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1. R22 100 000 ohm 5 REY16104 e R23 22000 ohm 104 REX16223 5 R24 d 22000 ohm 104 REX16223 77 R25 5600 ohm 10 16562 T1 Trans mge Main R26 270 000 ohm 104 REX16274 T2 Tr hen Out A 627 2 700 ohm 10 REX16272 T3 Costi TEN R28 100 000 ohm 5 16104 1 pos 8029 o 270 000 ohm 10 REX16272 830 100 000 ohm 5 16104 wa R31 150 000 ohm 104 REX8154 V 4 tes R32 150 000 ohm 10 REX8154 V KTG R33 R 47 000 ohm 20 REW8473 V 6 152 R34 47 000 ohm 20 REW8473 646 Part No REB3181 REX8101 REX8101 REY1683 REY2103 REG3302 RED3152 REY8275 3504 3504 REW16105 REW16105 REY8473 REY16104 REW16153 RED3201 REX8105 REW2223 REW2223 REY8104 REW9105 POD3105 REW9105 REW1633 7003 POT7003 REW9473 REX8514 CJS 4 AB CJS 4 AB 732281 132281 CJS 6 AB CJS 6 AB 500462 222034 501625 5 501 625 5 FCA0200 FCA0200 0200 0050 0050 SW8280 K15 518373 8 588280 15 248011 222006 1 135 024 202029 92021 274000 498000 1135019 VECC35 VKT66 VKT66 VUS2 V6V6 R 46 CELL 2 M n Add Ti Pie R 64 E A38 we Bal Hl All Cay 851 E OH 925 2200 Yl Fe A A 2 m 4 47 MONITOR VOLUME A 58 59 9 35 60 O 6A A I
2. 1 4 62 al R66 IMAIRE il i CONTROL Ill AIS 0 5 12 AIS 2700n OOZ ME 5 CHAS SIS IO li NOTES 25 WITH EXCITER CONNECTORS SHOWN VIEWED FROM WIRING SIDE 2 NUMBERS AGAINST CONTACTS OF SWITCH 4 CORRESPOND WITH CONTACT i NUMBERS SHOWN ON SWITCH ASSY DAG 248 011 AND ALSO ON SwiTCH 5 vv DAG 248 010 lt DUI 7 77 3 IF MONITOR SENSITIVITY 15 INSUFFICIENT REMOVE PURPLE LEAD DISC e ON OUTPUT TRANSFORMER 2 AND CONNECT 7 THE MONITOR 73 VOLUME CONTROL WILL THEN WORK IN REVERSE MAXIMUM MONI VOLUME IN FULL ANTI CLOCKWISE POSITION 4 SOME AMPLIFIERS 15 AND 16 HAVE THEIR POLES NUMBERED F Re zu 0 8 TOG IN THESE CASES READ PIN 1 FOR PINT PIN 2 FOR PINGS and SO ON KA o IT S THE CASES OF C21 622 23 24 6 C31 ARE INSULATED FROM CHASSIS i Sege H 6 VOLTAGES STATED ON DIAGRAM ARE TRUE VOLTAGES v OMO Cae 5 O OOI 7 SCREENED LEADS USE KI6M FOR EXCITER LEADS AND SPEC 451000 2 J 4 LEAD FOR MAINS FRAME INSULATED NOTE ALL SCREENED LEADS KI6M 8 WHEN REPLACING VALVE TYPE EF37A THE ALTERNATIVE VALWE TYPE 611 FROM CHASSIS EXCEPT WHERE OTHERWISE STA
3. dn AoTIng HOSE TT V 90940 19935 8228 070 106 dn 9 HSLETT TeTpey WUG FUTIESG Suyu 44611 orig dA 9 w m 9 Zuj seg PIPZ 18902 SUTSDOH 4 ps H 26 01 4922 guyadg 4 Alqm ssy dn eTpurds HOZEEO Utd UTLETT dn exep Assy Sujiseg miy USTEEO 19144725690 ON 3184 10144119690 ON 3484 5 HATHT DW ZADIA ISII 90370 4 49 609 TATON ATaWassv dn 509 1390044 namoy 90 MODEL PROJECTOR TYPE 1178 A PARTS LIST Circuit Ref Description Part No 77 Description CI Capacitor 0 005 mfd 0703 R35 180 oh Tos C 2 25 mfd 552484 R36 100 e 1 5 0 05 mfd 53082 R37 100 m ge 8 180 pf CY4052 R38 68 000 d n 9 5 25 mfd 0552484 39 10 000 h 010 4 mfd 51479 RAO 8000 his 550 011 0 02 mfd CS2855 R41 1500 ohm 17 i 0 25 mid CS3 204 R42 270 000 ohm 54 G R ern CX0703 R43 Potentiometer 0 5 meg ohm 4 ws CX1822 R44 0 5 meg ohm 1822 R46 Resistor 1 meg ohm 20 C20 50 mfd 2485 R47 1 ohm 204 c21 8 mfd 202073 R48 R 17 000 ohm 54 a 32 mfd 202073 849 100 000 ohm 57 050822 R50 15 000 ohm 20 m C50822 R51 200
4. 12789 Support Shutter Case Gear 50141 Serial No and type must always be guoted when ordering spares GB Bet Provecror Gear Case AsseEMBLY ES MODEL 609 PARTS LIST FIGURE 4 MOTOR ASSEMBLY Part No Description 04770 Mount Assembly Coil 025000 Holder Governor Brush Assembly 025069 Lever Assembly Gate Operating 025377 Coupling Shaft 112 Fillister Head Sorew 890 Gear Idler 891 Shaft Idler Gear 1587 Oval Head Screw 4573 Bearing 8mm Radial 4664 Brush Governor 0112 Hexagon Nut 5160 Block Gate Operating 5201 Nut Field Retaining 6715 Steel Ball 9117 Hexagon Nut 9718 Fillister Head Screw 10349 Fillister Head Screw 10356 Bearing 6mm Radial 10390 Washer Locking 10565 Motor Shaft Extension Knob 11178 Screw Round Head 117135 Washer 11988 Motor Brush Cap 12909 Spring Brush 12918 Brush Motor 15788R Switch S P S T 14842 Holder Motor Brush Complete 15706 Spring Motor Armature Preload 15721 Spacer Motor Armature 15726 Bushing Gate Adjustment 15764 Spacer Motor Armature 15774 Mount Coil 50000 Insulating Sleeve 50150 Housing Projector Motor 50131 Housing Projector Motor Brush 50152 Cover Governor M50155 Armature Projector Motor M50154 Field Motor 50127 Fillister Head Screw 50159 Governor Projector Motor 50140 Knob Hand Turnover 50245 Fan Projector Motor
5. 1871105 101811114 26 9 IOON usn g gT6z21 ysnig Sutads 60621 480 usnig 8898TI St eo 99 01 8606 Sulieeg 2606 dn exu p IOON 606 n x q s nyem y 1909dg _ 6906 PT TA INN 1026 BUTUT819y PNIS 0029 20204 FUTsnog 9967 D H 294511114 G L Assy 68180 Tquessy dej 20404 dn 9y8 J HES CSO 10114119690 ON 4484 st YENDIA 9 HOLON 42 HAVL ISII 54 4 4 45 609 THON iat AldWassy uoloarond 609 1300 9 1134 p qonb SASATS 99004 d43 ON Tetes 4116 4N dn oyeg 514194 098088 6806 201105 4110 1845 8806 1811114 20 8 Aeiog LETOSH ie teilen 4806 918 14 0 MOXOS 9 29 70712 19488 9806 heri dn 21 45 22851 000 4806 X UOQTSU L TTeg Dn34S 92 2 182195 dn eyel 2806 42845 wry do exe G9TTI UOTJ 70714 1 NS M 2806 dn 9191 3exosig MOTOS 2911114 9935
6. 9 8 Howe MODEL 609 16 mm SERVICE INSTRUCTIONS SECTION 2 REASSEMBLY PROCEDURE Reassembly Procedure REASSEMBLE MOTOR AND GOVERNOR 1 INSTALL MOTOR FIELD ARMATURE AND BRUSH BOX HOUSING a Insert the four field coil leads into the special outlet channel at the rear of motor casting No 50130 Fig 4 b The motor fields No M50134 Fig 4 should be carefully guided into place over the locating studs No M50337 Fig 4 and clamped in position by the four retaining nuts No 5201 Fig 4 Check the position of the leads at the outlet point to ensure that they will not make contact withany revolving part Solder the three wires at the front end of the field coil to their respective positions on the brush holders and speed switch No 13788R Fig 4 d Before assembling the armature No M50133 Fig 4 into the motor housing check to see that the spring washer No 15706 Fig 4 is in position in the rear ball race housing Insert the end of the armature shaft with the ball race No 4373 Fig 4 and cool ing fan No M50243 Fig 4 attached through the motor field Carefully press the arma ture inwards so that the rear ball race enters its housing squarely f Before placing the brush box housing No 50131 Fig 4 over the front end of the armature shaft check to see that the spacer No 15721 Fig 4 is in position the shaft next to the commutator g Check
7. ISEN Suluds 219484 uorsseadduo5 301105 PUTA N epruo Asqaqnus Dn3S 29441065 191710X7 4 Suiidg 2000 den 1998dS reysey FUT JUNON 46 Sutis q UoTidrioseq 793303 95809 22208 9205 GPSOG SSTOS ASTOS 9 OTTOS 06004 40009 98008 9 9 HEGLST Ay AST GGBYT T T TST 19921 6S9ET 98921 66708 11821 9 22 ON 4284 XTGMASSY ANNOS Hee rg Em em ge g emm 46100 od 4 ON Tepes 10114100 14917 5 189 195 66 N LM 29401145 1exooidg 34181485 MOTOS 193811014 M XOS 182 1 NS M psT nuy Teqqnus Isqqnugs 94574 MOTOS IOISTTITIX PeeH 194671714 9 X 22 9 MOTOS DS9H X919T11T4 199 ISISTTITX 49105 1 1811114 D H ATquessy 4193205 146 02009 punog Ligue S tis q duet 10410x3
8. ATquessy Alqm ssy 19211148246 lquessy 3 xoo ds 1115 1891440 Alqm ssy ietlou 10114712890 544 4 4 49 609 IHTOM 2 49811 69911 29211 79411 86941 4GATT 89211 47111 SPEOT 16801 0196 7176 9096 7944 2692 2685 9929 4616 LEST 940820 97670 69170 26960 06990 19760 94920 47220 ON 3484 GB Bea Moog OOQ Provector Sound HEAD AsseMBLY p onb oq Lem 9049 28209 Uen 10909795 dn aXe 49208 19USBM pispusjg 68906 3Tup dn QOP ag 48308 1848 000 96209 9151 1 14 66208 qouy uojyag dn y 72205 41146 I9eurureg run dn exe 28208 19AO0D dn 09809 dn 69205 62008 D H 938511114 4026 dn yez Suma ndur 260480 dn y n ATam ssy p soq 291 160480 dn oyeg ATQm ssy 2076 80680 ON Hed 10114112690 14 456 LINN dn AAYA TT 94876 uuvds 609 TICON ATEM3SSV 609 1300 9 oq 6 99100 9049 pue
9. GREEN i BLUE ORANGE BROWN TAKE UP MOTOR 000 RED HF CHOKE VE CHOKE F beze k l CHORE 900 CHOKE YELLOW WIRING DIAGRAM 230v MODEL 609 TAKE UP MOTOR CIRCUIT UN MSIE ee 025076 SHEET 2 ORANGE BWITSH TAKE UP PLUG RED r ge ORANGE 1 m 16 O O BRO wn j lucus dun J Bi PROJECTOR MOTOR WOH RED H F CHOKE pe 10 CHOKE 21 A lt lt CHOKE 230v MODEL 609 SOUND SPEED REGULATOR SILENT PEED REGULATOR al EXCITER LAMP AND PROJECTOR MOTOR CIRCUIT M 025062 SHEET BR T SH ACOUS USED ON ASSY No TOLERANCES UNLESS STATED WIRING 5 0 ON DECIMAL DIMS ON OTHER DMS MODEL 609 TA DAN SYP A DATE 7 1 52 OORL E NORMAL V MACHINED RNISH CKD BY APPD PR du qm FINISH SCALE FULL SIZE vv GROUMD OR ANE MACHINED FINE GROUND ANISH WITHOUT WHEELMARKS
10. 3 56 Fillister Head Shutter Support Shutter Spring Brush Brush Motor Washer Spacer Cap Bearing Retaining Spring Compression Retainer Spring Cover Exciter Lamp Switch S P S T Holder Motor Brush Complete Retainer Spring Snubber Stud Snubber Lever Screw Pilot Spacer Fan Shaft Long Spacer Fan Shaft Short Spring Fan Shaft Preload Spring Motor Armature Preload Cone Fan Housing Heat Housing Fan Spacer Motor Armature Bushing Gate Adjustment Shield Aperture Heat Cable Strain Relief Plate Guide Rewind Film Spring Compression Plate Patent Shoulder Spacer Motor Armature Arm Reel Mount 1 Part No 15778 15779 15780 15781 15782 15783 15784 15822 16198 16207 16243 16244 16246R 169308 21528 21550 50000 50025 50027 50090 50110 50120 50126 50127 M50130 50131 50138 M50133 M50134 50136 M50137 50138 M50139 M50140 Description Holder Filter Glass Filter Retainer Filter Glass Spring Filter Friction Housing Filter Baffle Light Baffle Blower Spring Take up Bush Spacer Spring Washer Tension Screw 1 4 20 Fillister Head Screw Fillister Head Pinion Motor Screw Compression Insulating Sleeve Special Screw Plug Plug Holder Dowel Pin Sound Head end Cover Film Rewind Bracket Casing Sound Head Housing Projector Motor Housing Projeotor Motor
11. the shuttle and shutter resulting in image ghost 4 ASSEMBLY OF SPROCKETS AND GUARDS 011 the shafts No 11758 Fig 2 and check that the gears revolve freely b Place the thrust washer No 6419 Fig 2 over the end of the shaft and into the gear Thoroughly oil the sprocket shaft and felt oiler on the inside of the sprocket Ease the sprocket No 03461 Fig 2 carefully over the shaft into the gear c Place the sprocket guard No 04946 2 Spring clip No 16243 Flg 2 and Spacer No 16244 Fig 2 in position on the end of the sprocket shaft and fasten in place with the special fillister head screw No 1175 Fig 2 The spring clip supplies the necessary tension to automatically close the guard and hold it so during the operation of the machine d Before locking the sprocket to the gear 002 piece of shim steel should be placed between the back of the sprocket gear hub and the spacing washer The end of the shim should be U shaped to fit round the Sprocket shaft e With the shim in position tighten the two 2 B A Allen set screws No 11859 Fig 2 located in the hub of the sprocket gear These two screws should be tightened a little at a time to avoid bending Remove the 002 shim The sprocket and gear must revolve freely f All sprockets are assembled in the same manner and the parts involved are the same g Assemble the upper and lower strippers No 11762 Fig 2 into place Faste
12. Allen set screws in the hub of the governor Place the motor extension shaft No M50140 Fig 4 over the end of the armature shaft and lock in position with the two 3BA Allen set screws The motor end cover No 00132 Fig 4 can now be fastened place by the two screws No 10349 Fig 4 REASSEMBLE GEAR CASE The instructions relating to the dis assembly of the gear case have dealt only with the refitting of minor components If during dis assembly it was found necessary to completely strip the gear case for cleaning or the replacement of worn parts the re as sembly of certain components will entail the use of some special tools and fixtures These tools are the same as those used on the Model 621 Gear Case and their applic ation is fully explained in the Model 621 Service Manual These instructions can in the main be applied to the Model 609 Gear Case There is however a variation in the de sign of the two gear cases and the instruct ions dealing with the timing of the fibre counter gear with the the shutter shaft Page 23 Section 5 Paragraph B must not be applied to the Model 609 Gear Case The in structions for the timing on the Model 609 Assembly is as follows The index slot on the cam of the shutter shaft must be diame trically opposite the index hole in the coun ter gear not adjacent as in the Model 621 Instructions Failure to observe most care fully this procedure will give mistiming of
13. Brush Cover Governor Armature Projector Motor Field Motor Plate Sound Head Cover Fillister Head Screw Counter Sunk Head Screw Governor Projector Motor Knob Hand Turnover Part No 50141 50149 50154 50155 50156 50245 50244 50245 50249 50250 50255 50254 50255 50256 50257 50259 50260 50265 50267 50268 50269 50282 M50285 M50509 50316 50525 M50337 50383 50426 202254 Description Case Gear Terminal Block Cover Plate Clip Spring Plate Switch on off Screw 6 32 Fillister Head Fan Projector Motor Oval Head Screw Tag Board Head Take up Housing up Unit Housing Cover Take up Unit Terminal Strip Post Take up Switch Knob Fillister Head Screw Rheostat Switch Take up Unit Standard Washer Belts up Sound Head Name Plate Take up Selector Main Plate Ring Retaining Shaft Fan Intake Fan Cap Fan Bearing Choke R F Rubber Surround Photo Cell Unit Cover Supressor Condenser Field Retainer Stud Rheostat Knob Switch D P D T Exciter Lamp 4 volt 75 amp 0 G B Bell 6 Howel MODEL 609 16 mm ARC PROJECTOR SECTION 5 ILLUSTRATIONS MODEL 609 SPARE PARTS LIST FIGURE 1 GEAR CASE Part No Description 05057 Lock Lens 03462 Clip Assy Film Tension Upper 03463 Clip Assy Film Tension Lower 03464 Shaft amp Knob Assembly 145 Ball Steel 46855 Spring Film Ga
14. M50309 Choke R F M50337 Field Retainer Stud Serial No and type must always be quoted when ordering spares ml 14 GB Be Howeu Move 609 Assems y Pro ECTOR MODEL 609 SPARE PARTS LIST FIGURE 5 HEATER FILTER ASSEMBLY Part 6201 15778 15779 15780 15781 15783 169508 Description Sorev Fillister Head Holder Filter Glass Filter Retainer Filter Glass Spring Filter Frictlon Baffle Light Sorev Fillister Head Serial No and type must always be quoted when ordering spares GB Be 8 Howe 609 PROJECTOR Hear Fitter AsseMBLY pi wf Lo Li LE iie Fic 5 MODEL 609 SPARE PARTS LIST FIGURE 6 HOUSING ASSEMBLY Part No Description 05002 Fan Assembly 1361 Screw Fillister Head 5225 Screw Fillister Head 9335 ocrew Fillister Head 10356 Bearing 6mm Radial 12087 Hexagon Nut 15703 Spacer Fan Shaft Long 15708 Cone Fen Housing Heat 15709 Housing Fan 15782 Housing Filter 15784 Baffle Blower 50282 Intake Fan M50283 Fan Bearing t dum Gem anb emm em Serial No and type must always be quoted when ordering spares GB Beta GOO Provector Fan Housinc 5 wd oe E ea 8 MODEL 609 SPARE PARTS LIST FIGURE 7 FAN HOUSING ASSEMBLY Part No 04758R 04769 4373 5195 5211 6403 8988
15. REMOVAL OF GEAR CASE AND BLOWER ASSEMBLY a The 470 ohm Motor resistance assembly No 04758R Fig 7 which is housed below the fan housing No 15709 Fig 7 should be dis connected from the main terminalstrip b Lay the Projector on its side and re move the cover plate No 50136 Fig 9 from the base of the soundhead assembly c Remove the three screws and lock washers which are located inside the sound head directly beneath the gear case d The gear case and blower assembly is now free of the soundhead assembly 3 REMOVAL OF GEAR CASE FROM FAN HOUSING ASSEMBLY The film guide rail No 5641 Fig 1 will freed by the removal of the two screws 5267 Fig 1 situated at the top and bottom of this part There is small spac ing washer No 4258 under the head of each Screw Remove and handle carefully to prevent loss of the washers when the screws are re moved b With the removal of the two fillister head screws No 5266 Fig 1 situated at the rear of the gear case immediately above and below the blower shaft the gear case can now be separated from the blower case Care should be taken when parting these two as semblies to avoid the possibility of damage to the fibre gear No 03135 Fig 3 Move the gear case slightly until the counter gear breaks mesh with the pinion gear No 21328 Fig 7 fitted to the fan shaft and until the dowel pin 9171 Fig 7 on the rear side of the fan case is free fro
16. 6 Fig 12 holding the motor to the main body of the take up unit The motor assembly is now free of the main unit b To remove the take up drive mechanism from the motor three fillister head screws 5266 Fig 13 holding the gear box cast ing to the front end of the motor should be removed This assembly can now be eased a way from the motor casting 19 REMOVAL OF ARMATURE AND FIELD COIL FROM TAKE UP MOTOR a Remove the motor brushes Remove the two fillister head screws No 9098 Fig 12 holding the motor brush housing to the main body of themotor The brush housing No 02158R Fig 12 can now be eased off Care should be taken on re assembly of this brush holder unit to avoid the wires connected to the brush holders coming into contact with the armature assembiy b Grip the armature No 9090 Fig 12 and remove fillister head screw 112 Fig 12 holding the spiral gear No 02519 Fig 12 to the front end of the armature shaft A key way is cut into the front end of the armature shaft into which a dowel pin fit ted to the spiral gear engages With the spiral gear removed the armature can be with drawn from the motor To remove the motor field coil No 9092 Fig 12 unscrew the two field retaining nuts No 5201 Fig 12 and withdraw the field coil from the motor housing Note the manner in which the wires leave the field and the way they are placed to avoid contact with any moving part
17. 9087 9088 9089 9090 9092 9093 9098 9117 9171 9208 9260 9305 Description Steel Ball Grade A Fillister Head Screw 5 40 x 9 32 Screw Bearing Shutter and Counter Shaft Shaft Shuttle Spring Ball Retaining Rail Guide 1 Fillister Screw Set Screw Screw Fillister Head Spacer Governor Connecting Link Washer Spring Steel Ball 1 l6th Fillister Head Screw Screw 6 32 x 3 8 Fillister Head Shoulder Screw Shuttle Double Tooth Fillister Head Screw Washer Friction Gear Take up Spiral Cap end Washer Friction Drive Retainer Bearing Washer Star Friction Spacer Armature Take up Fiel Motor Take up Retainer Fillister Head Screw Hexagon Nut Dovel Pin Bearing Roller Ball 1 16th Steel Fillister Head Sorew Part No 9335 9414 9415 9426 9427 9558 9718 10291 10545 10549 10556 10590 10529 10565 10925 10926 10927 10928 10929 11054 11055 11110 11147 11178 11268 11269 11277 11280 11281 11282 115718 115728 11575 11577 Description Screw Fillister Head Plate Snubber Bearing Snubber Bearing Felt Oiler Felt Oiler Baffle 011 Fillister Head Screw Knurled Head Screw Plug Fillister Head Screw Bearing 6mm Radial Washer Locking Washer Shim Motor Shaft Extension Knob Retainer Friction Block Block Friotion Screw Adjusting Cap Screw Spring Comp
18. 9171 15704 15705 15709 15731 15755 21328 21550 21331 50269 Deseription Resistor Assembly Shutter Assembly Fire Bearing mm Radial Washer Motor Pinion Fillister Head Screw Spacer Governor Connecting Link Fillister Head Screw Dowel Pin Spacer Fan Shaft Short Spring Fan Shaft Preload Housing Fan Shield Aperture Heat Screw Shoulder Pinion Motor Screw Compression Ring Retaining Shaft Fan ee GER Serial No and type must always be quoted when ordering spares GR Be 8 Howe 609 PROJECTOR Fan ipid ET 7 591645 p qonb eq 94676 48nu edi ON 1871195 Teoy miy sutadg Ay 4617 UT a oppna STASI 1 qqnus pnig 0 188914 2 Suiidg 62601 deg 82 601 4260 0 X9OTd 9260 20018 UOTPOTAg 52601 19035 149 MOTOS 785 49195 194511114 4616 31195 9 9 21 ieuug 1194 998y 198 z 3n0 098 Toa quessy 69270 ATqm ssy 28980 27280 101744710690 4184 4 4 97 WAV 7498 SI
19. FILM TECH THE INFORMATION CONTAINED IN THIS ADOBE ACROBAT PDF FILE IS PROVIDED AT YOUR OWN RISK AND GOOD JUDGMENT THESE MANUALS ARE DESIGNED TO FACILITATE THE EXCHANGE OF INFORMATION RELATED TO CINEMA PROJECTION AND FILM HANDLING WITH NO WARRANTIES NOR OBLIGATIONS FROM THE AUTHORS FOR QUALIFIED FIELD SERVICE ENGINEERS F YOU ARE NOT A QUALIFIED TECHNICIAN PLEASE MAKE NO ADJUSTMENTS ANYTHING YOU MAY READ ABOUT IN THESE ADOBE MANUAL DOWNLOADS WWW FILM TECH COM 6 8 Howel MODEL 609 16mm Arc Projector SERVICE MANUAL SPARE PARTS LISTS CARE amp MAINTENANCE RANK PRECISION INDUSTRIES LTD Cine amp Optical Division 37 41 MORTIMER STREET LONDON W 1 3rd EDITION JUNE 1956 Introduction We have pleasure in presenting for service purposes the following informa tion 1 2 3 4 5 6 7 Service Instructions covering the majority of assemblies and parts of the Model 609 Projector As there are many assemblies and parts which are common to both the Model 609 and Model 621 Projectors these instructions where applica ble are cross referenced to the Model 621 Service Manual G B Bell amp Howell Model 609 Arc Projector Spare parts List and Exploded Views G B Bell amp Howell Model 621 Service Manual which covers most of the gear case and some other assemblies which are common to both the Model 609 and Model 621 Projectors Circuit Diagram the Mod
20. OR BRUSHES Solder the four leads from the motor to their respective positions on the terminal strip Fit the cover No 50250 Fig ll in pos ition and secure with four long fillister head screws 50255 Fig 11 b The take up drive casting No 113795 Fig 13 must be placed carefully into posi tion over the spiral gear attached to the motor armature shaft This unit is secured to the motor body by three fillister head screws No 5266 13 Insert the motor brush No 12918 Fig 12 and springNo 12909 12 into the square hole of the brush holder If the brush is not new be sure the concave surface of the brush will fit the curve of the commutator The brush and spring are held in place with the motor brush cap 18 ASSEMBLE GEAR CASE TO F N UNIT a Carefully place the gear c8se assembly into position on the face of the fan unit so that the dowel pin No 9171 Fig 7 on the fan housing engages the corresponding hole in the gear case b Inasmuch as the fibre counter gear No 03135 Fig 3 and the fan shaft pinion gear No 21328 Fig 7 must be meshed when the gear case is assembled to the fan housing care must be taken that the teeth of the fibre gear are not damaged during the assembly At no time is it necessary to force the gear case into place and under no circumstances should it be done the event that some difficulty is encountered making the assembly the gear case should be carefull
21. RUCTION SECTION 3 ADJUSTMENTS Adjustments a GENERAL 1 It is important that the projector be carefully tested and that certain adjustments to various components be made upon completion of repairs which have included any disassembly and re assembly Besides the folloving spec ific adjustments the final inspection of a repaired machine should include the running Of a spool of sound reproduction b ADJUST PRESSURE PLATE 1 Adjustment may be necessary to ensure that the proper tension is applied to the film This adjustment can be made only after the gear case has been securely fastened to the blower housing and all screws securely tightened 2 Close the gate by moving the gate lever down as far as it will go 3 Loosen the locking screw located in the top side of the lug on the front plate in which the gate operating lever pivots With a suitable lever inserted into one of the holes of the eccentric bush turn the bush until the gate shoe just comes into con tact with the aperture plate Observe the shoulder of the two studs on the back of the gate shoe When tne separation between the stud shoulders and ihe retaining plate is approximately 002 inch the adjustment is correct The lens carrier must be closed all the way Tighten locking screws to lock adjustment 14 4 Too little or too much pressure may result in an unsteady projected picture c SPEED 1 Speed adjustment necessary must be very ac
22. TED SHOULD ONLY BE USED IF TYPE EF 37A 15 UNOBTAINABLE 9 SCREENED LEADS FROM PRIMARY SIDE OF TRANSFORMER ANO 35 m SHOULD BE IN 7 0076 446 1 H E D C OUTPUT TO ARC LAMP e o X 4 Y 1 P c v 2 bal ul o in Gi CH E Hi 1 o gt a x 3 U D r 2 u x gt 1 gt zu 4 d 9 4 2 9 29 lt 5 gt 2 gt s 544 Xx xut g 0 m D 2 4 go i 2 1 6 2 7 e xali QM gi 2 5 m RED 29 amps 0 0172 DC 001 28 50 5 RECT O Back lt TO INSPECTION LAMP IN D C 000 O 3Q D C OVERALL 000 240 250 220 230 200 210 4 Qd 5 Ga af 90 808 gt CASE KE 52 4 4 d 9 1 F 2 A Fr e e e 6 ae GN RUNE aT 24 BLACK THEORETIC m r APPD BY mW z H TYPE SWITCH 2 BANKS 1 SHOWN TAKE UP POSITIONS OF ei i ies AF er IF gSF Jr iB 4 4
23. VE HAVdS 609 TATON ATaWassy 1334 4 6O9 1290y lag 2 pejonb eq 94676 ysu ON Ter es 1940 run 1199 Punoizng 91208 MOTOS PRH 77503 8 81d 19402 10014 67109 M ZOS xung 1 4uno2 DS TOS peog punog 918614 9109 punog 941889 481048 pue Deen punog 02 08 UT8115 91480 85491 UST 1 10400 621 MOIOS PESH 193STTIJJ 9929 PUOH 48ST Tquessy 4100 1700 04040 490920 103404 dn ATQuessy 91489 240520 punog ATqm ssy 12906 pue 2 69170 1921114835 06960 ATqm ssy zoggnug 74930 10114729890 ON Med ATENNSSY 0406 LSII SLYVd 44 45 609 IHTON ATaNISSY ava H 609 1300 8 114440 502845 8 6476 GA 17104 dueg 91814 eusN Den punog punog 264 310 u0 yo4Tas 09612 punog 911660 UTTE 8014 5
24. be slipped from the end of the shaft Note that the end of the sprocket stem locates in the hub of the gear Remove the thrust washer No 6419 Fig 2 located between the end of each sprocket and gear 11 REMOVAL OF SHUTTER AND SHUTTLE a remov amp the hexagon nut 5112 Fig 3 from the shuttle shaft a special off set wrench should be used to hold the cam shaft below the flicker shutter while the hexagon nut is removed b In the event of a suitable wrench not being available it is possible to remove the nut if the shutter can be held still by an alternative method Every care must be taken to avoid damage to the flicker shutter and shuttle shaft When the hexagon nut is removed lift off the two shutter supports No 12789 Fig 3 and flicker shutter No 12788 Fig 3 Note that the stud on the bottom of the lower shutter support engages the indents of the flat surface on the shuttle shaft and that the stud on the bottom surface of the upper shutter support extends through the hole in the shutter and into the recess in the top of the lower shutter support The above assembiy should be carefully observed so that the various parts can be re assembled in the same manner d Lift up the oil baffle assemblies No 9558 Fig 3 and No 01078 Fig 3 clear the gear case Note the manner in which the oil baffle engages the slot in the gear case Casting Unscrew the two fillister head screws No 5123 Fig 3 ho
25. before any tension is felt on the snubber This means that the torsion spring in the snubber is at rest when the snubber is in position but upon raising the snubber about 1 16 of an inch the torsion spring begins exerting 15 pressure on the snubber As the snubber is raised the tension will build up strong enough to take care of all conditions YOKE AND ARM ASSEMBLY OSCILLATORY STAB ILIZER 1 Make an endless loop of buzz track Sound film which should be threaded through the second sprocket the yoke and arm assem bly oscillatory stabilizer and the third sprocket 2 With the mechanism running and the amplifier and the speaker turned on the stabilizer should be positioned the shaft on which it pivots by moving it in or out as necessary until the least amount of sound is audible The buzz track sound film has a low frequency along one edge of the sound track and a high frequency on the other edge of the sound track It is when the stabili zer is positioned so that it centres the sound track on the scanning beam that the minimum sound reproduction is audible from both tracks Thus positioned the stabilizer is correctly adjusted 3 conjunction with this setting another adjustment must be made The spring tension of the stabilizer should be adjust ed by turning the bearing retaining sleeve in which the two set screws are mounted so that the stabilizer comes to rest in its operating posit
26. bly armature No M50133 Fig 4 can now be withdrawn from the motor Note the Spacer No 15721 Fig 4 which is on the front end of the armature shaft and the spring washer No 15706 Fig 4 which is left in the ball race housing of the motor casting Care should be taken that these items are fitted correctly when re assembly takes place 6 REMOVAL OF MOTOR FIELD remove motor field M50134 Fig 4 unscrew the four field retaining nuts No 5201 Fig 4 and withdraw the field from the motor housing Note the manner in which the wires leave the field and the way they are placed to avoid contact with any moving part DiS ASSEMBLY OF GEAR CASE 1 REMOVAL OF FILM GUIDES AND LENS CARRIER Remove the pressure plate assembly by pulling on the movable visible metal frame b To remove the lens carrier assembly it is necessary at first that the film guides No 11761 Fig 2 be removed Unscrew the four screws No 7493 Fig 2 holding these two items and slip the upper and lower film guides from position These guides are the Same and can be interchanged c lens carrier retainers No 11799 Fig 1 are now accessible and must be unscrewed Lift straight up on the lens carrier assembly to remove it 8 REMOVAL OF SPROCKET GUARDS FILM ROLLER TENSION CLIPS AND APERTURE PLATE a To remove the upper and lower sprocket guards 04946 Fig 2 unscrew the two screws No 11757 Fig 2 which are lo
27. catedin the centre of each guard and in the end of the sprocket shafts As the guards are removed note the spring clips No 16243 Fig 2 and washers No 16244 Fig 2 located beneath the hinge part of the guard b Remove the upper and lower film strip pers No 11762 Fig 2 These parts are inter changeable Unscrew the two fillister head screws No 5021 Fig 1 holding the upper No 03462 Fig 1 and lover No 03463 Fig 1 film tension clip assemblies These tvo clips are situated on the film gate thrust spring 4255 Fig 1 vhich is also held in place by the same tvo screvs d The back edge of the film gate thrust spring rests against the inner edge of the aperture plate No 11852 1 and thus holds it in position on the gear case assembly When the film gate thrust spring has been removed the aperture plate can be separated rom the gear case 9 REMOVAL OF FRAME SHAFT AND KNOB a the back of the aperture plate are two prongs which fit over the eccentrice of the framer shaft and knob assembly No 03464 Fig 1 After the aperture plate has been removed the framer shaft and knob assembly can be withdrawn from the outside of the gear case casting 10 REMOVAL OF SPROCKETS a Each of the sprocket assemblies No 03461 Fig 2 is locked in place by two Allen set screws which are located in the hub of the upper and lower sprocket gears Use 2BA Allen key to loosen these screws The sprockets can
28. curate in order to obtain satisfactory sound quality and the only accurate method of checking the speed is with a tachometer When using a tachometer the reading is taken from the hand setting knobon the motor exten sion shaft At 16 frames per second silent speed the reading is 3 500 revolutions per minute At 24 frames per second sound speed the reading is 5 250 revolutions per minute 2 A somewhat simpler method of timing necessitates the use of an endless film loop exactly 80 frames long 2 feet long At sound speed the loop will pass through the mechanism 18 times per minute Count the as it passes a pre determined point At silent speed the loop will pass through the mechanism 12 times per minute 3 The speed is adjusted by means of the set screw located on eacli set of contact points on the governor These contacts oper ate under spring tension one set of points being for silent the other for sound speed The set of points with the weaker spring con trols silent speed and the strong spring controls sound speed 4 turning the set screws which ad just the gap between the contact points in creasing the gap the correct speed can be obtained d SPROCKET SYNCHRONIZATION 1 Toensure satisfactory sound reproduct ion it is essential that the sprocket on the Sound head is correctly set in relation to the second sprocket of the gear case so when film is laced it is held under ten
29. e support engages the index slot in the surface of the shuttle shaft Lay the shutter No 12788 Fig 3 in place and assemble the sec ond shutter support No 12789 Fig 3 on the top of the shutter so that the extruded stud of this support passes through the hole in the shutter and engages the slot on the top of the lower shutter support h Hold the cam partof the shuttle shaft with a special offset wrench and assemble the hexagon nut No 5112 Fig 2 on to the end of the shaft As stated in the dis assembly instructions in the event of a suitable wrench not being available this operation can be carried out by alternative methods but every care must be taken to ensure that no damage occurs to the shutter or shuttle shaft assemblies Tighten the nut securely Revolve the shutter and see that it does not strike the oil baffle or the casting at any point 7 REASSEMBLE BLOWER UNIT INSTALL FAN SHAFT AND BALL RACE The fan shaft No M50269 Fig 7 with the pinion gear No 21328 Fig 7 pinion wash _ ers and ball race No 4373 Fig 7 assembled should be guided into the front ball race housing of the blower case b The ball race should be carefully pressed or tapped into its housing so that it seats evenly and is not tilted 8 INSTALL FAN a The fan is not secured to the shaft by set screws but is held in position by the two spacers at each end of the fan hub b Before placing the fan No 05002 Fig 6 on the s
30. e corresponding two holes of the motor mounting plate b Secure the motor in position by four Screws two fillister head No M50137 Fig 4 and two oval head No 1587 Fig 4 As the motor is placed in position be sure that the coupling engages accurately in the keyway of the motor armature shaft 20 INSTALL LENS CARRIER AND FILM GUIDES a Place the gate operating block No o160 Fig 4 into the milled slide on the back of the lens carrier No 11750 Fig 1 Note that one side of this block has rounded corners The block should be placed into the slide so that the rounded corners rest against the lens carrier casting Lay the lens car rier assembly No 11750 Fig 1 and the gate operating block No 5160 Fig 4 into the milled channel of the gear case so that the hole in the gate operating block engages the stud on the gate lever No M025069 Fig 4 Place the two lens carrier retainers No 11799 Fig 1 in position so that the three prongs on the edge of each retainer holds the lens carrier in place Fasten in place with the four pilot screws No 15203 Fig 1 21 INSTALL AND ADJUST FILM GUIDES a The film guides No 11761 Fig 2 are held in place below the upper sprocket and above the lower sprocket each by two fillister head screws No 7493 Fig 2 b The clearance between the film guide and sprocket should be from 012 to 014 in ches and under no circumstances should it be set at less than the 012 inch mini
31. e the front armature shaft bearing No 10356 Fig 12 from its seat the new race should be carefully pressed or tap ped into place so that it seats evenly and IS hot tilted b Use a spanner wrench which fits the two slots in the top of the bearing retainer No 9093 Fig 12 and tighten it securely 11 15 INSTALL ARMATURE AND SPIRAL GEAR a Before installing armature into the motor housing check to see that the field wires are properiy placed so that there is no possibility of their rubbing on the arma ture b Insert the long grooved end of the armature shaft through the motor field and through the front bearing c Place tbe spiral gear No 02519 Fig 12 over the end of the shaft The dowel pin fitted to the gear engages in the grooved section of the shaft Hold the armature and secure the gear with the large fillister head Screw No 112 Fig 12 16 INSTALL MOTOR BRUSH CAP a As the motor brush cap No 02158R Fig 12 is pressed into place over the rear armature shaft bearing No 10356 Fig 12 this bearing is locked to the shaft by a special fillister head screw No 112 Fig 12 the leads attached to the brush holders must be carefully placed to avoid their making contact with the armature b Secure the motor brush cap in position with two long fillister head screws No 9098 Fig 12 Rotate armature snaft to check that its movement is free 17 ASSEMBLE COVER PLATE AND TAKE UP DRIVE AND MOT
32. el 609 Mechanism head and up Assembly Circuit Diagram for the Model 609 Amplifier Circuit Diagram for the Model 609 Arc Rectifier Spare Parts Catalogue for the G B Kalee Universal Arc Lamp The Model 609 Arc Lamp is identical in most respects to the G B Kalee Universal Arc Lamp and the Spare Parts Catalogue which is issued will for all practical purposes be most useful when ordering spare parts and also for maintenance purposes In the main the only differences will be the dowser assemblies and the inclusion of a pilot lamp in the Model 609 Arc Lamp We hope to publish shortly a leaflet covering more fully these variations G B Bell Howe MODEL 609 16 mm ARC PROJECTOR SERVICE INSTRUCTIONS SECTION 1 DISASSEMBLY PROCEDURE Disassembiy Procedure THE PROJECTOR HEAD 1 REMOVAL OF MOTOR UNIT Remove the cover plate No 50149 Fig 9 at the rear side of the casting Disconnect the motor wires from the terminal strip b Remove the four screws 2 No M50137 amp 2 No 1587 Fig 4 holding the motor unit to the front of the gear case The motor can now be taken from the Projector Head The drive coupling No M025119 Fig 4 connecting the rear endof the motor shaft to the cooling fan shaft should be removed The gate opera ting block No 5160 Fig 4 which is located in the channel at the back of the lens carrier should be removed to avoid any possibility of this part being lost 2
33. fficulty b The roller yoke and arm assembly No 03690 Fig 9 is removed by loosening two sets screws on the knurled collar and with drawing the entire assembly from the pivot stud Do not remove this assembly or tamper with its critical adjustment unless it fails to function satisfactorily Unless the rol ler will not revolve it is unlikely that any adjustment whatsoever is needed 16 REMOVE OPTICAL SLIT a The optical slit assembly No 02678 Fig 10 is assembled at the factory It is positioned in the sound head by means of several delicate precision instruments and is set to ensure the maximum efficiency Note that the tube is locked in place with the screw 5893 Fig 10 and that a coat ing of cement has been placed over the screw head Experience has shown us that it is not satisfactory to attempt the setting of this tube except at the Factory or with a special sound optics setting gauge 17 REMOVAL AND DIS ASSEMBLY OF FILM SNUBBER a The film snubber assembly can be re moved asa separate unit To do so the three fillister head screws No 5266 Fig 10 should be removed The entire snubber assembly 02674 Fig 9 can now be removed from the sound head DIS ASSEMBLY OF MOTOR TAKE UP UNIT 18 REMOVAL OF THE MOTOR UNIT a Remove the cover plate No 50250 Fig 11 at the rear of the take up casting Dis connect four motor leads from the terminal strip Remove the four fillister head screws No 5015
34. haft check to ensure that the spacer No 15704 Fig 7 is in position the shaft immediately behind the front ball Next place the fan No 05002 Fig 6 on the shaft The open end of the fan should face the rear end of the blover casting the air intake end Place the longer spacer No 15703 Fig 6 over the shaft against the hub of the fan 9 INSTALL REAR BALL RACE a Place the fan intake casting No 50282 Fig 6 in position against the blower casting and secure with three fillister head screws No 1361 Fig 6 b Before fitting the rear ball race place the preload spring No 15705 Fig 7 in position at the bottom of the ball race housing Place the ball race No 10356 Fig 6 over the threaded end of the shaft and press it squarely into its seating c Grip the fan shaft between the preload spring and the front ball race with a suit ably shaped pair of pliers and screw the hexagon nut No 12087 Fig 6 on to the end of the shaft d With the hexagon nut securely tight ened the rear bearing cap No M50283 Fig 6 can be screwed into position Check to see that the shaft is revolving freely 10 INSTALL HEAT FILTER HOUSING AND LIGHT Place the heat filter housing No 15782 Fig 6 position against the blower cast ing and fasten in place with three fillister head screws No 3225 Fig 6 10 b Next place the light baffle No 15783 Fig 5 in position and fasten to the heat filte
35. ion within 2 seconds after the mechanism has been started 4 Only by making these two critical ad justments correctly can the sound reproduction is absolutely true since it depends upon the oscillatory stabilizer functioning perfectly 8 FILM RUNNING TEST 1 Upon completion of repairs and after allthe necessary adjustments have been made it is always advisable to run film through the machine in order to check the mechanical and sound operation of the projector The film should be in good condition and one on which the sound is known to be satisfactory 28 820 2 Howell MODEL 609 16mm ARC PROJECTOR SECMON 4 SPARE PARTS LIST MODEL 609 SPARE PARTS LIST Part No Description 01078 Lubricator Assembly 01477 Oiler Assembly 021588 Take up Motor Assembly 021598 Worm Assembly Take up 02247 Roller Assembly Idler 02674 Snubber Assembly 02678 Optical Slit Assembly 02682 Spindle Assembiy Reel 03037 Look Lens 05155 Gear and Shaft Assembly Counter 055188 Arm amp Bearing Assy Take up 03520R Spindle amp Take up Pulley 05461 Sprocket Assembly 05462 Clip Film Tension Upper 03463 Clip Assy Film Tension Lower 03464 Shaft amp Knob Assembly 03466 Wheel Assembly Sprocket Worm L H 03690 Stabilizer Assembly 03692 Damper Assembly Exciter Lamp 04169 Bearing end Shaft Assembiy Sound Drum 04758R Resistor Assembly 04765 Screw Assembly Ree
36. l Am 04769 Shutter Assembly Fire 04770 Mount Assembly Coil 04946 Guard Assembly Sprocket 05002 Fan Assembly 025000 Holder Governor Brush Assembly 025067 Photo Cell Unit Assembly 025069 Lever Assembly Gate Operating 025075 Cable Assembly up Motor 025078 Socket Assembiy Exciter Lamp Part No 025085 025091 025092 MO25119 112 145 860 861 890 891 1361 1375 1587 2565 2464 5225 4255 4258 4575 4460 4664 49668 5021 5112 5115 5125 5148 5157 5160 5195 5200 5201 5211 Description Screw Assembly Take up Unit Tag Board Assembly up Unit Input Plug up Unit Coupling Shaft Fillister Head Screw Ball Steel Race Ball Outer Race Ball Inner Gear Idler Shaft Idler Gear Screw Fillister Head Washer Split Retaining Oval Head Screw Screw 10 32 Fillister Head Radial Bearing 6 m m amp Type 2176 Screw Fillister Head Spring Film Gate Thrust Washer Bearing Radial Fillister Head Brush Governor Housing Motor Take up Fillister Head Screw Hexagon Nut Pin Dowel Screw Special Fillister Head Screw Fillister Head Screw Block Gate Operating Washer Motor Pinion Stud Field Retaining Nut Field Retaining Fillister Head Screw Part No 9238 5266 5267 5296 5522 5618 5641 2845 0893 6201 6403 6419 6715 7493 7746 8918 8955 8988 9085 9084 9085 9086
37. lding the shuttle guide pins No 5113 Fig 3 in place The shuttle No 8933 Fig 3 can now be lifted clear of the shutter shaft andthe guide pins removed 12 DIS ASSEMBLY OF THE BLOWER UNIT a Remove the lisht baffle No 15783 Fig 5 which is held in place at rear of this assembly by four fillister head screws No 16930R Fig 5 Next remove heat filter housing No 15182 Fig 6 which is attached to the blower casting by three fillister head screws 3225 Fig 6 b The fan shaft No M50269 Fig 7 is removed in the following manner Remove the fan bearing cap No M50283 Fig 6 at the rear end of the blower shaft thus exposing the ball race No 10356 Fig 6 The shaft is locked to this ball race by a hexagon nut No 12087 Fig 6 Remove the nut and also the three fillister head screws No 1361 Fig 6 holding the fan intake casting 50282 Fig 6 to the main body This casting can now be withdrawn from the blower casting The ball race which is housed in the intake casting can now be removed Note the preload spring No 15705 Fig 7 housed in this casting beneath the ball race No 4373 Fig 7 c The cooling fan No 05002 Fig 6 and spacer washer No 15703 Fig 6 can now be removed from the shaft No M50269 Fig 7 Note the further spacing washer No 15704 Fig 7 which is situated immediately behind the front ball race of the fan shaft Care should be taken when re assembling this shaft to ensure that these
38. m the dowel hole 4 DIS ASSEMBLY OF MOTOR UNIT Remove the two screws No 10349 Fig 4 holding the cover No 50132 Fig 4 on the front end of the motor Use a 3BA Allen key and loosen the two Allen set screws in the motor extension shaft No M50140 Fig 4 The shaft can now be removed b The motor governor No M50139 is locked to the shaft by the two 4BA Allen set screws In addition there is a hexagon nut No 9117 Fig 4 which is locked in place by two prongs of the locking washer No 10390 Fig 4 behind it Firstly straighten these prongs hold the governor carefully and remove the hexagon nut The two Allen screws the hub of the governor should now be loosened and the governor removed Remove spacer No 15721 Fig 4 immediately behind the governor hub Remove the three governor brushes No 4664 Fig 4 fromthe brush holders the motor cap Note that these brushes must fit freely in the holders 5 REMOVAL OF BRUSH BOX HOUSING a Before removing the brush box assembly No 50131 Fig 4 from the the motor the two motor brushes should be removed b Remove four screws No 9718 Fig 4 securing the brush holder casting to the motor body Ease the complete assembly away from the motor housing Note the manner in which the wires leave the field and the way they are placed to avoid contact with any moving part It will not be possible to disconnect the three fieldcoil leads from this assem
39. mum To adjust loosen the two screws that hold the film guide in place and fit two thick nesses of film around the sprocket The film guide should just clear the two thicknesses of film and the film should not be pinched between the sprocket and the film guide two thicknesses of film are equivalent to approx imately 012 inches 22 INSTALL MOTOR GEAR CASE AND BLOWER ASSEMBLY ON SOUND HEAD a Place the motor and gear case assembly on the sound head so that the two dowel pins No 50110 Fig 10 engage the two dowel holes in the bottom of the gear case At the same time guide the two leads from the motor re sistence assembly 04758R Fig T Jattached to the blower casting through the two holes at the rear of the sound head casting Hold the gear case in position on the sound head and secure with three fillister head screws and lock washers on the inside of the sound head casting immediately below the gear case b Insert the four motor field leads through the special cover and into the sound head casting special cover can now be Secured to the sound head casting with the two fillister head screws Connect the four motor field leads and the two resistance leads to their respective positions on the main terminal strip c Secure the terminal cover plate No 00149 Fig 9 in position with three oval headed screws No 50244 Fig 9 13 G B Bell 6 Howell 16mm ARC PROJECTOR SERVICE INST
40. n with fillister head screws No 7493 Fig 2 9 ASSEMBLE APERTURE PLATE AND FILM TENSION CLIPS a Insert the framer shaft No 03464 Fig l into the hole at the side of the gear case Lay the aperture plate No 11852 Fig 1 in position on the gear case and see that the two prongs that extend to the back side of aperture plate engage the eccentric cam on framer shaft b The film gate thrust spring 4255 Fig 1 is next placed in position then the upper and lover film tension clips No 03462 1 amp No 03463 Fig 1 are placed in their respective positions Fasten the clips and thrust spring to the gear case with the two fillister head screws No 5021 Fig 1 c The back edge of the film gate thrust Spring rests against the inner edge of the aperture plate Itwillthus hold it in posi tion on the gear case during the remainder of the assembly The aperture plate will be solidly secured by two large headed screws No 5267 Fig 1 when the completed gear case assembly is fastened to the blower housing assembly 6 ASSEMBLE SHUTTLE AND SHUTTER INTO GEAR CASE a shuttles are made in six types in order to assure greater ease in good fit ting Each shuttle is marked either 00 0 1 2 3 4 For replacement a shuttle bearing the same number as that of the shuttle re moved should be used whenever possible b Insert the two shuttle dowel pins 5113 Fig 3 into the shuttle slides These dowel
41. ng 7495 Fillister Head Sorew 11147 Washer 11269 Headless Set Screw 11757 Fillister Head Screw 11758 Shaft Sprocket 11761 Guide Film 11762 Stripper Film 11859 Screw Headless Set 11868 Gear Upper 16243 Spring 16244 Washer Tension 50141 Case Gear Part No Description 01477 Oiler Assembly Serial No and type must always be quoted when ordering spares GB Bet a Howe 609 Provector Gear Case AssemBLy 2577000 arses UN S 1 1 AA ei WI Ba d se te SC zur mal u hs WEN 41454 Ez A m ed eS Zum EN zn ei See 7 17 e al E 2 Eens Zum 25 2 1 55 22 27 MODEL 609 SPARE PARTS LIST FIGURE 5 GEAR CASE Part No Deseription 01078 Lubricator Assembly 03135 Gear and Shaft Assembly Counter 5112 Hexagon Nut 5115 Pin Dowel 5125 Screw Special Fillister Head 5296 Bearing Shutter and Counter Shaft 5322 Shaft Shuttle 8918 Shoulder Screw 8955 Shuttle Double Tooth 9260 Ball 1 16th Steel 9426 Felt Oiler 9427 Felt Oiler 9558 Baffle Oil 10529 Washer Shim 11054 Spring Clamp 11055 Flat Head Screw 11110 Spring Compression 11277 Worm L H 11280 Collar 11281 Sooket Set Screw 11282 Sooket Set Sorew 12788 Shutter
42. ohm 54 er CS3204 R53 gt qnc 102 027 eee Rod R62 Reference only Part of 55 098 R 110 pf R63 Resistor 22000 ohm 20 CSTB2 R64 22000 ohr 20 029 0 001 mfd 52206 R65 100 000 oh 54 co 0 0001 mfd 52201 m d uu vg S n des p R67 Potentiometer 1 meg ohm Ge 300 pf 868 Resistor 1 meg ohm 20 iss i Ge 22203 R69 33 000 ohm 20 og 51479 Potentiometer 1 meg 036 0 02 5 Ge 7 R72 Resistor 47 000 ohm 20 R73 510 000 ohm 10 R 1 Resistor 1 meg ohm 10 REX8105 TR 470 000 ohm 5 6 meg ohm 10 REX8565 Sil Socket 777 m R3 s 47000 ohm 20 REW9473 12 R 4 4700 ohm 104 REX16472 73 Jack R 5 100 000 ohm 10 REX100104 R 6 2 2 meg ohm 104 REX8225 T3 F cket RT gt 470 000 ohm 104 REX8474 8 47 000 ohm 20 REW8473 R 9 1 meg ohm 20 REW16105 Plug R10 47 000 ohm 20 REW9473 S Bor R11 2 200 ohm 10 REX8222 cocker R12 100 000 ohm 104 REX8104 SN R13 470 000 chm 204 REW16474 R14 21000 ohm 10 REX8273 R15 Potentiometer 0 5 meg ohm POC3504 9 R16 Resistor 21000 ohm 104 REX16272 F 4 Pune 500 ma R17 Potentiomer 50 000 ohm 202077 7 R18 Resistor 5600 ohm 104 REX16562 2 R19 gt 120 ohm 10 REX16121 ind R20 Resistor 5600 ohm 10 16562 R21 10 000 ohm 10 16103 S 5
43. old the front bear ing support in place The light shield No 12145 Fig 10 will come off at the same time Partly withdraw the sound drum until the hexagon nut which holds the fly wheel on the shaft is accessible The front bearing is part of the sound shaft assembly and will lift out of position Before the sound drum shaft assembly No 04169 Fig 10 can be re moved from the sound head a Tommy Bar will have to be inserted in the hole in the sound shaft and the fly wheel released by undoing the hexagonal nut The fly wheel can then be slipped up from the end of the shaft d The sound drum and shaft 04169 Fig 10 should be considered a unit and should not be taken apart If it becomes damaged to such an extent that sound quality is affected the entire assembly should be replaced Any attempt to separate the sound drum from the shaft will result in loss of time and will be followed by difficulties which cannot be overcome These sound drum and shaft assemblies are carefully assembled balanced and aligned at the factory and can be replaced only as a unit 15 REMOVE ROLLER YOKE AND ARM ASSEMBLY a It is possible to adjust or repair the roller yoke and arm assembly but this unit requires an extraordinary amount of care It is precisely set for run out and smooth ness of operation Before disturbing these parts make every attempt to trace the trouble to its real source which in turn may save time and di
44. pins should have the minimum amount of play in shuttle slides but must slide freely c Place the shuttle No 8933 3 over the camon the shuttle shaft No 5322 Fig 3 so that the V shaped heel of the shuttle en gages the grooved cam section of the counter gear and shaft assembly 03135 Fig 3 fitting the two dowel pins into the half round milled grooves in the casting d Press the two dowel pins out towards the sides of the casting as far as possible and lock in place with the two large fillister head screws No 5123 Fig 3 e Turn the mechanism by revolving the counter gear shaft All parts should revolve freely and evenly Care must be taken that the V shaped heel on the shuttle is not too tight in the cam groove of the counter gear and shaft assembly and that the shuttle op erates freely around the cam of the shuttle shaft on the dowel pins The play in all three parts should be held to an absolute minimum but all parts must work freely and evenly f Before fittingtheoil baffle assembly No 9558 amp No 01078 Fig 3 into place sat urate all felts of the lubricator with oil Lay the entire assembly into place in the gear case and make certain that the tip on the end of the oil baffle fits into the slot in the easting which is immediately above the framer knob Place one of the shutter supports No 12789 Fig 3 over the end of the shuttle shaft so that the round extruded studof th
45. r housing with four fillister head screws No 16930R Fig 5 SOUND HEAD 11 ASSEMBLE SOUND SHAFT AND FLYWHEEL a Extreme care must be used to prevent any dirt lodging in the 6mm radial bearing No 12246 Fig 10 fitted to the rear end of the sound shaft Ifthe bearing does not re volve freely wash the bearing in spirit Lubricate with a very light oil b Insert the end pf the sound drum shaft No 04169 Fig 10 through the opening in the front of the sound head casting and slip the flywheel over the end of the shaft Lock the flywheel securely to the shaft with the hex agon nut Insert the end of the shaft into the rear ball race previously installed The collar the sound drum end of the shaft is fastened to the casting with three fillister head screw No 5266 Fig 10 One of these screws also holds the light control shield No 12145 Fig 10 in position This shield prevents extraneous light from striking the photo cell and should be ad justed so that it does not intercept the scanning beam d Before fitting the rear flywheel shaft bearing cap No 13656 Fig 10 in position ensure that the loading spring No 13659 Fig 10 and phosphor bronze plunger No 13661 Fig 10 are in place in the cap The bronze plunger must make clean contact with the polished pipon the endof the flywheel shaft purpose of this assembly is to discharge automatically to earth the staticelectricity generated in the flywheel as
46. ression Spring Clamp Flat Head Screw Spring Compression Washer Round Head Headless Set Screw Headless Set Screw Worm L H Collar Socket Set Screw socket Set Screw Pins Plunger Spring Housing Worm Gear Ring Bearing Retainer Part No Description 11378R Take up Spindle Drive 115808 Pulley Take up Drive 11381R Bracket Take up Tension 11468 Take up Arm Shaft 11715 Washer 11750 Gate and Lens Carrier Film 11753 Bushing Roller Inner 11754 Roller Film 11757 Fillister Head Sorev 11758 Shaft Sprocket 11761 Guide Film 11762 Stripper Film 11795 Nut Pressure Plate Adjusting 11796 Plate Pressure 11799 Retainer Lens Carrier 11852 Plate 11856 Screw Fillister Head 11857 Stud Roller Outer 11858 Guard Roller Film 11859 Screw Headless Set 11867 Gear 11868 Gear Upper 11888 Motor Brush Cap 12071 Spring Compression 12075 Screw Fillister Head 12087 Hexagon Nut 12145 Shield Light Control 12246 Bearing 600 Radial 12511 Stud Mounting 12526 Stud Bell Tensioner 12719 Carrier Pressure Plate 12720 Yoke Pressure Plate 12776 Cup Spring 12778 12788 12789 12909 12918 15499 15656 15659 15661 157208 157888 14842 14848 14849 14852 15205 15703 15704 15705 15706 15708 15709 15721 15726 15751 15742 15745 15747 1575385 15755 15764 15772 15774 Description Screw
47. sembly whilst it is rotating e Secure the rear bearing cap No 13656 Fig 10 in position by three fillister head Screws No 5266 Fig 10 Properly assembled the sound drum shaft must revolve with ab solute freedom and with no high spots or indications sluggishness It must fectly balanced 12 REASSEMBLE UP UNIT INSTALL MOTOR FIELD a Insert the two field coil leads through the outlet hole at the topof the motor cast ing No 4966R Fig 12 b The motor fields No 9092 Fig 12 should be carefully guided into place over the two locating studs No 5200 Fig 12 and clamped in position by the two retaining nuts No 5201 Fig 12 13 FIT MOTOR TO MAIN CASTING a Before completing the assembly of the motor unit it is advisable to secure the motor casting to the main body of the take up unit No 50249 Fig 11 b First guide the two leads attached to the motor brush holders between the outside of the fields and the motor casting thence through the outlet hole at the top of the motor casting together with the field coil Ieads C The four leads must now be guided through the special outlet channel of the main casting and up on to the terminal strip No 025091 11 At this point the motor should be secured to the main body by four fillister head screws No 50156 Fig 12 14 INSTALL ARMATUKE SH FT FRONT BEARING a If during disassembly it was found necessary to remov
48. sion over the sound reproducing drum by the oscillatory stabilizer When the two sprockets are cor rectly oriented and with length of film laced through the sound head the stabilizer should rest under tension approximately mid way between the two stop pins on the sound head casting This setting can be obtained in the following manner 2 Loosen the special screw which holds the film guard to the third sprocket so that the sprocket can be pulled forward slightly it may be necessary to remove the stripper thus disengaging the second and sound sprock et gears and making it possible to turn the Sound Sprocket independently of the second sprocket If the teeth on the third sprocket are not in position to give the desired set ting of the stabilizer with film laced pull out the sound sprocket enough to permit its rotation and turn to alter the mesh of the two gears until the desired setting is ob tained When this has been achieved press the sprocket back into position tightening the screw and replace the stripper e SNUBBER TENSI N 1 The three screws that fasten the snub ber to the sound head casting must be left loose while the tension of the snubber is being set 2 Note that by turning the bearing part of the snubber that extends into the sound head the tension of the snubber can be in creased or decreased as desired Turn the bearing until the snubber can raised about 1 16 of an inch from the snubber stop
49. spacers are fitted in their correct positions d To remove the cooling fan shaft M50269 Fig 7 this should be pressed out in a forward direction e If it is found necessary to remove the pinion gear No 21328 Fig 7 from the shaft the utmost care should be taken to avoid any possible damage occurring to the cir clip washer No 21331 Fig 7 holding the pinion gear and washers No 5193 Fig 7 in place The pressure applied by the com pression spring No 21330 Fig 7 against this washer must be relieved before the washer 21331 can be removed 13 DIS ASSEMBLY THE SOUND HEAD The motor switch No 50426 Fig 10 which is housed in the sound head in acces sible by removing the cover plate No 50120 Fig 9 This is situated at the rear end of the sound head and is held in position by four oval headed screws No 1587 Fig 9 The locking nut on the switch should be moved thus enabling the switch to be parti ally withdrawn from the casting so that the Soldered leads can be disconnected 14 REMOVE SOUND DRUM BEARING SHAFT ASSEMBLY AND FLY WHEEL At the back of the sound head casting isa ball bearing retaining cap 13656 Fig 10 held in place by three fillister head screws No 5266 Fig 10 Remove the cap and phosphor bronze plunger No 13661 Fig 10 together when its loading spring No 13659 Fig 10 will be exposed b Remove the three fillister head screws No 5266 Fig 10 which h
50. te Thrust 4258 Washer 5021 Fillister Head Screw 5148 5266 5 40 x 9 32 Fillister Head Screw 5267 Screw 5618 Spring Ball Retaining 5641 Rail Guide 9208 Bearing Roller 11750 Gate and Lens Carrier Film 11753 Bushing Roller Inner 11754 Roller Film 11795 Nut Pressure Plate Adjusting 11796 Plate Pressure 11799 Retainer Lens Carrier 11852 Plate Aperture 11856 Sorew Fillister Head 11857 Stud Roller Outer 11858 Guard Roller Film 12071 Spring Compression 12075 Fillister Head 12719 Carrier Pressure Plate 12720 Yoke Pressure Plate 12776 Cup Spring 12778 Screw 3 56 Fillister Head 15203 Screw Pilot 16198 Bush 16207 Spacer 50141 Case Gear Serial No and type must always be quoted when ordering spares GB Diri Mooe 609 PROJECTOR Gear Case ni 11753 Sr BM v 22 5 2 m T 1857 Ea not sela mo 03037 12075 15203 un ES 3 11799 ge iss 7 a T ra 2 15203 ge 15203 11852 425 5 5021 03462 5 03463 5021 1207 gt Ian l z778 A ME 03464 Fic 1 MODEL 609 SPARE PARTS LIST FIGURE 2 GEAR CASE 03461 Sprocket Assembly 03466 Wheel Assembly Sprocket Worm L H 04946 Guard Assembly Sprocket 4460 Fillister Head Screw 6419 washer Spri
51. to see that the three field vires connected to the brush box housing vill not rub against the armature as the housing is pressed into position h With the brush box housing in position fasten the assembly to the motor housing vith the four screws No 9718 4 AGAIN CHECK TO SEE THAT ALL WIRES ARE CLEAR OF THE ARMATURE 2 INSTALL MOTOR BRUSHES a Insert the motor brush No 12918 Fig 4 and spring No 12909 Fig 4 into the square hole of the brush holder If the brush is not new be sure the concave contact surface of the brush will fit the curve of the com mutator The brush and spring are held in place with the motor brush cap No 11888 Fig 4 3 INSTALL GOVERNOR a Assemble the three governor brushes No 4664 Fig 4 ensuring their free movement in the holders b Slip spacer No 15721 Fig 4 on to the end of the armature shaft followed by the governor No M50139 Fig 4 Place the locking washer 10390 Fig 4 over the threaded portionof the arma ture shaft and screw the hexagon nut 9117 Fig 4 on to the shaft Insert a suitably shaped piece of flat metal into slot cut in rear endof the armature shaft tohold it from turning and tighten the nut securely With the hexagon nut securely tight ened at least two of the prongs on the lock washer No 10390 Fig 4 should be bent up ag inst the sides of the nut to prevent it from coming loose Using a 4BA Allen Key tighten the two
52. y moved to mesh the fibre gear and pinion gear When the dowel pin in the blower case has been fitted to the hole in the gear case itis certain that the fibre and pinion gears are properly meshed and that the gear case is in its correct position Fasten the units together by the two fillister head screws No 9266 Fig 1 situated immediately above and below the driving shaft aperture of the gear case d The two large fillister head screws No 5267 Fig 1 are used to hold the guide rail and the aperture plate in place and to Secure the gear case to the blower housing Place the two spacing washers No 4285 Fig 1 into the large holes at the outside cor ners of the aperture plate No 11852 Fig 1 and lay the film guide No 5641 Fig 1 along the edge of the aperture plate Press the guide rail inwards so that the fingersof rail 12 rest against the inside edge of the slots in aperture plate Screw the two large head screws No 5267 Fig 1 firmly into place e The aperture plate should move up and down when the framing knob No 03464 Fig 1 is turned The spacing washers are used to prevent the aperture plate from binding when the screws which hold the film guide rail in place are tight 19 ASSEMBLE MOTOR UNIT TO GEAR CASE a With the drive coupling shaft No M025119 Fig 4 in position place the motor unit against the frontof the gear case The two dowel pins fitted to the front of the gear case must locate in th

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