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1. ARM ORO BOX PULLEY Le ADJUSTMENT SCREW FOR x Pal FELT BUMPERS ELASTIC RETURN RU DROP BOX ASSEMBLY LEFT SIDE SHOWN FROM REAR Page 9 32 OVERHEAD BEATER ASSEMBLIES optional equipment LEFT TOP HORIZONTAL RACKING ADJUSTMENT BOLTS AXLE 6025 THROUGH LOOM RACKING POSITION SHOWN FROM LEFT SIDE OVERHEAD BEATER Page 9 33 OVERHEAD BEATER ASSEMBLIES optional equipment Page 9 34 A The first step of this assembly is to mount the beater retainer to D inside face of the left cloth beam support Insert the 12 x 1 1 2 flat head wood screw through the beater retainer and into the pre drilled hole on the left cloth beam support see Figure 37 Leave the screw just loose enough so that the retainer is allowed to pivot around the screw The next step of this assembly is to mount the beater adjustment bases to the upper edge of each top horizontal on the assembled side frames of your loom see Figures 30 and 37 Attach these parts using the four 8 x 3 4 pan head wood screws Insert the screws from the top of the beater adjustment bases and screw them into the pre drilled holes on the top edge of each top horizontal see Figure 30 Tighten the four screws securely Locate the two uprights see Figure 736 Lay the uprights on the floor spaced apart a distance that is approximately equal to the width
2. AUTO ADVANTAGE AXLE AUTO ADVANGE GOES THROUSH LOOM MECHANISM OVERHEAD BEATER WITH AUTO ADVANCE MECHANISM SHOWN FROM LEFT SIDE FIG 34 Page 9 21 OVERHEAD BEATER ASSEMBLIES optional equipment ADJUSTAENT BOLTS AXLE THROWSH LOXOM RACKING POSITION OVERHEAD BEATER A The first step of this assembly is to mount the beater retainer to the inside face of the left cloth beam support Insert the 12 x 1 1 2 flat head wood screw through the beater retainer and into the pre drilled hole on the inside of the left cloth beam support see Figure 33 Leave the screw just loose enough so that the retainer is allowed to pivot around the screw Page 9 22 OVERHEAD BEATER ASSEMBLIES optional equipment B D E The next step of this assembly is to mount the beater adjustment bases to the upper edge of each top horizontal on the assembled side frames of your loom see Figures 30 and 33 Attach these parts using the four 8 x 3 4 pan head wood screws Insert the screws from the top of the beater adjustment bases and screw them into the pre drilled holes on the top edge of each top horizontal see Figure 30 Tighten the four screws securely Locate the two uprights see Figure 32 Lay the uprights on the floor with the notched sides facing up Space them apart a distance that is approximately equal to the width of your loom The ends with the metal brackets will be the t
3. the bolt near the wooden pulley using a 5 32 allen wrench and place this bolt through the looped end of the cable and replace the bolt into the tension arm Now referring to Figure 23 complete the cable tie up The cable comes away from the bolt in the tension arm over the top of the tension arm pulley and down to meet the front of the sectional beam brake drum Now wrap the cable around the sectional beam drum three times as shown with the first wrap toward the outside of the loom The last portion of this tie up is the tension cord adjustment At the very end of this assembly is an eyebolt Remove one hex nut and washer from the eyebolt and insert it from the inside of the loom through the hole located at the very back of the upper left horizontal frame piece Replace and tighten the hex nut and washer on the eyebolt Now locate the tension arm weight It is a heavy black disk with a knob on one side of it To attach the weight to the arm you will need to remove the screw from the end of the tension arm using a 3 16 allen wrench Position it so that the weight disk is on the inner side of the tension arm and the knob faces the outside of the loom The weight will stay anywhere on the tension arm that you place it as long as you tighten the knob on the weight Be certain that you replace the screw at the end of the tension arm This screw serves as a stop to keep the weight from accidentally slipping off Proper adjustment of th
4. you do it will help in creating proper alignment of the beater parts Place the beater in the loom For now it will just sit in the loom resting on top of the cloth beam supports just in front of the har nesses The assembly may tend to fall forward or backward but don t worry about that You now have some other assemblies to complete before actually attaching the beater Page 9 23 OVERHEAD BEATER ASSEMBLIES optional equipment Page 9 24 G H I The next step is to mount the hanging arms to the uprights on the shuttle race assembly see Figures 29 and 32 Using an 1 8 allen wrench remove the 3 8 stop collars from the metal shafts at the tops of each upright and install the hanging arms onto these shafts making sure that the right and left hanging arms are in their proper positions There is a screweye that has been mounted near the middle of each hanging arm These screweyes should face the front of the loom Also be certain to include the small spacer as shown in Figure 29 The stop collars are then replaced and tight ened making sure to leave enough clearance for this pivot point to swing freely Now look at the other end the top of one of the hanging arms Notice that there is a block of wood at this end that the beater adjustment screw goes through As shown in Figure 30 the foot at the bottom end of the beater adjustment screw should be set into the notch in the center of the beater adjustment
5. Beater Shift Handle Four Box Shift Handle Cable To Drop Box Solenoid Box Installation AVL 40 Component Box Placement Page 9 41 9 42 9 43 9 44 9 45 9 45 9 46 9 47 9 48 9 49 9 49 CD 1 CD 3 NOLLO YGO LLNI INTRODUCTION No doubt you want to get to the business and the fun of setting up your loom O K but first a few words of advice There s probably some of you who don t like to read directions or think that this manual is entirely too thick and you don t have time to read all the way through it Please read through the directions and follow them step by step with us You will spend less time and will end up with the loom looking and working as we have planned it There are those of you who have never touched a hex bolt and are not even sure you know what one is To you we say Try it If you follow the instruc tions step by step and take your time you will be surprised at what you can do To members of the two above camps and to all those in between we say Stick with it and we are certain you will find this to be a good experience and a great way to get to know your loom Remember if you are at all serious about weaving a thorough knowledge of your equipment is vital So think of this as an opportunity not as a liability Page 1 1 PREFACE HOW TO USE THIS MANUAL Page 1 2 The two purposes of this assembly manual are 1 To assist the loom owner in assembling and getting to know
6. Figures 27 and 30 Attach these parts using the four 8 x 3 4 pan head wood screws Making sure that the notched ends of these parts face upward insert the screws from the top of the beater adjustment bases and screw them into the pre drilled holes on the top edge of each top horizontal see Figure 30 Tighten the four screws securely C Locate the two uprights see Figures 26 and 29 Lay the uprights on the floor spaced apart a distance that is approximately equal to the width of your loom The ends with the metal brackets will be the top of this assembly Now lay the shuttle race on top of the two uprights so that it covers the two holes in the face of each upright as shown in Figure 26 Page 9 7 OVERHEAD BEATER ASSEMBLIES optional equipment LEFT SEDE FRAME HORTZOMTAL LEFT HANGING ARM SEE FIG 29 BEATER Js 2 i RA WT LEFT UPRIGHT AXLE m OVERHEAD STANDARD BEATER Page 9 8 OVERHEAD BEATER ASSEMBLIES optional equipment BEATER ADJUSTMENT BASE SEE FES 30 LEFT HORIZONTAL SEE FIG 29 PUSH ARM 2 LEFT ABA BEATER RETURN 11 BEATER RETAINER AXLE MOUNTING K UFRIGHT BLOCK AXLE 5 THSOUBH LOM OVERHEAD STANDARD BEATER SHOWN FROM LEFT SIDE FIG 27 Page 9 9 OVERHEAD BEATER ASSEMBLIES optional equipment HANGING ARM PUSH ARM SPRING REAR SIDE
7. Laying the Harness Cables a Itis helpful for this next step to stand on a sturdy bench or chair Set the bench or stand between the lower front and the spring lever support Take hold of the number 1 harness cable and route it over the pulley directly above it Now bring that same cable both ends over the number 1 pulley in the next set of pulleys Repeat this procedure with each of the remaining cables until all of the harness cables are over all of the pulleys on the right side of the loom b Onlarger width looms you will also have yokes that connect the harness wires to the harness The yoke forms a Y by connecting to a pair of screweyes YOKE CABLE FOR UDL 40 Berkeley Clip Loop Cable Y 8 10 X 12 looms Page 4 1 HARNESS TIE UP Page 4 2 4 5 Replacing the Cable Retainers Now replace the cable retainer above the right set of pulleys tightening the screws so that it almost touches the pulleys Don t tighten the cable retainers down far enough that they impede the movement of the pulleys It is essential to the proper functioning of the loom that they be free to move The cable retainer s only purpose is to keep the cables from jumping off of their pulleys Routing the Cables Route the long ends of each of the cables over the far left of the pulleys After all cables are in place on each pulley check to see that no cables have crossed over each other When you are certain that all is as
8. Menu Settings Control Panel Device Manager Ports Click on the Ports icon the plus sign and see how many Communication Ports are available on your computer Click on a Port then click the Properties button it should say Device Status This device is working properly If not contact your computer dealer or try another port Check the software Make sure it s compatible with your Compu Dobby That is make sure it is set for Compu Dobby II Page CD 9
9. SUPPORT AUTO ADVANCE MECHANISM OVERHEAD BEATER WITH AUTO ADVANCE MECHANISM SHOWN FROM LEFT SIDE FIG 28 Page 9 10 OVERHEAD BEATER ASSEMBLIES optional equipment LEFT HANGING ARM 378 STOP COLLAR LEFT UPRIGHT OVERHEAD BEATER PIVOT BRACKET SHOWN FROM FRONT Page 9 11 OVERHEAD BEATER ASSEMBLIES optional equipment 1 Lm 1 BEATER ADJUSTMENT X LEFT HANGIMG ARM SCRE BEATER ADJUSTMENT BASE HORIZOMTAL OVERHEAD BEATER ADJUSTMENT BASE Page 9 12 OVERHEAD BEATER ASSEMBLIES optional equipment RACKING ADJUSTMENT BOLTS AXLE GOES THRU LOOM RACKING POSITION OVERHEAD BEATER Page 9 13 OVERHEAD BEATER ASSEMBLIES optional equipment Page 9 14 D E There is groove cut in one side of the shuttle race which must be oriented to the top and back of the race which means that it should for now be facing down toward the floor Attach the shuttle race to the uprights with two 5 16 x 3 1 4 carriage colts one on each side You will see that there are two holes on each end of the shuttle race that correspond with the two holes on either upright For now only the innermost hole on each end will be used The outer holes take a different bolt and will be used later Attach the washers and hex nuts to these carriage bolts but do not tighten them just yet as you will be making some adjustments shortly Temporarily attach th
10. To do this you will need to locate the axle mounting blocks attached previously to each rear side support Make certain that the axle hole is in the lower position as shown in Figure 37 before you do this assembly Now you can insert the axle a long black pipe with holes at each end through each of these blocks so that the axle goes all of the way through the loom There is no particular right or left orientation for this axle as it is he same on both ends Now you can center the axle in the loom and place an axle spacer a round wooden piece on each exposed end of the axle Now locate the two tilting arm assemblies They are stamped L and and are to be mounted at each end of the axle as shown in Figure 37 It is important to mount this assembly correctly as shown with the push arms to the outside and the tilting arms to the inside The tilting arms are attached to the ends of the axle with 5 16 x 2 3 4 hex bolts with washers and hex nuts provided Do not tighten these bolts yet They will be part of a critical adjustment coming up shortly You will see a spring cord eyebolt assembly hanging from the end of each tilting arm Just let them hang for now They will be attached later Page 9 35 OVERHEAD BEATER ASSEMBLIES optional equipment Page 9 36 I J K Next mount each push arm to the back face of each upright see Figure 37 using two 5 16 x 4 1 2 hex bolts washers and square nuts
11. You want to leave it a little bit loose so that the beater supports can pivot during adjustment Since the nut is a locknut it will not loosen Now locate two 11 2 long screws located in the beater hardware package Position metal bracket that s attached to the front of the beater support over the two holes and insert the screws Tighten them down Repeat this process for the left side 1 Standard Beater If you have ordered a single box flyshuttle beater proceed to 2 Single Box Flyshuttle Beater optional equipment Locate the following see Figure 24 shuttle race beater top two legs reed reed supports hardware Page 9 1 BOTTOM SWING BEATER ASSEMBLIES STANDARD BEATER METAL BRACKET STANDARD BEATER SUPPORT Page 9 2 BOTTOM SWING BEATER ASSEMBLIES Now pick up the shuttle race and orient it so that the lengthwise groove is to the top and is facing toward the rear of the loom Position it in the loom so that it is resting on the cloth beam supports between the cloth beam and the harnesses Now empty your hardware bag onto a table top Pick up the four 5 16 x 3 1 4 carriage bolts with washers and hex nuts Now locate the beater legs Notice that they have been marked to designate left and right Using each leg orient them so that with the bottom slot riding in the center pin on the beater support the tapered side of each leg faces away from the loom Insert the bolts from
12. bolts washers and square nuts These bolts go through the shuttle race and uprights and end up in a square nut in the nut access hole of each push arm OVERHEAD BEATER ASSEMBLIES optional equipment J You can go ahead and tighten these bolts making sure that the outer face of each push arm is relatively flush with the outer edge of their mating uprights This is also a good time to go ahead and tighten the other bolts that we previously told you to leave loose While tightening these bolts you should see that the beater is relatively square and centered in the loom The last bolts to tighten are the hex bolts that we shall for now call the Racking Adjustment Bolts that connect the tilting arms to the axle see Figure 35 These bolts should be tightened while the entire beater is being held firmly against the beater bumpers Figure 35 shows the beater being pushed toward the front of the loom In reality however you can align the beater by pushing the tilting arms toward the front or by pushing the race against the rear bumpers The important thing is to have the beater touching both the left and right bumpers at the same time As shown in Figure 35 push the tilting arms so that the beater race contacts both front beater bumpers Now tighten the racking adjustment bolts securely This operation will take two people If in the future the beater comes out of square the beater contacts one bumper before the othe
13. dog who is not sleeping If the beater should come out of square in the future if it should hit one bumper before the other you will need to repeat this adjustment loosening the bolts before you start and tightening them securely after Page 9 15 OVERHEAD BEATER ASSEMBLIES optional equipment J L Now is a good time to attach the beater return spring assembly This is the previously mentioned spring cord eyebolt assembly that hangs from each tilting arm To attach this assembly simply remove one hex nut and washer from each eyebolt and place the eyebolt through the hole provided on each bottom horizontal of the side frame assembly see Figure 27 The eye of the bolt should be to the outside of the side frame Replace the washer and hex nut and tighten securely This assembly is used to assist the weaver in returning the beater to the back position It is not necessarily intended to hold the beater in this position as that is the purpose of the beater retainer The beater return spring assembly is adjustable It is tightened by pulling on the ends of the white cord while squeezing the black mini cord lock on the assembly Whenever an adjustment is made on one side of the beater a similar adjustment should be made on the other side as well The amount of tension you set these springs at is strictly a matter of preference Generally speaking the stronger the tension the harder you will have to pull against t
14. for now They will be attached later Next mount each push arm to the back face of each upright see Figure 27 using two 5 16 x 4 1 2 hex bolts washers and square nuts These bolts go through the shuttle race and uprights and end up in a square nut in the nut access hole of each push arm You can go ahead and tighten these bolts making sure that the outer face of each push arm is relatively flush with the outer edge of their mating uprights This is also a good time to go ahead and tighten the other bolts that we previously told you to leave loose While tightening these bolts you should see that the beater is relatively square and centered in the loom The last bolts to tighten are the hex bolts that we shall for now call the Racking Adjustment Bolts that connect the tilting arms to the axle see Figure 31 These bolts should be tightened while the entire beater is being held firmly against the beater bumpers Figure 31 shows the beater being pushed toward the front of the loom In reality you can align the beater by pushing the tilting arms toward the front or the rear bumpers The important thing is to have the beater touching both the left and the right bumpers at the same time As shown in Figure 31 push on the upper end of each tilting arm and while the beater is in contact with both of the bumpers securely tighten the racking adjustment bolts This operation will take two people unless you have a well trained
15. her his loom by providing complete and detailed instructions and drawings 2 allow the weaver to enjoy a well cared for and properly functioning loom for many years by providing a care and maintenance schedule This manual was written to be read and followed from beginning to end Some of the information is quite basic and there are those of you who will want to skip those sections entirely Instead of skipping them we suggest you skim them there just may be important information hidden right in the middle of a very basic section All of the major sections are in the index in case you need to refer back for any reason We at AVL know that a picture is indeed worth a thousand words and for that reason have included many detailed drawings to help clarify our instructions Since all of our parts are not numbered you can use these drawings to help identify certain parts You will find Figure 1 to be particularly useful and may wish to pin or tape it up in a handy place for easy reference This draw ing shows all the major parts of the loom and is valuable in determining the relative position of parts The parts list following Figure 1 should be kept within easy reach as well This manual includes assembly instructions for sixteen or twenty four harness full frame dobby looms Also included are instructions for options such as second plain beams sectional beams tension box raddle single and multiple box flys
16. here later on After the bolts are in place gently let the loom down again Your loom should now look like the one in Figure 5 Check to see that it does Page 2 6 LOOM ASSEMBLY 4 Spring Lever Assembly 11 Locate the spring lever assembly This assembly consists of two long pieces attached by rods with many short thin rectangular spring levers between Orient this assembly so that the stamp bottom front is toward the front of the loom and facing the floor Make certain that the shorter spring levers are to the front of the loom Using four 5 16 x 3 1 4 hex bolts washers and square nuts attach the spring lever assembly between the side frames a foot or so above the treadle pulley assembly as shown in Figure 1 5 Spring Installation see Figure 6 Now it s time to hook the springs to the spring levers Locate your springs with the chain attached Starting with the rear most spring lever attach the spring to the wire hook on one side and the chain to the wire hook on the other side The chain is for adjusting the harness tension so for right now just attach the last link to the wire hook and you can adjust it if need be after you get your first warp on Make sure that the wire hooks are free to pivot on the metal pins in the spring levers otherwise they may get bent and won t work properly mi E SPRING ADJUSTING CHAIN SPRING LEVER SPRING INSTALLATION FIG 6 Page 2
17. in their proper positions Also be certain to include the small spacer as shown in Figure 29 The stop collars are then replaced and tightened making sure to leave enough clearance for this pivot point to swing freely Now look at the other end the top of one of the hanging arms Notice that there is a block of wood at this end that the beater adjustment screw goes through As shown in Figure 30 the foot at the bottom end of the beater adjustment screw should be set into the notch in the center of the beater adjustment base which you attached to the loom in step B of this assembly Once you have both of the beater adjustment screws in place the assembly of the hanging arms is complete The next step is a simple one Insert the axle shown in Figure 44 into the loom It will go through the large holes in your rear side supports of the side frame assembly There is no particular right or left orientation for this axle as it is the same on both ends After the axle is inserted place an axle spacer on each exposed end of the centered axle Now locate the tilting arm assemblies 2 They are stamped L and R and are to be mounted at each end of the axle as shown in Figures 44 and 41 It is important to mount this assembly cor rectly as shown with the push arms to the outside and the tilting arms to the inside The tilting arms are attached to the ends of the axle with 5 16 x 2 3 4 hex bolts with washers and hex nuts pro
18. of these bolts so that a washer can also be placed between the front vertical and the seat bracket A 5 16 x 2 3 4 carriage bolt goes through the right front vertical at the bottom of the bracket and is used to adjust the seat angle for comfortable sitting this seat can also be used as a back rest during thread ing if you want to try it out as a back rest just leave the carriage bolt to the side for now and insert it following threading Page 7 1 NOLLV l IV LSNI NOISNAL 1 TENSION ARM INSTALLATION lower position Standard Warp Beam and Half Yard Sectional Beam Tension Arm If you have ordered a standard warp beam or a half yard sectional beam you will have received tension arm 16 Proceed with this section If you have ordered only one beam and it is a one yard sectional beam you will have received tension arm 385 Please skip this section and go to 3 One Yard Sectional Beam Tension Arm upper position Orient the arm so that the face of the pulley will lie against the inside of the left rear vertical as shown in Figure 21 refer to Figure 1 to locate the relative position of the lower tension arm LEFT BEAR _ VERTICAL w SJTSIDE SIDE FRAME PROT WASHER PULLEY SCREW IFE SECTIONAL ARM STANDARD WARP BEAM DIAGRAM SHOW O20 FARTS TEHSIOR ADTUSTMEH mma LEFT BOTTOM HORIZONTAL FA STANDARD WARP BEAM TENSION ARM 2
19. roller 26 into the slotted brackets see Figure 1 for placement Then pick up the lower cloth roller also 26 and slip one end into its pinned slot Pull the pin out of the other bracket drop the roller in replace the pin and you ve done it At this point you should have one roller left 28 It is a bit longer than the others and the open end of the roller has a small notch in it This tube will be installed later when we complete the cloth storage system You can set this part aside for now Installing the Standard Plain Warp Beam or Half Yard Sectional Warp Beam Install the standard plain warp beam in the lower two slots in the back edge of the rear verticals see Figure 16 The axle of the warp beam is locked in place by the swiveling thumb screw latches Included in the contents of your hardware bag were two thumbscrews These can now be screwed slightly into the threaded inserts directly above each warp beam slot Lift up the warp beam and with the large round wooden drum to the left side of the loom seat the beam axle into the slots Swing the thumb screw latches around to meet the thumb screws When the latches have captivated the axle and are in a vertical position tighten them down Warp Beam Handle Locate your warp beam handle 42 see Figure 16 Remove the wing nut washer and bolt from the end of the handle Place the hole in the handle over the left end of the warp beam axle making sure the handl
20. than 3A COMPU DOBBY INSTALLATION amp ADJUSTMENT INSTRUCTIONS Troubleshooting Solenoid Box Adjustment This section identifies and offers solutions for some of the common problems you may encounter when you work with and install the Compu Dobby If you are unable to solve a problem after reading this section call the AVL support line at 1 888 893 0913 Some Harnesses Don t Lift The solenoid box is too close to the dobby fingers Use an 1 8 allen wrench to move the Box away from the dobby fingers The dobby cables may not all be captured by the dobby fingers Each dobby finger has a slot for a corresponding dobby cable You should be able to push a dobby finger with your finger and see the correct cable slide into the appropriate slot on the Dobby Arm Insert Turn the Compu Dobby off wait ten seconds and turn it back on Listen to each solenoid as it clicks through the sequence Each should make a solid sound a loud clack If it makes a soft thunk then the solenoid box is probably too close to the fingers If there is no sound at all then it may be a burned out solenoid Ifthis is the case then call AVL immediately The harnesses may be sticking Check the spring levers to see that they aren t hanging up I Treadle But Nothing Happens Windows You may have selected the wrong Comm Port in your software Try a different Comm Port Windows Your Comm Ports may not be active Go to the Start
21. the leather loop down and toward the outside into the slots between the box sides Repeat for the other side making sure that the left picker loop is down and toward the outside Now locate the flystring supports 43 These are two small wooden bars that each have a screweye at one end They were packed with the flystring tie up These flystring supports should be attached to the inside face of each top horizontal side frame piece Insert two 5 16 x 2 1 4 carriage bolts from the outside of the two holes on each top horizontal directly above the beater assembly These supports should hang down from the top horizontal with the screweye end on the bottom Tighten the supports securely with washers and hex nuts Attach the clip at the end of the cord coming from the picker to the screweye on the left and right flystring supports that you just installed Now notice that there is a snubber attached to the front box on each side of the race the snubbers are the small round wooden pieces above each shuttle box The cord should go over each snubber This completes the assembly of the single box flyshuttle beater OVERHEAD BEATER ASSEMBLIES optional equipment NOTE Since the beater system uses a lot of carriage bolts the following information may be helpful There is a square shape below the head of each carriage bolt This square portion does not fit easily into the pre drilled holes You will find it necessary to tap these bolts into pl
22. the plastic spacers from the axle From the outside of the loom insert the axle of the drum through the metal bushing located near the front end of the right top horizontal of the loom frame see Figure 20 for relative position Slide the spacer and crank back onto the axle with the knob facing the inside of the loom Tighten the set screw of the crank onto the flat portion of the axle in such a way that the assembly can rotate freely String Guide Pulleys Locate the remaining string guide pulley It is a small wooden pulley like the one that is mounted near the bottom of the right rear vertical as shown in Figure 18 This pulley will go on the outer face of the bottom right horizontal frame piece directly below the cloth take up drum that you just installed Attach this pulley with the 5 16 x 2 1 4 hex bolt provided Make sure that there is a washer on either side of the bronze bushing The nut should end up with a washer on the inside of the loom frame Page 6 3 CLOTH STORAGE ASSEMBLY AND TIE UP 5 Weight Track and Weight Locate the weight track It is a long thin piece of wood with two small rubber bumpers at one end of it This track is already attached to the outer face of the right front vertical frame piece ACCESS HOLE FRONT PULLEY HORIZONTAL RIGHT TIE EMOTS OUTSIDE PULLEY TO WEIGHT SIGE VIEW CLOTH STORAGE WEIGHT ASSEMBLY Page 6 4 CLOTH STORAGE ASSEMBLY AND TIE UP Now locate
23. 1 Page 8 1 TENSION ARM INSTALLATION lower position Page 8 2 Remove the long bolt from the pulley end of the tension arm Keeping one washer on the bolt push the bolt through the lower hole in the rear vertical from the outside Now put another washer on and slip the tension arm with its metal bushing onto the bolt Now another washer and the hex nut tighten it down and it s on After tightening check to make sure the arm swings freely Now the cord tie up can be attached The tension arm comes without the cord attached Locate the tension arm cord labeled 16 Attach this cord to the tension arm by removing the shoulder bolt the bolt near the wooden pulley using a 5 32 allen wrench and place this bolt through the looped end of the cord and replace the bolt into the tension arm Now referring to Figure 21 complete the cord tie up The cord comes away from the bolt in the tension arm over the top of the pulley and down to meet the front side of the drum on the warp beam Now wrap the cord around the warp beam drum three times with the first wrap toward the outside of the loom O K so far so good The last portion of this tie up is the tension cord adjustment At the very end of this cord assembly is an eyebolt Remove one hex nut and washer from the eyebolt and insert it from the inside of the loom through the hole located in the upper rear portion of the left bottom horizontal see Figure 21 Replace the hex nut an
24. 7 LOOM ASSEMBLY 6 Harness Pulley Support 10 Locate the harness pulley support This assembly has three rows of sixteen or twenty four sheaves pulleys between two long crossmembers Using four 5 16 x 7 1 2 hex bolts washers and hex nuts remember that you ll need washers under the hex bolts and the hex nuts attach the harness pulley support assembly to the side frame as shown in Figures 1 and 77 When correctly positioned the left side will be flush with the left side ofthe loom and the right side will stick out a few inches beyond the right side frame pieces HARNESS PULLEY SUPPORT 10 RIGHT SIDE OF LOOM HARNESS CABLES HARNESS ASSEMBLY HARNESS PULLEY SUPPORT INSTALLATION Page 2 8 7 8 LOOM ASSEMBLY Overhead Beater Axle Mounting Blocks overhead beater only If your loom is to be equipped with an overhead beater locate the package from box 3 marked Axle Blocks These blocks have a large hole in them Using the 5 16 x 5 carriage bolts in the package mount these blocks to the back edge of each rear side support look ahead to Figure 27 The heads of the carriage bolts should end up in the holes provided for them on the front edge of each rear side support Beater Bumpers Locate the beater bumpers 40 see Figures 1 and 9 The left is stamped L and the right one is stamped R They are each mounted to the outside of the cloth beam suppor
25. AVL 40 User s Manual AVL Looms 3851 Morrow Lane Suite 9 Chico CA 95928 8305 U S A 530 893 4915 530 893 1372 fax info avlusa com e mail www avlusa com Copyright 2002 All Rights Reserved Worldwide TABLE OF CONTENTS Figure Index Introduction Preface How to Use this Manual Loom Orientation Tools Needed for Assembly Full Frame Dobby Loom Parts List Loom Assembly Unpacking Identifying Parts 1 Hardware Identifying and Measuring Bolt and Nut Hints 2 Identifying Side Frame Parts Joining Side Frames Upper and Lower Backs Lower Front Spring Lever Assembly Spring Installation Harness Pulley Support Overhead Beater Axle Mounting Blocks Beater Bumpers Installation ofthe Dobby Head 1 Mounting the Dobby Harness Tie Up Cable Retainers Laying the Harness Cables Replacing the Cable Retainers Routing the Cables Harness Assembly Locating and Identifying the Harnesses Preparing for Harness Assembly Understanding Your Heddles Harness Assembly polyester heddles Metal Heddle Harness Frames Attaching the Spring Lever Chain Realigning the Dobby Cables i 1 1 1 2 1 2 1 3 1 4 1 6 2 1 2 1 2 1 2 1 2 3 2 4 2 5 2 5 2 6 2 7 2 7 2 8 4 1 4 1 4 2 4 2 4 3 4 3 4 3 4 3 4 4 4 6 4 7 4 7 Page i TABLE OF CONTENTS Page ii Installing Beams and Rollers 1 Rear Cloth Storage System Rollers Upper and Lower Rollers 2 Installing the Standard Plain Warp Be
26. Box Flystring Tie Up and remove its contents These pieces can now be assembled on the loom as shown in Figures 36 and 39 Use the mounting screws to attach this assembly to the bottom edge of the pre drilled front harness pulley support as shown in the illustrations making sure that you include the small wedge shaped piece of wood as part of this assem bly When assembled correctly these pulleys should be angled slightly toward the front of the loom Also make certain that the pulleys are to the rear or away from the weaver We suggest that you refer to Figures 36 and 39 before and during this next step of the assembly Remove the flystring tie up from the bag This tie up consists of a long dacron cord with a spring at tached to one end of it You should now attach the loop at the free end of this spring to the screweye that is affixed to the top of the left picker The pickers are the plastic hammers that slide horizontally through the drop box assembly at each end of the beater assembly Now route the end of the cord under the pulley that is mounted on the rear face of the left upright making sure that the cord goes between the pulley and the attached retainer From this point route the cord up to the upper pulley assembly that you just installed a few minutes ago Route the cord over both of these pulleys and continue routing the cord on the right side of the loom exactly like you just did on the left side Now remove the recei
27. Figure 41 push the tilting arms so that the beater race contacts both front beater bumpers Now tighten the racking adjustment bolts securely This operation will take two people If in the future the beater comes out of square the beater contacts one bumper before the other you will need to loosen the racking adjustment bolts push the beater against both bumpers and se curely tighten the nuts Locate your left drop box assembly these assemblies are marked L and R You will notice that there are two holes through the back plate in the lower right corner and one in the upper right corner with an intersecting hole coming from the right edge Looking at the left upright you will find a horizontal hole through the width of the upright just below the slot for the beater top This hole should be offset to the front of the shuttle race side of the upright Take a 5 16 x 4 1 2 hex bolt with a washer on it insert it through the hole in the upright from the inside through the hole in the edge of the upper right corner of the drop box assembly and thread it onto a square nut inserted in the nut access hole in the back plate Do not tighten this yet Your drop box assembly should now be attached to the upright with this one bolt with the moveable boxes in the front Attached the drop box assembly to the shuttle race with two 5 16 x 2 3 4 carriage bolts inserted from the front with washers and hex nuts behi
28. Figures 46 and 47 This is done so that the ball will be seated into a small opening that has been machined for it on the bottom of the plate Once the cable is attached to the drop box assembly you can run the cable over the drop box pulley that is located on the larger cast metal piece directly above the drop box assembly Also make sure that the cable runs under the small pulley that is attached near the end of the beater top see Figures 42 and 43 Repeat this procedure on the other side of the loom You may find it handy to use the following trick when attaching or adjusting the drop box cable Page 9 55 OVERHEAD BEATER ASSEMBLIES optional equipment Page 9 56 R To give yourself some slack in the cable it may be helpful to raise the drop box on the side you are working on to its uppermost position To hold it in this position you can insert one of your shuttles halfway into the box that is now aligned with the shuttle race This will hold the box in the upper position and both of your hands will be free to fiddle with the cable Once both cables are attached you will need to adjust the cable lengths Notice that the cable has a threaded rod crimped onto it at the end that attaches to the shift handle see Figure 46 Notice that there is a lock nut there as well Loosen the lock nut and you can shorten or lengthen the cable by screwing this threaded end into or out of the plate at the end of the shift handle When you
29. LYSHUTTLE BEATER HARNESS SLIFPORT DROP BOX ASSEMBLY OVERHEAD FOUR BOX FLYSHUTTLE BEATER SHOW FROM FRONT Page 9 45 OVERHEAD BEATER ASSEMBLIES optional equipment SEE FIG 30 HANGING ARM TILTING ARM BEATER BEATER RETAINER RETURN SPRING REAR SIDE SUPPORT AXLE MOUNTING OVERHEAD FOUR BOX FLYSHUTTLE BEATER SHOWN FROM LEFT SIDE Page 9 46 OVERHEAD BEATER ASSEMBLIES optional equipment HANGING ARM E e PUSH ARM TILTING ARM BEATER RETURN SPRING AUTO AXLE ADVANCE AXLE MOUNTING LINKAGE BLOCK AUTO ADVANCE MECHANISM OVERHEAD BEATER WITH AUTO ADVANCE MECHANISM SHOWM FROM LEFT SIDE Page 9 47 OVERHEAD BEATER ASSEMBLIES optional equipment HARNESS PULLEY LEFT HANGING ARM UPPER DROP BOX DROP BOX ASSEMBLY BEARING UPRIGHT OVERHEAD FOUR BOX FLYSHUTTLE BEATER SHOWN FROM FRONT Page 9 48 OVERHEAD BEATER ASSEMBLIES optional equipment SHIFT HAMOLE FOUR BOX FLYSHUTTLE BEATER SHIFT HANDLE UPPER BROP BOX BEARIMG SECTION THRU BEARING FOUR BOX SHIFT HANBLE CABLE TO DROP BOX Page 9 49 OVERHEAD BEATER ASSEMBLIES optional equipment Page 9 50 A The first step of this assembly is to mount the beater retainer to D inside face of the left cloth beam support Insert the 12 x 1 1 2 flat head wood screw through the beater retainer and into the pre drilled holes on the
30. NESS ASSEMBLY Attaching the Spring Lever Chain Now that you have assembled and hung all of your harness sticks you can hook them up to the spring lever chain Near the outside end of each spring lever is a chain Please note the chain length varies as you move further back so the chains for harness 1 are about 6 1 4 number 40 s are 7 1 2 Take the end link of your last spring lever on the left side and hook it to the left screweye on the underside of the last harness stick Repeat for the right side Now hook up all of the harnesses in the same fashion Realigning the Dobby Cables Your dobby head has been thoroughly tested at the AVL factory At that time all of the cables were in their proper positions for use Frequently during shipping however the cables get jostled out of position and must be straightened out Now s the time to do that If you look up at your dobby from underneath you will notice that there are forty fingers each with a slot in the back side of it There are also forty cables There should be one cable in each slot If there isn t carefully rearrange them so that the first cable is inside the first finger slot etc Page 4 7 Std I IO ANV ONITIVILSNI 1 2 3 INSTALLING BEAMS AND ROLLERS Rear Cloth Storage System Rollers A Upper and Lower Rollers Now the roller tubes for the rear cloth storage system can be installed Here s all there is to it Drop the upper cloth
31. These bolts go through the shuttle race and uprights and end up in a square nut in the nut access hole of each push arm You can go ahead and tighten these bolts making sure that the outer face of each push arm is relatively flush with the outer edge of their mating uprights This is also a good time to go ahead and tighten the other bolts that we previously told you to leave loose While tightening these bolts you should see that the beater is relatively square and centered in the loom The last bolts to tighten are the hex bolts that we shall for now call the Racking Adjustment Bolts that connect the tilting arms to the axle see Figure 41 These bolts should be tightened while the entire beater is being held firmly against the beater bumpers Figure 41 shows the beater being held against the front bumpers although you may use either the front or back bumpers for this adjustment The important this is that both bumpers are in contact with the beater at the same time Push the tilting arms toward the front of the loom so that both bumpers contact the beater race Now tighten the racking adjust ment bolts securely This operation will take two people If in the future the beater comes out of square the beater contacts one bumper before the other you will need to loosen the racking adjustment bolts push the beater against both bumpers and se curely tighten the nuts See Figure 40 Locate your left drop box as
32. ace to properly seat the bolts This will cause the bolt to bite into the wood and stay in place while you tighten the nut 1 Overhead Standard Beater optional equipment If you have ordered the overhead single box flyshuttle beater proceed to section 2 Overhead Single Box Flyshuttle Beater optional equipment If you have ordered the overhead double box flyshuttle beater proceed to section 3 Overhead Double Box Flyshuttle Beater optional equipment If you have ordered the overhead four box flyshuttle beater proceed to section 4 Overhead Four Box Flyshuttle Beater optional equipment This system 15 shipped partially disassembled to facilitate packing Follow the instructions below to complete the assembly Please refer to Figures 26 through 31 for help with terminology and locations They are all located together for ease in locating them as they will need to be referred to many times A The first step of this assembly is to mount the beater retainer to inside face of the left cloth beam support Insert the 12 x 1 1 2 flat head wood screw through the beater retainer and into the pre drilled hole on the inside of the left cloth beam support see Figure 27 Leave the screw just loose enough so that the retainer is allowed to pivot around the screw B The next step of this assembly is to mount the beater adjustment bases to the upper edge of each top horizontal on the assembled side frames of your loom see
33. actually put the handle through this loop and bring the string of the loop all the way back up to the top of the handle Now pull straight down on the handle tightening the cord around the brass pin This procedure should automatically center the handle on the tie up Now you are going to tie an overhead knot in the cord between the two upper pulleys see Figure 39 To do this make a small mark on the cord where the cord goes between the two pulleys and pull it straight down a few inches to where you can tie a simple overhand knot with the handle already in place Once the knot is tied release the cord and let it return to its resting position If the knot was placed correctly the pickers should still return to the end of the picker rod at each end of the beater and the cord should stop before the knot stops the cord from moving any farther Now is a good time to attach the beater return spring assembly This is the previously mentioned spring cord eyebolt assembly that hangs from each of the tilting arms To attach this assembly simply remove one hex nut and washer from the eyebolt and place the eyebolt through the hole provided on each bottom horizontal of the side frame assembly see Figure 37 The eye of the bolt should be to the outside of the side frame Replace the washer and hex nut and tighten securely This assembly is used to assist the weaver in returning the beater to the back position It is not necessarily intended to h
34. allation and Assembly Instructions Mounting the Track Arms Mounting the Track Mounting the Tension Box Introduction Install the Solenoid Box Cables and Component Box Internal Sensor Wire Serial Cable RS 232 Component Box to Solenoid Box Power Extension Cord Power Cord Set Up Your Computer Secure the Cords Surge Protector IMPORTANT Solenoid Box Adjustment To Adjust Maintenance Clean the Filters Fuse Replacement Troubleshooting Solenoid Box Adjustment 10 1 10 1 10 1 10 1 10 2 CD 1 CD 1 CD 2 CD 3 CD 3 CD 3 CD 4 CD 4 CD 4 CD 5 CD 6 CD 6 CD 6 CD 6 CD 8 CD 8 CD 8 CD 9 CD 9 Page iii XAGNI FIGURE INDEX Figure Drawing Title 1 Full Frame Dobby Loom 2 Tools Needed For Assembly 3 Hardware Identification Chart 4 Assembling Lower Left Back Corner 5 Side Frames Rear And Front Of Loom 6 Spring Installation 7 Harness Pulley Support Installation 9 Beater Bumper Block 10 Dobby Front View Yoke Cable for UDL 40 11 Cutting the Heddles Apart 12 Metal Heddle Frame 16 Warp Beam and Handle Mounting Assembly 17 Cloth Beam Assembly 18 Cloth Storage Drum 19 Cloth Storage Weight Assembly 20 Cloth Storage 21 Standard Beam Tension Arm 22 Second Plain Beam Tension Arm 23 One Yard Sectional Beam Tension Arm 24 Standard Beater Support 25 Single Box Flyshuttle Beater 26 Overhead Standard Beater Front 27 Overhead Standard Beater Left 28 Overhead Beater
35. am or Half Yard Sectional Warp Beam 3 Warp Beam Handle 4 Installing Second Plain Warp Beam 5 Installing Tension Box Mounting Studs 6 Installing the Sectional Beam 7 Installing the Cloth Beam A Removing the Cloth Beam Support B Assembling the Cloth Beam Handle Assembling the Cloth Beam Cloth Storage Assembly and Tie Up 1 Cloth Storage Drum and Cloth Storage Ratchet 2 Cloth Storage Roller 3 Cloth Take Up Drum Assembly 4 String Guide Pulleys 5 Weight Track and Weight 6 Weight Stop 7 Routing the Cloth Storage Cord Installing the Seat Tension Arm Installation 1 Standard Warp Beam and Half Yard Sectional Beam Tension Arm 2 Second Standard or Second Half Yard Sectional Warp Beam Tension Arm 3 One Yard Sectional Beam Tension Arm Bottom Swing Beater Assemblies Beater Supports 1 Standard Beater 2 Single Box Flyshuttle Beater Overhead Beater Assemblies 1 Overhead Standard Beater 2 Overhead Single Box Flyshuttle Beater 3 Overhead Double Box Flyshuttle Beater Multiple Box Flystring Tie Up Assembly Vertical Pull Flystring Tie Up 4 Overhead Four Box Flyshuttle Beater Vertical Pull Flystring Tie Up 5 1 5 1 5 1 5 1 5 1 5 3 5 3 5 3 5 4 5 4 5 4 5 5 6 1 6 1 6 3 6 3 6 3 6 4 6 6 6 6 7 1 8 1 8 3 8 5 9 1 9 1 9 1 9 4 9 7 9 7 9 17 9 27 9 37 9 37 9 41 9 53 Raddle TABLE OF CONTENTS Tension Box 1 2 3 Compu Dobby II Inst
36. at are not in access holes to prevent damage to the wood E Carriage bolts usually require a tap or two from the hammer to seat the square part of the bolt s head into the wood 2 Identifying The side frames are the parts that came in the biggest box They are shipped Side Frame Parts with the insides facing each other just as they will be when the loom is set up To determine which is the right side and which is the left first orient them as they are oriented in Figure 1 1 with the wider pieces at the back and at bottom Now look at the front vertical piece The right side will have a thin dark strip of wood screwed to the inside face of it POSITION OF SEPARATION ROLLER FOR OME YARD SECTIOMAL BEAM POSITION OF ROLLER FOR PLAIN BEAM OR HALF SECTIONAL BEAM SIDE FRAMES A FIG 5 Page 2 4 LOOM ASSEMBLY JOINING SIDE 1 Locate the cross member hardware package and examine it From its FRAMES contents please locate the following items Dobby Loom Hardware with washers and nuts Location 1 5 16 x 4 1 2 Hex Bolt Seat to Frame 1 5 16 x 3 1 2 Hex Bolt Seat to Frame or Seat Support or Flat Head Machine Screw 1 5 16 x 2 3 4 Carriage Bolt Seat to Frame 4 5 16 x 3 Carriage Bolts Beater Bumper Blocks to Loom Frame 1 5 16 x 3 1 2 Hex Bolt Seat Support to Lower Front 40 and 48 only 11 5 16 x 3 1 4 Hex Bolts Most Crossmemb
37. base which you attached to the loom in step B of this assembly Once you have both of the beater adjustment screws in place the assembly of the hanging arms is complete The next step is to mount the axle To do this you will need to locate the axle mounting blocks that were installed previously onto the rear side supports Now you can insert the axle a long black pipe with holes at each end through each of these blocks so that the axle goes all of the way through the loom There is no particular right or left orientation for this axle as it is the same on both ends Now you can center the axle in the loom and place an axle spacer a round wooden piece on each exposed end of the axle Now locate the tilting arm assemblies 2 They are stamped L and R and are to be mounted at each end of the axle as shown in Figures 33 34 and 35 It is important to mount this assembly correctly as shown with the push arms to the outside and the tilting arms to the inside The tilting arms are attached to the ends of the axle with 5 16 x 2 3 4 hex bolts with washers and hex nuts provided Do not tighten these bolts yet They will be part of a critical adjustment coming up shortly You will see a spring cord eyebolt assembly hanging from the end of each tilting arm Just let them hang for now They will be attached later Next mount each push arm to the back face of each upright see Figure 33 using two 5 16 x 4 1 2 hex
38. by a stamp Orient it so that the cut out section faces the front of the loom and the tapered side of the leg is to the outside Position the small notch located at the bottom end of the leg over the center pin in the beater support Now attach the race to the leg using two of the 5 16 x 3 1 4 carriage bolts Slip on the washers and nuts and attach loosely Repeat the procedure above for the left side making sure the tapered side of the beater leg faces away from the loom Leave these nuts loose for the moment From your hardware package locate either six seven or nine depend ing upon the width of your loom 5 16 x 3 carriage bolts with washers and wing nuts attached Remove the washers and wing nuts Push the carriage bolts through the race so that their heads sit flat on the front of the beater race don t be afraid to use a hammer to tap these bolts in place Now carefully slide the reed support onto these bolts so that the lengthwise groove in it faces the groove in the race Leave enough room so that you can fit the reed between the race and the reed support Once the reed is in and centered the washers and wing nuts can be fitted onto the carriage bolts and tightened BOTTOM SWING BEATER ASSEMBLIES mo d ZE 27 T 74 yr SHUTTLE RACE SINGLE BOX FLYSHUTTLE BEATER Page 9 5 BOTTOM SWING BEATER ASSEMBLIES Page 9 6 Now orient your beater top so that the gr
39. d washer on the outside of the loom and tighten the eyebolt placing it so that it sets as far inward as possible no threads protruding beyond the nut on the outside of the loom Now locate the tension arm weight It is a heavy black disk with a knob on one side of it To attach the weight to the arm you will need to remove the stop screw from the end of the tension arm using a 3 16 allen wrench Place the arm through the clamp on the side of the weight Position it so the weight is on the same side of the arm as the wooden disk is and the clamp faces the inside of the loom The weight will stay anywhere on the tension arm that you place it as long as you tighten the knob on the weight Be certain that you replace the screw at the end of the tension arm This screw serves as a stop to keep the weight from accidentally slipping off Proper adjust ment of the tension arm will be covered later in the weaving section of the manual TENSION ARM INSTALLATION lower position 2 Second Standard or Second Half Yard Sectional Warp Beam Tension Arm upper position optional equipment If you have not ordered a second beam proceed to the next section Bottom Swing Beater Assemblies If you have ordered a second beam and it is a one yard sectional beam proceed to section 3 One Yard Sectional Beam Tension Arm upper position If you have ordered a second beam and it is a standard beam or a half yard sectional beam proceed from here Locate th
40. d indicate that the front of the loom is to the left of the page and the rear of the loom to the right If the arrow were pointing left then the rear of the loom is to the left The right and left of the dobby head is oriented as if you were standing right in front of it Page 1 3 TOOLS NEEDED FOR ASSEMBLY There are a few tools you ll need before we can get started These are a phillips head screwdriver a light hammer a pair of pliers four or six Inch crescent wrench A ratchet socket set is very helpful and will speed up the assembly process but it is not essential except in the case of mounting the tension box track arms For this assembly you will need a 1 2 socket o a aa fae en LI ed t Sun ua RATCHET CRESCENT AND SCREW DRIVER HAMMER PLIERS WRENCH SOCKET PHILLIPS HEAD TOOLS NEEDED FOR ASSEMBLY FIG 2 Page 1 4 LOOM ORIENTATION Page 1 5 FULL FRAME DOBBY LOOM PARTS LIST Page 1 6 Part IR 2R IL 2L 3R 3L 4R 4L E 6 7 8R 8L 9R 9L 10 11 14 15 16 17 18 23 24 25 26 28 29 30 31 32 33 34 35 37 38 39 40 41 42 43 Part Name Right Front Vertical Side Frame Right Rear Vertical Side Frame Left Front Vertical Side Frame Left Rear Vertical Side Frame Right Top Horizontal Left Top Horizontal Right Lower Side Left Lower Side Upper Back Lower Back Lower Front Right Cloth Beam Sup
41. d of the cord and replace the bolt into the tension arm Now referring to Figure 22 complete the cord tie up The cord comes away from the bolt in the tension arm over the top of the tension arm pulley then down to meet the front of the second warp beam drum Now wrap the cord around the warp beam drum three times as shown with the first wrap toward the outside of the loom The last portion of this tie up is the tension cord adjustment At the very end of this assembly is an eyebolt Remove one hex nut and washer from the eyebolt and insert it from the inside of the loom through the hole located at the very back of the left top horizontal frame piece Replace and tighten the hex nut and washer on the eyebolt Now locate the tension arm weight It is a heavy black disk with a knob on one side of it To attach the weight to the arm you will need to remove the screw from the end of the tension arm using a 3 16 allen wrench Place the arm through the clamp on the side of the weight Position it so the weight is on the same side of the arm as the wooden disk is and that the clamp faces the inside of the loom The weight will stay anywhere on the tension arm that you place it as long as you tighten the knob on the weight Be certain that you replace the screw at the end of the tension arm This screw serves as a stop to keep the weight from accidentally slipping off Proper adjustment of the tension arm will be covered later in the weaving s
42. e Figure 1 for relative position These holes are used to mount the raddle for warping both the standard beam and the second beam Be certain that the removable portion of the raddle is to the top Once mounted into the holes the raddle is not only held firmly in place but is also perfectly centered and can be left in place while weaving TENSION BOX optional equipment Locate your tension box track hardware and tension box refer back to Figure 16 1 Mounting the Track Arms If you have ordered a sectional beam and have been following the directions you ll have already mounted the tension box track arm mounting studs If you ordered a tension box and no sectional beam here s how to install the track arms Locate the four 5 16 x 2 1 2 carriage bolts black discs and bushings washers and hex nuts Insert the bolt through the hole in the black disc so that the square part under the head of the bolt makes contact with the countersunk portion of the disc Slide the black bushing onto the bolt Now install this assembly from the outside of the loom through one of the two holes provided on either rear vertical as shown in the drawing Slip the washer and nut on the inside of the loom frame and tighten with a 1 2 socket wrench Repeat this process with the three remaining bolts 2 Mounting the Track Now mount the track to the brackets on the track arms using the four 5 16 x 2 1 2 hex bolts washers and square nut
43. e beater top to the uprights with two 1 4 x 2 1 4 carriage bolts with washers and wing nuts behind the uprights The beater top should be attached to the same side of the uprights as the shuttle race with the long groove facing downward Insert the carriage bolts through the holes near each end of the beater top and then through the slots that are located just below the metal bracket of each upright You do not need to put the beater top on now but if you do it will help in creating proper alignment of the beater parts Place the beater in the loom For now it will just sit in the loom resting on top of the cloth beam supports just in front of the har nesses The assembly may tend to fall forward or backward but don t worry about that You now have some other assemblies to complete before actually attaching the beater The next step is to mount the hanging arms to the uprights on the shuttle race assembly see Figures 26 and 29 Using an 1 8 allen wrench remove the 3 8 stop collars from the metal shafts at the tops of each upright and install the hanging arms onto these shafts making sure that the right and left hanging arms are in their proper positions Also be certain to include the small spacer as shown The stop collars are then replaced and tightened making sure to leave enough clearance for this pivot point to swing freely Now look at the other end the top of one of the hanging arms Notice that there is a block o
44. e faces away from the loom Line up the hole in the axle with the carriage bolt and push it through Reattach the washer and wing nut and tighten Page 5 1 INSTALLING BEAMS AND ROLLERS WASHER AND HEX NUT BUSHING TENSION BOX MOUNTING ASSEMBLY SECTIONAL BEAM LEFT REAR VERTICAL 22 UPPER SEPARATION ROLLER 7 22 LOWER SEPARATION ny THUMB SCREW SEE DETAIL ABOVE a ah BRACKET ARM BOLTS THUMB SCREW WARP BEAM NUT ANG BOLT PLAIN WARP BEAM amp HANDLE 42 23 WARP BEAM AND HANDLE MOUNTING ASSEMBLY FIG 16 Page 5 2 4 5 6 INSTALLING BEAMS AND ROLLERS Installing the Second Plain Warp Beam optional equipment Install the second plain warp beam in the upper slots to the outside edge of the rear verticals Loosen the black thumb screws enough so that the warp beam retainer latches can be swung off to the side Lift up the second warp beam and with the drum to the left side of the loom seat the beam axle into the slots Swing the thumb screw latches around to meet the thumb screws and when the latches have captivated the axle and are in vertical posi tion tighten them down Installing Tension Box Mounting Studs optional equipment see Figure 16 If you ve ordered a tension box and a sectional beam you ll need to assemble the tension box track arm mounting studs to the side frame prior to installing the sectional beam Here s how to do i
45. e tension arm 38 Orient the arm so that the face of the pulley will lie against the inside of the left rear vertical as shown in Figure 22 refer to Figure 1 to locate the relative position of the upper tension LEFT REAR VERTICAL O SIDE FRAME BACE END TOP HORIZONTAL FRONT E ee ADJUSTMENT WASHER F PALEY TENSION WEIGHT ma T SPRING oar LEFT REAR we STOP SCREW 1 ARM HEX BOLT CAITSIDE OF LOGN LAGAN SHOWING ORDER OF PART SECOND PLAIN WARP BEAM TENSION ARM IN THE UPPER POSITION FIG 22 Page 8 3 TENSION ARM INSTALLATION lower position Page 8 4 Remove the long bolt with its nut and washers from the pulley end of the tension arm Put one of the washers back on the bolt and push the bolt through the upper hole in the left rear vertical side frame member from the outside Now put another washer on and slip the tension arm with its metal bushing onto the bolt Now another washer the hex nut tighten it down and it s on After tightening check to make sure the arm swings freely Now the cord tie up can be made The tension arm comes without the cord attached Locate the tension arm cord 38P Attach this cord to the tension arm by removing the shoulder bolt the bolt near the wooden pulley using a 5 32 allen wrench and place this bolt through the looped en
46. e tension arm will be covered later in the weaving section of the manual Now it s time to sit back have a cup of tea and admire your loom Coming along quite nicely isn t it Very good now back to the fun Page 8 6 Beater Supports BOTTOM SWING BEATER ASSEMBLIES If your beater is of the Overhead type proceed to the next section titled OVERHEAD BEATER ASSEMBLIES NOTE Since the beater system uses a lot of carriage bolts the following information may be helpful There is a square shape below the head of each carriage bolt This square portion does not fit easily into the pre drilled holes You will find it necessary to tap these bolts into place to properly seat the bolts This will cause the bolt to bite into the wood and stay in place while you tighten the nut The beater supports can now be bolted to the loom First locate your beater supports 34 There s one for each side of the loom so we ll start on the right side and you can refer to Figures 1 and 24 for correct placement Orient one of them so that the round spacers and metal pins are facing toward the loom and the spacer with the threaded rod and metal bracket is toward the front of the loom Remove the hex nut and washer from the rear spacer and insert the bolt through the right lower horizontal Slip the washer and nut back on and tighten the nut just to the point where is almost cinches the two parts together
47. each side You will see that there are two holes on each end ofthe shuttle race that correspond with the two holes on either upright For now only the innermost hole on each end will be used The outer holes take a different bolt and will be used later Attach the washers and hex nuts to these carriage bolts but do not tighten them just yet as you will be making some adjust ments shortly Temporarily attach the beater top to the uprights with two 1 4 x 2 carriage bolts with washers and wing nuts behind the uprights The beater top should be attached to the same side of the uprights as the shuttle race with the shift handle on top You do not need to put the beater top on now but if you do it will help in creating proper alignment ofthe beater parts OVERHEAD BEATER ASSEMBLIES optional equipment E F G H Place the beater in the loom For now it will Just sit in the loom resting on top of the cloth beam supports just in front of the har nesses The assembly may tend to fall forward or backward but don t worry about that You now have some other assemblies to complete before actually attaching the beater The next step is to mount the hanging arms to the uprights on the shuttle race assembly see Figures 42 and 29 Using a 1 8 allen wrench remove the 3 8 stop collars from the shafts at the tops of each upright and install the hanging arms onto these shafts making sure to put the right and left hanging arms
48. ection of the manual TENSION ARM INSTALLATION lower position 3 One Yard Sectional Beam Tension Arm upper position Locate the tension arm 385 It is a long black bar with a wooden disk at one end Orient the arm so that the face of the pulley will lie against the inside of the left rear vertical as shown in Figure 23 refer to Figure 1 to locate the relative position of the upper tension arm LEFT REAR VERTICAL OUTSIDE SIDE FRAME kK INSERT EYEBOLT nmt INTO OF i TOP HORIZONTAL STEEL TOGBLE ici BUSHING T WASHER iDIUSTMENT PULLEY TENSION WEIGHT LEFT REAR VERTICAL SIDE FRAME SECTIONAL BEAM PARTIALLY SHOW ONE YARD SECTIONAL BEAM TENSION ARM Page 8 5 TENSION ARM INSTALLATION lower position Remove the long bolt with its nut and washers from the pulley end of the tension arm Put one of the washers back on the bolt and push the bolt through the upper hole in the left rear vertical from the outside Now put another washer on and slip the tension arm with its metal bushing onto the bolt Now another washer the hex nut and tighten it down After tightening check to make sure the arm swings freely Now the coated cable tie up can be made The tension arm comes without the cable and tension adjustment attached Locate the tension arm cable 4385 Attach this cable to the tension arm by removing the shoulder bolt
49. ened the hex nuts on the adjustment brackets Next create a peg plan that fires two solenoids at a time Set up a 2 38 twill so you can treadle through and see each shaft lift The system requires little maintenance but the little maintenance it does require is important and should be performed conscientiously Otherwise the life of the unit may be shortened The Solenoid Box has a fan filter It needs to be cleaned at least every two weeks Simply unsnap the plastic cover remove the foam filter wash in soapy water rinse and air dry Please do not replace the filter while wet moisture is extremely hostile to electrical equipment If there is something in your studio setting that makes it especially dusty clean your filters more often The Compu Dobby is protected by 250v 3 amp fuse This is contained in a fuse block at the back of the Control Box where the power cord plugs in You will perhaps never have occasion to replace your fuse but on the off chance you do Disconnect the power cord at the rear of the Control Box Locate the fuse cover immediately to the right of the power cord port See the small slot Insert a small screwdriver here and pry the cover loose Pull out the fuse block and inspect the fuse If it s blown replace with an equivalent 250v 3A fuse Replace the fuse block and power cord WARNING Never under any circumstances should you install a fuse with an amperage rating greater
50. ent Box place the box with the corresponding holes on top of the pins jutting out from the Harness Pulley Support You ve a mess of cables and maybe you re a little worried cause they look like so much spaghetti Relax they re easily sorted out The trick is in the ends Each cable has a distinct set of connectors mak ing it readily identifiable from the others AVL 40 Component Box Placement Component Box 7 FRONT VIEW SIDE VIEW Let s begin with the Internal Sensor wire This cable is identified by the same color as the solenoid and component box Serial Cable RS 232 The serial cable generically called an RS 232 is different depending on whether you have a Macintosh or IBM computer In either case one end will have a male connector with two rows of pins nine in all The connector at the other end will be clearly different and may be male or female Page CD 3 COMPU DOBBY INSTALLATION amp ADJUSTMENT INSTRUCTIONS Page CD 4 Find this cable and push the pin end into the port that is second from the Component Box Use your small bladed screwdriver to run the side screws in These provide strain relief Allow the free end of the cable to hang for now Later you ll connect it at the rear of your computer Component Box to Solenoid Box For this connection you ll need the slender cable that looks like a piece of phone cord It is a piece of phone cord and has phone connectors a
51. ers to Frame 2 5 16 x 3 3 4 Hex Bolts Right End of Lower Front to Frame 1 5 16 x 3 3 4 Hex Bolt Lower Right End of Upper Back with Pulley to Frame 4 5 16 x 7 1 2 Hex Bolts Harness Pulley Supports to Frame 4 5 16 x 3 1 4 Hex Bolts Spring Lever Supports to Frame The above hardware will be used to assemble the seat and crossmembers The remaining hardware will be used later 2 Upper and Lower Backs Locate the upper back 5 the lower back 6 the warp beam separa tion roller 39 and if you ordered a second beam the second separation roller 39 It would be best if you had a helper for steps 2 and 3 Page 2 5 LOOM ASSEMBLY Using three 5 16 diameter x 3 1 4 hex bolts and the one 5 16 x 3 3 4 hex bolt with the wooden pulley attached to it attach the lower back to the side frames using the longer bolt with the pulley as the lower bolt on the right side see Figure 5 Get the nuts started on the bolts but don t tighten them yet see Figure 4 At this point you must install the separation roller 39 Refer to Figure 5 for the relative position of this or these parts If you have ordered one beam you will have received one separation roller If that beam is a plain beam or a half yard sectional beam the separation roller will go in the lower position as shown On the other hand if that beam is a one yard sectional beam the separation roller will go in the upper p
52. f wood at this end that the beater adjustment screw goes through As shown in Figure 30 the foot at the bottom end of the beater adjustment screw should be set into the notch in the center of the beater adjustment base which you attached to the loom in step B of this assembly Once you have both of the beater adjustment screws in place the assembly of the hanging arms is complete OVERHEAD BEATER ASSEMBLIES optional equipment I Now you can insert the axle a long black pipe with holes at each end through each of the axle mounting blocks see Figure 27 so that the axle goes all of the way through the loom There is no particular right of left orientation for this axle as it is the same on both ends Now you can center the axle in the loom and place an axle spacer a round wooden piece on each exposed end of the axle Now locate the two tilting arm assemblies They are stamped L and and are to be mounted at each end of the axle as shown in Figures 27 28 and 31 It is important to mount this assembly correctly as shown with the push arms to the outside and the tilting arms to the inside The tilting arms are attached to the ends of the axle with 5 16 x 2 3 4 hex bolts with washers and hex nuts provided Do not tighten these bolts yet They will be part of a critical adjustment coming up shortly You will see a spring cord eyebolt assembly hanging from each tilting arm Just let them hang
53. ge of the hollowed out portion of the wooden drum You will know right away if the hook caught on the pin because if it did catch the drum will want to unwind in a counter clockwise direction which is just what it is supposed to do Once you have gotten your drum to behave properly you will need to install the remaining washer and a 3 8 stop collar onto the end of the steel axle with the knot facing the inside of the loom Tighten the set screw of the stop collar using an allen wrench onto the flat portion of the axle making sure to leave a small amount of clearance so that the drum and axle assembly can rotate freely Leave the cord wrapped around the drum for now It will be dealt with soon 2 3 4 CLOTH STORAGE ASSEMBLY AND TIE UP Cloth Storage Roller Locate the cloth storage roller 28 It has a metal axle sticking out one end and a notch cut out of the other end Line the notch up with the pin on the small knob shaped portion of the cloth storage ratchet see Figure 18 Push the roller toward the ratchet until the roller seats itself against the ratchet face Slip the other end of the roller into the angled slot on the bracket on the left rear vertical Cloth Take Up Drum Assembly Locate the cloth take up drum assembly 30 It is a wooden drum with two grooves around its perimeter There is a steel axle attached to this drum with a small crank attached to it Using an allen wrench remove the crank and one of
54. ging below the upper pulley assembly Feed the loop down from the top of the handle through the hole on either side of the brass pin that divides the hole Now feed the loop back through the hole on the other side of the brass pin Now form a larger loop 6 or so and run it back over either end of handle To do this you actually put the handle through this loop and bring the string of the loop all the way back up to the top of the handle Now pull straight down on the handle tightening the cord around the brass pin This procedure should automatically center the handle on the tie up Now you are going to have to tie an overhead knot in the cord between the two upper pulleys see Figure 739 To do this make a small mark at the top of the vertical section of the cord and pull it straight down a few inches to where you can tie a simple overhead knot with the handle already in place Once the knot is tied release the cord and let it return to its resting position If the knot was placed correctly the pickers should still return to the end ofthe picker rod at each end of the beater and the cord should stop before the knot stops the cord from moving any farther Now is a good time to attach the beater return spring assembly This is the previously mentioned spring cord eyebolt assembly that hangs from each ofthe tilting arms To attach this assembly simply remove one hex nut and washer from the eyebolt and place the eyebolt through the h
55. h washers and wing nuts behind Before attaching the nuts install the bottom edge of your reed in the void created by the slots in the reed support and shuttle race Center the reed between the two uprights and tighten the wing nuts if your beater top is in place you will need to remove it to install the reed There is a slot in the underneath side of the beater top which slides over the top edge of the reed Push the beater top down on the reed and tighten the wing nuts which hold it in place The final step is to attach the drop boxes to the shift handle and adjust the cable lengths There is a long dark wooden handle located at the top and center of the beater top This is the shift handle By moving this handle laterally you will be able to shift from one shuttle box to another but first you will have to attach the handle to each set of drop boxes This is accomplished by unwrap ping the cable that is attached to each end of the shift handle and running each cable over to its respective drop box At the end of each cable you will find a steel ball and shank To attach the cable you will need to insert this balled end of the cable into the slot provided in the cast metal piece located at the top and center of the drop box it is the piece that the vertical steel rod goes through Insert the ball end of the cable into the large end of the slot and slide the cable to the other end of the slot and then pull straight up on the cable see
56. he shuttle You may wish to experiment with these adjustments in order to come up with a setting that works best for you and any particular warp Locate the reed support the long thin wooden part with up to seven holes and a slot similar to the one in the shuttle race Attach the reed support to the back of the shuttle race with the slot to the top and facing the shuttle race using seven 5 16 x 3 carriage bolts inserted from the front with washers and wing nuts behind Before attaching the nuts install the bottom edge of your reed in the void created by the slots in the reed support and shuttle race Center the reed between the two uprights and tighten the wing nuts There is a slot in the underneath side of the beater top which slides over the top of the reed Push the beater top down on the reed and tighten the wing nuts which hold it in place Take the string tie up and handle from its bag As you can see there are three screweyes coming out of the handle One at the top and two at the sides Hold the handle up by the clip attached to the string at the top of the handle This clip will get attached to the screweye that is taped to the bottom or side of the front harness pulley support see Figure 32 However the screweye must first be screwed into the hole on the underside of the harness pulley support Screw the screweye in so that no screw threads are show ing Then attach the clip to it At this point there are two picker
57. heddle belongs to which harness and lessens the chance of threading errors Now pick up your single harness assembly by the top harness the one farthest away from you on the table Bring it over to your loom and hook up your last harness cables the ones closest to the back of the loom to the screweyes in the harness stick There you ve completed one harness now the rest should be easy Repeat the steps above for each harness assembly Always have the top harness stick be the one furthest away from you with the screweyes facing away Page 4 5 HARNESS ASSEMBLY Page 4 6 5 Metal Heddle Harness Frames The metal heddle harness frames come fully assembled with the excep tion of the heddles themselves The heddles should be installed onto the harness frames before you hang them in the loom To do this remove the clips from either end of the heddle rods and transfer the desired amount of heddles onto each harness see Figure 12 A pair of transfer rods have been included to help with this process To use them simply transfer the required amount of heddles onto each of these thin flexible rods and then transfer the heddles onto the heddle rods After replacing the end clips on the heddles rods you can hang the harness frames in the loom by connecting them to the waiting ends of the harness cables HARNESS STICK SCREW EYE 7 IU SR HEDOLE ROD _ HEDDLE ROD CLIP METAL HEDDLE FRAME 6 7 HAR
58. hese springs during the beat At the same time however it will be easier to hold the beater away from you while opening a shed and throwing the shuttle You may wish to experiment with these adjustments in order to come up with a setting that works best for you and any particular warp Locate the reed support the long thin wooden part with seven holes and a slot similar to the one in the shuttle race Attach the reed support to the back of the shuttle race with the slot to the top and facing the shuttle race using seven 5 16 x 3 carriage bolts inserted from the front with washers and wing nuts behind Before attaching the nuts install the bottom edge of your reed in the void created by the slots in the reed support and shuttle race Center the reed between the two uprights and tighten the wing nuts There is a slot in the underneath side of the beater top which slides over the top edge of the reed Push the beater top down on the reed and tighten the wing nuts which hold it in place This completes the assembly of your standard beater Check your assembly with Figures 26 through 31 to be certain you ve gotten everything correct Page 9 16 OVERHEAD BEATER ASSEMBLIES optional equipment 2 Overhead Single Box Flyshuttle Beater optional equipment NOTE The single box flyshuttle system now incorporates removable shuttle boxes This allows the weaver to completely remove the boxes and flystring tie up from the loom any
59. huttle beaters You need only read the sections for the kind of loom or option s you have ordered LOOM ORIENTATION Before we really get going there are a few things you should know in order to better understand our instructions First and very important is what we mean when we say the front of the loom The front of the loom is the end where the seat is the back of the loom then is where the warp beam is Everything is oriented as if you were sitting in the weaving position The right side of the loom is the side to your right as you are sitting at the loom and the left side is to your left A piece marked bottom would of course go toward the floor There is a full drawing of the loom on the following page This can be re ferred to as often as necessary to obtain relative placements of assemblies Following this is a parts number list Since this list includes the names and part numbers of all parts and assemblies you may need to refer back to it Study all the drawings carefully and make certain that your assembly looks like the one in the drawings before continuing Where applicable and necessary on the drawings we have included a weaver symbol to help clarify the view of the drawing This symbol shows a weaver seated at the weaving bench Remember the symbol 15 included only to help clarify the orientation of the drawing In the example shown the weaver is sitting looking toward the right of the page That woul
60. ieval LEFT HANGING ARAL SPACER 3 6 STOP LEFT UPRISHT OVERHEAD BEATER PIVOT BRACKET 5HOWT FROM FRONT Page 9 27 OVERHEAD BEATER ASSEMBLIES optional equipment nme BEATER ADJUSTMENT LEFT HANGING ARM SCREW IEEE m BEATER ADJUSTMENT BASE HORTIZONTAL OVERHEAD BEATER ADJUSTMENT BASE Page 9 28 OVERHEAD BEATER ASSEMBLIES optional equipment REAR VIEW FRONT HARNESS PLILLE Y ibus s SEE FIG 30 SEE FIG 39 LEFT HANGING ARM III pnt SEE FIG 29 SEE FIG 40 RACE UPRIGHT ASSEMBLY OVERHEAD DOUBLE BOX FLYSHUTTLE BEATER FIG 36 Page 9 29 OVERHEAD BEATER ASSEMBLIES optional equipment SEE FIG 30 LEFT TOP HORIZONTAL PUSH ARAM LEFT TOL TIMG ARAM __ RETAINER k ex a a ut i uh ed lt m BEATER RETURN SPRING AXLE MOUNTING BLOCK OVERHEAD DOUBLE BOX FLYSHUTTLE BEATER SHOWN FROM LEFT SIDE Page 9 30 OVERHEAD BEATER ASSEMBLIES optional equipment HANGING ARM AUTO ADVANCE 2 LINKAGE MECHANISM OVERHEAD BEATER WITH AUTO ADVANCE MECHANISM SHOWN FROM LEFT SIBE Page 9 31 OVERHEAD BEATER ASSEMBLIES optional equipment FRONT HARNESS PULLEY SUPPORT SMALL EDGE UPPER PULLEY TOWARD FRONT ASSEMBLY TO HANDLE X VERTICAL PULL UPPER PULLEY ASSEMBLY SEEN FROM FRONT LIOM REAR VIEW
61. ilitarian and pleasing Now you re ready to plug in the computer and Compu Dobby We should talk about surge protectors Surge protectors are electronic protection devices that limit the amount of electrical current that can be delivered to your equipment Though your power supply is regulated by your utility company occasional load fluctuations can result in power spikes A power spike can rip the heart out of sensitive elec tronic equipment your computer or Compu Dobby for example We strongly recommend that you install a surge protector between your electrical socket and computer Compu Dobby Plug in the power cord on your computer Plug in the power cord on your Compu Dobby In order for your Compu Dobby to function properly you ll need to make one adjustment This adjustment is made at the front of the Dobby head This is the critical adjustment Without this your Compu Dobby won t work Recall that you earlier installed the two brackets that hold the Solenoid Box into the plywood Dobby Head The set screws in the middle of these brackets are your adjusting points You ve previously backed these screws out so they are now properly located for the start of your adjustment Slightly loosen the hex nuts through which each screw is threaded Your goal is to locate the Solenoid Box so that when each solenoid is extended it pushes the corresponding cable into a slot in the metal bar on the Dobby Arm If you take a moment t
62. inst the adjustment brackets Now use the 1 8 allen wrench to turn the left set screw clockwise This will cause the Solenoid Box to move forward Continue to turn the screw until the left most extended solenoid just pushes its steel cable to the rear of the slot REMEMBER The cable should just touch the rear of its slot If it is pushed too far back it will cause problems later with your harness lifts Hold the set screw stationary with the allen wrench and use your wrench to snug down the hex nut This will lock the adjustment Repeat this procedure on the right side NOTE The key point is that the solenoids won t work properly unless they are fully extended So WHEN IN DOUBT BACK IT OUT In other words better to have solenoids away from the dobby fingers then too close This is a bit counter intuitive but it is critical If 1 and 40 work then all the rest will follow Page CD 7 COMPU DOBBY II INSTALLATION amp ADJUSTMENT INSTRUCTIONS Maintenance Clean the Filters Fuse Replacement Page CD 8 If your harnesses are either not lifting or are dropping the Solenoid Box requires further adjustment Check the position of the cables relative to their slots Again each should just touch the rear of the slot where the solenoid is extended too far in or out and it won t behave properly Once you ve established that you re getting good lifts you may assume that the Solenoid Box is adjusted Please make sure you ve tight
63. it should be replace and tighten the left cable retainer as you did the right one Very good Now on to the next step HARNESS ASSEMBLY Your loom may be equipped with either polyester or metal heddles If your loom has polyester heddles start at step 1 below If your loom has metal heddles skip ahead to step 5 1 2 3 Locating and Identifying the Harnesses Locate your harness sticks They are long thin pieces of wood with screweyes on either end There should be two groups One group is labeled Tops Preparing for Harness Assembly You ll need a table top for this next step What you are going to do is assemble the harnesses so that you can hang them on the cables Untape the bundle of harness sticks labeled Tops Lay one of these on the table about a foot and a half in from the edge with the screweyes facing away from you Understanding your Heddles Now locate the bag of heddles Open it and look at your heddles but DO NOT remove the twist ties yet Now locate your harness wires those are the long wires with copper stops near one end Pick up a bundle of heddles there are approximately one hundred heddles in each bundle and hold them up by one end allowing the other end to hang freely Notice that there are four twist ties two above the eye of the heddle and two below the eye Now with the thumb and index finger of your right hand take hold of the upper right twist tie Grasp the upper left
64. left cloth beam support see Figure 744 Leave the screw just loose enough so that the retainer is allowed to pivot around the screw The next step of this assembly is to mount the beater adjustment bases to the top edge of each top horizontal on the assembled side frames of your loom see Figures 44 and 30 Attach these parts using the four 8 x 3 4 pan head wood screws Insert the screws from the top of the beater adjustment bases and screw them into the pre drilled holes on the top edge of each top horizontal see Figure 30 Tighten the four screws securely Locate the two uprights see Figures 42 and 43 Lay the uprights on the floor spaced apart a distance that is approximately equal to the width of your loom These uprights are labeled left and right and it is important that they be properly oriented The ends ofthe uprights with the metal brackets will be the top of this assembly The metal rods should be pointed inward or toward each other There is a metal pulley attached to the back face of each upright These pulleys should now be touching the floor Lay the shuttle race on top of the two uprights so that it covers the two holes in the face of each upright There is a groove cut in one side of the shuttle race which must be oriented to the top and back of the shuttle race which means that it should for now be facing down toward the floor Attach the shuttle race to the uprights with two 5 16 x 3 1 4 carriage bolts one on
65. n Chart on the following page to famil iarize yourself with the hardware Page 2 1 LOOM ASSEMBLY 11 HEX BOLT CARRIAGE BOLT FLAT HEAD THESE ALWAYS GET A WASHER THESE WEWER GET WASHER MACHINE SCREW BETWEEN THE HEAD OF THE BOLT BETWEEN THE HEAD OF THE BOLT D THE WOCO THE WOOD EI FLAT WASHER HEX NUT SQUARE NUT WING NUT THESE ALWAYS HAVE THESE ALWAYS GO TH A THESE ALWAYS HAVE WASHER BETWEEN THE AMD THE WOOD AMD THEY TWIT WASHER MT AND THE Wb THEY ATTACH HEX BOLTS AMBE TWEEN THE ATTACH TO CARREAGE ADRIASE BOLTS WOOD TO BOLTS BOLTS 1 ALLEN WRENCH BLACK KNOB MEASURING BOLTS HARDWARE IDENTIFICATION CHART FIG 3 Now you know all that you need to know about hardware to set up and main tain your loom Page 2 2 LOOM ASSEMBLY Bolt and Nut A Ifa bolt is a little tight going in the hole give it a light friendly tap with a Hints hammer B start the threads a square nut in a nut access hole it is often helpful to hold the nut in place with the end of a screwdriver or the tip of your finger C Always have the larger nut access hole see Figure 4 facing toward the inside of the loom unless otherwise specified ACCESS HOLE LEFT REAR FRAME SQUARE NUTS ASSEMBLING LOWER LEFT BACK CORNER Page 2 3 LOOM ASSEMBLY D Remember to put washers under the heads of the hex bolts and the ex posed nuts nuts th
66. n the loom Now bring down the left end of the beam and fit the pin belonging to the lower portion of the cloth beam support into the slot belonging to the upper portion Reinstall the bolt and tighten the square nut Page 5 5 dA HIL ANV ATHINASSV HOVUOLS CLOTH STORAGE ASSEMBLY AND TIE UP 1 Cloth Storage Drum and Cloth Storage Ratchet The cloth storage drum 29 is a wooden drum about 5 1 2 in diameter with a large flat wound return spring like a clock spring set into one face of it This drum is going to be attached to the outside face of the right rear vertical of the loom frame Refer to Figure 18 during this assembly CLOTH STORAGE DELIA STOP COLLAR ASHER Ho WAS RIGHT BEAR VERTICAL CLOTH STORAGE PAWL PULL WITH RING m AOTH STORAGE RACHET CLOTH STORAGE ROLLER STRING GUIDE PULLEY CLOTH STORAGE DRUM Page 6 1 CLOTH STORAGE ASSEMBLY AND TIE UP Page 6 2 A Locate the cloth storage ratchet It is a steel axle with an alumi B num ratchet and knob attached to one end of it This axle should now be inserted into the metal sleeve that is about one foot up from the floor on the right rear vertical frame piece Insert the axle from the inside Check to see that the wooden pawl called the cloth storage pawl on the inside of the loom frame engages with the teeth of the ratchet Now locate the previously mentioned cloth storage drum Notice that
67. nd the back plate Now tighten all bolts holding the drop box assembly to the beater OVERHEAD BEATER ASSEMBLIES optional equipment IMPORTANT The face of the back plate must be precisely flush with the face of the upright Check this alignment by laying a straight edge across the two surfaces L Repeat this procedure for the right drop box assembly Vertical Pull Flystring Tie Up M Locate the bag marked Multiple Box Flystring Tie Up and remove its contents These pieces can now be assembled on the loom as shown in Figures 43 and 39 Use the screw to attach this assem bly to the bottom edge of the pre drilled front harness pulley support as shown in the illustrations making sure that you include the small wedge shaped piece of wood as part of this assembly When as sembled correctly these pulleys should be angled slightly toward the front of the loom Also make certain that the pulleys are to the rear or away from the weaver We suggest that you refer to Figures 43 and 39 before and during this next step of the assembly Remove the flystring tie up from the bag This tie up consists of a long dacron cord with a spring at tached to one end of it You should now attach the loop at the free end of this spring to the screweye that is affixed to the top of the left picker The pickers are the plastic hammers that slide horizontally through the drop box assembly at each end of the beater assembly Now route the end of
68. ng the beater top over the race and reed slide the bolts into the slots at the top of the beater legs and once the reed is securely inside the groove in the beater top attach the washers and wing nuts and tighten them At this point you should center the beater assembly in the loom and tighten the bolts that attach the beater legs to the shuttle race Centering the beater will insure that the legs will not rub on the loom frame Page 9 3 BOTTOM SWING BEATER ASSEMBLIES Page 9 4 2 Single Box Flyshuttle Beater optional equipment NOTE The single box flyshuttle system now incorporates removable shuttles boxes This allows the weaver to completely remove the boxes and flystring tie up from the loom any time that an extensive amount of handshuttle weaving becomes necessary It also makes it much easier to convert any other AVL beater system to a single box flyshuttle beater Locate the following see Figure 25 shuttle race beater top two legs hardware string tie up reed reed support Pick up the race and orient it so that the lengthwise groove is facing toward the rear of the loom and the shorter flyshuttle box sides are towards the front Now lay the race across the loom in the approximate position it will be when in use Empty your hardware bag on a table top Separate the 5 16 x 3 1 4 carriage bolts washers and hex bolts Look at your beater legs They are identified as to left and right
69. nt such as Loctite and apply a drop or two to each of these screws where the screws go into the cast metal brackets R The final step is to attach the drop boxes to the shift handle and adjust the cable lengths On each side there is a cable attached to the drop box which has an eyebolt on the end This cable is routed over the top of the drop box pulley and the eyebolt threads into the turnbuckle on the end of the cable coming from the shift handle Once you have both sides attached they are adjusted as follows With the shift handle shifted to its rightmost adjust the left drop box turnbuckle so that the box is against its top stop and the spring at the turnbuckle is slightly extended Shift the handle to the left and adjust the right turnbuckle in the same manner ATTENTION When shifting the leading end of the handle must be raised first If the trailing end of the handle is lifted first the handle will lock up and not shift Also you want to make sure that the turnbuckles are not adjusted so tightly as to not allow the boxes to drop to their full down position Once properly adjusted tighten the lock nut of each turnbuckle to keep them from moving That completes the assembly of your double box flyshuttle beater Check your assembly with Figure 36 to be certain you ve gotten everything correct OVERHEAD BEATER ASSEMBLIES optional equipment 4 Overhead Four Box Flyshuttle Beater optional equipment This system 15 ship
70. o look up into the Dobby Head you ll see that each solenoid pushes against a wooden lever like a piano key and that each lever in turn moves a cable into position against a multi slotted black metal bar the Dobby Arm Insert by name There are two things to check here That each cable is centered side to side in the corresponding slot in the black metal bar Dobby Arm Insert That each solenoid tip is approximately centered side to side on its corresponding Dobby Finger strip COMPU DOBBY INSTALLATION amp ADJUSTMENT INSTRUCTIONS The trick is to adjust the Solenoid Box in or out until the cables are each deposited just to the rear of each slot If the cables are pushed too far back or not back far enough the harnesses will not lift properly In order to make this adjustment you must have your solenoids ex tended Before you make your actual adjustment you ll need to move to your computer and create a peg plan that activates the outer two harnesses 1 and 40 Then proceed through the steps necessary to begin weaving Having sent your adjusting peg plan to the Compu Dobby return to your loom and treadle once You should hear the solenoids activate they make an abrupt snapping sound If this doesn t happen repeat your treadling Return to the Solenoid Box and peering in from the bottom verify that the two solenoids are extended Loosen each hex nut Pull back on the Solenoid Box so that it rests aga
71. of your loom These uprights are labeled left and right and it is important that they be properly oriented The ends of the uprights with the metal brackets will be the top of this assembly The metal rods should be pointed inward or toward each other There isa metal pulley attached to the back face of each upright These pulleys should now be touching the floor Lay the shuttle race on top of the two uprights so that it covers the two holes in the face of each upright There is a groove cut in one side of the shuttle race which must be oriented to the top and back of the race which means that it should for now be facing down toward the floor Attach the shuttle race to the uprights with two 5 16 x 3 1 4 carriage bolts one on each side You will see that there are two holes on each end of the shuttle race that correspond with the two holes on either upright For now only the innermost hole on each end will be used The outer holes take a different bolt and will be used later Attach the washers and hex nuts to these carriage bolts but do not tighten them just yet as you will be making some adjustments shortly Temporarily attach the beater top to the uprights with two 1 4 x 2 1 4 carriage bolts with washers and wing nuts behind the uprights The beater top should be attached to the same side of the uprights as the shuttle race with the shift handle on top You do not need to put the beater top on now but if you do it will help in creating p
72. old the beater in this position as that is the purpose of the beater retainer OVERHEAD BEATER ASSEMBLIES optional equipment 0 The beater return spring assembly is adjustable It is tightened by pulling on the ends of the white cord while squeezing the black mini cord lock on the assembly Whenever an adjustment is made on one side of the beater a similar adjustment should be made on the other side as well The amount of tension you set these springs at is strictly a matter of preference Generally speaking the stronger the tension the harder you will have to pull against these springs during the beat At the same time however it will be easier to hold the beater away from you while opening a shed and throwing the shuttle You may wish to experiment with these adjustments in order to come up with a setting that works best for you and any particular warp Locate the reed support the long thin wooden part with up to seven holes and a slot similar to the one in the shuttle race Attach the reed support to the back of the shuttle race with the slot to the top and facing the shuttle race using seven 5 16 x 3 carriage bolts inserted from the front with washers and wing nuts behind Before attaching the nuts install the bottom edge of your reed in the void created by the slots in the reed support and shuttle race Center the reed between the two uprights and tighten the wing nuts if your beater top is in place yo
73. ole provided on each bottom horizontal of the side frame assembly see Figure 742 The eye of the bolt should be to the outside of the side frame Replace the washer and hex nut and tighten securely This assembly is used to assist the weaver in returning the beater to the back position It is not necessarily intended to hold the beater in this position as that is the purpose ofthe beater retainer The beater return spring assembly is adjustable It is tightened by pulling on the ends of the white cord while squeezing the black mini cord lock on the assembly Whenever an adjustment is made on one side of the beater a similar adjustment should be made on the other side as well The amount of tension yet set these springs at is strictly a matter of preference OVERHEAD BEATER ASSEMBLIES optional equipment 0 Generally speaking the stronger the tension the harder you will have to pull against these springs during the beat At the same time however it will be easier to hold the beater away from you while opening a shed and throwing the shuttle You may wish to experi ment with these adjustments in order to come up with a setting that works best for you and any particular warp Locate the reed support the long thin wooden part with seven holes and a slot similar to the one in the shuttle race Attach the reed support to the back of the shuttle race using seven 5 16 x 3 carriage bolts inserted from the front wit
74. oove is facing down and the cut outs at either end are facing toward the rear of the loom Insert 1 4 x 2 1 4 carriage bolts into the holes located at each end starting them from the front Placing the beater top over the race and reed slide the bolts into the slots at the top of the beater legs and once the reed is securely inside the groove in the beater top attach the washers and wing nuts and tighten Now securely tighten the carriage bolts that attach the legs to the race At this point you should center the beater assembly in the loom and tighten the bolts that attach the beater legs to the shuttle race Centering the beater will insure that the legs will not rub on the loom frame Take the string tie up and handle from its bag As you can see there are three screweyes coming out of the handle One at the top and two at the sides Hold the handle up by the clip attached to the string at the top of the handle This clip will get attached to the screweye that is located in the beater hardware package However the screweye must first be screwed into the center hole on the underside of the front harness pulley support Now screw the screweye in so that no screw threads are show ing Then attach the clip to it At this point there are two pickers hanging below the handle Take one of these and orient it so that the leather loop is toward the bottom Now take it to the very outside of the race on the right side Slide the picker with
75. op of this assembly The metal rods should be pointing inward or toward each other Now lay the shuttle race assembly on top of the two uprights so that it covers the two holes in the face of each upright as shown in Figure 32 There is a groove cut in one side of the shuttle race which must be oriented to the top and back of the race which means that it should for now be facing the floor The two rear plywood box sides should fit into the notches on the front face of each upright Attach the shuttle race to the uprights with two 5 16 x 3 1 4 carriage bolts one on each side You will see that there are two holes a foot or so from each end of the shuttle race that correspond with the two holes on either upright For now only the innermost hole on each side will be used The outer holes take a different bolt and will be used later Attach the washers and hex nuts to these carriage bolts but do not tighten them just yet as you will be making some adjustments shortly Temporarily attach the beater top to the uprights with two 1 4 x 2 1 4 carriage bolts with washers and wing nuts behind the uprights The beater top should be attached to the same side of the uprights as the shuttle race with the long groove facing downward Insert the carriage bolts through the holes near each end of the beater top and then through the slots that are located just below the metal brackets of each upright You do not need to put the beater top on now but if
76. orage roller Always use the crank to lift the weight up a bit before disengaging the weight lock NOTE The retaining pin with ring attached can be removed from the cloth storage ratchet to allow the cloth storage roller to spin This is a handy feature as it will allow you to unwind woven goods from the roller without having to remove the roller from the loom However you must exercise extreme cau tion when doing this and never remove the pin unless the cloth storage weight is either in the full up and locked or full down position Otherwise the heavy weight will fall rapidly toward the floor Page 6 7 DIVAS ONPTIVISNI INSTALLING THE SEAT The seat 14 can now be put into place see Figure 1 The metal bracket that is attached to it goes against the right front vertical with a 5 16 x 4 1 2 hex bolt going through the front vertical the bracket and the seat itself Use the remaining bolt to attach the other end of the seat If your loom is a 48 model this end of the seat will attach to the vertical seat support 15 with a 5 16 x 3 1 2 flat head machine screw If your loom is a 60 or 72 model the seat will go all of the way across the loom and attach to the left front vertical with a 5 16 x 3 1 2 hex bolt On the 60 and 72 looms you will notice that there are two holes in the right front vertical and one hole in the left one for mounting the seat An extra washer has been supplied with each
77. osition If you have ordered two beams you will have received two separation rollers and you will install one in the upper and one in the lower position To install the separation roller gently spread the side frames and insert the rollers into the holes provided Note that these holes do not go all the way through the loom frame If they do you are using the wrong holes Now install the upper back 5 using two 5 16 x 3 1 4 hex bolts washers and square nuts as shown in Figure 5 Tighten these now as well as the bolts and nuts on the lower back that we left loose in the previous step 3 Lower Front 7 Locate the lower front If your loom is a 40 or 48 model this would be a good time to install the seat support 15 see Figure 1 This part attaches to the lower front with a 5 16 x 3 1 4 hex bolt washer and a square nut If your loom is a 60 or 72 model proceed to the next paragraph Now the lower front assembly 7 can be put on the loom From the outside of the loom insert the two 5 16 x 3 1 4 hex bolts halfway into the holes in the left side frame and two 5 16 x 3 3 4 hex bolts in the right side frame where the lower front will be attached Now kindly ask your helper to prop up the front of the loom so that you can bolt the lower front to the side frames Go ahead and tighten the bolts on the left side but leave the ones on the right side a bit loose for now A bracket will be attached
78. ou insert the end of the harness into the space in the heddles CUTTING THE HEDDLES APART FIG 11 HARNESS ASSEMBLY Remember that each individual bundle contains one hundred heddles see Figure 11 for information as to where to cut the heddles Now pick up one of the harness wires and notice that there is a copper stop near one end of it That end is the top Insert the bottom end of the harness wire into the hole located at the end of the top harness stick and down through the hole in the bottom harness stick Repeat this for the holes on the other end of the upper and lower harness sticks When you are certain you ve done this correctly you can untie the twist ties Now if you will spread the heddles out along the lengths of the harness sticks you will notice that the heddles are all attached to one another at the top or bottom These connecting loops can be cut to make threading easier This will neither weaken or unravel the heddles see Figure 11 Another hint to make threading easier while you have your heddles spread out between two harnesses mark above the eye of each one with a colored pen For instance you may use four colors of pen and mark the eyes on the heddles of harness 1 with purple the eyes of harness 2 with red the eyes of harness 3 with blue and the eyes of harness 4 with orange Harness 5 s code color will be purple harness 6 s code color red and so on This makes it easier to tell which
79. out of the loom simply and easily by removing the upper section of either cloth beam support see Figure 17 In our example we ll remove the upper portion of the left cloth beam support Using your crescent wrench or socket turn the upper bolt shown clearly in the drawing counter clockwise until the nut disengages it Pull the bolt until the upper portion of the cloth beam support can be lifted out RIGHT CLOTH BEAM SUPPORT UPPER PORTION OF THE LEFT CLOTH BEAM SUPPORT METAL WOODEN SPACER RING CLOTH BEAM RATCHET CLOTH BEAM ASSEMBLY B Assembling the Cloth Beam Handle Locate the cloth beam It is the beam with the abrasive covering and a ratchet on one end Now locate your cloth beam handle and wooden spacer ring 25 Insert the ratchet end of the cloth beam into the hole in the cloth beam handle with the wooden knob of the handle facing the inside of the loom then into the spacer ring Insert the other end of the cloth beam into the large hole in the upper portion of the cloth beam support that was removed in step A INSTALLING BEAMS AND ROLLERS _ Assembling the Cloth Beam NOTE Before installing the cloth beam to the loom make certain that the metal pawl is in the off position or pulled back around so that it is out of the way of the cloth beam ratchet Slip the end of the cloth beam with the ratchet handle and spacer ring into the corresponding hole in the cloth beam support that is still o
80. ped partially disassembled to facilitate packing Follow the instructions below to complete the assembly Please refer to Figures 29 39 39 and 41 through 48 for help with terminology and locations These drawings are all located in one place for easy retrieval LEFT HANGING ARM SPACER PIVOT BRACKET _ 3 8 STOP COLLAR LEFT UPRIGHT OVERHEAD BEATER PIVOT BRACKET SHOWN FROM FRONT Page 9 41 OVERHEAD BEATER ASSEMBLIES optional equipment BEATER ADJUSTMENT _ S LEFT HANGING ARM SCREW MEME BEATER ADJUSTMENT BASE HORIZONTAL OVERHEAD BEATER ADJUSTMENT BASE Page 9 42 OVERHEAD BEATER ASSEMBLIES optional equipment FRONT HARNESS PULLEY SUPPORT MOUNTING SCREWS WEDGE r SMALL EDGE i p UPPER PULLEY TOWARD FRONT ASSEMBLY Ew HANDLE Be VERTICAL PULL UPPER PULLEY ASSEMBLY SEEN FROM FRONT oF Loom Page 9 43 OVERHEAD BEATER ASSEMBLIES optional equipment LEFT TOP HORIZONTAL RACKING ADJUSTMENT BOLTS i AXLE GOES THROUGH LOOM RACKING POSITION SHOWN FROM LEFT SIDE OVERHEAD BEATER Page 9 44 OVERHEAD BEATER ASSEMBLIES optional equipment FRONT 55 PULLEY SUPPORT mnm n P VR SEE FIG 39 ENGT LEFT HANSING i 2 11 im ih SEE FIG 40 a DROP BDX RACE ASSEMBLY SHOWN FROM REAR OVERHEAD DOUBLE BOX F
81. port Left Cloth Beam Support Right Vertical Support Assembly Left Vertical Support Assembly Harness Pulley Support Assembly Spring Lever Assembly Seat Seat Support optional Tension Arm Assembly Standard Harness Assembly not shown Dobby Head Warp Beam Standard Cloth Beam Cloth Beam Ratchet Handle not shown Upper and Lower Cloth Rollers Rear Cloth Storage Roller Cloth Storage Drum Cloth Take Up Drum Cloth Take Up Pulleys Weight Track Weight Beater Supports bottom swing Beater not shown Second Warp Beam not shown Second Warp Beam Tension Arm Warp Beam Separation Roller s one or two Beater Bumpers Raddle Warp Beam Handle not shown Flyshuttle Cord Supports not shown ATEHINASSV INOO I UNPACKING IDENTIFYING PARTS 1 Hardware Identifying and Measuring LOOM ASSEMBLY The very first thing you need to do is take a nice deep breath and slowly exhale Now you can unpack your boxes being very careful not to throw any parts away with the packing paper Remove all strapping tape and bubble pack Lay all of the parts so that you will be able to identify each one as they are called for Pick up your bag marked cross member hardware Empty its contents onto a table top In the bag are hex bolts carriage bolts washers hex nuts square nuts wing nuts allen wrenches two black knobs possibly two machine screws Now look at the Hardware Identificatio
82. r you will need to loosen the racking adjustment bolts push the beater against both bumpers and se curely tighten the nuts Now is a good time to attach the beater return spring assembly This is the previously mentioned spring cord eyebolt assembly that hangs from the end of each tilting arm To attach this assembly simply remove one hex nut and washer from each eyebolt and place the eyebolt through the hole provided on each bottom horizontal of the side frame assembly see Figure 33 The eye of the bolt should be to the outside of the side frame This assembly is used to assist the weaver in returning the beater to the back position It is not necessarily intended to hold the beater in this position as that is the purpose ofthe beater retainer The beater return spring assembly is adjustable Itis tightened by pulling on the ends ofthe white cord while squeezing the black mini cord lock on the assembly Whenever an adjustment is made on one side of beater a similar adjustment should be made on the other side as well The amount of tension you set these springs at is strictly a matter of preference Generally speaking the stronger the tension the harder you will have to pull against these springs during the beat Page 9 25 OVERHEAD BEATER ASSEMBLIES optional equipment Page 9 26 L M At the same time however it will be easier to hold the beater away from you while opening a shed and throwing t
83. r other peripherals including your Compu Dobby When we take your order we try to establish which configura tion you have so that we can provide the correct cable If you did not receive a serial cable that corresponds to your particular port configuration please call AVL Customer Service Unless you have access to a full service computer store it s unlikely you ll find the cable you need One decided disadvantage of rapid change in the computer industry is the difficulty we all have in staying current with the latest trends We have supplied you with an adaptor from 9 to 25 pins so if your computer has a 25 pin port it will still work Newer Macs use USB ports You ll need a serial USB adaptor to connect the Mac to the Compu Dobby We recommend the Dual Adaptor from KeySpan or the Belkin adaptor Older Macs usually have two serial ports These are round and contain holes for eight pins and are labeled modem or printer you may connect to either If you have a Macintosh system you ll be asked to specify which port you connected to This happens later and you ll be prompted by your weaving software Page CD 5 COMPU DOBBY II INSTALLATION amp ADJUSTMENT INSTRUCTIONS Secure the Cords Surge Protector IMPORTANT Solenoid Box Adjustment To Adjust Page CD 6 We ve provided you with a number of adhesive backed anchors and plastic zip ties Use these to bundle your cords in the fashion you find most ut
84. roper alignment ofthe beater parts OVERHEAD BEATER ASSEMBLIES optional equipment G H Place the beater in the loom For now it will just sit in the loom resting on top of the cloth beam supports just in front of the har nesses The assembly may tend to fall forward or backward but don t worry about that You now have some other assemblies to complete before actually attaching the beater The next step is to mount the hanging arms to the uprights on the shuttle race assembly see Figure 29 Using a 1 8 allen wrench remove the 3 8 stop collars from the shafts at the tops of each upright and install the hanging arms onto these shafts making sure to put the right and left hanging arms in their proper positions Also be certain to include the small spacer as shown in Figure 29 The stop collars are then replaced and tightened making sure to leave enough clearance for this pivot point to swing freely Now look at the other end the top of one of the hanging arms Notice that there is a block of wood at this end that the beater adjustment screw goes through As shown in Figure 30 the foot at the bottom end of the beater adjustment screw should be set into the notch in the center of the beater adjustment base which you attached to the loom in step B of this assembly Once you have both of the beater adjustment screws in place the assembly of the hanging arms is complete The next step is to mount the axle
85. s Orient the track so that the lengthwise groove is on top You may wish to refer back to Figure 16 to clarify this procedure Page 10 1 TENSION BOX optional equipment Page 10 2 3 Mounting the Tension Box The AVL tension box track mounting system now employs a quick release advantage To install the track arm assembly you simply place the track arms between the two externally mounted studs that you attached to each rear vertical of the loom earlier The track arms should initially go in at an angle with the front stud fit into the notch on the upper edge of the track arm Then lower the track arm assembly to a horizontal position at which point the lower notch on the track arm should align with the rear stud This will hold your tension box in place while warping your loom When you are finished with the tension box the track can be removed easily if it is in the way while you are weaving ATHINASSV NV NOLLV T IV LSNI Il AdHOGQ 1dliOO COMPU DOBBY INSTALLATION amp ADJUSTMENT INSTRUCTIONS Introduction Before you start you ll want to gather a few tools Medium Phillips screwdriver Small bladed screwdriver Scissors Pliers Crescent or 9 16 wrench Needle nose pliers Scotch or masking tape An extra pair of hands about 10 minutes worth SOLENOID BOX INSTALLATION Set Screw Solenoid Box Retainer Pillow Block Wood Screws Dobby Head po ud 1 In
86. s hanging below the handle Take one of these and orient it so that the leather loop is toward the bottom Now take it to the very outside of the race on the right side Slide the picker with the leather loop down and toward the outside into the slots between the box sides Now look up at the right hanging arm About halfway down there is a screweye on the front face of the arm The clip at the end of the cord that attaches to the picker should be clipped to the screweye at this point OVERHEAD BEATER ASSEMBLIES optional equipment Pick up the left picker With the leather loop down and toward the outside slide it into the grooves in the left box sides from the very outside of the race Attach the clip at the end of the cord to the screweye on the left hanging arm Notice that there is a snubber attached to the front box on each side of the race The cord should go over the snubbers small wooden spools above each shuttle box on each side of the loom This completes the assembly of your single box flyshuttle beater Check your assembly with Figure 32 to be certain you ve gotten everything correct 3 Overhead Double Box Flyshuttle Beater optional equipment This system 15 shipped partially disassembled to facilitate packing Follow the instructions below to complete the assembly Please refer to Figures 29 30 and 36 through 41 for help with terminology and locations These drawings are located in one place for easy retr
87. sembly they are marked L and R You will notice that there two holes through the back plate in the lower right corner and one in the upper right corner with an intersecting hole coming from the right edge Looking at the left upright you will find a horizontal hole through the width of the upright just below the slot for the beater top This hole should be offset to the front ofthe shuttle race side ofthe upright Take a 5 16 x 4 1 2 hex bolt with a washer on it insert it through the hole in the upright from the inside through the hole in the edge of the upper right corner of the drop box assembly and thread it onto a square nut inserted in the nut access hole in the back plate Do no tighten this yet Your drop box assembly should now be attached to the upright with this one bolt with the moveable boxes in the front Attach the drop box assembly to the shuttle race with two 5 16 x 2 3 4 carriage bolts inserted from the front washers and hex nuts behind the back plate Now tighten all bolts holding the drop box assembly to the beater Multiple Box Flystring Tie Up Assembly OVERHEAD BEATER ASSEMBLIES optional equipment IMPORTANT The face of the back plate must be precisely flush with the face of the upright Check this alignment by laying a straight edge across the two surfaces L Repeat this procedure for the right drop box assembly Vertical Pull Flystring Tie Up M Locate the bag marked Multiple
88. sert the Solenoid Box into the Dobby Head as Shown 2 Insert the spring and secure with the retainer and the screws at each side 3 Adjust the tension with the set screws and tighten the locking nut around the set screws You can now use the Mounting Struts themselves to locate the rear holes Page CD 1 COMPU DOBBY INSTALLATION amp ADJUSTMENT INSTRUCTIONS Install the Solenoid Box Page CD 2 Look at the Solenoid Box You ll see three rows of white tipped rods These are the solenoid ends and they ll take the place of your dobby bars and pegs You ll also note a small plastic block on each side of the box See the holes in the blocks Place one spring in each hole Orient the box so that the solenoids face the Dobby and are at the bottom of the box Align the blocks with the slots in the Dobby head and slowly slide the unit into the wooden case see Solenoid Box Installation At the end of each slot you ll see a hole Seat the free end of each spring in this hole You can see now that the springs will keep the Solenoid Box under a bit of physical tension This tension helps keep the box in proper adjust ment Place the two aluminum Adjustment Brackets see drawing This will keep the Solenoid Box in place We ll return later to adjust the box page 18 COMPU DOBBY INSTALLATION amp ADJUSTMENT INSTRUCTIONS Cables and You ll need to mount the Component Box on top of the loom It s simple Just Compon
89. slide the shift handle back and forth notice that there are four detents or places where the shift handle can be stopped Each of these four detents corresponds to the four shuttle boxes The best way to adjust these cables is to slide the shift handle to either the far left or far right detent position This will put one drop box in the upper position and the other one in the lower position Now all you have to do is adjust the cable as mentioned above so that the drop box shelf is at the same height as the top of the shuttle race It may help you to lay a straight edge across the shuttle race and drop box when doing this to assist you in getting the two perfectly aligned When you have it properly adjusted secure the lock nuts on the threaded studs Once you have adjusted both cables it s a good idea to put the shift handle in each detent position and check the boxes on each side for alignment It is possible that there will be some slight variation in the spacing of the drop box shelves so you may not get absolutely perfect alignment If this is the case for you go for an average adjustment That completes the assembly of your four box flyshuttle beater Check your assembly with Figures 42 and 43 to be certain you ve gotten everything correct A THINASSV RADDLE optional equipment The Raddle 41 is inserted into the holes in the back edge of the rear vertical side frame members se
90. t Out of your tension box hardware bag locate four 5 16 x 2 1 2 carriage bolts black discs and bushings washers and hex nuts Insert the bolt through the hole in the black disc so that the square part under the head of the bolt makes contact with the countersunk portion of the disc Slide the black bushing onto the bolt Now install this assembly from the outside of the loom through one of the two holes provided on either rear vertical as shown in Figure 16 Slip the washer and nut on the inside of the loom frame and tighten with a 9 16 socket wrench Repeat this process with the remaining three bolts Installing the Sectional Beam optional equipment Install the sectional beam in the upper slots to the outside edge of the rear verticals as shown in Figure 16 Loosen the black thumb screws enough so that the thumb screw latches also called warp beam retainer latches can be swung off to the side this next step 1s easiest with the help of a friend Now lift the sectional beam up to the back of the loom Make sure that the large drum end of the beam is toward the left side of the loom Fit the axle into the slots and swing the thumb screw latches around to meet the thumb screws When the latches have capti vated the axle and are in a vertical position tighten them down Page 5 3 INSTALLING BEAMS AND ROLLERS Page 5 4 7 Installing the Cloth Beam A Removing the Cloth Beam Support The cloth beam can be taken in and
91. t both ends Push one end into the next lowest port on the side of the Com ponent Box Insert the other end into the appropriate port on the top of the Solenoid Box Power Extension Cable This cable is the same at both ends chrome plugs with fifteen pins Connect one end to the remaining port at the back of the Com ponent Box Connect the remaining end to the appropriate port in the top of the Solenoid Box Power Cord You ve one cord remaining the power cord Connect the female end to the rear of the Component Box Let s watt a bit before we add power COMPU DOBBY INSTALLATION amp ADJUSTMENT INSTRUCTIONS Set Up Your Computer If you haven t already set your computer up at the right side of the loom Once you make the necessary connections you can move it to a position you find most user friendly Leave the computer unplugged for the moment You re going to plug the free end of the serial cable RS 232 into a port on the back of your computer You left this cord hanging from the second port on the Component Box First you need to locate the serial port on the back of your computer Here s what to look for Most recently manufactured name brand PCs are configured with one 9 pin external serial port always a male port Older PCs will usually have two or more external serial ports 9 and 25 pin The 9 pin port is used for the mouse The 25 pin port is available fo
92. the front of the race through the race and into the corresponding holes in the beater leg These are the two innermost holes The two outer holes on each end will not be used on this assembly They are for a single or multiple box flyshuttle beater should you ever care to adapt your loom Attach the washers and nuts and tighten slightly Repeat this procedure for the other side of the loom making sure that the tapered side of the leg is always facing away from the loom Attach the washers and nuts leaving them loose for the moment From your hardware package locate either six seven or nine depend ing upon the width of your loom 5 16 x 3 carriage bolts with washers and wing nuts attached Remove the washers and wing nuts Push the carriage bolts through the race so that their heads sit flat on the front of the beater race don t be afraid to use a hammer to tap these bolts in place Now carefully slide the reed support onto these bolts so that the lengthwise groove in it faces the groove in the race Leave enough room so that you can fit the reed between the race and the reed support Once the reed is in and centered the washers and wing nuts can be fitted onto the carriage bolts and tightened Now orient your beater top so that the groove is facing down and the cut outs at either end are facing toward the rear of the loom Insert 1 4 x 2 1 4 carriage bolts into the holes located at each end starting them from the front Placi
93. the cord under the pulley that is mounted on the rear face of the left upright making sure that the cord goes between the pulley and the attached retainer From this point route the cord up to the upper pulley assembly that you just installed a few minutes ago Route the cord on the right side of the loom exactly like you just did on the left side When you get to the right picker you will find that there is a spring attached to its screweye You now need to tie a good strong knot at the loop on the free end of this spring Where you tie this knot in relation to the end of the cord will deter mine the operating height of the flystring handle which you will attach ina moment If you tie the knot very near to the end of the cord the handle will be at its lowest possible position if it went much lower the flystring handle could collide with the shift handle or beater top when it reached the bottom of its throw We suggest that you try this position first as a lower handle position will gener ally be less fatiguing Page 9 53 OVERHEAD BEATER ASSEMBLIES optional equipment Page 9 54 Now go back to the upper pulley assembly where the cord passed over both of the pulleys taking up all of the slack and forming a large loop at the center of the loom Locate the flyshuttle handle It is a small dark colored piece of wood with a hole and a brass pin through the center of it Form a tight loop at the center of the cord that is now han
94. the weight It is a heavy black rectangular piece of steel with two wooden runners attached to it Take the weight to the bottom of the track and guide the weight onto the loom so that the track is between the two runners on either side of the weight see Figures 19 and 20 making sure that the end with the cord coming from it is toward the top This cord will be attached soon _____ WEIBHT TRACK CLOTH STORAGE STRIMG GUIDE PULLEYS CLOTH STORAGE FIG 20 Page 6 5 CLOTH STORAGE ASSEMBLY AND TIE UP Page 6 6 6 7 Weight Stop The weight stop is a small metal bracket with two rubber bumpers attached to it It will also be attached to the outside face of the right front vertical just below the weight track While holding the weight up a few inches so it is out of the way loosen the two bolts that hold the right end of the lower front in place Back off the bolts just enough so that you can slide the slotted edge of the bracket behind the heads of the bolts Then retighten the bolts and gently set the weight down on this floor protecting weight stop Routing the Cloth Storage Cord Unwrap the cord that comes from the weight and bring the end of it straight up to the cloth take up drum Feed the end of the cord through the small hole in the outer groove of the drum see Figure 19 Pull the cord through the access hole on the inner face of the drum this may require a slight rotation of the drum and
95. there are two pieces of tape holding the spring in place Do not remove this tape yet It should stay in place until the drum is firmly attached to the loom frame Before you put the drum on the loom place a washer on the axle as it sticks out from the outer face of the loom frame Now take a look at the flat wound return spring in the drum Notice how it is attached to the drum at its inner end by a small steel pin Also notice how there is a similar hook shaped bend at the outer end of the spring Now look at the loom frame and notice a small steel pin just above the drum axle that you just installed By now you ve probably figured out that the hooked end of the spring and this steel pin will come together as part of this assembly We re telling you this now because it s hard to see it happening when the drum is actually being put on the loom Speaking of that you can now place the drum on the axle that you installed in step A Carefully remove the tape making certain that the spring stays inside of the drum At this point the trick is to get the hook at the outer end of the spring to catch on the steel pin above the axle The best way to do this is to position the drum on the axle so that the hook is just a bit to the left of the steel pin and then hold the drum against the outer face of the loom frame while slowly turning the drum in a clockwise direction making sure that the pin is between the outer coil of the spring and the outer ed
96. tie a double overhand knot at the end of the string Now turn the crank counter clockwise as you are looking at it from the inside of the loom and the weight will rise to the top of the track At this point you engage the weight lock by turning the knob above the tool holder to a horizontal position This will hold the weight in the upper position which is where you want it now Now go back to the cloth storage drum at the rear of the loom and remove the tape that is holding the cord in place Route the cord as in Figure 20 around the two lower string guide pulleys and clip it to the cord hanging down from the cloth take up drum There should be no slack in the back drum Tension has been loaded into the cloth storage drum spring The spring allows the weight to automatically rewind onto the drum when the weight is returned to its upper position Unwinding the cord from the back cloth storage drum is somewhat akin to pulling out the tape in a tape measure As you pull the cord down and around the two pulleys you are increasing tension If you were to let go it would wind back up like the tape measure Clipping it puts the correct tension on the system CLOTH STORAGE ASSEMBLY AND TIE UP This completes the assembly of the cloth storage system Please note that you should never let the weight fall freely from its upper position The weight lock must always be used to hold the weight up when there is no cloth at tached to the rear cloth st
97. time that handshuttle weaving becomes necessary It also makes it much easier to convert any other AVL beater system to a single box flyshuttle beater This system 15 shipped partially disassembled to facilitate packing Follow the instructions below to complete the assembly Please refer to Figures 29 30 and 32 through 35 for help with terminology and locations These are all located in one place for easy retrieval LEFT HANGING ARM SPACER PIVOT BRACKET _ 3 8 STOP COLLAR LEFT UPRIGHT OVERHEAD BEATER PIVOT BRACKET SHOWN FROM FRONT Page 9 17 OVERHEAD BEATER ASSEMBLIES optional equipment 3 BEATER ADJUSTMENT X LEFT HANGING ARM SCREW HORIZONTAL OVERHEAD BEATER ADJUSTMENT BASE Page 9 18 OVERHEAD BEATER ASSEMBLIES optional equipment LEFT UPRIGHT OVERHEAD SINGLE BOX FLYSHUTTLE BEATER SHOWN FROM FRONT Page 9 19 OVERHEAD BEATER ASSEMBLIES optional equipment Page 9 20 BEATER ADJUSTMENT BASE SEE 30 PUSH ARM LEFT TILTING ARM BEATER RETLIBI OVERHEAD SINGLE BOX FLYSHUTTLE BEATER SHOWN FROM LEFT SIDE FTG 33 OVERHEAD BEATER ASSEMBLIES optional equipment ve BEATER ADJUSTMENT BASE E SEE FIS 30 LEFT TOP HORIZONTAL ARM SEE FIG 29 PUSH ARM w _ LEFT CLOTH BEAM SUPPORT
98. ts with 5 16 x 3 carriage bolts washers and hex nuts Orient these beater bumpers so that the bumper faces the front of the loom and the stamp faces the cloth beam support that it will be mounted to It is best to situate the carriage bolts so that the washers and nuts are to the outside of the loom leaving the smooth head of the carriage bolt on the inside of the loom frame Now take a look at your loom Shaping up nicely isn t it CAITSIDE SLIRF ACE BEATER BUMPER BLOCK 40 Page 2 9 HO NOLLV T IV LSNI INSTALLATION OF THE DOBBY HEAD 1 Mounting the Dobby 18 On the back side of the dobby head you will find two bolts with washers and hex nuts attached Remove these washers and nuts making sure you don t unseat the carriage bolt heads Check back to Figure 1 to see where on the right side of the loom the dobby is mounted Now lift up the dobby unit and insert the protruding bolts into the corresponding holes in the upper horizontal Replace the washers and hex bolts and tighten DOBBY FRONT VIEW 17 Figure 10 Not to Scale Page 3 1 NTEINASSV IN V SSHUNUVH 1 2 3 HARNESS TIE UP Harness cables already attached to the dobby head Cable Retainers Mounted on top of the harness pulley supports are two wooden cross bars with felt on their undersides Using a phillips screwdriver temporarily remove these parts from the loom see Figure 14
99. twist tie likewise with your left hand Gently pull apart and notice that all of the strings are captivated in either the right or left twist tie If you had four hands you could grasp the bottom two twist ties in the same manner Then you would realize that there is indeed some order and reason to this twist tie business Into the space that is created by pulling apart the twist ties you will later insert a harness Now that you understand twist ties you can see that if they were to be removed at this point you would experience chaos Page 4 3 HARNESS ASSEMBLY Page 4 4 4 Harness Assembly polyester heddles With one group of the heddles in hand return to the table with the harness stick laying on it Now insert the harness stick into the space that was created by pulling apart the twist ties As this point you should have an assembly made up of one harness stick with screweyes facing away from you and one bundle of heddles still possessing four twist ties Around the end of the harness should be the heddles The heddles should be oriented so that the eyes of the heddles are between you and the harness stick Notice that there is another space between the twist ties that should be lying between the eyes of the heddles and you that will accommodate another harness stick O K now untape the bundle of four harness sticks with the highest number Take one of these har nesses to the table and with the screweyes facing y
100. u will need to remove it to install the reed There is a slot in the underneath side of the beater top which slides over the top edge of the reed Push the beater top down on the reed and tighten the wing nuts which hold it in place The next thing is to adjust the movement of the drop boxes them selves see Figure 40 You will notice that the boxes slide up and down on a metal rod which is fixed at both ends to cast metal pieces In each of these cast metal pieces you will find a brass adjustment screw with a lock nut These brass screws provide a stop for the boxes at their upper and lower extremes of movement Adjust the top screw so that when the boxes are all the way up the lower box is in precise alignment with the shuttle race Adjust the bottom screw so that when the boxes are all the way down the upper box is in precise alignment with the shuttle race This adjustment is critical Please make it carefully It is wise to lay a straight edge across the shuttle race and drop box when doing this to assist you in getting the two perfectly aligned When you have it properly adjusted secure the lock nuts on the brass screws Do these adjust ments on both the left and right drop boxes If your shuttle flight is erratic re check these adjustments Page 9 39 OVERHEAD BEATER ASSEMBLIES optional equipment Page 9 40 To make sure that the adjustment screws stay in place you might want to purchase a small tube of a thread locking age
101. vided Do not tighten these bolts yet They will be part of a critical adjustment coming up shortly You will see a spring cord eyebolt assembly hanging from the end of each tilting arm Just let them hang for now They will be attached later Page 9 51 OVERHEAD BEATER ASSEMBLIES optional equipment Page 9 52 I J K Next mount each push arm to the back face of each upright see Figure 44 using two 5 16 x 4 1 2 hex bolts washers and square nuts These bolts go through the shuttle race and uprights and end up in a square nut in the nut access hole of each push arm You can go ahead and tighten these bolts making sure that the outer face of each push arm is relatively flush with the outer edge of their mating uprights This is also a good time to go ahead and tighten the other bolts that we previously told you to leave loose While tightening these bolts you should see that the beater is relatively square and centered in the loom The last bolts to tighten are the hex bolts that we shall for now call the Racking Adjustment Bolts that connect the tilting arms to the axle see Figure 41 Figure 41 shows the beater being pushed toward the front of the loom In reality how ever you can align the beater by pushing the tilting arms toward the front or by pushing the race against the rear bumpers The important thing is to have the beater touching both the left and right bumpers at the same time As shown in
102. ving small spring from the bag and attach it to the screweye You now need to tie a good strong knot at the loop on the free end of this spring Where you tie this knot in relation to the end of the cord will determine the operating height of the flystring handle which you will attach ina moment If you tie the knot very near to the end of the cord the handle will be at its lowest possible position if it went much lower the flystring handle could collide with the shift handle or beater top when it reached the bottom of its throw We suggest that you try this position first as a lower handle position will generally be less fatiguing Page 9 37 OVERHEAD BEATER ASSEMBLIES optional equipment Page 9 38 Now go back to the upper pulley assembly where the cord passed over both of the pulleys You now want to route the cord down between the two pulleys taking up all of the slack and forming a large loop at the center of the loom Locate the flyshuttle handle It is a small dark colored piece of wood with a hole and a brass pin through the center of it Form a tight loop at the center of the cord that is now hanging below the upper pulley assembly Feed the loop down from the top of the handle through the hole on either side of the brass pin that divides the hole Now feed the loop back through the hole on the other side of the brass pin Now form a larger loop 6 or so and run it back over either end of the handle To do this you
103. with Automatic Advance Mechanism 29 Overhead Beater Pivot Bracket 30 Overhead Beater Adjustment Base 31 Overhead Beater Racking Position 29 Overhead Beater Pivot Bracket 30 Overhead Beater Adjustment Base 32 Overhead Single Box Flyshuttle Beater Front 33 Overhead Single Box Flyshuttle Beater Left 34 Overhead Beater with Automatic Advance Mechanism 35 Overhead Beater Racking Position 29 Overhead Beater Pivot Bracket 30 Overhead Beater Adjustment Base 36 Overhead Double Box Flyshuttle Beater Rear 37 Overhead Double Box Flyshuttle Beater Left 38 Overhead Beater with Automatic Advance Mechanism 39 Vertical Pull Upper Pulley Assembly 40 Drop Box Assembly 41 Overhead Beater Racking Position Page 1 5 1 4 222 2 3 2 4 2 7 2 8 2 9 341 4 1 4 4 4 6 5 2 5 4 6 1 6 4 6 5 8 1 8 3 8 5 9 2 9 5 9 8 9 9 9 10 9 11 9 12 9 13 9 17 9 18 9 19 9 20 9 21 9 22 9 27 9 28 9 29 9 30 9 31 9 32 9 32 9 33 Page i FIGURE INDEX Page ii Figure Drawing Title 29 30 39 41 42 43 44 45 46 47 48 Overhead Beater Pivot Bracket Overhead Beater Adjustment Base Vertical Pull Upper Pulley Assembly Racking Position Overhead Beater Overhead Four Box Flyshuttle Beater From Rear Overhead Four Box Flyshuttle Beater From Front Overhead Four Box Flyshuttle Beater From Left Overhead Beater With Automatic Advance Mechanism Four Box Vertical Pull Backplate Assembly Four Box Flyshuttle

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