Philips VARI-LITE VL4000 Service Manual
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Philips VARI-LITE VL4000 Service Manual

Beamwash luminaire
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20 June 2017
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  • Page 1 20 June 2017...
  • Page 2 10911 Petal Street Dallas, Texas 75238 USA This manual is for informational use only and is subject to change without notice. Philips Entertainment assumes no responsibility or liability for any claims resulting from errors or inaccuracies that may appear in this manual.
  • Page 3 Note: *When returning products to Philips Entertainment Lighting for repairs (warranty or out-of- warranty) from a country other than the USA, “Philips Lighting Controls Division”, must appear in the address block as the Importer of Record (IOR) on all shipping documentation, Commercial Invoices, etc.
  • Page 4 Declaration of Conformity We, Philips Entertainment Lighting B.V. 10911 Petal Street, Dallas, Texas 75238 USA, declare under our responsibility for the products: Product Range...
  • Page 5 1. VARI❋LITE luminaires have been designed for use with specific lamp types. VL4000 BeamWash Luminaires is supplied with an 1200W Philips MSR Gold FastFit lamp or other lamps as approved by Philips Entertainment Lighting. Installing another type of lamp not approved by Philips Entertainment Lighting may be hazardous.
  • Page 6 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1. Many VARI❋LITE luminaires use a lamp that produces UV radiation. DO NOT look directly at lamp. 2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired.
  • Page 7 HINWEISE ZUM FEUERSCHUTZ 1. VARI❋LITE -Scheinwerfer sind ausschließlich für den Einsatz mit bestimmten Lampentyps. Achten Sie auf den Lampentyp (1200W Philips MSR Gold FastFit lamp), bevor Sie die jeweiligen Lampen ersetzen. Die Installation eines anderen Lampentyps kann gefährlich sein. 2. Scheinwerfer können auf jeder beliebigen Oberfläche montiert werden, solange Sie die Montageanweisungen befolgen.
  • Page 8 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL WARNUNG: HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG 1. Viele VARI❋LITE -Scheinwerfer verwenden die Lampentyp, der UV-Strahlen abgibt. SCHAUEN SIE NICHT direkt in die Lampe. 2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch sichtbare Beschädigung (z.
  • Page 9 1. Les luminaires VARI❋LITE ont été conçus pour être utilisés uniquement avec certaines type de lampes. Vérifier le type de lampe (1200W Philips MSR Gold FastFit lamp) avant de remplacer les lampes. L’installation d’un autre type de lampe peut poser un danger.
  • Page 10 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1. Plusieurs luminaires VARI❋LITE utilisent une lampe qui produit des rayons UV. NE PAS fixer son regard sur la lampe. 2.
  • Page 11 INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO 1. Las luminarias VARI❋LITE han sido diseñadas para ser usadas solamente con algunas lámparas. Tome nota del tipo de lámpara (1200W Philips MSR Gold FastFit lamp) antes de reemplazarla. Instalación de otro tipo de lámpara puede ser peligroso.
  • Page 12 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN EXCESIVA DE RADIACIÓN ULTRA VIOLETA 1. Muchas luminarias VARI❋LITE usan un tipo de lámpara que produce radiación UV. NO mire directamente a la lámpara. 2.
  • Page 13 OREWORD 02.97 04.601 0 A...
  • Page 14 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL 02.970 4.6010 A...

  • Page 15: Table Of Contents

    ABLE OF ONTENTS Table of Contents Cables are only available as complete assemblies. The information contained in this Note: section is for reference only. Introduction About This Manual ........................1 Additional Documentation......................1 Customer Service ........................2 Technical Bulletins and Notices....................2 Chapter 1.
  • Page 16 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Pan Driver Board ........................35 Low Voltage Supply (LVS) ..................... 36 Upper Enclosure Fan....................... 37 Neutrik True One AC Input Connector................... 38 DMX PCB Assembly......................39 Display Overlay ........................40 USB Port ..........................41 Upper Enclosure Air Filters (To Clean or Replace)..............
  • Page 17 ABLE OF ONTENTS Prism Assembly......................... 87 Prism Arm Sensor......................88 Prism Rotate Sensor ......................89 Prism Arm Motor ......................90 Prism Arm Belt........................91 Prism Rotate Belt....................... 92 Prism Rotate Motor ......................93 Prism Glass Change......................94 Wash Lens Sensor ......................95 Wash Lens Motor ......................
  • Page 18 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL CTO Filters........................140 Yellow Filters ........................141 Cyan Filters ........................142 Magenta Filters........................ 143 CYM Color Sensor ......................144 Color Belt Assembly ....................... 145 Color Motor Assembly ....................146 Strobe Assembly......................147 Strobe Blades........................
  • Page 19 ABLE OF ONTENTS Back End Assembly ......................194 Reflector Assembly....................... 196 Lamp Cover Assembly......................197 Gobo/Animation Module Assembly ..................199 Gobo Wheel 1 Assembly ...................... 205 Gobo Wheel 2 Assembly ...................... 207 Gobo 1 Sensor Index Assembly.................... 209 Gobo 2 Sensor Index Assembly.................... 210 Concurrent Animation Wheel Assembly ................
  • Page 20 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 Color Bulkhead 1 Cable Assembly................. 272 VL4000 Color Bulkhead 2 Cable Assembly................. 273 VL4000 Color Bulkhead 3 Cable Assembly................. 274 VL4000 Color Bulkhead 4 Cable Assembly................. 275 VL4000 Color A to Color B Cable Assembly ..............276 VL4000 Pan / Power Distribution Input Cable Assembly............

  • Page 21: Introduction

    Manual. This manual is only available in electronic (PDF) format: • VL4000 BeamWash Luminaire User’s Manual (02.9704.6002) Note: The user’s manual is available on the Philips Entertainment Lighting web site at www.philips.com/entertainmentlighting in the Product Downloads Section. For more information regarding DMX512 systems, refer to the DMX512/1990 & AMX 192 Standards publication available from United States Institute for Theatre Technology, Inc.

  • Page 22: Customer Service

    Customer Service Our Goal At Philips Entertainment Lighting, we are committed to providing you the highest quality in customer service. Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Philips Entertainment Lighting customer. Whether your needs are telephone troubleshooting assistance, product training or technical service, our full-time staff of experienced professionals are on-hand to provide support.

  • Page 23: Chapter 1. Description

    HAPTER Description This chapter contains descriptions of luminaire features and components. • Features • Components 02.97 04.601 0 A...

  • Page 24: Features

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Features Product Features All VL4000 BeamWash Luminaires have the following standard features: Color System A three filter CYM cross fading system capable of extremely smooth movements at both slow and fast speeds, and a variable CTO color temperature correction system.

  • Page 25: Technical Specifications

    AC supply voltage. Source • 1200W Short Arc Lamp, Philips MSR Gold FastFit. Technical Specifications For additional technical specifications and information, please refer to VL4000 BeamWash Luminaire User’s Manual (02.9704.6002) and the product specification sheet. These documents can be found in the product downloads section of the Vari-Lite web site at www.vari-lite.com.

  • Page 26: Components

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Components External Luminaire Components The following illustration shows the external luminaire components and controls. Head Assembly Backcap Assembly Houses color system, gobos, animation Provides access to lamp for replacement wheel, strobe, iris and optics mechanisms and provides controls for beam adjustment.

  • Page 27: Head And Yoke Components

    OMPONENTS EAD AND OMPONENTS Head and Yoke Components The following illustration shows the major sub-assemblies which are located in the luminaire head and yoke assemblies. Gobo/Animation Assembly Head Cover Contains two rotating gobo / effects wheels, (attached by tether) one rotating animation wheel, and iris mechanism Backend Assembly Color Module Assembly...

  • Page 28: Enclosure Components

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Enclosure Components The following illustration shows the major sub-assemblies which are located in the luminaire enclosure assembly. (Yoke and head assemblies not shown for clarity.) Enclosure Top Covers Pan Tube Assembly 36 VDC / Low-Voltage Power Supply Pan Motor Assembly...

  • Page 29: Chapter 2. Maintenance & Service

    HAPTER Maintenance & Service This chapter contains test, service, and standard maintenance procedures. • Troubleshooting • Routine Maintenance Procedures • Service Procedures WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Never remove cover or backcap while lamp is in oper- ation.

  • Page 30: Troubleshooting

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Troubleshooting Error Messages If a problem occurs during luminaire calibration, at the end of the calibration sequence the Menu Display will cycle through any applicable error message(s) until the end of the list is reached. To review the error messages again, it will be necessary to access them using the Status function.

  • Page 31: Troubleshooting Guide

    ROUBLESHOOTING ROUBLESHOOTING UIDE Troubleshooting Guide If a problem is suspected, try recalibrating the luminaire to prompt an error message. If a problem is suspected, first try recalibrating the luminaire to prompt an error message (refer to “Error Messages” on page 10).

  • Page 32: Routine Maintenance Procedures

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Routine Maintenance Procedures WARNING: As with any repairs or maintenance to VARI❋LITE luminaires, service should only be performed by a trained and qualified service technician or at an Authorized VARI❋LITE Service facility.
  • Page 33 OUTINE AINTENANCE ROCEDURES EMOVAL AND NSTALLATION Step 5. To remove lamp, grasp lamp base by hand, twist lamp counter-clockwise until lamp’s tabs align with slots in lamp socket (see Figure 2-2 on page 13 for more information), and remove lamp by pulling it straight out of socket. Step 6.

  • Page 34: Fixed Color Wheel Filter Removal And Installation

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Fixed Color Wheel Filter Removal and Installation To remove and replace fixed color filters: Step 1. Before removing power from luminaire, move Edge towards front of luminaire with control console or via luminaire menu system. WARNING: Remove power from luminaire and allow luminaire to cool completely before performing this procedure.
  • Page 35 OUTINE AINTENANCE ROCEDURES IXED OLOR HEEL ILTER EMOVAL AND NSTALLATION Step 4. At fixed color wheel, slowly rotate wheel by hand until filter to be removed is visible on assembly as shown in Figure 2-5. Step 5. At filter to be removed, (1) press filter out of fixed color wheel with fingers and (2) guide filter up and away from fixed color wheel.

  • Page 36: Rotating Gobo Removal And Installation

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Rotating Gobo Removal and Installation CAUTION: VL4000 BeamWash Luminaires accept glass gobos only. Use of metal gobos in these luminaires may damage gobo assembly and will void the luminaire warranty. To remove and replace rotating gobos: Step 1.
  • Page 37 OUTINE AINTENANCE ROCEDURES OTATING EMOVAL AND NSTALLATION CAUTION: Wear protective gloves or other protective covering while handling gobos to avoid leaving fingerprints. If dirty, clean with isopropyl alcohol and a soft, lint-free cloth. Note: For the standard load of rotating gobos, refer to “Rotating Gobo Wheel 1”...
  • Page 38 ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Retaining Tabs Rotating Gobo Assembly (Retaining clips need to be (gear side towards front of seated in pins but are not luminaire) used to aid in removal) Do not touch glass with bare fingers. CAUTION: Handle by gobo carrier only.

  • Page 39: Animation Wheel Removal And Installation

    OUTINE AINTENANCE ROCEDURES NIMATION HEEL EMOVAL AND NSTALLATION Animation Wheel Removal and Installation To remove and replace animation wheel: Step 1. Before removing power from luminaire, move Edge towards front of luminaire with control console or via luminaire menu system. WARNING: Remove power from luminaire and allow luminaire to cool completely before performing this procedure.
  • Page 40 ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL CAUTION: Be careful not to lose belt bearing, washer, screw or post. These will be required for reassembly and installation. Step 6. Slip belt off of animation wheel. Remove wheel. See Detail Animation Wheel Assembly (Detail) Animation Wheel Assembly Belt Bearing...

  • Page 41: Prism Removal And Installation

    OUTINE AINTENANCE ROCEDURES RISM EMOVAL AND NSTALLATION Prism Removal and Installation To remove and replace prism: Step 1. Before removing power from luminaire, move Edge towards front of luminaire with control console or via luminaire menu system. WARNING: Remove power from luminaire and allow luminaire to cool completely before performing this procedure.
  • Page 42 ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Step 6. As indicated in Figure 2-13 remove two screws securing prism to arm. IMPORTANT! Be careful not to lose removed screws. These will be required for reassembly and installation. Step 7. Install new prism using screws removed in previous step. Step 8.

  • Page 43: Cleaning Optical Lenses And Filters

    OUTINE AINTENANCE ROCEDURES LEANING PTICAL ENSES AND ILTERS Cleaning Optical Lenses and Filters WARNING: Remove power from luminaire before performing maintenance. WARNING: Acetone is a harsh cleaning agent and solvent. Acetone is very flammable. Please handle acetone according to manufacturer’s safety instructions and precautions. The front lens, optics/color filters, and reflector may require cleaning after extended use.

  • Page 44: Service Procedures

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Service Procedures WARNING: As with any repairs or maintenance to VARI❋LITE luminaires, service should only be performed by a trained and qualified service technician or at an Authorized VARI❋LITE Service facility. Upper Enclosure Covers Removal Vari-Lite Part No: 21.9704.0850 (Connector side and Display side) To remove the upper enclosure covers:...

  • Page 45: Pfc Insulating Duct

    : PFC I ERVICE ROCEDURES NSULATING PFC Insulating Duct Vari-Lite Part No: 10.9704.0874 (PFC Insulating Duct) Vari-Lite Part No: 10.9704.1835 (Air Seal) Note: There are two versions of the duct. Original version mounts with 4 screws. Current version mounts with only 2 screws. Note: The top foam air seal is not part of the duct.

  • Page 46: Lamp Driver Insulation Duct Removal

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Lamp Driver Insulation Duct Removal Vari-Lite Part No: 10.9704.1857 (Lamp Driver Insulation Duct) Note: There are two versions of the duct. Original version mounts with 3 screws. Current version will mount with only 2. Note: The top foam air seal is not part of the duct.

  • Page 47: Lamp Driver Insulation Duct Air Seal Replacement

    ERVICE ROCEDURES RIVER NSULATION EPLACEMENT Lamp Driver Insulation Duct Air Seal Replacement Vari-Lite Part No: 10.9704.1835 (Air Seal) To replace lamp driver insulation duct air seal: Step 1. Remove required upper enclosure cover following the procedure described in “Upper Enclosure Covers Removal” on page Step 2.

  • Page 48: Main Control Board (Mcb)

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Main Control Board (MCB) Vari-Lite Part No: 21.9704.0880 To remove MCB: Step 1. Remove display side upper enclosure cover following the procedure described in “Upper Enclosure Covers Removal” on page Step 2. Remove Lamp Driver Insulation Duct following the procedure described in “Lamp Driver Insulation Duct Removal”...
  • Page 49 (MCB) ERVICE ROCEDURES ONTROL OARD Step 5. Using ¼" wrench, remove 2 x 6-32 x 13/16" Standoffs at MCB. Standoffs Mounting Bracket Note: Drawing exploded and some components removed for clarity. Step 6. Carefully tilt MCB in towards the lamp driver. Step 7.

  • Page 50: Lamp Driver

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Lamp Driver Vari-Lite Part No: 69.9704.1400 Note: There are two different versions of hardware mounting these Lamp Drivers. They QTY in () is for the older spot versions. To replace the lamp driver: Step 1.

  • Page 51: Pan Encoder Pcb

    ERVICE ROCEDURES NCODER Pan Encoder PCB Vari-Lite Part No: 17.9704.0910 To replace pan encoder PCB: Step 1. Remove both enclosure covers following the procedure described in “Upper Enclosure Covers Removal” on page Step 2. At pan encoder, disconnect wiring harness. Note: Drawing exploded and some Pan Bearing /...

  • Page 52: Pan Motor Assembly

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Pan Motor Assembly Vari-Lite Part No: 22.9704.3820 Note: There are two different mounts for pan motor assemblies. On current versions, follow steps in this section. If an older unit, that does not have a notch in motor mounting plate on lamp driver side, follow instructions to replace pan belt.
  • Page 53 ERVICE ROCEDURES OTOR SSEMBLY Step 9. Remove 2 x 8-32 x ¾" PPZ SEMS screws and remove belt tension roller bridge and rollers. Note: Drawing exploded and some components removed for clarity. Pan Motor Tension Roller Bridge Assembly Pan Belt Step 10.

  • Page 54: Pfc

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Vari-Lite Part No: 69.9704.2450 Note: There are two different versions of hardware mounting the PFC. They QTY in () is for the older spot versions. To replace PFC: Step 1. Remove connector side upper enclosure cover following the procedure described in “Upper Enclosure Covers Removal”...

  • Page 55: Pan Driver Board

    ERVICE ROCEDURES RIVER OARD Pan Driver Board Vari-Lite Part No: 24.9704.1907 To remove pan driver board: Step 1. Remove both upper enclosure covers following the procedure described in “Upper Enclosure Covers Removal” on page Step 2. At pan driver board, disconnect all wiring from board. Step 3.

  • Page 56: Low Voltage Supply (Lvs)

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Low Voltage Supply (LVS) Vari-Lite Part No: 69.9704.0300 To replace LVS: Step 1. Remove both upper enclosure covers following the procedure described in “Upper Enclosure Covers Removal” on page Step 2. Remove pan driver board following the procedure described in “Pan Driver Board”...

  • Page 57: Upper Enclosure Fan

    ERVICE ROCEDURES PPER NCLOSURE Upper Enclosure Fan Vari-Lite Part No: 22.9704.1850 Note: This part number is a service only item. It consists of all parts (fan, rubber fan mounts, and washers) needed to change one (1) fan in the upper enclosure. The upper enclosure has four (4) fans. Refer to “Side Mount Fan Assembly”...

  • Page 58: Neutrik True One Ac Input Connector

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Neutrik True One AC Input Connector Vari-Lite Part No: 25.9704.0830 To replace Neutrik True One AC input connector: Step 1. Remove connector side enclosure cover following the procedure described in “Upper Enclosure Covers Removal”...

  • Page 59: Dmx Pcb Assembly

    : DMX PCB A ERVICE ROCEDURES SSEMBLY DMX PCB Assembly Vari-Lite Part No: 24.9664.4895 To replace DMX PCB assembly: Step 1. Remove connector side enclosure cover following the procedure described in “Upper Enclosure Covers Removal” on page Step 2. Disconnect wiring from DMX PCB. Step 3.

  • Page 60: Display Overlay

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Display Overlay Vari-Lite Part No: 11.9704.0846 To replace display overlay: Step 1. Remove both enclosure covers following the procedure described in “Upper Enclosure Covers Removal” on page Step 2. Remove 8 x 6-32 x 3/8" PFSS-B screws and remove front cover. Display Note: Overlay...

  • Page 61: Usb Port

    : USB P ERVICE ROCEDURES USB Port Vari-Lite Part No: 46.9704.0853 To replace USB port: Step 1. Remove both enclosure covers following the procedure described in “Upper Enclosure Covers Removal” on page Step 2. Disconnect wiring from MCB (refer to information in “Main Control Board (MCB)”...

  • Page 62: Upper Enclosure Air Filters (To Clean Or Replace)

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Upper Enclosure Air Filters (To Clean or Replace) Vari-Lite Part No: 10.9704.1842 To remove, clean, and replace air filters: WARNING: Remove power from luminaire and allow luminaire to cool completely before performing this procedure.

  • Page 63: Pan Belt

    ERVICE ROCEDURES Pan Belt Note: This procedure is also for old-style pan motor assemblies (with no notch) as described in “Pan Motor Assembly” on page Vari-Lite Part No: 54.9698.0224 To remove pan belt or old-style pan motor assemblies (with no notch): Step 1.
  • Page 64 ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Step 5. Rotate enclosure to access 1 of the 4 ¼-20 x 2" SOC screws. ¼-20 x 2" SOC Screw (x4) Note: Spacer (x4) Drawing exploded and some components removed for clarity. Step 6.

  • Page 65: Yoke Arm Covers Removal

    ERVICE ROCEDURES OVERS EMOVAL Yoke Arm Covers Removal Vari-Lite Part No: 22.9704.6732 To remove yoke arm covers: WARNING: Remove power from luminaire and allow luminaire to cool completely before performing this procedure. Failure to remove power from luminaire can result in serious injury or death! Step 1.

  • Page 66: Yoke Base Cover

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Yoke Base Cover Vari-Lite Part No: 10.9704.1733 To remove yoke base cover: Step 1. Remove both yoke arm covers following the procedure described in “Yoke Arm Covers Removal” on page Step 2. At each yoke side, remove 2 per side 8-32 x 5/16" PPZ screws and remove yoke base cover. Screws (both sides) Note: Drawing exploded and some...

  • Page 67: Igniter Assembly

    ERVICE ROCEDURES GNITER SSEMBLY Igniter Assembly Vari-Lite Part No: 24.9704.1126 To replace igniter assembly: Step 1. Remove tilt lock side yoke arm cover following the procedure described in “Yoke Arm Covers Removal” on page Step 2. At igniter, remove 4 x 6-32 terminal screws and remove input and output wiring. Note these screws MUST be used to attach wiring.

  • Page 68: Tilt Lock Arm Assembly

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Tilt Lock Arm Assembly Vari-Lite Part No: 10.9704.1751 (Rod) Vari-Lite Part No: 10.9704.0753 (Lever, x2) Vari-Lite Part No: 10.9704.1752 (Locking Pin) To replace tilt lock assembly or its parts: Step 1. Remove tilt lock side yoke arm cover following the procedure described in “Yoke Arm Covers Removal”...

  • Page 69: Tilt Driver

    ERVICE ROCEDURES RIVER Tilt Driver Vari-Lite Part No: 24.9704.1908 To replace the tilt driver: Step 1. Remove yoke arm cover opposite tilt lock following the procedure described in “Yoke Arm Covers Removal” on page Step 2. Disconnect wiring from tilt driver. Step 3.

  • Page 70: Tilt Encoder

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Tilt Encoder Vari-Lite Part No: 17.9704.1911 Note: After performing this procedure, the tilt center position will need to be reset via the luminaire’s menu system. Refer to the luminaire’s user’s manual for procedure. To replace the tilt encoder: Step 1.

  • Page 71: Tilt Motor Assembly

    ERVICE ROCEDURES OTOR SSEMBLY Tilt Motor Assembly Vari-Lite Part No: 21.9704.0764 To remove tilt motor assembly: Step 1. Remove yoke arm cover opposite tilt lock following the procedure described in “Yoke Arm Covers Removal” on page Step 2. Disconnect wiring harness from tilt motor assembly. Note: Drawing exploded an components remove...
  • Page 72 ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL 3) Tighten screw to hold roller with loose tension. Tilt Motor Assembly Tension Roller Tension Spring Note: Drawing exploded and some components removed for clarity. b. Type 2 1) To loose belt tension, loosen 3 x #8 KEPS nuts and slide tensioner toward motor Step 4.

  • Page 73: Tilt Belt

    ERVICE ROCEDURES Tilt Belt Vari-Lite Part No: 54.9698.0224 To remove and replace tilt belt: Step 1. Remove yoke arm cover opposite tilt lock following the procedure described in “Yoke Arm Covers Removal” on page Step 2. Disconnect wiring from tilt driver board, tilt motor, and tilt encoder. Step 3.
  • Page 74 ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL b. Type 2 1) To loose belt tension, loosen 3 x #8 KEPS nuts and slide tensioner toward motor. 2) Remove 4 x 6-32 x 3/8" PPZ SEMS screws and remove motor assembly Step 6.

  • Page 75: Yoke Assembly

    ERVICE ROCEDURES SSEMBLY Yoke Assembly Vari-Lite Part No: 22.9704.6705 Note: This procedure is for replacing the yoke assembly only. You will transfer several parts to the replacement yoke assembly. To replace the yoke assembly: Step 1. Remove both yoke arm covers following the procedure described in “Yoke Arm Covers Removal”...
  • Page 76 ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Step 9. At each side, remove 2 (4 total) 8-32 KEPS nut and remove tilt bearing clamp plate. Tilt Bearing Clamp Plate Tilt Bearing Clamp Plate 8-32 KEPS Nuts 8-32 KEPS Nuts Yoke Assembly Head...
  • Page 77 ERVICE ROCEDURES SSEMBLY Step 11. On inside of yoke at tilt motor side, remove 1 8-32 x 5/16" PPZ screw (nearest outside of yoke) and loosen 1 8-32 x 5/16" PPZ screw nearest pan tube and slide pan safety plate away from pan tube.

  • Page 78: Luminaire Head Covers Removal

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Luminaire Head Covers Removal Vari-Lite Part No: 22.9704.6670 WARNING: Remove power from luminaire and allow luminaire to cool completely before performing this procedure. Failure to remove power from luminaire can result in serious injury or death! Note: Top head cover is side with serial number on yoke.

  • Page 79: Front Side Rail Covers

    ERVICE ROCEDURES RONT OVERS Front Side Rail Covers Vari-Lite Part No: 10.9704.6672 Input Air Filter Vari-Lite Part No: 10.9704.6641 To remove front side rail covers and input air filters: Step 1. Remove both luminaire head covers following the procedure described in “Luminaire Head Covers Removal”...

  • Page 80: Rear Side Rail Cover Removal

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Rear Side Rail Cover Removal Vari-Lite Part No: 10.9704.6673 To remove side rail covers: Step 1. Remove both head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. Remove 4 x 6-32 x 3/8" PPB screws and remove cover. Note: Drawing exploded and some components removed for clarity.

  • Page 81: Rear Cover Removal

    ERVICE ROCEDURES OVER EMOVAL Rear Cover Removal Vari-Lite Part No: 21.9704.6671 BeamWash To remove rear cover: Step 1. Remove 2 x 6-32 x 5/8" PPB screws at outside. Note: Drawing exploded and some components removed for clarity. Rear Cover Rear Cover Screw (x2) Step 2.

  • Page 82: Gobo / Animation Assembly

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Gobo / Animation Assembly Vari-Lite Part No: 21.9704.6200 To remove gobo / animation assembly: Step 1. Remove head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. At driver board C, disconnect DC power in and 2 x inline COM connectors. Remove wires from Kurly Loc.

  • Page 83: Color Assembly

    ERVICE ROCEDURES OLOR SSEMBLY Color Assembly Vari-Lite Part No: 21.9704.7400 To remove color assembly: Step 1. Remove head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. Either remove gobo assembly following procedure in “Gobo / Animation Assembly” on page 62 or perform following: a.

  • Page 84: Nose Cover

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Nose Cover Vari-Lite Part No: 10.9704.6674 To remove nose cover: Step 1. Remove head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. Remove 8 x 6-32 x 3/8" PPB screws and remove cover. Nose Cover Nose Cover Screw (x8)

  • Page 85: Optics Assembly

    ERVICE ROCEDURES PTICS SSEMBLY Optics Assembly Vari-Lite Part No: 21.9704.6150 To remove optics assembly: Step 1. Remove nose cover following procedure in “Nose Cover” on page Step 2. At driver board G, disconnect DC power in and COM inline connector. Note placement of and cut any cable ties connecting dc power cable to fixture.

  • Page 86: Inlet Fan

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Inlet Fan Vari-Lite Part No: 23.9704.0003 To replace inlet fan: Step 1. Remove tilt lock side front side rail cover following procedure in “Front Side Rail Covers” on page Step 2. Disconnect fan wiring from driver board. Note placement of and cut any cable ties as required.

  • Page 87: Power Distribution Board

    ERVICE ROCEDURES OWER ISTRIBUTION OARD Power Distribution Board Vari-Lite Part No: 24.9704.2909 To replace power distribution board: Step 1. Remove tilt lock side rear side rail cover following procedure in “Rear Side Rail Cover Removal” on page Step 2. At power distribution board, disconnect all wiring. Step 3.

  • Page 88: Base Lamp Fan

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Base Lamp Fan Vari-Lite Part No: 23.9704.0003 To replace base lamp fan: Step 1. Remove power distribution board following procedure in “Power Distribution Board” on page Step 2. At fan, disconnect wiring harness. Step 3.

  • Page 89: Tip Lamp Fan

    ERVICE ROCEDURES Tip Lamp Fan Vari-Lite Part No: 23.9704.0003 To replace tip lamp fan: Step 1. Remove non tilt lock side rear side rail cover following procedure in “Rear Side Rail Cover Removal” on page Step 2. At fan, disconnect wiring harness. Step 3.

  • Page 90: Uv Glass Assembly

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL UV Glass Assembly Vari-Lite Part No: 22.9704.0630 To replace UV glass assembly: Step 1. Remove color assembly following procedure in “Rear Side Rail Cover Removal” on page 60“Color Assembly” on page Step 2.

  • Page 91: Bottom Exhaust Fin Assembly

    ERVICE ROCEDURES OTTOM XHAUST SSEMBLY Bottom Exhaust Fin Assembly Vari-Lite Part No: 22.9704.1620 To remove bottom exhaust fin assembly: Step 1. Remove bottom head cover following procedure in “Luminaire Head Covers Removal” on page Step 2. Remove 4 x 6-32 x 3/8" PPZ SEMS screws. Top Exhaust Fin Assembly Note: Drawing exploded and some...

  • Page 92: Top Exhaust Fin Assembly

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Top Exhaust Fin Assembly Vari-Lite Part No: 22.9704.1620 To remove top exhaust fin assembly: Step 1. Remove top head cover following procedure in “Luminaire Head Covers Removal” on page Step 2. At tip fan duct, remove 1 x 6-32 x 3/8" PPZ plastic thread cutting screw and 1 6-32 x 3/8" PPZ SEMS screw.

  • Page 93: Reflector Assembly

    ERVICE ROCEDURES EFLECTOR SSEMBLY Reflector Assembly Vari-Lite Part No: 21.9704.6619 To replace reflector assembly: Step 1. Remove lamp following procedure in “Lamp Removal and Installation” on page Step 2. Remove rear cover following the procedure described in “Rear Cover Removal” on page Step 3.

  • Page 94: Retro Reflector

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Retro Reflector Vari-Lite Part No: 42.9704.0151 To replace retro reflector: Step 1. Remove reflector assembly following procedure in “Reflector Assembly” on page Step 2. Loosen 4 x 6-32 x 3/16" PPZ screws, pivot retainer clips and remove retro reflector. Note: Drawing exploded and some components removed for clarity.

  • Page 95: Ellipsoidal Reflector

    ERVICE ROCEDURES LLIPSOIDAL EFLECTOR Ellipsoidal Reflector Vari-Lite Part No: 42.9704.6150 To replace ellipsoidal reflector: Step 1. Remove reflector assembly following procedure in “Reflector Assembly” on page Step 2. Loosen 4 x 6-32 x 3/16" PPZ screws, pivot retainer clips and remove ellipsoidal reflector. Retro Reflector Retainer Clip (x4) Retainer Clip Screw (x4)

  • Page 96: Lamp Socket

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Lamp Socket Vari-Lite Part No: 71.8101.0050 To replace lamp socket assembly: Step 1. Remove lamp following procedure in “Lamp Removal and Installation” on page Step 2. Remove rear cover following procedure in “Rear Cover Removal”...

  • Page 97: Optics Components

    ERVICE ROCEDURES PTICS OMPONENTS Optics Components Driver Board G (7 Way Board) Vari-Lite Part No: 24.9704.1913 To replace driver board G: Step 1. Remove top side head cover following procedure in “Luminaire Head Covers Removal” on page Step 2. Disconnect wiring a.
  • Page 98 ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Step 3. Remove 4 x 4-40 x ¼" PPZ SEMS screws and remove board. Note the two screws have cable saddles. 4-40 x 1/4" PPZ SEMS Screw (x4) Driver Board G Note: Drawing exploded and some components removed for clarity.

  • Page 99: Edge & Zoom Sensor

    ERVICE ROCEDURES PTICS OMPONENTS Edge & Zoom Sensor Vari-Lite Part No: 25.9687.0020 To replace edge and zoom sensor: Step 1. Remove both head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. At sensor to be replaced, disconnect inline wiring connector. Step 3.

  • Page 100: Lenticular Lens Assembly

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Lenticular Lens Assembly Vari-Lite Part No: 21.9704.6310 To replace lenticular lens assembly: Step 1. Remove both head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. Remove driver board G following procedure in “Driver Board G (7 Way Board)”...

  • Page 101: Lenticular Lens Sensor

    ERVICE ROCEDURES PTICS OMPONENTS Lenticular Lens Sensor Vari-Lite Part No: 25.9687.0020 To replace lenticular lens sensor: Step 1. Remove both head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. Disconnect inline wiring connector. Step 3. Remove 2 x 4-40 x ¼" PPZ SEMS screws and remove sensor. Note: Drawing exploded and some components removed for clarity.

  • Page 102: Lenticular Rotate Sensor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Lenticular Rotate Sensor Vari-Lite Part No: 24.9704.6314 To replace lenticular rotate sensor: Step 1. Remove lenticular lens assembly following procedure in “Lenticular Lens Assembly” on page Step 2. At sensor, remove 2 x 3/16" HEX standoffs*. There are spacers underneath and this will loosen belt tension.

  • Page 103: Lenticular Lens Belt

    ERVICE ROCEDURES PTICS OMPONENTS Lenticular Lens Belt Vari-Lite Part No: 54.9704.5317 To replace lenticular lens belt: Step 1. Remove lenticular lens assembly following procedure in “Lenticular Lens Assembly” on page Step 2. At sensor, loosen 2 x 3/16" HEX standoffs*. Note: *On some fixtures these standoffs are ¼"...

  • Page 104: Lenticular Arm Motor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Lenticular Arm Motor Vari-Lite Part No: 44.9687.1209 To replace lenticular arm motor: Step 1. Remove lenticular lens assembly following procedure in “Lenticular Lens Assembly” on page Step 2. Remove 3 x 4-40 x 5/16" PPZ SEMS screws. 4-40 x 5/16"...

  • Page 105: Lenticular Arm Belt

    ERVICE ROCEDURES PTICS OMPONENTS Lenticular Arm Belt Vari-Lite Part No: 54.9704.6316 To replace lenticular arm belt: Step 1. Remove lenticular lens belt following procedure in “Lenticular Lens Belt” on page Step 2. Loosen 2 x 6-32 x 3/16" cone set screw and remove rotate pulley and spacer from shaft. Step 3.

  • Page 106: Lenticular Rotate Motor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Lenticular Rotate Motor Vari-Lite Part No: 44.9704.0217 To replace lenticular rotate motor: Step 1. Remove lenticular arm belt following procedure in “Lenticular Arm Belt” on page Step 2. Remove spacer between arm and motor. Step 3.

  • Page 107: Prism Assembly

    ERVICE ROCEDURES PTICS OMPONENTS Prism Assembly Vari-Lite Part No: 21.9704.6330 To replace prism assembly: Step 1. Remove both head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. At light shield, remove 4 x 6-32 x 3/8" PPZ SEMS screws and remove. Note: Drawing exploded and some components removed for clarity.

  • Page 108: Prism Arm Sensor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Prism Arm Sensor Vari-Lite Part No: 25.9687.0020 To replace prism arm sensor: Step 1. Remove both head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. Disconnect inline wiring connector. Step 3.

  • Page 109: Prism Rotate Sensor

    ERVICE ROCEDURES PTICS OMPONENTS Prism Rotate Sensor Vari-Lite Part No: 24.9704.6314 To replace prism rotate sensor: Step 1. Remove prism assembly following procedure in “Prism Assembly” on page Step 2. At sensor, remove 2 x 3/16" HEX standoffs*. There are spacers underneath and this will loosen belt tension.

  • Page 110: Prism Arm Motor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Prism Arm Motor Vari-Lite Part No: 44.9687.1209 To replace prism motor: Step 1. Remove prism assembly following procedure in “Prism Assembly” on page 87.. Step 2. Remove 3 x 4-40 x 5/16" PPZ SEMS screws and remove motor. (Note connector orientation.

  • Page 111: Prism Arm Belt

    ERVICE ROCEDURES PTICS OMPONENTS Prism Arm Belt Vari-Lite Part No: 54.9704.1390 To replace prism arm belt: Step 1. Remove prism assembly following procedure in “Prism Assembly” on page Step 2. Remove prism arm sensor following procedure in “Prism Arm Sensor” on page Step 3.

  • Page 112: Prism Rotate Belt

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Prism Rotate Belt Vari-Lite Part No: 54.9704.5333 To replace prism rotate belt: Step 1. Remove prism arm belt following procedure in “Prism Arm Belt” on page Step 2. At sensor, loosen 2 x 3/16" HEX standoffs*. Slide tension roller away from belt and remove belt.

  • Page 113: Prism Rotate Motor

    ERVICE ROCEDURES PTICS OMPONENTS Prism Rotate Motor Vari-Lite Part No: 44.9704.1213 To replace prism rotate motor: Step 1. Remove prism rotate belt following procedure in “Prism Arm Belt” on page Step 2. Loosen 1 x 6-32 x 3/16" cone set screw and remove collet and spacer from shaft. Step 3.

  • Page 114: Prism Glass Change

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Prism Glass Change Vari-Lite Part No: 21.9704.6395 (5 facet step - ships with product) Vari-Lite Part No: 21.9704.6397 (7 facet) Vari-Lite Part No: 21.9704.6393 (3 facet) To change prism glass: Step 1. Remove both head covers following procedure in “Luminaire Head Covers Removal”...

  • Page 115: Wash Lens Sensor

    ERVICE ROCEDURES PTICS OMPONENTS Wash Lens Sensor Vari-Lite Part No: 25.9687.0020 To replace wash lens sensor: Step 1. Remove both head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. At sensor, disconnect inline connector in wiring. Step 3.

  • Page 116: Wash Lens Motor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Wash Lens Motor Vari-Lite Part No: 44.9704.0418 To replace wash lens motor: Step 1. Remove both head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. At motor, disconnect wiring harness. Step 3.

  • Page 117: Wash Lens Belt Or Wash Lens

    ERVICE ROCEDURES PTICS OMPONENTS Wash Lens Belt or Wash Lens Vari-Lite Part No: 54.9704.1390 (Wash Lens Belt) Vari-Lite Part No: 21.9704.6355 (Wash Lens) To replace wash lens belt or wash lens: Step 1. Remove both head covers following procedure in “Luminaire Head Covers Removal”...

  • Page 118: Zoom Belt

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Zoom Belt Vari-Lite Part No: 54.9704.6172 To replace zoom belt: Step 1. Remove both head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. Remove 1 x 8-32 x 3/8" PPZ SEMS screw and belt drive clamp. Step 3.

  • Page 119: Zoom Stabilizer

    ERVICE ROCEDURES PTICS OMPONENTS Zoom Stabilizer Vari-Lite Part No: 21.9704.0330 To replace zoom stabilizer: Step 1. Remove both head covers following procedure in “Luminaire Head Covers Removal” on page Step 2. At zoom motor, loosen 2 x 4-40 x 5/16" PPZ SEMS screws and remove 1 x 4-40 x 3/8" PFZ screw.

  • Page 120: Zoom Motor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Zoom Motor Vari-Lite Part No: 44.9704.1216 To replace zoom motor: Step 1. Remove zoom stabilizer following procedure in “Zoom Stabilizer” on page Step 2. Remove 2 x 4-40 x 5/16" PPZ SEMS screws and remove motor. Zoom Motor Assembly Motor Mount Screws Motor...

  • Page 121: Edge Belt

    ERVICE ROCEDURES PTICS OMPONENTS Edge Belt Vari-Lite Part No: 54.9704.6165 To replace edge belt: Step 1. Remove prism assembly following procedure in “Prism Assembly” on page Step 2. Remove 1 x 8-32 x 3/8" PPZ SEMS screw and belt drive clamp. Step 3.

  • Page 122: Edge Stabilizer

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Edge Stabilizer Vari-Lite Part No: 21.9704.0330 To replace edge stabilizer: Step 1. Remove prism assembly following procedure in “Prism Assembly” on page Step 2. At edge motor, loosen 2 x 4-40 x 5/16" PPZ SEMS screws and remove 1 x 4-40 x 3/8" PFZ screw.

  • Page 123: Edge Motor

    ERVICE ROCEDURES PTICS OMPONENTS Edge Motor Vari-Lite Part No: 44.9704.1216 To replace edge motor: Step 1. Remove edge stabilizer following procedure in “Edge Stabilizer” on page 102. Step 2. Remove 2 x 4-40 x 5/16" PPZ SEMS screws and remove motor. Edge Motor Assembly Motor Mount Screws (remove) Motor...

  • Page 124: Gobo Assembly

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Gobo Assembly Driver Board C Vari-Lite Part No: 24.9704.2901 To replace driver board C: Step 1. Remove gobo assembly following procedure in “Gobo / Animation Assembly” on page Step 2. Remove 3 x 4-40 x 3/8" PPZ SEMS screws that mount driver board clamp and remove clamp.
  • Page 125 ERVICE ROCEDURES SSEMBLY 4) 4 - CS4 G INDEX 1 - Gobo Wheel 1 Index Sensor c. Motor 1 - 4 1) 1 - CM1 G INDEX 2 - Gobo Wheel 2 Index Motor 2) 2 - CM2 G ROT 2 - Gobo Wheel 2 Wheel Motor 3) 3 - CM3 G ROT 1 - Gobo Wheel 1 Wheel Motor 4) 4 - CM4 G INDEX 1 - Gobo Wheel 2 Index Motor Step 4.

  • Page 126: Driver Board D

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Driver Board D Vari-Lite Part No: 24.9704.2901 To replace driver board D: Step 1. Remove gobo assembly following procedure in “Gobo / Animation Assembly” on page Step 2. Remove 3 x 4-40 x 3/8" PPZ SEMS screws that mount driver board clamp and remove clamp.
  • Page 127 ERVICE ROCEDURES SSEMBLY 3) 5 - DM5 IRIS - Iris Motor Step 4. Remove 1 x 4-40 x ¼" PPZ SEMS screw and remove board. Step 5. On replacement board, set dip switches as follows: a. DIP SW 1 ON b.

  • Page 128: Iris Assembly

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Iris Assembly Vari-Lite Part No: 21.9704.6272 To replace iris assembly: Step 1. Remove gobo assembly following procedure in “Gobo / Animation Assembly” on page Step 2. Disconnect wiring from motor. Step 3. Remove 4 x 6-32 x 3/8" PPZ SEMS screws and remove assembly. Screw (x4) Iris Assembly Note:...

  • Page 129: Iris Motor

    ERVICE ROCEDURES SSEMBLY Iris Motor Vari-Lite Part No: 44.9704.0208 To replace iris motor: Step 1. Remove iris assembly following procedure in “Iris Assembly” on page 108. Step 2. Loosen 2 x 6-32 x 3/16" cone set screw from pulley. Step 3. Remove 3 x 4-40 x ¼" PPZ SEMS screw and remove motor and mount from pulley. Step 4.

  • Page 130: Iris Cable

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Iris Cable Vari-Lite Part No: 14 inches of 54.9704.6293 (14-Inches) Vari-Lite Part No: 52.8298.2216 (Ferrule, x2) How to replace iris cable: Step 1. Remove iris assembly following procedure in “Iris Assembly” on page 108.
  • Page 131 ERVICE ROCEDURES SSEMBLY b. Feed cable through slots in pulley so that center mark lines up with shaft when slot is facing iris. c. Wrap into grooves of pulley. Step 6. Hold wire down with cable clamps and tighten 4 x 0-80 x 7/32" PFSS screws. Step 7.

  • Page 132: Iris Assembly

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Iris Assembly Vari-Lite Part No: 22.9704.0275 To replace iris assembly: Step 1. Remove iris cable following procedure in “Iris Cable” on page 110 up through Step 3 of the procedure. Do not cut iris cable! It will be reinstalled. Step 2.

  • Page 133: Animation Assembly

    ERVICE ROCEDURES SSEMBLY Animation Assembly Vari-Lite Part No: 21.9704.6353 To replace animation assembly: Step 1. Remove gobo assembly following procedure in “Gobo / Animation Assembly” on page Step 2. Disconnect wiring from index motor and sensor. Step 3. Remove 3 x 6-32 x 3/8" PPZ SEMS screws. Animation Assembly 6-32 x 3/8"...

  • Page 134: Animation Wheel Arm Sensor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Animation Wheel Arm Sensor Vari-Lite Part No: 21.9687.2500 To replace animation wheel arm sensor: Step 1. Disconnect wiring harness from sensor. Step 2. Remove 2 x 4-40 x ¼" PPZ SEMS screws and remove sensor. Animation Wheel Arm Sensor Animation Assembly...

  • Page 135: Animation Index Belt & Animation Wheel Removal

    ERVICE ROCEDURES SSEMBLY Animation Index Belt & Animation Wheel Removal Vari-Lite Part No: 54.9704.0392 (Belt) Vari-Lite Part No: 22.9704.6343 (Animation Wheel - Concurrent) To replace animation index belt or remove animation wheel: Step 1. Remove animation assembly following procedure in “Animation Assembly”...

  • Page 136: Animation Index Motor & Arm Belt

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Animation Index Motor & Arm Belt Vari-Lite Part No: 44.9704.1213 (Motor) Vari-Lite Part No: 54.9704.1390 (Belt) To replace animation index motor or arm belt: Step 1. Remove animation wheel index belt following procedure in “Animation Index Belt &...
  • Page 137 ERVICE ROCEDURES SSEMBLY Step 4. Remove 4 x M3 x 5mm PFZ screws and remove motor. Index Motor Note: M3 x 5mm Drawing exploded and some PFZ Screw (x4) components removed for clarity. Step 5. Replace in reverse. 02.97 04.601 0 A Note: All procedures are done with the power completely removed.

  • Page 138: Animation Index Sensor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Animation Index Sensor Vari-Lite Part No: 17.9704.0906 To replace animation index sensor: Step 1. Remove 2 x 2-56 x 3/8" PPZ screws that mount sensor board and connector clamp. Note: Drawing exploded and some components removed for clarity.

  • Page 139: Gobo Wheel 1 Rotate Belt

    ERVICE ROCEDURES SSEMBLY Gobo Wheel 1 Rotate Belt Vari-Lite Part No: 54.9704.0290 To replace gobo wheel 1 rotate belt: Step 1. Remove gobo assembly following procedure in “Gobo / Animation Assembly” on page Step 2. Remove 4 x 4-40 x ¼" PFZ screws from gobo 1 shaft assembly. Step 3.

  • Page 140: Gobo Wheel 1 Index Belt

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Gobo Wheel 1 Index Belt Vari-Lite Part No: 54.9698.0002 To replace gobo wheel 1 index belt: Step 1. Remove gobo assembly following procedure in “Gobo / Animation Assembly” on page Step 2. Loosen 2 x M3 x .5 x 5mm PPB screws at index motor, remove belt from drive pulley. Step 3.

  • Page 141: Gobo Wheel 2 Index Belt & Rotate Belt

    ERVICE ROCEDURES SSEMBLY Gobo Wheel 2 Index Belt & Rotate Belt Vari-Lite Part No: 54.9704.0290 (Index Belt) Vari-Lite Part No: 54.9698.0002 (Rotate Belt) To replace gobo wheel 2 index belt or rotate belt: Step 1. Remove animation wheel assembly following procedure in “Animation Assembly”...
  • Page 142 ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Step 4. At index sensor, remove 2 x 4-40 x ¼" PFZ screws and remove index sensor bracket. Rotate Note: Gobo Wheel 2 Belt Drawing exploded and some components removed for clarity. Gobo 2 Shaft Assembly Index Belt...

  • Page 143: Gobo Wheel 2 Index Sensor

    ERVICE ROCEDURES SSEMBLY Gobo Wheel 2 Index Sensor Vari-Lite Part No: 17.9704.0904 To replace gobo wheel 2 index sensor: Step 1. Remove gobo assembly following procedure in “Gobo / Animation Assembly” on page Step 2. At index sensor, remove 2 x 4-40 x ¼" PFZ screws and remove index sensor bracket. Note: Drawing exploded and some components removed for clarity.

  • Page 144: Gobo Wheel 1 Index Motor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Gobo Wheel 1 Index Motor Vari-Lite Part No: 44.9704.0217 To replace gobo wheel 1 index motor: Step 1. Remove driver board C following procedure in “Driver Board C” on page 104. Step 2.

  • Page 145: Gobo Wheel 1 Rotate Motor

    ERVICE ROCEDURES SSEMBLY Gobo Wheel 1 Rotate Motor Vari-Lite Part No: 44.9704.0217 To replace gobo wheel 1 rotate motor: Step 1. Remove gobo assembly following procedure in “Gobo / Animation Assembly” on page Step 2. Disconnect wiring from motor. Step 3. Remove 2 x M3 x .5 x 8mm PPZ screws and 1 x m3 x .5 x 8mm PFZ screw and remove motor and spacer.

  • Page 146: Gobo Wheel 2 Rotate Motor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Gobo Wheel 2 Rotate Motor Vari-Lite Part No: 44.9704.0217 To replace gobo wheel 2 rotate motor: Step 1. Remove gobo assembly following procedure in “Gobo / Animation Assembly” on page Step 2. Disconnect wiring form motor. Step 3.

  • Page 147: Gobo Wheel 2 Index Motor

    ERVICE ROCEDURES SSEMBLY Gobo Wheel 2 Index Motor Vari-Lite Part No: 44.9704.0217 To replace gobo wheel 2 index motor: Step 1. Remove gobo assembly following procedure in “Gobo / Animation Assembly” on page Step 2. Disconnect wiring. Step 3. Remove 2 x M3 x .5 x 5mm PPB screws and 1 x M3 x .5 x 5mm PFB screw and remove motor.

  • Page 148: Gobo Wheel 1 Index Sensor & Wheel 1 Rotate Sensor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Gobo Wheel 1 Index Sensor & Wheel 1 Rotate Sensor Vari-Lite Part No: 17.9704.0905 (Index Sensor) Vari-Lite Part No: 24.9678.3240 (Rotate Sensor) To replace gobo wheel 1 index sensor or rotate sensor: Step 1.

  • Page 149: Gobo Wheel 2 Rotate Sensor

    ERVICE ROCEDURES SSEMBLY Gobo Wheel 2 Rotate Sensor Vari-Lite Part No: 24.9678.3240 To replace gobo wheel 2 rotate sensor: Step 1. Remove gobo assembly following procedure in “Gobo / Animation Assembly” on page Step 2. Disconnect wiring from sensor. Step 3. Remove 1 x 4-40 x 1/8" PFZ and 1 x 4-40 x ¼" PPZ screws from bracket. Rotate Sensor 4-40 x 1/4"...

  • Page 150: Animation Arm Motor & Motor Stabilizer

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Animation Arm Motor & Motor Stabilizer Vari-Lite Part No: 44.9704.0209 (Motor) Vari-Lite Part No: 21.9698.0330 (Motor Stabilizer) To replace animation arm motor or motor stabilizer: Step 1. Remove animation wheel assembly following procedure in “Animation Assembly”...

  • Page 151: Color Assembly Components

    ERVICE ROCEDURES OLOR SSEMBLY OMPONENTS Color Assembly Components Vari-Lite Part No: 21.9704.7400 Driver Board B Vari-Lite Part No: 24.9704.2901 To replace driver board B: Step 1. Remove color assembly following procedure in “Color Assembly” on page Step 2. Remove 3 x 4-40 x 3/8" PPZ SEMS screws that mount driver board clamp and remove clamp.
  • Page 152 ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL 4) 4 - BS4 YEL - Yellow Sensor e. Motor 1 - 4 1) 1 - BM1 MAG - Magenta Motor 2) 2 - BM2 FIX 2 - Fixed Color Wheel 2 Motor 3) 3 - BM3 FIX 1 - Fixed Color Wheel 1 Motor 4) 4 - BM4 YEL - Yellow Motor Step 4.

  • Page 153: Driver Board A

    ERVICE ROCEDURES OLOR SSEMBLY OMPONENTS Driver Board A Vari-Lite Part No: 24.9704.2901 To replace driver board A: Step 1. Remove color assembly following procedure in “Color Assembly” on page Step 2. Remove 3 x ¼"HEX standoffs that mount driver board clamp and remove clamp. Note: Drawing exploded and some components removed for clarity.
  • Page 154 ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL 5) 5 - AM5 STRB 1 - Strobe 1 Motor Step 4. Remove remaining ¼" HEX standoff and remove board. Step 5. On replacement board, set dip switches as follows: a. DIP SW 1 OFF b.

  • Page 155: Color Wheel 2 Sensor

    ERVICE ROCEDURES OLOR SSEMBLY OMPONENTS Color Wheel 2 Sensor Vari-Lite Part No: 17.9704.0904 To replace color wheel 2 sensor: Step 1. Remove color assembly following procedure in “Color Assembly” on page Step 2. Remove 2 x 2-56 x 3/8' PFZ screws and remove connector clamp. Color Wheel 1 Color Wheel 2 Sensor Note:...

  • Page 156: Fixed Color Wheel 1 Assembly & Color Wheel 1 Sensor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Fixed Color Wheel 1 Assembly & Color Wheel 1 Sensor Vari-Lite Part No: 21.9704.0415 (Fixed Color Wheel 1) Vari-Lite Part No: 17.9704.0904 (Color Wheel 1 Sensor) To replace fixed color wheel 1 or color wheel 1 sensor: Step 1.

  • Page 157: Fixed Color Wheel 1 & 2 Motor

    ERVICE ROCEDURES OLOR SSEMBLY OMPONENTS Fixed Color Wheel 1 & 2 Motor Vari-Lite Part No: 44.9704.0418 To replace fixed color wheel 1 & 2 motor: Step 1. Remove fixed color wheel assembly following procedure in “Fixed Color Wheel 1 Assembly & Color Wheel 1 Sensor” on page 136.

  • Page 158: Fixed Color Wheel 2 & Belt

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Fixed Color Wheel 2 & Belt Vari-Lite Part No: 21.9704.0435 (Fixed Color Wheel 2) Vari-Lite Part No: 54.9704.0390 (Belt) To replace fixed color wheel 2 and belt: Step 1. Remove fixed color wheel assembly following procedure in “Fixed Color Wheel 1 Assembly &...

  • Page 159: Fixed Color Wheel 1 & Belt

    ERVICE ROCEDURES OLOR SSEMBLY OMPONENTS Fixed Color Wheel 1 & Belt Vari-Lite Part No: 21.9704.0430 (Fixed Color Wheel 1) Vari-Lite Part No: 54.9698.0002 (Belt) To replace fixed color wheel 1 and belt: Step 1. Remove fixed color wheel assembly following procedure in “Fixed Color Wheel 1 Assembly &...

  • Page 160: Cto Filters

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL CTO Filters Vari-Lite Part No: 22.9704.6478 (x2) To replace CTO filters: Step 1. Remove fixed color wheel assembly following procedure in “Fixed Color Wheel 1 Assembly & Color Wheel 1 Sensor” on page 136.

  • Page 161: Yellow Filters

    ERVICE ROCEDURES OLOR SSEMBLY OMPONENTS Yellow Filters Vari-Lite Part No: 22.9704.6476 (x2) To replace yellow filters: Step 1. Remove CTO filters following procedure in “CTO Filters” on page 140. Step 2. At top filter, remove 2 x 2-56 x 3/16" PPZ screws and lift filter from slide. Step 3.

  • Page 162: Cyan Filters

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Cyan Filters Vari-Lite Part No: 22.9704.6474 (x2) To replace cyan filters: Step 1. Remove yellow filters following procedure in “CTO Filters” on page 140. Step 2. At top filter, remove 2 x 2-56 x 3/16" PPZ screws and lift filter from slide. Step 3.

  • Page 163: Magenta Filters

    ERVICE ROCEDURES OLOR SSEMBLY OMPONENTS Magenta Filters Vari-Lite Part No: 22.9704.6472 (x2) To replace magenta filters: Step 1. Remove cyan filters following procedure in “Cyan Filters” on page 142. Step 2. At top filter, remove 2 x 2-56 x 3/16" PPZ screws and lift filter from slide. Step 3.

  • Page 164: Cym Color Sensor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL CYM Color Sensor Vari-Lite Part No: 24.9704.0903 To replace CYM color sensor: Step 1. Remove fixed color wheel assembly following procedure in “Fixed Color Wheel 1 Assembly & Color Wheel 1 Sensor” on page 136.

  • Page 165: Color Belt Assembly

    ERVICE ROCEDURES OLOR SSEMBLY OMPONENTS Color Belt Assembly Vari-Lite Part No: 21.9704.0412 To replace color belt assembly: Step 1. Remove required color filters following procedure in “CTO Filters” on page 140 “Yellow Filters” on page 141 “Cyan Filters” on page 142 “Magenta Filters”...

  • Page 166: Color Motor Assembly

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Color Motor Assembly Vari-Lite Part No: 44.9704.1213 To replace color motor assembly: Step 1. Remove fixed color wheel assembly following procedure in “Fixed Color Wheel 1 Assembly & Color Wheel 1 Sensor” on page 136.

  • Page 167: Strobe Assembly

    ERVICE ROCEDURES OLOR SSEMBLY OMPONENTS Strobe Assembly Vari-Lite Part No: 21.9704.0431 (Left) Vari-Lite Part No: 21.9704.0432 (Right) To replace the left or right strobe assembly: Step 1. Remove color assembly following procedure in “Color Assembly” on page Step 2. Disconnect wiring from strobe motors. Step 3.

  • Page 168: Strobe Blades

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Strobe Blades Vari-Lite Part No: 22.9704.0453 (Left) Vari-Lite Part No: 22.9704.0454 (Right) To replace left or right strobe blades: Step 1. Remove strobe assembly following procedure in “Strobe Assembly” on page 147.
  • Page 169 ERVICE ROCEDURES OLOR SSEMBLY OMPONENTS Step 4. Replace by following these sub steps in order: a. Power motor. b. Place blade assembly on motor shaft. c. Align to mark on stop in closed position as described in Step 2. OR, 0.060" for right, 0.035"...

  • Page 170: Strobe Motor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Strobe Motor Vari-Lite Part No: 44.9687.1204 To replace strobe motor: Step 1. Remove strobe blade following procedure in “Strobe Blades” on page 148. Step 2. Remove 2 x 4-40 x ¼" PPZ SEMS screws and 1 x 4-40 x ¼" PFZ screw and remove motor, noting connector position in relation to bracket.

  • Page 171: Dimmer Flags

    ERVICE ROCEDURES OLOR SSEMBLY OMPONENTS Dimmer Flags Vari-Lite Part No: 22.9704.5480 (Rear) Vari-Lite Part No: 22.9704.5470 (Front) To replace dimmer flags: Step 1. Remove strobe assembly following procedure in “Strobe Assembly” on page 147. Step 2. At rear flag, remove 2 x 2-56 x 3/16" PPZ screws and lift flag from slide. Step 3.

  • Page 172: Dimmer Belt

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Dimmer Belt Vari-Lite Part No: 21.9704.0411 To replace dimmer belt: Step 1. Remove dimmer flags following procedure in “Dimmer Flags” on page 151. Step 2. Loosen belt tension by loosening 1 x 6-32 x 3/8" PPZ screws through slot and sliding roller. Step 3.

  • Page 173: Dimmer Motor

    ERVICE ROCEDURES OLOR SSEMBLY OMPONENTS Dimmer Motor Vari-Lite Part No: 44.9704.1214 To replace dimmer motor: Step 1. Remove strobe assembly following procedure in “Strobe Assembly” on page 147. Step 2. Disconnect wiring from motor. Step 3. Loosen belt tension by loosening 1 x 6-32 x 3/8" PPZ screw through slot and sliding roller. Step 4.

  • Page 174: Dimmer Sensor

    ❋ VARI LITE - VL4000 B UMINAIRES ERVICE ANUAL Dimmer Sensor Vari-Lite Part No: 24.9698.1231 To replace dimmer sensor: Step 1. Remove strobe assembly following procedure in “Strobe Assembly” on page 147. Step 2. Disconnect wiring from sensor. Step 3. Remove 2 x 4-40 x 3/16" PPZ screws and remove sensor. Note: Drawing exploded and some components removed for clarity.

  • Page 175: Chapter 3. Illustrated Parts Breakdown

    HAPTER Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL4000 BeamWash Luminaire assemblies. • Drawing Trees • Principle of Operation • Top Assembly • Head Assembly • Yoke Assembly • Enclosure Assembly • Cable Assemblies 02.97 04.601 0 A...

  • Page 176: Drawing Trees

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Drawing Trees VL4000 BeamWash Luminaire (Part 1) VL4000 BeamWash Luminaire 20.9704.0002 Rev. A Included Items Kit, VL4000 Color Module Assembly Gobo/Animation Module BeamWash 21.9704.7400 Rev. C Assembly 28.9704.0002 Rev. C 21.9704.6200 Rev. E (note, this item includes all included/ standard gobos) Continued on...

  • Page 177: Vl4000 Beamwash Luminaire (Part 2)

    : VL4000 B RAWING REES UMINAIRE VL4000 BeamWash Luminaire (Part 2) Continued from “VL4000 BeamWash Luminaire (Part 1)” on Continued on “VL4000 VL4000 BeamWash Generic BeamWash Luminaire (Part 3)” Luminaire Assembly on page 158. 21.9704.6010 Rev. C Upper Enclosure Assembly Head Frame Assembly 21.9704.0800 Rev.

  • Page 178: Vl4000 Beamwash Luminaire (Part 3)

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 BeamWash Luminaire (Part 3) Continued from “VL4000 BeamWash Luminaire (Part 2)” on VL4000 BeamWash Generic Luminaire Assembly 21.9704.6010 Rev. C VL4000 Lamp Base & Tip Fan Extension Cable Assembly 25.9704.1602 Rev. B Upper Enclosure Assembly VL4000 Color Power Distribution 21.9704.0800 Rev.

  • Page 179: Vl4000 Beamwash Luminaire (Part 4)

    : VL4000 B RAWING REES UMINAIRE VL4000 BeamWash Luminaire (Part 4) Continued from “VL4000 BeamWash Luminaire (Part 1)” on page 156. VL4000 BeamWash Luminaire 20.9704.0002 Rev. A Gobo/Animation Module Assembly 21.9704.6200 Rev. E Gobo Wheel 1 Assembly Concurrent Animation Wheel 21.9704.0211 Rev.

  • Page 180: Vl4000 Beamwash Luminaire (Part 5)

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 BeamWash Luminaire (Part 5) Continued from “VL4000 BeamWash Luminaire (Part 2)” on page 157. VL4000 BeamWash Optics Assembly 21.9704.6150 Rev. D Prism Assembly Wash Assembly 21.9704.6355 Rev. F 21.9704.6330 Rev. C Prism Arm Assembly Wash Arm Motor Assembly 21.9704.6335 Rev.

  • Page 181: Vl4000 Beamwash Luminaire (Part 6)

    : VL4000 B RAWING REES UMINAIRE VL4000 BeamWash Luminaire (Part 6) Continued from “VL4000 BeamWash Luminaire (Part 1)” on page 156. Color Module Assembly 21.9704.7400 Rev. C 240 Groove Belt Assembly 21.9704.0412 Rev. B 210 Groove Belt Assembly 21.9704.0411 Rev. B Cross-Flow Blower Assembly 21.9704.0420 Rev.

  • Page 182: Principle Of Operation

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Principle of Operation VL4000 BeamWash Functional Block Diagram VL4000 BeamWash Prism Prism Rotate Rotate Luminaire Functional Sensor Block Diagram Rotating Rotating Rotating Rotating Gobo 2 Gobo 1 Gobo 1 Gobo 2 Sensor Sensor Prism...

  • Page 183: Top Assembly

    GOBO ASSY, VERTICAL BARS (POS 2-4) 41.9704.4414 GOBO ASSY, LATTICE (POS 2-5) 41.9704.4415 GOBO ASSY, WAVY TRIANGLE (POS 2-6) 41.9704.4416 GOBO ASSY, DOT BUFFET (POS 2-7) 41.9704.4291 GOBO ASSY, QUADCONE, RED (POS 2-8) 71.9704.1200 LAMP, 1200 WATT, PHILIPS MSR GOLD FASTFIT 02.97 04.601 0 A...
  • Page 184 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Included Items Kit, VL4000 BeamWash (continued) (x2) VL4000 BeamWash Luminaire QuickStart Guide Stacked Ovals Chopped Sliced Night Sky Blades Psyclone Circle of Holes Circle of Eights Punch Card Vertical Bars Lattice Wavy Triangle Dot Buffet Quadcone, Red...

  • Page 185: Vl4000 Beamwash Luminaire

    : VL4000 B SSEMBLY UMINAIRE VL4000 BeamWash Luminaire 20.9704.0002 Rev. A Refer to Figure 3-8 Item Qty. Description 04.9704.6001 VL4000 BEAMWASH PRODUCT ID LABEL 04.9704.6145 LABEL VL4000 BEAMWASH, WARNING AND COMPLIANCE 10.9704.6641 FILTER, FOAM, HEAD INLET 10.9704.6672 FRONT SIDE RAIL COVER 10.9704.6673 REAR SIDE RAIL COVER 10.9704.6674...
  • Page 186 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 BeamWash Luminaire (continued) (x2) (x16) (x2) (x2) (x2) (x4) 14 Ref. (x2) Figure 3-8: VL4000 BeamWash Luminaire 02 .9 704 .60 10 A...

  • Page 187: Vl4000 Beamwash Generic Luminaire Assembly

    : VL4000 B SSEMBLY ENERIC UMINAIRE SSEMBLY VL4000 BeamWash Generic Luminaire Assembly 21.9704.6010 Rev. C Refer to Figure 3-9 Item Qty. Description 04.9704.0137 LABEL, LAMP CHANGE, 1200W FASTFIT 10.9704.0706 BEARING SPACER, SHORT 10.9704.0707 PULLEY, DRIVEN, TILT 10.9704.0711 TILT STOP 10.9704.0734 COVER MOUNT, YOKE ARM 10.9704.1712 TILT BEARING HOLDER...
  • Page 188 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Item Qty. Description 55.6503.0004 WASHER, #8 FLAT ZINC 02 .9 704 .60 10 A...
  • Page 189 : VL4000 B SSEMBLY ENERIC UMINAIRE SSEMBLY VL4000 BeamWash Generic Luminaire Assembly (continued) (x2) (x2) (x4) (x6) (x4) (x3)* (x2)*, (x2) (x4)* (x2) (x16)* (x5)* *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-9: VL4000 BeamWash Generic Luminaire Assembly 02.97 04.601 0 A...

  • Page 190: Vl4000 Beamwash Head Cover Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 BeamWash Head Cover Assembly 22.9704.6670 Rev. A Refer to Figure 3-10 Item Qty. Description 07.5049.0001 LANYARD, NYLON COATED, 8" LG 10.9704.6670 COVER, HEAD, TOP/BOTTOM 53.5655.0250 SCREW, #6 X 1/4" PPZ PLASTIC THD 53.6685.0500 SCREW, #6-32 X 1/2"...

  • Page 191: Vl4000 Beamwash Yoke Arm Cover Assembly

    : VL4000 B SSEMBLY OVER SSEMBLY VL4000 BeamWash Yoke Arm Cover Assembly 22.9704.6732 Rev. A Refer to Figure 3-11 Item Qty. Description 10.9704.6732 COVER, YOKE ARM, BEAMWASH 53.2008.0008 NUT, #8 PUSH 53.6521.0001 SCREW, 8-32 X 1/2 PPB (x4) (x4) Figure 3-11: VL4000 BeamWash Yoke Arm Cover Assembly 02.97 04.601 0 A...

  • Page 192: Stabilizer Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Stabilizer Assembly 21.9704.1767 Rev. A Refer to Figure 3-12 Item Qty. Description 10.9704.1762 BRACKET, STABILIZER 10.9704.1757 STABILIZER, TILT, 1.600" SHAFT DIA 53.6610.0003 SCREW, 6-32 X 7/16" PPZ 55.6568.0075 SPRING, EXTN, 0.375" OD, 1.0" LG 0.041" WIRE DIA Figure 3-12: Stabilizer Assembly 02 .9 704 .60 10 A...

  • Page 193: Back Cover Assembly

    SSEMBLY OVER SSEMBLY Back Cover Assembly 21.9704.6671 Rev. A Refer to Figure 3-13 Item Qty. Description 10.9704.0671 COVER, HEAD, REAR 53.6614.0001 SCREW, 6-32 X 5/8", PPB 55.6538.0002 WASHER, #6 NYLON, NATURAL 55.6879.0006 WASHER, #6, SELF RETAINING, 0.032 THK, NYLON (x6) (x6) (x6) Figure 3-13: Back Cover Assembly...
  • Page 194 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Notes 02 .9 704 .60 10 A...

  • Page 195: Head Assembly Head Frame Assembly

    SSEMBLY RAME SSEMBLY Head Assembly Head Frame Assembly 21.9704.6600 Rev. B Refer to Figure 3-14 Item Qty. Description 04.9704.6699 LABEL, FAN LABEL BLACKOUT 10.9704.0640 GUIDE, MODULE, HEAD 10.9704.0701 TILT TUBE 21.9704.6150 ASSY, OPTICS 21.9704.6615 ASSY, BACK END, BEAMWASH 22.9704.1629 ASSY, VL4K TILT MAGNET 22.9704.6605 ASSY, SIDE RAIL, RIGHT 22.9704.6608...
  • Page 196 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Head Frame Assembly (continued) (x3) (x2) (x4) (x4)* (x4) (x4) (x2) (x8)* (x8) (x4) (x3) (x2) *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-14: Head Frame Assembly 02 .9 704 .60 10 A...

  • Page 197: Vl4000 Beamwash Optics Assembly

    : VL4000 B SSEMBLY PTICS SSEMBLY VL4000 BeamWash Optics Assembly 21.9704.6150 Rev. D Refer to Figure 3-15 Figure 3-16 Item Qty. Description 10.9704.0240 SPACER, 0.197" ID, 0.250" OD, 0.032" THK 10.9704.6170 LIGHT BAFFLE, LENS GROUP 1 10.9704.6174 SHIELD, OPTICS MOTORS 10.9704.6180 RAIL MOUNT, VL4000 BEAMWASH OPTICS 10.9704.6181...
  • Page 198 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Item Qty. Description 53.6575.0009 SCREW, 8-32 X 3/8" PPB SEMS 53.6599.0001 SCREW, 4-40 X 3/8" PFZ 53.6601.0002 SCREW, 4-40 X 3/16" PTZ 53.6608.0001 SCREW, 6-32 X 3/8" PFB 53.6682.0002 SCREW, 4-40 X 1/4" PPZ SEMS 53.6682.0022 SCREW, 8-32 X 3/8"...
  • Page 199 : VL4000 B SSEMBLY PTICS SSEMBLY VL4000 BeamWash Optics Assembly (continued) (x4) RTV Bead** (x4)* (x8) 30 Ref 30 Ref (x3) 30 Ref (x8) 30 Ref *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. **APPLY APPROX 1.25" BEAD OF RTV TO INTERSECTION OF BAFFLE AND LENS GROUP 1 APPROX LOCATION MIDWAY BETWEEN TWO MOUNTING...
  • Page 200 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 BeamWash Optics Assembly (continued) RTV Bead** (x3) 33 42 (x4)* (x5)* (x3) 26, 39, 38 (x3) (x4) *APPLY LOCTITE 242 TO THREADS 23, 43 (x12)* PRIOR TO INSTALLATION. (x6) **APPLY APPROX 1.25" BEAD OF RTV TO INTERSECTION OF BAFFLE AND LENS GROUP 1 APPROX LOCATION MIDWAY BETWEEN TWO...

  • Page 201: Edge Lens Motor Assembly

    SSEMBLY OTOR SSEMBLY Edge Lens Motor Assembly 21.9704.6185 Rev. E Refer to Figure 3-17 Item Qty. Description 10.9678.1131 FORWARD PULLEY SHAFT, BEARING 10.9704.1212 MOTOR PULLEY W/ FLANGES 10.9704.6185 MOUNT PLATE, BELT DRIVE 21.9704.0330 ASSY, DAMPER, MOTOR SHAFT, 5 MM 44.9704.1216 MOTOR, SIZE 17, 24 MM SHAFT, HIGH TORQUE 53.5560.0187 SCREW, SET 8-32 X 3/16"...

  • Page 202: 5Mm Motor Shaft Damper Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL 5mm Motor Shaft Damper Assembly 21.9704.0330 Rev. B Refer to Figure 3-18 Item Qty. Description 55.6568.0113 COMPRESSION SPRING 10.9698.0335 DAMPER, MOTOR SHAFT, 5MM 53.6556.0001 SCREW, 4-40 X 3/4" PPZ .200 REF INITIAL SETTING Figure 3-18: 5mm Motor Shaft Damper Assembly 02 .9 704 .60 10 A...

  • Page 203: Zoom Lens Motor Assembly

    SSEMBLY OTOR SSEMBLY Zoom Lens Motor Assembly 21.9704.6195 Rev. D Refer to Figure 3-19 Item Qty. Description 10.9678.1131 FORWARD PULLEY SHAFT, BEARING 10.9704.1212 MOTOR PULLEY W/ FLANGES 10.9704.6195 MOUNT PLATE, BELT DRIVE 21.9704.0330 ASSY, DAMPER, MOTOR SHAFT, 5 MM 44.9704.1216 MOTOR, SIZE 17, 24 MM SHAFT, HIGH TORQUE 53.5560.0187 SCREW, SET 8-32 X 3/16"...

  • Page 204: Lenticular With Motors Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Lenticular with Motors Assembly 21.9704.6310 Rev. C Refer to Figure 3-20 Item Qty. Description 10.9704.0240 SPACER, 0.197" ID, 0.250" OD, 0.032" THK 10.9704.1233 PULLEY, 16 GRV, 0.125" WD, ANIMATION ARM DRIVE 10.9704.6315 MOTOR MOUNT, LENTICULAR 10.9704.6318...
  • Page 205 SSEMBLY ENTICULAR WITH OTORS SSEMBLY Lenticular with Motors Assembly (continued) Note, connector for item 13 on this side. (x4)* (x3) (x2) (x2) See Detail (x2)* Item 8 Detail (x4) (x2) *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-20: Lenticular with Motors Assembly 02.97 04.601 0 A...

  • Page 206: Lenticular Arm Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Lenticular Arm Assembly 21.9704.6315 Rev. B Refer to Figure 3-21 Item Qty. Description 10.9704.0238 ROLLER, TENSION ADJUST, ANIMATION WHEEL 10.9704.6311 ARM, LENTICULAR 10.9704.6313 INDEX PULLEY, LENTICULAR 10.9704.6322 FLAG, LENTICULAR 10.9704.6362 TEFLON BEARING, BORE, LENTICULAR 10.9704.6391 SPACER, TEFLON, LENTICULAR 10.9704.6394...
  • Page 207 SSEMBLY ENTICULAR SSEMBLY Lenticular Arm Assembly (continued) (x2) (x2) (x3)* (x3)* *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-21: Lenticular Arm Assembly 02.97 04.601 0 A...

  • Page 208: Prism Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Prism Assembly 21.9704.6330 Rev. C Refer to Figure 3-22 Item Qty. Description 10.9704.0233 DRIVE PULLEY, ANIMATION/FIXED COLOR 10.9704.0240 SPACER, 0.197" ID, 0.250" OD, 0.032" THK 10.9704.1233 PULLEY, 16 GRV, 0.125" WD, ANIMATION ARM DRIVE 10.9704.6173 COLLET, MOTOR SHAFT 10.9704.6318...
  • Page 209 SSEMBLY RISM SSEMBLY Prism Assembly (continued) (x2)* (x4)* (x2) (x2) (x2) (x2) (x3) See Detail (x2) Position connector this side. Item 9 Detail (x5)* *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-22: Prism Assembly 02.97 04.601 0 A...

  • Page 210: Prism Arm Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Prism Arm Assembly 21.9704.6335 Rev. B Refer to Figure 3-23 Item Qty. Description 10.9704.6313 INDEX PULLEY, LENTICULAR 10.9704.6321 ARM, PRISM 10.9704.6324 FLAG, ANIMATION ARM 10.9704.6327 COUPLER, PRISM ARM 21.9704.6395 ASSY, 5-FACET LINEAR PRISM, INTERCHANGEABLE 53.5564.0188 SCREW, 6-32 X 1/4"...

  • Page 211: Wash Assembly

    SSEMBLY SSEMBLY Wash Assembly 21.9704.6355 Rev. F Refer to Figure 3-24 Item Qty. Description 10.9704.6317 INDEX PULLEY, ARM 10.9704.6319 CLAMP, WASH GLASS 10.9704.6320 PULLEY FLANGE, WASH 10.9704.6351 ARM, WASH 42.9704.6155 GLASS, WASH 53.6559.0001 SCREW, 4-40 X 1/4" PFZ 53.6659.0006 SCREW, 2-56 X 3/16" PPZ 53.6659.0012 SCREW, 2-56 X 1/8"...

  • Page 212: Wash Arm Motor Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Wash Arm Motor Assembly 21.9704.6360 Rev. B Refer to Figure 3-25 Item Qty. Description 10.9704.1233 PULLEY, 16 GRV, 0.125" WD, ANIMATION ARM DRIVE 10.9704.6325 ARM STOP MOUNT 10.9704.6352 FROST PIVOT MOTOR MOUNT 25.9687.0020 SWITCH, SLOTTED OPTICAL 44.9704.0418...

  • Page 213: Slotted Optical Switch

    SSEMBLY LOTTED PTICAL WITCH Slotted Optical Switch 25.9687.0020 Rev. A Refer to Figure 3-26 Note: This part is only available as an assembly. Shown for reference only. Item Qty. Description 25.9687.0020 SWITCH, SLOTTED OPTICAL Figure 3-26: Slotted Optical Switch 02.97 04.601 0 A...

  • Page 214: Back End Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Back End Assembly 21.9704.6615 Rev. F Refer to Figure 3-27 Item Qty. Description 0-100071 SCREW, PHMS, PH, 10-32 X 1.75", S, BO 10.9704.0613 MOUNT, HOT BOX 10.9704.0628 LIGHT SEAL, FIN ASSY 10.9704.1639 DIVERTER, LAMP TIP 10.9704.2614...
  • Page 215 SSEMBLY SSEMBLY Back End Assembly (continued) (x2) (x2) (x4)* 18 Ref 18 Ref (x8) (x6) (x2), (x2) (x3) (x2) 18 Ref (x2) (x4) 23 Ref (x3) (x18) (x3) *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-27: Back End Assembly 02.97 04.601 0 A...

  • Page 216: Reflector Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Reflector Assembly 21.9704.6619 Rev. A Refer to Figure 3-28 Item Qty. Description 10.9704.0618 CLIP, REFLECTOR MOUNT 10.9704.6617 REFLECTOR MOUNT PLATE 42.9704.0151 REFLECTOR, RETRO 42.9704.6150 REFLECTOR, PRIMARY, SMOOTH 53.6525.0188 SCREW, 6-32 X 3/16" LG PPZ (x8) See Note (x8)

  • Page 217: Lamp Cover Assembly

    SSEMBLY OVER SSEMBLY Lamp Cover Assembly 21.9704.0632 Rev. B Refer to Figure 3-29 Item Qty. Description 10.9638.0233 TETHER, REMOVABLE COVER 10.9704.1630 HEAD COVER, LAMP SOCKET 53.5655.0250 SCREW, #6 X 1/4" LG PLASTIC THREADING 55.2233.2003 DZUS RAPIER, 1/4-TURN STUD RETAINER, 5 MM 55.2233.2005 DZUS RAPIER, 1/4-TURN STUD, 5 MM, 12 MM LG (x2)
  • Page 218 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Notes 02 .9 704 .60 10 A...

  • Page 219: Gobo/Animation Module Assembly

    SSEMBLY NIMATION ODULE SSEMBLY Gobo/Animation Module Assembly 21.9704.6200 Rev. E Refer to Figure 3-30, Figure 3-31, Figure 3-32, and Figure 3-33 Item Qty. Description 04.9704.0203 DIPSWITCH LABEL, GOBO BOARD C 04.9704.0204 DIPSWITCH LABEL, GOBO BOARD D 21.9698.0330 ASSY, DAMPER, MOTOR SHAFT 5MM COMPRISED OF: 10.9698.0335 DAMPER, MOTOR SHAFT 5 MM 53.6604.0500...
  • Page 220 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Item Qty. Description 44.9704.0217 MOTOR, SIZE 17, 24 MM SHAFT, SHORT STACK 53.6513.0019 SCREW, M3 X .5 X 5 MM LG, PPB, METRIC 53.6513.0008 SCREW, M3 X .5 X 5 MM LG, PFB, METRIC 53.6513.0023 SCREW, M3 X .5 X 8 MM LG PFZ METRIC 53.6513.0024...
  • Page 221 SSEMBLY NIMATION ODULE SSEMBLY Gobo/Animation Module Assembly (continued) (x2) (x4) (x2) 49 Ref* (x3) (x3)* (x2) (x2) (x4) (x3) (x8)* 46 Ref (x9)* 45 Ref (x2) 29 Ref* (x2)* (x6)* 35 Ref* (x4) *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-30: Gobo/Animation Module Assembly (Part 1) 02.97 04.601 0 A...
  • Page 222 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Gobo/Animation Module Assembly (continued) (x3) See Detail (x2) Item 3 Detail *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-31: Gobo/Animation Module Assembly (Part 2) 02 .9 704 .60 10 A...
  • Page 223 SSEMBLY NIMATION ODULE SSEMBLY Gobo/Animation Module Assembly (continued) (x5) (x2) 40 Ref* (x2) (x6)* 38 Ref (x2) (x4) *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-32: Gobo/Animation Module Assembly (Part 3) 02.97 04.601 0 A...
  • Page 224 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Gobo/Animation Module Assembly (continued) (x2) (x8)* *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-33: Gobo/Animation Module Assembly (Part 4) 02 .9 704 .60 10 A...

  • Page 225: Gobo Wheel 1 Assembly

    SSEMBLY HEEL SSEMBLY Gobo Wheel 1 Assembly 21.9704.0211 Rev. D Refer to Figure 3-34 Item Qty. Description 10.9704.0219 HUB, GOBO WHEEL 10.9704.0228 PULLEY, DRIVEN, GOBO WHEEL 1 INDEX 10.9704.0229 CAP, HUB, GOBO WHEEL 1 10.9704.0236 DRIVEN PULLEY, GOBO ROTATE 22.9704.0220 PLATE ASSY, ROTATING GOBO WHEEL 22.9704.0222 SUN GEAR, GOBO ROTATE WITH MAGNET...
  • Page 226 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Gobo Wheel 1 Assembly (continued) (x3)* Note, this slot is not used. (x4)* (x3) (x3)* Notes: *APPLY ONE DROP OF LOCTITE (ITEM 13) TO SCREW THREADS DURING INSTALLATION. CLEAN AREA AROUND MAGNET SLOT IN WHEEL THOROUGHLY WITH SOLVENT. INSTALL MAGNET (ITEM 12) INTO SLOT, SOUTH POLE FACING OUT, USING TAPE (ITEM 14).

  • Page 227: Gobo Wheel 2 Assembly

    SSEMBLY HEEL SSEMBLY Gobo Wheel 2 Assembly 21.9704.0212 Rev. F Refer to Figure 3-35 Item Qty. Description 10.9704.0219 HUB, GOBO WHEEL 10.9704.0236 DRIVEN PULLEY, GOBO ROTATE 10.9704.1216 SUN GEAR, GOBO ROTATE 22.9704.0207 DRIVEN PULLEY WITH MAGNET, GOBO WHEEL 2 INDEX 22.9704.0220 PLATE ASSY, ROTATING GOBO WHEEL 53.6659.0023...
  • Page 228 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Gobo Wheel 2 Assembly (continued) (x3)* 10** Note, this slot is not used. (x4)* (x3) (x3)* Notes: *APPLY ONE DROP OF LOCTITE (ITEM 13) TO SCREW THREADS DURING INSTALLATION. **CLEAN AREA AROUND MAGNET SLOT IN WHEEL THOROUGHLY WITH SOLVENT. INSTALL MAGNET (ITEM 10) INTO SLOT, SOUTH POLE FACING OUT, USING TAPE (ITEM 12).

  • Page 229: Gobo 1 Sensor Index Assembly

    SSEMBLY ENSOR NDEX SSEMBLY Gobo 1 Sensor Index Assembly 21.9704.0230 Rev. B Refer to Figure 3-36 Item Qty. Description 10.9704.0232 GOBO WHEEL 1 SENSOR BRACKET 17.9704.0905 PCB ASSY, GOBO 1 INDEX SENSOR 24.9678.3240 BRD ASSY, GOBO POSITION 53.6659.0012 SCREW, 2-56 X 1/8" PPZ 55.2203.0001 SCREW, 4-40 X 1/4"...

  • Page 230: Gobo 2 Sensor Index Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Gobo 2 Sensor Index Assembly 21.9704.0260 Rev. B Refer to Figure 3-37 Item Qty. Description 10.9704.0290 CLAMP, CONNECTOR, SENSOR BOARD 10.9704.0253 MOUNT, SENSOR BOARD, GOBO INDEX 53.2009.0006 NUT, 2-56 HEX NYLON LOCK SS 17.9704.0904 PCB ASSY, WHEEL POSITION SENSOR 53.6659.0014...

  • Page 231: Concurrent Animation Wheel Assembly

    SSEMBLY ONCURRENT NIMATION HEEL SSEMBLY Concurrent Animation Wheel Assembly 21.9704.6353 Rev. E Refer to Figure 3-38 Item Qty. Description 10.9704.0240 SPACER, 0.197" ID, 0.250" OD, 0.032" THK 10.9704.0319 FLAG, ANIMATION ARM 10.9704.0372 SPACER, ROLLER, SHUTTER ROTATE 10.9704.0373 SPACER, ROLLER, SHUTTER ROTATE 10.9704.0375 SHIELD, BELT, ANIMATION 10.9704.1311...
  • Page 232 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Concurrent Animation Wheel Assembly (continued) (x4) (x5) (x6) (x4)* (x4)* (x2)*/*** (x3)* (x2) *APPLY ONE DROP OF LOCTITE TO SCREW THREADS DURING INSTALLATION. **NOTE FLAG ORIENTATION. ***PRESS FIRMLY DOWN ON OUTSIDE PULLEY TO REMOVE ALL FREE SPACE IN PARTS STACK BEFORE TIGHTENING SET SCREWS IN OUTSIDE PULLEY.

  • Page 233: Animation Wheel 2 Motor Assembly

    SSEMBLY NIMATION HEEL OTOR SSEMBLY Animation Wheel 2 Motor Assembly 21.9704.0332 Rev. D Refer to Figure 3-39 Item Qty. Description 10.9704.1308 MOTOR MOUNT, ANIMATION WHEEL 2 21.9687.2500 ASSY, SENSOR, COLOR BULKHEAD 21.9704.0239 ASSY, TENSION ADJUST, ANIMATION WHEEL 44.9704.1213 MOTOR, SIZE 14, SHAFT 24 MM LG 53.6513.0002 SCREW, M3 X 5 MM PFZ 53.6558.0009...

  • Page 234: Front Gobo Bulkhead With Iris Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Front Gobo Bulkhead with Iris Assembly 21.9704.6505 Rev. C Refer to Figure 3-40 Item Qty. Description 10.9704.0218 SENSOR BRACKET, GOBO WHEEL 2 10.9704.0693 CLAMP, CONN, 5 DRIVER BOARD 10.9704.6234 BULKHEAD, FRONT, GOBO MODULE 21.9704.6272 ASSY, IRIS MODULE 24.9678.3240...
  • Page 235 SSEMBLY RONT ULKHEAD WITH SSEMBLY Front Gobo Bulkhead with Iris Assembly (continued) (x4)* (x4) (x2) (x6) (x2) (x2) *APPLY ONE DROP OF LOCTITE TO SCREW THREADS DURING INSTALLATION. Figure 3-40: Front Gobo Bulkhead with Iris Assembly 02.97 04.601 0 A...

  • Page 236: Iris Module Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Iris Module Assembly 21.9704.6272 Rev. C Refer to Figure 3-41 Item Qty. Description 10.9704.0254 MOTOR MOUNT, IRIS, SIZE 15 10.9704.6273 CLAMP, CABLE DRIVE 10.9704.6278 DRIVE PULLEY, IRIS, CABLE 10.9704.6282 APERTURE PLATE, GOBO BULKHEAD 10.9704.6284 BULKHEAD, IRIS MODULE 22.9704.0275...
  • Page 237 SSEMBLY ODULE SSEMBLY Iris Module Assembly (continued) (x4)* (x3) (x2)* (x3)* (x2)** *APPLY ONE DROP OF LOCTITE TO SCREW (x4)* (x4)* THREADS DURING INSTALLATION. (x2) **CRIMP FERRULES ONTO ENDS OF CABLE WITH PLIERS TO SECURE. Figure 3-41: Iris Module Assembly 02.97 04.601 0 A...
  • Page 238 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Notes 02 .9 704 .60 10 A...

  • Page 239: Color Module Assembly

    SSEMBLY OLOR ODULE SSEMBLY Color Module Assembly 21.9704.7400 Rev. C Refer to Figure 3-42, Figure 3-43 Figure 3-44 Item Qty. Description 10.9704.0406 GUIDE ROD, COLOR FLAG 10.9704.0407 SLIDE, COLOR FLAG 10.9704.0408 SLIDE, COLOR FLAG, OPPOSITE 10.9704.0410 PULLEY, DRIVE, COLOR FLAG 10.9704.0434 STANDOFF, BULKHEAD, FIXED COLOR WHEEL 10.9704.0461...
  • Page 240 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Item Qty. Description 25.9704.0400 CABLE ASSY, VL4000 COLOR BLKHED CABLE 1 (NOT SHOWN) 25.9704.0401 CABLE ASSY, VL4000 COLOR BLKHED CABLE 2 (NOT SHOWN) 25.9704.0402 CABLE ASSY, VL4000 COLOR BLKHED CABLE 3 (NOT SHOWN) 25.9704.0403 CABLE ASSY, VL4000 COLOR BLKHED CABLE 4 (NOT SHOWN) 25.9704.0711...
  • Page 241 SSEMBLY OLOR ODULE SSEMBLY Color Module Assembly (continued) Blower Cyan Dimmer Strobe Fixed Colors Yellow Magenta Driver PCBs Refer to Figure 3-43 Refer to Figure 3-44 page 222 for this portion of page 223 for this portion of the assembly. the assembly.
  • Page 242 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Color Module Assembly (continued) (x10) (x4) (x4) (x16)* Dimmer (x2) (x10) (x5) (x5) (x5) (x2) (x4) (x6) (x6) (x2)* (x2) (x8) (x2) (x3) *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. (x3) (x2) Refer to...
  • Page 243 SSEMBLY OLOR ODULE SSEMBLY Color Module Assembly (continued) Assembly continued from Figure 3-43 on page 222. (x10) (x5) (x4) (x10)* (x3) (x4)* (x5) (x5) (x3) (x5) (x4) Cyan Yellow Magenta (x4) (x10) (x2) (x6) (x4)* (x6) (x2) (x2) (x5) (x2) *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION.

  • Page 244: 210 Groove Belt Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL 210 Groove Belt Assembly 21.9704.0411 Rev. B Refer to Figure 3-45 Item Qty. Description 10.9704.0442 CLAMP, COLOR BELT 53.6661.0003 SCREW, 0-80 X 3/16" LG PFSS 54.9704.0401 BELT, TIMING, MXL, 210 GRV, 125 WD, SIL/KEV (x2) (x4) Figure 3-45: 210 Groove Belt Assembly...

  • Page 245: Groove Belt Assembly

    : 240 G SSEMBLY ROOVE SSEMBLY 240 Groove Belt Assembly 21.9704.0412 Rev. B Refer to Figure 3-46 Item Qty. Description 10.9704.0442 CLAMP, COLOR BELT 53.6661.0003 SCREW, 0-80 X 3/16" LG PFSS 54.9704.0402 BELT, TIMING, MXL, 240 GRV, 125 WD, SIL/KEV (x2) (x4) Figure 3-46: 240 Groove Belt Assembly...

  • Page 246: Fixed Color Wheel Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Fixed Color Wheel Assembly 21.9704.0415 Rev. G Refer to Figure 3-47 Item Qty. Description 21.9704.0430 ASSY, FIXED COLOR WHEEL 1 21.9704.0435 ASSY, FIXED COLOR WHEEL 2 21.9704.0419 ASSY, MOTOR, FIXED COLOR 54.9698.0002 BELT, TIMING, MXL, 150 GR 0.125"...
  • Page 247 SSEMBLY IXED OLOR HEEL SSEMBLY Fixed Color Wheel Assembly (continued) (x2) (x2)* (x4)* (x2) (x4)* (x2) (x2) (x2), (x2) (x2) (x4)* (x2) (x3)* (x2) *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-47: Fixed Color Wheel Assembly 02.97 04.601 0 A...

  • Page 248: Fixed Color Wheel 1 Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Fixed Color Wheel 1 Assembly 21.9704.0430 Rev. D Refer to Figure 3-48 Item Qty. Description 10.9686.1478 MAGNET, PLANET GEAR INDEX 10.9704.0425 HUB, FIXED COLOR WHEEL 10.9704.0426 PLATE, COLOR WHEEL 10.9704.1431 SPRING PLATE, FIXED COLOR WHEEL 41.9704.0490 FILTER, RED 41.9704.0491...
  • Page 249 SSEMBLY IXED OLOR HEEL SSEMBLY Fixed Color Wheel 1 Assembly (continued) (x2) Congo Blue (x5)* Dark Fuchsia South Pole Kelly Green Orange Open (No Filter) *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION.INSTALL MAGNET (ITEM 1) AND MAGNET TAPE (ITEM 12) USING LOCTITE 49 FLUSH TO FRONT SURFACE AS SHOWN WITH SOUTH POLE OF MAGNET FACING DIRECTION SHOWN.

  • Page 250: Fixed Color Wheel 2 Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Fixed Color Wheel 2 Assembly 21.9704.0435 Rev. E Refer to Figure 3-49 Item Qty. Description 10.9686.1478 MAGNET, PLANET GEAR INDEX 10.9704.0425 HUB, FIXED COLOR WHEEL 10.9704.0426 PLATE, COLOR WHEEL 10.9704.1431 SPRING PLATE, FIXED COLOR WHEEL 41.9704.0495 FILTER, BLUE 41.9704.0496...
  • Page 251 SSEMBLY IXED OLOR HEEL SSEMBLY Fixed Color Wheel 2 Assembly (continued) (x2) Blue Amber (x5)* Green South Pole Lavender Minus Green Open (No Filter) *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION.INSTALL MAGNET (ITEM 1) AND MAGNET TAPE (ITEM 12) USING LOCTITE 49 FLUSH TO FRONT SURFACE AS SHOWN WITH SOUTH POLE OF MAGNET FACING DIRECTION SHOWN.

  • Page 252: Fixed Color Motor Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Fixed Color Motor Assembly 21.9704.0419 Rev. A Refer to Figure 3-50 Item Qty. Description 10.9704.0432 PLATE, MOTOR ADJUST, FIXED COLOR 10.9704.0465 SPACER, FIXED COLOR MOTOR 44.9704.0418 MOTOR, SIZE 17, SHAFT 0.55" 53.6513.0029 SCREW, M3 X .5 X 12 MM LG PFZ METRIC (x3)

  • Page 253: Cross-Flow Blower Assembly

    SSEMBLY ROSS LOWER SSEMBLY Cross-Flow Blower Assembly 21.9704.0420 Rev. E Refer to Figure 3-51 Item Qty. Description 10.9704.0455 MOUNT, BLOWER, COLOR 23.9704.1004 FAN ASSY, VL4000 COLOR BULKHEAD BLOWER 53.6527.0187 SCREW, 6-32 X 3/16" LG PPZ THD FORMING 55.6818.0002 STANDOFF, 45-DEG, NYLOC KURLY-LOC (x3) Figure 3-51: Cross-Flow Blower Assembly 02.97 04.601 0 A...

  • Page 254: Left Strobe Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Left Strobe Assembly 21.9704.0431 Rev. G Refer to Figure 3-52 Item Qty. Description 10.9704.0420 MOUNT PLATE, STROBE 22.9704.0453 ASSY, STROBE BLADE 44.9687.1204 MOTOR, SIZE 17, SHAFT 0.455" 53.6682.0002 SCREW, 4-40 X 1/4" PPZ SEMS 55.6738.0005 0.625 TUBING, SILICONE RUBBER, 4 MM ID, 8 MM OD, SOFT RED...
  • Page 255 SSEMBLY TROBE SSEMBLY Left Strobe Assembly (continued) (x2) *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. 0.035” BETWEEN HUB AND MOUNT SURFACE 0.311” NOTE CLOCKING OF MOTOR CONNECTOR Figure 3-52: Left Strobe Assembly 02.97 04.601 0 A...

  • Page 256: Right Strobe Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Right Strobe Assembly 21.9704.0432 Rev. D Refer to Figure 3-53 Item Qty. Description 10.9704.0420 MOUNT PLATE, STROBE 22.9704.0454 ASSY, STROBE BLADE 44.9687.1204 MOTOR, SIZE 17, SHAFT 0.455" 53.6559.0001 SCREW, 4-40 X 1/4" PFZ 55.6738.0005 0.625 TUBING, SILICONE RUBBER, 4 MM ID, 8 MM OD, SOFT RED...
  • Page 257 SSEMBLY IGHT TROBE SSEMBLY Right Strobe Assembly (continued) NOTE MOTOR CONNECTOR CLOCKING *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. INSTALL ITEM 6 WITH HIGHLY REFLECTIVE SIDE TOWARD MOTOR. BEND TABS (A) OVER ENDS OF (x2) MOTOR MOUNT TO SECURE ENDS, TWO PLACES.

  • Page 258: Control Belt Idler Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Control Belt Idler Assembly 21.9704.5443 Rev. B Refer to Figure 3-54 Item Qty. Description 10.9704.5409 IDLER PULLEY, COLOR FLAG 10.9704.5423 IDLER SHAFT, PULLEY, COLOR BULKHEAD 10.9704.5428 IDLER BRACKET, COLOR BULKHEAD 53.6597.0001 SCREW, 4-40 X 3/16"...

  • Page 259: Color Flags Sensor Board Assembly

    SSEMBLY OLOR LAGS ENSOR OARD SSEMBLY Color Flags Sensor Board Assembly 21.9704.0440 Rev. B Refer to Figure 3-55 Item Qty. Description 04.9704.0403 LABEL, COLOR SENSOR BOARD 10.9704.0422 MOUNT BRACKET, SENSOR BOARD 24.9704.0903 PCB, QUAD COLOR OPTICAL SENSOR 55.2203.0001 SCREW, 4-40 X 1/4" PPZ (x2) (x2) *APPLY LABEL OVER SILKSCREEN DENOTING COLORS ON BOARD..
  • Page 260 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Notes 02 .9 704 .60 10 A...

  • Page 261: Yoke Assembly Yoke Assembly

    SSEMBLY SSEMBLY Yoke Assembly Yoke Assembly 21.9704.6700 Rev. B Refer to Figure 3-56 Item Qty. Description 10.9704.0736 SAFETY PLATE, PAN 10.9704.0743 BRACE, TILT LOCK 10.9704.0751 ROD, PAN LOCK 10.9704.0753 LEVER, PAN/TILT LOCK 10.9704.0754 SPRING, PAN/TILT LOCK 10.9704.0768 STANDOFF, TILT MOTOR 10.9704.1719 BASE REINFORCEMENT, YOKE 10.9704.1751...
  • Page 262 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Yoke Assembly (continued) (x4) (x14) (x4) (x4) (x2) (x3)* (x6)* (x2) (x4)* (x3) (x4) (x2) (x4) (x2) (x8)* (x4)* (x7) (x12)* *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-56: Yoke Assembly 02 .9 704 .60 10 A...

  • Page 263: Double Rollers Tilt Motor Assembly

    SSEMBLY OUBLE OLLERS OTOR SSEMBLY Double Rollers Tilt Motor Assembly 21.9704.1765 Rev. B Refer to Figure 3-57 Item Qty. Description 04.9704.0701 DIPSWITCH LABEL, TILT BOARD 10.9704.2705 TILT ENCODER BRACKET MOUNT 10.9704.2763 TILT MOTOR PLATE 17.9704.1911 SENSOR BOARD, TILT 21.9704.0764 ASSY, TILT MOTOR WITH PULLEY 21.9704.1760 TILT BELT TENSION ROLLERS 53.2200.0008...
  • Page 264 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Double Rollers Tilt Motor Assembly (continued) (x2) (x2) (x2) (x3) (x3) (x4) (x4)* *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-57: Double Rollers Tilt Motor Assembly 02 .9 704 .60 10 A...

  • Page 265: Tilt Motor With Pulley Assembly

    SSEMBLY OTOR WITH ULLEY SSEMBLY Tilt Motor with Pulley Assembly 21.9704.0764 Rev. A Refer to Figure 3-58 Item Qty. Description 10.9698.1749 17T 2 MM TIMING PULLEY, WIDE BELT 44.9698.0680 MOTOR, 3 PHASE SZ 23 HI-TRQ, MOONS 53.5560.0187 SCREW, SET 8-32 X 3/16" L NOTES: APPLY ONE DROP OF LOCTITE 603 (BY OTHERS) TO SHAFT.

  • Page 266: Tilt Belt Tension Rollers Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Tilt Belt Tension Rollers Assembly 21.9704.1760 Rev. A Refer to Figure 3-59 Item Qty. Description 53.6545.0010 8-32 X 1" UNDERCUT FLAT HEAD PHILLIPS 10.9704.2702 PLATE, BELT TENSION, TILT 10.9704.0766 ROLLER, TENSION ADJUST, TILT 10.9704.2701 TILT BELT TENSION ROLLER (x2)

  • Page 267: Enclosure Assembly Upper Enclosure Assembly

    NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Enclosure Assembly Upper Enclosure Assembly 21.9704.0800 Rev. Y Note: For this assembly, there are several breakout drawings for clarity. Each drawing is proceeded with a bill of materials (BOMs) for the parts of the section of the assembly shown. Refer to the following BOMs and their associated drawings: •...

  • Page 268: Upper Enclosure Assembly - Part 1

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Upper Enclosure Assembly - Part 1 Refer to Figure 3-60 Item Qty. Description 10.9687.0840 MOUNTING BUTTON 10.9704.0802 PAN MODULE, THREADED SPACER 10.9704.0829 SAFETY HOOK 10.9704.0836 REINFORCING BRACKET, RIGHT 10.9704.0851 SAFETY HOOK COVER 10.9704.1811 MAIN PLATE, UPPER ENCLOSURE 10.9704.1816...
  • Page 269 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Upper Enclosure Assembly - Part 1 (continued) (x14) (x4) 14 (ref) (x2) (x4)* (x4)* 13 (ref) (x16)* (x8) (x4) (x8) (x8) (x8) (x2) *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-60: Upper Enclosure Assembly Part 1 02.97 04.601 0 A...

  • Page 270: Upper Enclosure Assembly - Part 2

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Upper Enclosure Assembly - Part 2 Refer to Figure 3-61 Item Qty. Description 10.9704.0804 UNTHREADED SPACER 21.9704.0840 PAN BEARING / PULLEY ASSY 21.9704.0870 PAN / FAN DRIVER BOARD 21.9704.1820 PAN ASSY MODULE 53.5808.0001 SCREW, 6-32 X 0.50"...
  • Page 271 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Upper Enclosure Assembly - Part 2 (continued) (x4)* (x4)* (x2) (x2) (x2) (x2) (x4) Item 8 is same as item 17 in Figure 3-60. (x4)* *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-61: Upper Enclosure Assembly Part 2 02.97 04.601 0 A...

  • Page 272: Upper Enclosure Assembly - Part 3

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Upper Enclosure Assembly - Part 3 Refer to Figure 3-60 Item Qty. Description 04.9704.0892 LABEL, VL4000 BALLAST 04.9704.0893 LABEL, BALLAST DANGER WARNING 10.9678.0896 4.5-INCH AIR SEAL, UPPER ENCLOSURE 10.9704.0874 INSULATING DUCT, PFC 10.9704.1835 TOP FOAM AIR SEAL 10.9704.1857...
  • Page 273 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Upper Enclosure Assembly - Part 3 (continued) (x2) (x4) (x2) (x2) (x4)* (x4) (x2) (x4) (x4) (x16) (x2) Ref Only - part of 20.9704.0002 (x4)* *APPLY LOCTITE 242 TO THREADS PRIOR TO INSTALLATION. Figure 3-62: Upper Enclosure Assembly Part 3 02.97 04.601 0 A...

  • Page 274: Upper Enclosure Assembly - Part 4

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Upper Enclosure Assembly - Part 4 Refer to Figure 3-61 Item Qty. Description 10.9704.1846 UPPER ENCLOSURE, SIDE COVER, HI TEMP 10.9704.1847 UPPER ENCLOSURE, SIDE ARM COVER, HI TEMP 10.9704.1849 UPPER ENCLOSURE, FRONT/REAR COVER, HI TEMP 21.9704.0850 UPPER ENCLOSURE COVER 53.5636.0375...
  • Page 275 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Upper Enclosure Assembly - Part 4 (continued) (x2)** (x2) (x2) (x38) (x2) (x4) **APPLY LOCTITE 272 PRIOR TO INSTALLING. SCREW IN UNTIL SCREW HEAD TOUCHES COVER. DO NOT OVER TIGHTEN. Figure 3-63: Upper Enclosure Assembly Part 4 02.97 04.601 0 A...

  • Page 276: Side Mount Fan Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Side Mount Fan Assembly 21.9704.0810 Rev. E Refer to Figure 3-64 Item Qty. Description 10.9704.1817 UPPER ENCLOSURE SIDE WALL FAN MOUNT 22.9704.1850 FAN ASSY WITH RUBBER MOUNTS (NOTE: EACH ASSEMBLY IS 4 RUBBER FAN MOUNTS, 1 FAN, AND 4 NYLON WASHERS) Part of Item 2 (x4)

  • Page 277: Front Panel Assembly

    NCLOSURE SSEMBLY RONT ANEL SSEMBLY Front Panel Assembly 21.9704.0825 Rev. G Refer to Figure 3-61 Item Qty. Description 10.9679.0850 BACKING PLATE, NEUTRIK 11.9704.0846 DISPLAY OVERLAY 10.9704.1815 FRONT PANEL 21.9704.0880 ASSY, MCB/DISPLAY 10.9704.0886 MCB BRACKET MOUNT 10.9704.1826 PAN ASSY, SUPPORT BRACKET 24.9664.4895 PCB ASSY, DMX INPUT 25.9704.0830...
  • Page 278 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Front Panel Assembly (continued) (x2) (x2) (x6) Figure 3-65: Front Panel Assembly 02 .9 704 .60 10 A...

  • Page 279: Side Mount Filter Holder Assembly

    NCLOSURE SSEMBLY OUNT ILTER OLDER SSEMBLY Side Mount Filter Holder Assembly 21.9704.2815 Rev. C Refer to Figure 3-66 Item Qty. Description 10.9704.1842 AIR FILTER 10.9704.2819 SIDE FILTER GRILL 10.9704.3818 UPPER ENCLOSURE FILTER SIDE 53.2200.0006 NUT, 6-32 KEP SS (x2) (x6) Figure 3-66: Side Mount Filter Holder Assembly 02.97 04.601 0 A...

  • Page 280: Pan Bearing / Pulley Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Pan Bearing / Pulley Assembly 21.9704.0840 Rev. F Refer to Figure 3-60 Item Qty. Description 10.9704.0863 BRACKET SUPPORT 10.9704.4891 BRACKET, STABILIZER, PAN 10.9704.1809 EXTENSION, PAN TUBE 53.6536.0001 SCREW, 4-40 X 1/2" PFZ 53.6609.0001 SCREW, 6-32 X 3/8"...
  • Page 281 NCLOSURE SSEMBLY EARING ULLEY SSEMBLY Pan Bearing / Pulley Assembly (continued) (x2)* (x4)* (x2) (x5)* (x5)* *APPLY LOCTITE 242 TO THE THREADS OF ALL SCREWS PRIOR TO INSTALLATION. Figure 3-67: Pan Bearing / Pulley Assembly 02.97 04.601 0 A...

  • Page 282: Pan / Fan Driver Board Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Pan / Fan Driver Board Assembly 21.9704.0870 Rev. G Refer to Figure 3-64 Item Qty. Description 04.9704.0801 DIPSWITCH LABEL, PAN BOARD 10.9704.2837 SENSOR BOARD MOUNT PLATE 24.9704.1907 PAN DRIVER BOARD 52-0406 THERM PAD, VO GAP PAD ULT-SOFT, 0.45"...

  • Page 283: Pan Module Assembly

    NCLOSURE SSEMBLY ODULE SSEMBLY Pan Module Assembly 21.9704.1820 Rev. G Refer to Figure 3-69 Item Qty. Description 54.1255.0001 BEARING ASSY, BLACK FLUSH MOUNT 54.9698.0224 BELT, TIMING, S2M 210GRV 15 MM WIDE URTH/KVLR 10.9704.1867 BRIDGE, BELT TENSION ROLLERS 53.6505.0022 CARRIAGE BOLT, 3/8"-16 X 3/4" 53.2200.0008 NUT, 8-32 KEPS SS 53.2019.0004...
  • Page 284 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Pan Module Assembly (continued) (x4)* (x2) (x6) (x2) (x2)* (x2) (x2)* *APPLY BLUE LOCTITE TO THE THREADS OF ALL SCREWS PRIOR TO INSTALLATION. Figure 3-69: Pan Module Assembly 02 .9 704 .60 10 A...

  • Page 285: Upper Enclosure Cover Assembly

    NCLOSURE SSEMBLY PPER NCLOSURE OVER SSEMBLY Upper Enclosure Cover Assembly 21.9704.0850 Rev. A Refer to Figure 3-70 Item Qty. Description 10.9704.0858 COVER LATCH SPRING 53.2200.0004 NUT, KEPS, 4-40 10.9704.0839 UPPER ENCLOSURE COVER (x4) (x2) Detail See Detail Figure 3-70: Upper Enclosure Cover Assembly 02.97 04.601 0 A...
  • Page 286 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Notes 02 .9 704 .60 10 A...

  • Page 287: Cable Assemblies

    : LVS C ABLE SSEMBLIES HASSIS ROUND ABLE SSEMBLY Cable Assemblies LVS Chassis Ground Cable Assembly 25.9687.0025 Rev. A Refer to Figure 3-71 Figure 3-71: VL4000 Pan / Tilt Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 288: Vl4000 Pan / Tilt Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 Pan / Tilt Cable Assembly 25.9704.1703 Rev. D Refer to Figure 3-72 Figure 3-72: VL4000 Pan / Tilt Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 289: Vl4000 Color Power Distribution Cable Assembly

    : VL4000 C ABLE SSEMBLIES OLOR OWER ISTRIBUTION ABLE SSEMBLY VL4000 Color Power Distribution Cable Assembly 25.9704.0708 Rev. D Refer to Figure 3-73 Figure 3-73: VL4000 Color Power Distribution Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 290: Vl4000 Lamp Base & Tip Fan Extension Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 Lamp Base & Tip Fan Extension Cable Assembly 25.9704.1602 Rev. B Refer to Figure 3-74 Figure 3-74: VL4000 Lamp Base & Tip Fan Extension Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 291: Vl4000 Data Network Extension Cable Assembly

    : VL4000 D ABLE SSEMBLIES ETWORK XTENSION ABLE SSEMBLY VL4000 Data Network Extension Cable Assembly 25.9704.0711 Rev. B Refer to Figure 3-75 Figure 3-75: VL4000 Data Network Extension Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 292: Vl4000 Color Bulkhead 1 Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 Color Bulkhead 1 Cable Assembly 25.9704.0400 Rev. A Refer to Figure 3-76 Figure 3-76: VL4000 Color Bulkhead 1 Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 293: Vl4000 Color Bulkhead 2 Cable Assembly

    : VL4000 C ABLE SSEMBLIES OLOR ULKHEAD ABLE SSEMBLY VL4000 Color Bulkhead 2 Cable Assembly 25.9704.0401 Rev. A Refer to Figure 3-77 Figure 3-77: VL4000 Color Bulkhead 2 Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 294: Vl4000 Color Bulkhead 3 Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 Color Bulkhead 3 Cable Assembly 25.9704.0402 Rev. A Refer to Figure 3-78 Figure 3-78: VL4000 Color Bulkhead 3 Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 295: Vl4000 Color Bulkhead 4 Cable Assembly

    : VL4000 C ABLE SSEMBLIES OLOR ULKHEAD ABLE SSEMBLY VL4000 Color Bulkhead 4 Cable Assembly 25.9704.0403 Rev. A Refer to Figure 3-79 Figure 3-79: VL4000 Color Bulkhead 4 Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 296: Vl4000 Color A To Color B Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 Color A to Color B Cable Assembly 25.9704.0712 Rev. A Refer to Figure 3-80 Figure 3-80: VL4000 Color A to Color B Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 297: Vl4000 Pan / Power Distribution Input Cable Assembly

    : VL4000 P ABLE SSEMBLIES OWER ISTRIBUTION NPUT ABLE SSEMBLY VL4000 Pan / Power Distribution Input Cable Assembly 25.9704.2704 Rev. A Refer to Figure 3-81 Figure 3-81: VL4000 Pan / Power Distribution Input Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 298: Vl4000 Enclosure Pfc Input Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 Enclosure PFC Input Cable Assembly 25.9704.1800 Rev. A Refer to Figure 3-82 Figure 3-82: VL4000 Enclosure PFC Input Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 299: Vl4000 Enclosure Pfc Output Cable Assembly

    : VL4000 E PFC O ABLE SSEMBLIES NCLOSURE UTPUT ABLE SSEMBLY VL4000 Enclosure PFC Output Cable Assembly 25.9704.1801 Rev. A Refer to Figure 3-83 Figure 3-83: VL4000 Enclosure PFC Output Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 300: Vl4000 Dmx Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 DMX Cable Assembly 25.9704.0802 Rev. A Refer to Figure 3-84 Figure 3-84: VL4000 DMX Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only. 02 .9 704 .60 10 A...

  • Page 301: Vl4000 Ballast Control Cable Assembly

    : VL4000 B ABLE SSEMBLIES ALLAST ONTROL ABLE SSEMBLY VL4000 Ballast Control Cable Assembly 25.9704.0803 Rev. A Refer to Figure 3-85 Figure 3-85: VL4000 Ballast Control Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 302: Vl4000 Usb Interface Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 USB Interface Cable Assembly 25.9704.0804 Rev. A Refer to Figure 3-86 Figure 3-86: VL4000 USB Interface Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 303: Vl4000 Thermal Control Cable Assembly

    : VL4000 T ABLE SSEMBLIES HERMAL ONTROL ABLE SSEMBLY VL4000 Thermal Control Cable Assembly 25.9704.1805 Rev. A Refer to Figure 3-87 Figure 3-87: VL4000 Thermal Control Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 304: Vl4000 Chassis To Yoke Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 Chassis to Yoke Cable Assembly 25.9704.0716 Rev. B Refer to Figure 3-88 Figure 3-88: VL4000 Chassis to Yoke Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 305: Vl4000 Ac Input Connector Assembly

    : VL4000 AC I ABLE SSEMBLIES NPUT ONNECTOR SSEMBLY VL4000 AC Input Connector Assembly 25.9704.0830 Rev. A Refer to Figure 3-89 Figure 3-89: VL4000 AC Input Connector Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 306: Vl4000 Tilt With Shield Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 Tilt with Shield Cable Assembly 25.9704.2717 Rev. B Refer to Figure 3-90 Figure 3-90: VL4000 Tilt with Shield Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 307: Vl4000 Beamwash Power Dist Cable Assembly

    : VL4000 B ABLE SSEMBLIES OWER ABLE SSEMBLY VL4000 BeamWash Power Dist Cable Assembly 25.9704.6705 Rev. D Refer to Figure 3-91 Figure 3-91: VL4000 BeamWash Power Dist Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 308: Vl4000 Main From Mcb Data Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 Main from MCB Data Cable Assembly 25.9704.6713 Rev. B Refer to Figure 3-92 Figure 3-92: VL4000 Main from MCB Data Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 309: Vl4000 Main To Bulkheads Data Cable Assembly

    : VL4000 M ABLE SSEMBLIES AIN TO ULKHEADS ABLE SSEMBLY VL4000 Main to Bulkheads Data Cable Assembly 25.9704.6714 Rev. B Refer to Figure 3-93 Figure 3-93: VL4000 Main to Bulkheads Data Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 310: Vl4000 Beamwash Inlet Fan Extension Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 BeamWash Inlet Fan Extension Cable Assembly 25.9704.6601 Rev. B Refer to Figure 3-94 Figure 3-94: VL4000 BeamWash Inlet Fan Extension Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 311: Vl4000 Ballast To Ignitor Cable Assembly

    : VL4000 B ABLE SSEMBLIES ALLAST TO GNITOR ABLE SSEMBLY VL4000 Ballast to Ignitor Cable Assembly 25.9704.1702 Rev. A Refer to Figure 3-95 Figure 3-95: VL4000 Ballast to Ignitor Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 312: Vl4000 Beamwash Gobo Bulkhead 1 Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 BeamWash Gobo Bulkhead 1 Cable Assembly 25.9704.6200 Rev. C Refer to Figure 3-96 Figure 3-96: VL4000 BeamWash Gobo Bulkhead 1 Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 313: Vl4000 Beamwash Gobo Bulkhead 2 Cable Assembly

    : VL4000 B ABLE SSEMBLIES ULKHEAD ABLE SSEMBLY VL4000 BeamWash Gobo Bulkhead 2 Cable Assembly 25.9704.6201 Rev. C Refer to Figure 3-97 Figure 3-97: VL4000 BeamWash Gobo Bulkhead 2 Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 314: Vl4000 Beamwash Optics Bulkhead Cable Assembly

    ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL VL4000 BeamWash Optics Bulkhead Cable Assembly 25.9704.6100 Rev. B Refer to Figure 3-98 Figure 3-98: VL4000 BeamWash Optics Bulkhead Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.

  • Page 315: Vl4000 Beamwash Lamp Socket Cable Assembly

    : VL4000 B ABLE SSEMBLIES OCKET ABLE SSEMBLY VL4000 BeamWash Lamp Socket Cable Assembly 25.9704.7701 Rev. A Refer to Figure 3-99 Figure 3-99: VL4000 BeamWash Lamp Socket Cable Assembly Cables are only available as complete assemblies. The information contained in this Note: section is for reference only.
  • Page 316 ❋ VARI LITE - VL4000 B UMINAIRE ERVICE ANUAL Notes Cables are only available as complete assemblies. The information contained in this Note: section is for reference only. 02 .9 704 .60 10 A...

  • Page 317: Appendix A. Technical Notices & Bulletins

    A : VL4000 B PPENDIX UMINAIRE PPENDIX Technical Notices & Bulletins VL4000 BeamWash Luminaire The following tables identify the current technical notices and bulletins associated with the VL4000 BeamWash Luminaire. These improvements have been incorporated into this manual (where applicable) and are available on the Vari-Lite web site at www.vari-lite.com. Please note that not all bulletins or notices are applicable to all versions of the fixtures included in this manual.
  • Page 318 VARI❋LITE - VL4000 B UMINAIRE ERVICE ANUAL Notes 02 .9 704 .60 10 A...
  • Page 320 Philips Entertainment Lighting 10911 Petal Street Dallas, Texas 75238 USA 1.877.VARI-LITE ❋ Fax 1.214.647.8038 www.philips.com/entertainmentlighting Date: 20 June 2017 / Manual Part Number: 02.9704.6010 A ©2017 Philips Entertainment Lighting, a Philips Group Company. All rights reserved. Produced in the U.S.A.

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