembly (1 of 2) Reference Figure 49


1 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg 2 008219-01 Cover, Dummy Head 3 008218-01 Base, Dummy Head 4 690439-04 Washer, Flat, M4 5 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg 6 008275-01 Bracket, Mounting, Keyboard 7 008135-01 Frame, Dummy Head 8 343109-01 Grommet, Rubber, .125" ID 9 008226-01 Shelf, Monitor10 671910-12 Screw, Pan Head Phillips, Self-Tapping, #10 x 3/4" Lg11 008347-01 Monitor Shelf Support Angle

49-2


User Station Assembly (2 of 2)

Figure 50

50-1


User Station Assembly (2 of 2) Reference Figure 50


1* 008032-01 Keyboard 1a* 344231-01 Keyboard, XT/AT Compatible 1b* 007759-01 Trackball 2 005169-01 Monitor, 14", VGA, Color 3 004244-01 PCB, Disk Drive Controller 4 005386-01 PCB, Video Controller 5 006435-01 PCB, CPU386 6 291644-02 Cord, AC Power, 9’ 10" Lg

*NOTE: If only the trackball function of Item 1 (008032-01) is not operatingcorrectly then only Item 1b (007759-01) is required. If the keyboard function of Item 1 (008032-01) is not operating correctlythen both Item 1a (344231-01) and Item 1b (007759-01) are required.

50-2


Harness Assembly (Power Distribution Box)

Figure 51

51-1


Harness Assembly (Power Distribution Box) Reference Figure 51


1 007811-01 Harness, 3KVA, Transformer Primary 2 007814-01 Harness, 3KVA, Transformer Secondary 3 007815-01 Cable, Ground 4 007828-01 Cable, Auxiliary Fuse Input (Quantity 4) 5 007829-01 Harness, Motor Drive Power 6 007830-01 Harness, DC Power Supply Input 7 007836-01 Cable, Rectifier Output 8 007834-01 Assembly, 24V Transformer 9 007837-01 Cable, 24V Cap Center10 007840-01 Cable, 24V Ground11 007841-01 Harness, E-Stop Control12 007844-01 Cable, Relay Power (Quantity 2)13 007845-01 Cable, Neutral Jumper14 007846-01 Harness, Power Output15 007816-01 Assembly, AC Outlets16 007827-01 Assembly, Fan, 115VAC, 120 CFM17 007809-01 Cord, Power Input

51-2


Harness Assembly (Logic Control Box)

Figure 52

52-1


Harness Assembly (Logic Control Box) Reference Figure 52


1 008007-01 Harness, Grabber/Color Motors 2 008003-01 Harness, Jump Stitch 3 008015-01 Harness, Encoder, X/Y/Z Axis 4 008002-01 Harness, Under Thread Control, Heads 1-6 5 008006-01 Harness, Cutter Solenoid 6 008004-01 Harness, Picker 7 008009-01 Harness, X-Y Home 8 007804-01 Harness, X/Y/Z Control 9 008008-01 Harness, Under Thread Control, Heads 7-1210 008005-01 Harness, Thread Break/Mode, Heads 7-1211 008013-01 Harness, Start/Stop12 007632-01 Cable, DC Power13 007620-01 Harness, Keypad14 007651-01 Cable, Floppy Disk Data15 007647-01 Cable, Floppy Disk Power16 004243-01 Disk Drive, 3 1/2"17 007619-01 Harness, Cutter Home/Hat18 008014-01 Harness, Color Change19 008001-01 Harness, Thread Break/Mode, Heads 1-6

52-2


Harness Assembly (Heads 1-12)

Figure 53

53-1


Harness Assembly (Heads 1-12) Reference Figure 53


1 008013-01 Harness, Stop/Start 2 007646-01 Harness, E-Stop 3 008163-02 Way, Cable, 54.96" Lg 4 008163-03 Way, Cable, 62.99" Lg 5 008163-01 Way, Cable, 66.93" Lg 6 007620-01 Harness, Keypad 7 008003-01 Harness, Jump Stitch 8 008001-01 Harness, Thread Break/Mode, Heads 1-6 8a 008005-01 Harness, Thread Break/Mode, Heads 7-12 9 008000-01 Harness, Thread Break Sensor10 005839-01 Harness, Arm, Under Thread Control11 008002-01 Harness, Under Thread Control, Heads 1-611a 008008-01 Harness, Under Thread Control, Heads 7-1212 007619-01 Harness, Cutter Home/Hat13 008004-01 Harness, Picker14 008382-01 Tie Bar, Dummy Head15 690439-06 Washer, Flat, M616 671686-12 Screw, Socket Head Cap, M6 x 1.0 x 12 Lg17 690439-04 Washer, Flat, M418 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg

53-2


Harness Assembly (Motor Power & Lighting)

Figure 54

54-1


Harness Assembly (Motor Power & Lighting) Reference Figure 54


1 007715-01 Assembly, Motor, Y-Drive 2 007542-01 Assembly, Motor, Z-Drive 3 007543-01 Assembly, Motor, X-Drive 4 007804-01 Harness, X/Y/Z Control 5 007634-01 Cable, AC Power, X/Y/Z 6 008362-01 Cable, Supply, Fluorescent Lamps 7 007632-01 Cable, DC Power 8 007646-01 Harness, E-Stop 9 008015-01 Harness, Encoder, X/Y/Z Axis10 008361-01 Cable, Connecting, Fluorescent Lamps11 008396-01 Harness, Motor

54-2


Sash Hoop Assemblies (1 of 2)

Figure 55

55-1


Sash Hoop Assemblies (1 of 2) Reference Figure 55


1* 003509-04 Screw, Button Head Socket, M4 x 0.5 x 4 Lg 2* 007595-01 I/F Bracket, 25cm, Slotted 3* 007592-01 Hoop, 25cm, w/Arms 4* 007594-01 I/F Bracket, 25cm, 2-Hole 5 008334-01 Screw, Thumb, M4 x 0.7 x 10 Lg 6 006793-01 Hoop, Spider, 21cm 7 005404-01 Hoop Set, 21cm Round, w/Arms 7a 007535-01 Hoop Set, 21cm Round, wo/Arms 8 005413-01 Frame, Spider Net, Hoop, 18cm 8a 005407-01 Frame, Spider Net, Hoop, 15cm 8b 005414-01 Frame, Spider Net, Hoop, 12cm 8c 005415-01 Frame, Spider Net, Hoop, 9cm 8d 005416-01 Frame, Spider Net, Hoop, 7cm 9 005408-01 Hoop, Round, 18cm 9a 005409-01 Hoop, Round, 15cm 9b 005410-01 Hoop, Round, 12cm 9c 005411-01 Hoop, Round, 9cm 9d 005412-01 Hoop, Round, 7cm

*NOTE: Items 1-4 should be replaced as a factory built assembly:008429-01 Assembly, Hoop, Sash, Round, 25cm

55-2


Sash Hoop Assemblies (2 of 2)

Figure 56

56-1


Sash Hoop Assemblies (2 of 2) Reference Figure 56


1* 003136-06 Screw, Button Head Socket, M3 x 0.5 x 6 Lg 2* 007595-01 Bracket, Hoop, I/F, 36 x 30, Front 3* 006454-01 Hoop, 36cm x 30cm, w/Insert 4* 007594-01 Bracket, Hoop, I/F, 36 x 30, Rear

*NOTE: Items 1-4 should be replaced as a factory built assembly:008297-01 Assembly, Hoop, Sash, 36cm x 30cm

56-2


Sash Frame Assembly

Figure 57

57-1


Sash Frame Assembly Reference Figure 57


1 008334-01 Screw, Thumb 2 008176-01 Frame, Border LH 3 008178-03 Support, Sash, Delrin, .35M 4 008174-01 Sash Frame, Joint 5 671852-10 Screw, Socket Head Cap, M5 x 0.8 x 10 Lg 6 690439-05 Washer, Flat, M5 7 001926-10 Screw, Counter Sunk Head, M4 x 0.7 x 10 Lg 8 008175-01 Frame, Border, Front & Rear 9 008177-01 Clip, Border Frame, 300mm10 007598-01 Clip, Border Frame, 220mm11 008173-01 Sash Frame, Plate12 008172-01 Sash Frame, Right13 008178-02 Support, Sash, Delrin, .75M14 008326-01 Running Strip, Rear Sash15 008169-01 Sash Frame, Rear16 008178-01 Support, Sash, Delrin, 5.3M17 008310-01 Frame, Border, RH18 008242-01 Insert, Threaded19 008327-01 Running Strip, Front Sash20 008170-01 Sash Frame, Front21 008322-01 Insert, Threaded22 008171-01 Sash Frame, Left23 672018-10 Screw, Socket Head Cap, M4 x 0.7 x 10 Lg24 008333-02 Sash Frame, Plate, Runner, Rear25 008333-01 Sash Frame, Plate, Runner, Front26 008323-01 Bearing, Block27 008324-01 Bracket, Bearing Rear28 690439-04 Washer, Flat, M429 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8 Lg30 008363-01 Sewing Area Screenprint

57-2


Melco Cap Frame Assembly

Figure 58

58-1


Melco Cap Frame Assembly (005938-01) Reference Figure 58


1 004938-01 Base, Cap Frame, Assembly 2* 005485-01 Frame, Weldment, w/Rubber 3* 007197-01 Strap, Clamping, 82mm, w/Rubber 4 002629-01 Bracket, Hinge 5 005071-01 Holder, Cord, Visor Clamp 6 005487-01 Catch, Pull 7 005486-01 Bracket, Latch 8 004904-01 Block, Locator, Brim 9 002632-01 Spacer10 004240-01 Ring, Retainer, E-Style11 006021-01 Nut, Wing, M312 690439-03 Washer, Flat, M313 680430-03 Nut, Hex, M314 690033-36 Washer, Lock, Split, #6 15 004963-01 Screw, Special, Cap Frame16 005068-01 Terminal, Shock Cord17 005073-01 Cord, Shock, Cap Frame18 670174-06 Screw, Pan Head, Phillips, 6-32 x 3/8"19* 006004-01 Strap, Clamping, 82mm, 6 Panel, Melco20* 006010-01 Frame, Lower, w/Rubber, 6 Panel, Melco21 006019-01 Screw, Flat Head Phillips, 3mm x 0.5 x 8 Lg22 690427-03 Washer, Lock, Split, M323 005934-01 Screw, Flat Head Phillips, 3mm x 0.5 x 6 Lg24* 007196-01 Strap, Clamping, 72mm, w/Rubber25* 005491-01 Strap, Clamping, 62mm, w/Rubber26* 006008-01 Strap, Clamping, 62mm, 6 Panel, Melco27* 006898-01 Strap, Clamping, 72mm, 6 Panel, Melco

*NOTE: Items 2, 3 and 24 are standard and are part of Assembly (p/n 005938-01)

Items 19, 20 and 25-27 are available as options

58-2


Cap Frame Drive Assembly

Figure 59

59-1


Cap Frame Drive Assembly (008475-01) Reference Figure 59


1* 452732-01 Ring, Drive, Cap Frame 2* 006496-01 Hub, Cap Driver, Phase II 3* 552912-01 Locator, Cap Frame 4* 004229-01 Clip, Roller, Cap Frame Driver, Assembly 5* 454861-01 Bracket, Drive 6 008330-01 Interface Plate, Cap Frame 7* 552915-01 Washer, Flat, Rectangle 8* 402913-01 Cable, Drive Ring 9* 452916-01 Bracket, Cable10* 442917-01 Bar, Guide11 006522-01 Shaft, Cap Frame12* 005342-08 Bearing, Sleeve, Frelon13* 670131-03 Screw, Pan Head Phillips, 4-40 x 3/16"14* 690034-34 Washer, Flat, #415 006521-01 Mount, Cap Frame, Male16* 672982-06 Screw, Pan Head Phillips, 8-32 x 3/8"17 670174-04 Screw, Pan Head Phillips, 6-32 x 1/4"17 690033-36 Washer, Lock, Split, #619* 670267-06 Screw, Button Head Cap, 8-32 x 3/8"20 670149-06 Screw, Socket Head Cap, 8-32 x 3/8"21* 670131-02 Screw, Pan Head Phillips, 4-40 x 1/8"22 660830-16 Pin, Groove, 1/8" OD x 1.0" Lg23* 671852-16 Screw, Socket Head Cap, M5 x 0.8 x 16 Lg24* 006538-01 Knob, Knurled, M5, Black25 690439-04 Washer, Flat, M426 672018-08 Screw, Socket Head Cap, M4 x 0.7 x 8 Lg27 342872-08 Collar, Shaft, 1/2" ID

*NOTE: Items 1-5, 7-10, 12-14, 16, 19 and 21 should be replaced as a factory builtassembly: 006667-01 Ring, Drive, Assembly

Items 23 and 24 should be replaced as a factory built assembly:006714-05 Screw, Thumb, 16mm Lg

59-2


Melco Cap Gauge Assembly

Figure 60

60-1


Melco Cap Gauge Assembly (005050-01) Reference Figure 60


1* 005100-01 Shaft Cover, Frame Holder 2* 004958-01 Shaft, Frame Holder, Gauge Set 2a* 680032-04 Nut, Hex, 1/4-20 (Included with Item 2) 3* 004957-01 Bracket, Frame Holder, Gauge Set 4* 670038-08 Screw, Socket Head Cap, 10-32 x 1/2" 5 005051-01 Gauge, Cap Frame, Weldment 6 004229-01 Clip, Roller, Cap Frame Driver, Assembly 7 690034-34 Washer, Flat, #4 8 690033-34 Washer, Lock, Split, #4 9 680032-34 Nut, Hex, 4-4010 004949-01 Block, Mounting, Cap Gauge, Assembly11* 004952-01 Nut, Swivel, 3/8-1612* 004950-01 Screw, Thumb, Wing-Head, 3/8-16 x 1.5"13 670828-06 Screw, Flat Head Socket, 4-40 x 3/8"

*NOTE: Items 1-4 should be replaced as a factory built assembly:004956-01 Holder, Frame, Gauge Set, Assembly

Items 11 and 12 are part of Item 10 and should be replaced as assembly:004949-01 Block, Mounting, Cap Gauge, Assembly

60-2


Tubular Hoop Assemblies

Figure 61

61-1


Tubular Hoop Assemblies Reference Figure 61


1* 006454-01 Hoop, 36cm x 30cm, w/Insert 2* 008316-01 Bracket, Tubular, I/F, Rear 3* 003136-06 Screw, Button Head Socket, M3 x 0.5 x 6 Lg 4 008334-01 Screw, Thumb, M4 x 0.7 x 10 Lg 5* 008253-01 Bracket, Tubular, I/F, Right 6* 008254-01 Bracket, Tubular, I/F, Left 7* 007541-01 Hoop, Round, 21cm, wo/Arm 7a* 007557-01 Hoop, Round, 18cm, wo/Arm 7b* 007539-01 Hoop, Round, 15cm, wo/Arm 7c* 007537-01 Hoop, Round, 12cm, wo/Arm 8* 008255-01 Bracket, Hoop, I/F, Right 9* 007540-01 Hoop, Tubular Inner, 21cm 9a* 007556-01 Hoop, Tubular Inner, 18cm 9b* 007538-01 Hoop, Tubular Inner, 15cm 9c* 007536-01 Hoop, Tubular Inner, 12cm10* 008256-01 Bracket, Hoop, I/F, Left11 003509-04 Screw, Button Head Socket, M4 x 0.7 x 4 Lg

*NOTE: Items 7, 8, 9 and 10 should be replaced as a factory built assembly:008424-01 Assembly, Hoop, Tubular, Round, 21cm

Items 7a, 8, 9a and 10 should be replaced as a factory built assembly:008425-01 Assembly, Hoop, Tubular, Round, 18cm

Items 7b, 8, 9b and 10 should be replaced as a factory built assembly:008426-01 Assembly, Hoop, Tubular, Round, 15cm

Items 7c, 8, 9c and 10 should be replaced as a factory built assembly:008427-01 Assembly, Hoop, Tubular, Round, 12cm

Items 1, 2, 3, 5, and 6 should be replaced as a factory built assembly:008428-01 Assembly, Hoop, Tubular, 36cm x 30cm

61-2


Tube Frame Assembly

Figure 62

62-1


Tube Frame Assembly Reference Figure 62


1 008213-01 Locator, Tubular Sash, Right Hand 2 003573-03 Nut, Nylock, M3 3 008208-01 Spring, Tubular Sash 4 008214-01 Locator, Tubular Sash, Left Hand 5 008334-01 Screw, Thumb, M4 x 0.7 x 10 Lg 6 008212-01 Sash, Tubular Arm 7 008331-01 Bearing, Ball 8 008215-01 Bearing, Spigot 9 690439-06 Washer, Flat, M610 342500-16 Nut, Hex, M611 690439-04 Washer, Flat, M412 690427-04 Washer, Lock, Split, M413 672018-65 Screw, Socket Head Cap, M4 x 0.7 x 65 Lg14 003509-06 Screw, Button Head Socket, M4 x 0.7 x 6 Lg15 008369-01 Cover, Bearing, Sash16 008368-01 Bracket, Sash Bearing17 008367-01 Pillar, Sash Frame18 672018-14 Screw, Socket Head Cap, M4 x 0.7 x 14 Lg19 008366-01 Assembly, Plate, Bearing, Sash20 008169-01 Sash Frame, Rear21 690439-07 Washer, Flat, M7

62-2


Date post:	08-Apr-2016
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EMC 10-12T Technical Manual Model Num 008410-01 Serial Num 10100xx

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