Kodak Projector 4200-KK User's Manual
Contents
1. Replacing the WORM PULLEY and MECHANISM BELT Warning Dangerous Voltage 1 Disconnect the main power 2 Do the replacement procedure for the LOWER HOUSING ASSEMBLY 3 Do the replacement procedure for the MOTOR except do not disconnect the wires from the MOTOR 4 Remove the Torx SCREW from the WORM PULLEY ASSEMBLY 5 Move the TAB on the WORM PULLEY ASSEMBLY out 6 Remove the WORM PULLEY ASSEMBLY and MECHANISM BELT 8 18NOV97 SM5440 1 Replacements and Installations WORM PULLEY SCREW A091 4017GCA A091 4017GA Installing the WORM PULLEY and MECHANISM BELT amp Important When installing the FAN and MECHANISM BELTS install the MECHANISM BELT on the small MOTOR PULLEY and the FAN BELT on the large MOTOR PULLEY 1 Do the replacement procedure for the WORM PULLEY and MECHANISM BELT in reverse order A091 4015BCA A091 4015BA SM5440 1 18NOV97 9 SERVICE MANUAL Replacing the THERMAL FUSE ASSEMBLY A Warning Dangerous Voltage 1 Disconnect the main power 2 Do the replacement procedure for the LOWER HOUSING ASSEMBLY 3 Cut and remove the necessary WIRE TIES 4 Remove the black wire from the THERMAL FUSE ASSEMBLY on the POWER SWITCH 5 Remove the gray wire from the THERMAL FUSE ASSEMBLY from the POWER CORD 6 Loosen the Jorx SCREW on the PREHEAT DUCT approximately half way 7 Pull the THERMAL FUSE ASSEMBLY out of hole of the LOWER LIGHT BAFFLE AS2. 6 7 8 9 Disconnect the main power Do the replacement procedure for the LOWER HOUSING ASSEMBLY Cut and remove the necessary WIRE TIES Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD Pull the SMALL CIRCUIT BOARD up Do the replacement procedure for the MECHANISM ASSEMBLY Remove the Torx SCREW from the WORM PULLEY Remove the WORM PULLEY Remove the 2 Hex SCREWS from the CYCLE SOLENOID 10 Remove the CYCLE SOLENOID 11 Remove the Phillips SCREW from the AUTO FOCUS BRACKET ASSEMBLY 12 Pull and remove the AUTO FOCUS BRACKET ASSEMBLY through the hole where the CYCLE SOLENOID was a 2 _ Pie a SCREW 2 P WORM D PULLEY LES FOCUS me CYCLE BRACKET L A091 4023BCA SOLENOID ASSEMBLY A091 4023BA Installing the AUTO FOCUS BRACKET ASSEMBLY 1 Do the replacement procedure for the AUTO FOCUS BRACKET ASSEMBLY in reverse order Replacing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY Warning Dangerous Voltage 1 2 3 4 5 6 14 Disconnect the main power Do the replacement procedure for the MECHANISM ASSEMBLY Remove the INDEXER LEVER ASSEMBLY from the TOP PLATE of the MECHANISM ASSEMBLY Remove the Torx SCREW from the WORM PULLEY ASSEMBLY Remove the WORM PULLEY ASSEMBLY Remove the DIRECTION LEVER LINK from the DIRECTION LEVER 18NOV97 SM5440 1 Replaceme
3. Dangerous Voltage 1 2 3 4 5 6 7 8 9 10 11 12 Disconnect the main power Do the replacement procedure for the LOWER HOUSING ASSEMBLY Cut and remove the necessary WIRE TIES Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD Pull the SMALL CIRCUIT BOARD up Disconnect all wires connected to the MECHANISM ASSEMBLY 1 yellow wire from CYCLE SWITCH 1 orange wire from WIRE NUT 1 green wire from POWER CORD 2 green ground wires from the lower MECHANISM ASSEMBLY Remove the FOCUS KNOB from the FRONT PANEL Hemove the 3 Torx SCREWS from the LENS MOUNT ASSEMBLY Lift and move the LENS MOUNT ASSEMBLY up Do the replacement procedure for the MOTOR Remove the 3 Torx SCREWS from the MECHANISM ASSEMBLY Loosen the SCREW on the STABILIZER WALL approximately half way Caution There might be a bind between the SELECT LEVER and the SELECT BUTTON when removing the MECHANISM ASSEMBLY Do not use force this might cause damage to the SELECT BUTTON 13 Remove the MECHANISM ASSEMBLY To insert the SELECT BUTTON into the hole in the SELECT LEVER when installing the MECHANISM ASSEMBLY hold the SELECT BUTTON completely down 1 Do the removal procedure for the MECHANISM ASSEMBLY in reverse order SM5440 1 18NOV97 13 SERVICE MANUAL Replacing the AUTO FOCUS BRACKET ASSEMBLY A Warning Dangerous Voltage 1 2 3 4 5
4. MECHANISM RUNNING FIXTURE position 1 position 2 A091 0008HCA A091 0008HA Adjustment Specification Use a MECHANISM RUNNING FIXTURE Use TL 3001 to measure the height of the SLIDE LIFT LEVER The LEVER should make contact with the low surface of TL 3001 The LEVER should not make contact with the high surface of TL 3001 26 18NOV97 SM5440 1 Adjustments Adjusting the SLIDE LIFT LEVER MANUAL with MECHANISM Out Warning Dangerous Voltage 1 2 3 4 5 6 SLIDE LIFT LEVER GUAGE TL 3001 Disconnect the main power Do the removal for the MECHANISM ASSEMBLY Place the MECHANISM ASSEMBLY on the MECHANISM RUNNING FIXTURE Press and hold the SELECT LEVER down to move the SLIDE LIFT LEVER to the highest position Measure the height of the SLIDE LIFT LEVER Use SLIDE LIFT LEVER GAUGE TL 3001 The SLIDE LIFT LEVER should make contact with the low surface of the SLIDE LIFT LEVER GAUGE TL 3001 the SLIDE LIFT LEVER should not make contact with the high surface of the SLIDE LIFT LEVER GAUGE TL 3001 Bend the SLIDE LIFT LEVER until the adjustment is correct m SLIDE LIFT O O tever not shown A091 0016BCA Sud A091 0016BA Adjustment Specification Use MECHANISM RUNNING FIXTURE Use TL 3001 to measure the height of the SLIDE LIFT LEVE
5. 11 12 13 14 15 16 17 18 FOCUS MOTOR Remove the 3 SCREWS from the LENS MOUNT ASSEMBLY Lift and remove the LENS MOUNT ASSEMBLY Remove the FOCUS SHAFT SPRING from the LENS MOUNT BRACKET Remote models only Remove the SPRING from the CLAMP LEVER on the LENS MOUNT BRACKET Remove the SPRING from the PHOTOCELL BRACKET Remove the E RING and SPACER from the FOCUS SHAFT ASSEMBLY Remove the SCREW from the LENS SUPPORT BRACKET Lift and remove the LENS SUPPORT BRACKET Remote models Remove the AUTO FOCUS SWITCH ASSEMBLY Remote models Remove the SCREW from the RACK SOLENOID ASSEMBLY Remote models Remove the RACK SOLENOID ASSEMBLY and PLUNGER Hemote models Remove the SCREW from the FOCUS MOTOR BRACKET ASSEMBLY Remove the FOCUS MOTOR BRACKET ASSEMBLY Push the RACK LEVER away from the FOCUS SHAFT ASSEMBLY Remove the FOCUS SHAFT ASSEMBLY CLAMPLEVER SCREW g FOCUS SHAFT SPRING SPRING _ gt P RACK LEVER du not shown FOCUS SHAFT BRACKET RACK SOLENOID PLUNGER E RING LENS SUPPORT BRACKET PHOTOCELL SPRING SWITCH A091 4029HCA ASSEMBLY AO91 4029HA 22 18NOV97 SM5440 1 Replacements and Installations Installing the FOCUS SHAFT ASSEMBLY amp Important Do the adjustments for the PHOTOCELL NULL and AUTO FOCUS CLAMP after installation See the Adjustments section Replacing the FOCUS SHAFT ASSEMBLY Non Auto
6. FAN INDEXER LEVER and TOP PLATE e WORM PULLEY ASSEMBLY CAM STACK ASSEMBLY e CYCLE LEVERS PIVOT SHAFT and LEVERS LENS MOUNT ASSEMBLY 36 A091_4037GA 18NOV97 SM5440 1 Lubrication A gt S aN A s d hos zz SW mmm M po mem 3 V NC 37 SM5440 1 18NOV97 SERVICE MANUAL A091 0022DA 38 18NOV97 SM5440 1 Tools Section 4 Tools Tools TL 1744 AUTO FOCUS GAUGE TL 2264 FOCUS TEST flat field TL 3002 AUTO FOCUS TARGET SLIDE TL 3003 ADJUSTMENT T BAR TL 3005 ADJUSTMENT TOOL TL 3255 Torx DRIVER SET TL 4276 SUPER LUBE DIGITAL MULTIMETER The LOWER HOUSING ASSEMBLY is a part of the cooling function To operate the projector with the LOWER HOUSING removed make a FAN COVER TOOL Cut here 7 an FAN COVER L TOOL 11 5 4 5 in A091 0024GCA A091 0024GA SM5440 1 18NOV97 39 SERVICE MANUAL Section 5 Specifications Desription Electrical Supply Standard U S Models 110 125 V Japan J Models 100 V AC 60 Hz only Korea KK Models 220 V AC 60 Hz only Power Consumption 400 W Dimensions Height 119 mm 4 69 in without TR
7. Focus Models Warning Dangerous Voltage 1 Disconnect the main power 2 Do the replacement procedure for the LOWER HOUSING ASSEMBLY 3 Remove the FOCUS KNOB 4 Remove the 3 SCREWS from the LENS MOUNT ASSEMBLY 5 Lift and remove the LENS MOUNT ASSEMBLY 6 Remove the FOCUS SHAFT SPRING from the LENS MOUNT BRACKET 7 Remove the E RING and SPACER from the FOCUS SHAFT ASSEMBLY 8 Remove the SCREW from the LENS SUPPORT BRACKET 9 Lift and remove the LENS SUPPORT BRACKET 10 Remove the E RING and SPACER from the FOCUS SHAFT ASSEMBLY 11 Remove the SCREW from the FOCUS MOTOR BRACKET ASSEMBLY 12 Remove the FOCUS MOTOR BRACKET ASSEMBLY 13 Remove the FOCUS SHAFT ASSEMBLY SCREW FOCUS SHAFT FOCUS SHAFT ASSEMBLY FOCUS MOTOR BRACKET LENS SUPPORT BRACKET 4 A091 0020HCA A091 0020HA E RING SM5440 1 18NOV97 23 SERVICE MANUAL Installing the FOCUS SHAFT ASSEMBLY 1 Do the replacement procedure for the FOCUS SHAFT ASSEMBLY in reverse order 97 SM5440 1 Adjustments Section 2 Adjustments Adjustment Specification Use T BAR TL 3003 to bend the CYCLE LEVER to adjust the CYCLE SOLENOID Adjusting the CYCLE SOLENOID Warning Dangerous Voltage 1 Connect the main power amp Important 1 The CYCLE SOLENOID must operate correctly to do this adjustment 2 The MECHANISM ASSEMBLY does not have to be removed to do this adju
8. MOUNT ASSEMBLY 5 Remove the 3 SCREWS from the LENS MOUNT ASSEMBLY 6 Lift and remove the LENS MOUNT ASSEMBLY 7 Remove the gray red and black wires from the grey red AUTO FOCUS SWITCH ASSEMBLY SWITCH LEVER wires Important A091 4028GCA Keep the AUTO FOCUS SWITCH LEVER that is AUTO FOCUS SWITCH ASSEMBLY A091 40286A connected to the AUTO FOCUS SWITCH so you can install it on the new AUTO FOCUS SWITCH 8 To disconnect and remove the AUTO FOCUS SWITCH bend the LOCKING TAB on the FOCUS MOTOR BRACKET until it is aligned with the hole in the AUTO FOCUS SWITCH Installing the AUTO FOCUS SWITCH ASSEMBLY amp Important Align the 2 TABS on the AUTO FOCUS SWITCH with the FOCUS MOTOR BRACKET checking that the end of the AUTO FOCUS LEVER engages with the CYCLE SOLENOID PLUNGER After the AUTO FOCUS SWITCH is in the correct position bend the LOCKING TAB to hold the AUTO FOCUS SWITCH in place 1 Do the replacement procedure for the AUTO FOCUS SWITCH in reverse order Replacing the FOCUS SHAFT ASSEMBLY Auto Focus Models Warning Dangerous Voltage 1 Disconnect the main power SM5440 1 18NOV97 21 SERVICE MANUAL 2 3 Do the replacement procedure for the LOWER HOUSING ASSEMBLY Remove the FOCUS KNOB amp Important It is necessary to push the AUTO FOCUS BRACKET backward and forward to allow access to the SCREWS on the LENS MOUNT ASSEMBLY 4 5 6 7 8 9 10
9. RECEPTACLE Standard Models 82 V AC approximately 85 86 V AC without a LAMP MODULE installed Long Life Models 74 V AC 76 V AC without LAMP DROPPING RESISTOR Move to the LO LAMP 3 0 W 10 4 V AC drop across position Power Illumination and Cooling Malfunctions The MOTOR does not operate Check the continuity across the THERMAL FUSE ASSEMBLY and MOTOR FUSE Check that the primary voltage on the MAIN MOTOR is correct Check that the voltage on POWER SWITCH is correct The FAN does not operate MOTOR operates Check that the FAN BELT is not broken Check and remove obstructions in the FAN area There is excessive noise in the FAN Check and remove obstructions in the FAN area Check that the tension is correct on the FAN BELT 3 Check that the FAN BELT is clean 4 Check the condition of the BEARING in the FAN ASSEMBLY The LAMP does not operate Check the LAMP for damage 2 Check the LAMP RECEPTACLE 3 Check the LAMP TERMINAL ASSEMBLY in the LAMP MODULE ASSEMBLY for damage There is an obstruction in the light path Check the DARK SHUTTER for correct operation See the adjustment for the DARK SHUTTER Check the LIGHT BAFFLE in the MECHANISM for damage it should not cause a jam in the SHUTTER SM5440 1 18NOV97 45 SERVICE MANUAL Slide Transport Malfunctions Forward and reverse do not operate using the FRONT PANEL BUTTONS or REMOTE CONTROL Forward does not operate rever
10. 0 Installing the LENS MOUNT ASSEMBLY Non Auto Focus Model 20 Replacing the AUTO FOCUS SWITCH 21 Installing the AUTO FOCUS SWITCH 21 Replacing the FOCUS SHAFT ASSEMBLY Auto Focus Models 21 Installing the FOCUS SHAFT ASSEMBLY 23 Replacing the FOCUS SHAFT ASSEMBLY Non Auto Focus Models 23 Installing the FOCUS SHAFT ASSEMBLY 24 ie oe HAE PGES 25 Adjusting the CYCLE 10 25 Adjusting the INDEXER LEVER ASSEMBLY 26 Adjusting the SLIDE LIFT LEVER MANUAL with MECHANISM Out 27 Adjusting the SLIDE LIFT LEVER POWER with Mechanism Qut 27 AH 2 18NOV97 5 5440 1 SM5440 1 18NOV97 Adjusting the Focus Light Path Auto Focus Models Adjustment Specification Adjusting IDE NULL cossis os a Se oe QA Adjusting the PHOTOCELL Adjusting the CLAMP PAD Adjusting the DARK SHUTTER c 5 ob ois Se tht bbe Gah wba Lb Eee 22 BOS ob er ee eo en BOR edU TTTCQCITTQTOIT I MAIN MOTOR Voltages PHOTOCE
11. 4027BA PAD A091 4027BCA Warning Dangerous Voltage 13 Connect the main power amp Important It is necessary to make a FAN COVER TOOL See the Tools section 14 Install the FAN COVER TOOL over the FAN area and the LAMP MODULE See the Tools section 15 Install and hold the AUTO FOCUS TARGET SLIDE TL 3002 until it is fully seated in the GATE MECHANISM 32 18NOV97 SM5440 1 Adjustments 16 Set the projector to the LO LAMP position 17 Observe the image of the focus light path on the bottom of the FAN the light path should be in the center of the hole in the FAN CAP 18 Bend the CLAMP PAD ASSEMBLY until the image is in the center of the hole in the FAN CAP 19 Assemble the PHOTOCELL MASK FILTERS and PHOTOCELL BOARD T BAR TL 3003 light image FAN CAP CLAMP PAD ASSEMBLY AUTO FOCUS TARGET SLIDE A091 4030BCA TL 3002 A091 4030BA Adjustment Specification Use TL 1744 to check that the CLAMP PAD ASSEMBLY moves forward and backward SM5440 1 18NOV97 33 SERVICE MANUAL Adjusting the CLAMP PAD ASSEMBLY CLAMP PAD ASSEMBLY A091 4041GCA A091 4041GA Adjustment Specification Warning Dangerous Voltage 1 Disconnect the main power 2 Do the removal for the LOWER HOUSING ASSEMBLY amp Important Itis necessary to make a FAN COVER TOOL See the Tools section 3 Install the F
12. 440 1 18NOV97 11 SERVICE MANUAL Replacing the CYCLE SOLENOID ASSEMBLY CYCLE SOLENOID SCREW 2 b 3 CYCLE 7 SOLENOID lt PLUNGER V A100 0017GCA A100 0017GA Installing the CYCLE SOLENOID ASSEMBLY 12 Warning Dangerous Voltage 1 2 3 4 5 6 7 8 9 10 11 Disconnect the main power Do the replacement procedures for the LOWER HOUSING ASSEMBLY and the MOTOR Cut and remove the necessary WIRE TIES Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD Pull the SMALL CIRCUIT BOARD up Hemove the SCREW from the WORM PULLEY SHAFT Move the TAB on the WORM PULLEY ASSEMBLY out of the MECHANISM ASSEMBLY Lift and remove the WORM PULLEY ASSEMBLY Remove the 2 Hex 1 4 in SCREWS from the 2 CYCLE SOLENOID GROMMETS Pull the CYCLE SOLENOID ASSEMBLY up and out If necessary remove the CYCLE SOLENOID PLUNGER ASSEMBLY amp Important Do the adjustment for the CYCLE SOLENOID ASSEMBLY See the Adjustments section 1 Do the replacement procedure for the CYCLE SOLENOID ASSEMBLY in reverse order 18NOV97 SM5440 1 Replacing the MECHANISM ASSEMBLY _ SCREW 3 FOCUS KNOB A091 4047CCA A091 4047CA Installing the MECHANISM ASSEMBLY amp Important MECHANISM ASSEMBLY Replacements and Installations Warning
13. AN COVER TOOL over the FAN area and the LAMP MODULE See the Tools section 4 Connect the REMOTE CONTROL ASSEMBLY EC 3 to the REMOTE RECEPTACLE Warning Dangerous Voltage 5 Connect the main power 6 Loosen the NUT on the CLAMP PAD ASSEMBLY 7 Energize the REMOTE FOCUS in either direction 8 Rotate the SCREW on the CLAMP PAD ASSEMBLY to adjust the pressure of the REMOTE FOCUS CLAMP on the CLAMP PAD ASSEMBLY until the CLAMP PAD ASSEMBLY does not move 9 Release the REMOTE FOCUS 10 Tighten the NUT on the CLAMP PAD ASSEMBLY 11 Install the AUTO FOCUS GAUGE TL 1744 in the MECHANISM GATE The CLAMP PAD ASSEMBLY should move forward and backward using TL 1744 If not adjust the SCREW on the CLAMP PAD ASSEMBLY again the CLAMP PAD ASSEMBLY adjustment is too tight and not correct The PRESSURE PAD should be aligned with the DARK SHUTTER Adjusting the DARK SHUTTER 1 Do the removal for the LOWER HOUSING 2 Insert a thin SLIDE into the GATE MECHANISM the DARK SHUTTER should open 3 Check the the PRESSURE PAD is correctly aligned with the the DARK SHUTTER 4 Bend the PRESSURE PAD to adjust the alignment 34 18NOV97 SM5440 1 SM5440 1 18NOV97 Adjustments DARK SHUTTER PRESSURE PAD A091 0013GCA A091 0013GA 35 SERVICE MANUAL Section 3 Lubrication Apply lubricant SUPER LUBE TL 4276 to the following parts and areas of the projector see the illustrations
14. AY Width 238 mm 12 93 in Length 295 mm 11 6 in 35 mm 50 x 50 mm 2x 2 in Slide change time 1 second LAMP and voltages EXR 82 V 300 W 35 hours average life EXW 82 V 300 W 15 hours average lamp life FHS 82 V 300 W 70 hours average life EXY 82 V 300 W 200 hours average life On Long Life models the LAMP voltage is 74 V AC Lumen Output 800 minimum with EXH lamp EXTRA BRIGHT LAMP MODULE has a 3096 increase in lumen output Lowest corner to center ratio is 5596 minimum Test method Ektagraphic 102 mm F 2 8 LENS aperture 24 x 36 mm compatible with European specification DIN 19027 Operating temperature 45 C 40 1596 humidity in low 49 C 120 F 15 humidity in high 21 27 C 70 80 F 20 60 humidity optimum Cooling Fan speed is 2780 or 3000 RPMs 1360 BTUs per hour to cool projector Approval Environmental storage Complies with storage test specifications TS 172 Environmental operation Complies with climactic test specifications TS 218 Safety e 3 GROUNDED POWER CORDS detachable Heat sensitive interrupt fuses 117 C power to motor lamp fuse 171 C MOTOR Dielectric strength Apply 1200 V AC 60 Hz for 1 second maximum leakage current is 2 5 mA 0 18NOV97 SM5440 1 i Specifications 000 wm Automatic Timer Operates between the following times e Fast 3 1 second e Slow 22 6 seconds Auto Focus System e After the initial focus adju
15. CUIT BOARD up 6 Remove the Torx SCREW from the BLOWER COVER ASSEMBLY 7 Lift the GRILLE ASSEMBLY in front of the BLOWER COVER ASSEMBLY up 8 Loosen the Torx SCREW on the right track of the LOWER LIGHT BAFFLE ASSEMBLY appoximately half way 9 Lift the LOWER LIGHT BAFFLE ASSEMBLY off the TAB on the BLOWER COVER ASSEMBLY WIRE TIE not shown 4 KK models BLOWER COVER WIRE TIE A GRILLE ASSEMBLY A100_0031HCA A100_0031HA 10 Remove the 2 long Torx SCREWS from the BLOWER COVER ASSEMBLY 11 Lift the BLOWER COVER ASSEMBLY up 12 Remove the 3 Hex 1 4 in SCREWS from the MOTOR 13 Lift the MOTOR until you observe the FAN BELT and MECHANISM BELT 14 Remove the FAN BELT and MECHANISM BELT off the MOTOR PULLEY Use SPHING HOOK TL 1165 Caution Move the MOTOR to allow access to the parts wires are still connected to the MOTOR Do not cause damage to the MOTOR wires 15 Remove the RETAINER CLIP from the FAN SHAFT 16 Pull the FAN up and off the FAN SHAFT to allow access to the FAN BELT 17 Remove the FAN BELT 18 Remove the 3 Torx SCREWS from the FAN SHAFT ASSEMBLY SM5440 1 18NOV97 5 SERVICE MANUAL 19 Lift and remove the FAN SHAFT ASSEMBLY RETAINER CLIP MOTOR FAN FAN PLATE ASS4EMBLY FAN BELT MECHANISM BELT A100 0014HCA A100 0014HA St Installing the FAN
16. F CYCLE SOLENOID LEVER 21 Remove the CYCLE SOLENOID 22 Slide the PLUNGER and PLUNGER SPRING off the CYCLE LEVER 23 Remove the HALF CYCLE SPRING between the CYCLE LEVER ASSEMBLY and the HALF CYCLE LEVER 24 Disconnect the INDEX LEVER SPRING from the MECHANISM ASSEMBLY 25 Push the INDEX LEVER back 26 Remove the 2 E RINGS 1onthe CYCLE LEVER ASSEMBLY 1onthe HALF CYCLE LEVER Caution Keep both the CYCLE LEVER ASSEMBLY and the HALF CYCLE LEVER together and observe the orientation of both LEVERS 27 Slide both the CYCLE LEVER and HALF CYCLE LEVER off the SHAFT HALF CYCLE LEVER SPRING CYCLE LEVER PLUNGER SPRING CYCLE SOLENOID SCREW 2 INDEX LEVER and SPRING A091 0009CCA not shown A091 0009CA Installing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY Caution Keep both the CYCLE LEVER ASSEMBLY and the HALF CYCLE LEVER together and observe the orientation of both LEVERS 1 Do the replacement procedure for the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY in reverse order SM5440 1 18NOV97 17 SERVICE MANUAL Replacing the LAMP SOCKET TERMINAL ASSEMBLY Style 1 LAMP SOCKET TERMINAL ASSEMBLY SCREW LAMP DOOR PLATE ASSEMBLY PROJECTOR WIS LAMP OS LAMP EJECTOR LAMP SOCKET TERMINAL ASSEMBLY LENS HEAT ABSORBING TAB 2 CONDENSER GLASS A091 0018CCA A091 0018CA
17. Installing the FAN SHAFT ASSEMBLY Replacing the MOTOR onem erre ER Od wow ee Sond ari Installing the Replacing the WORM PULLEY and MECHANISM BELT Installing the WORM PULLEY and MECHANISM BELT Replacing the THERMAL FUSE ASSEMBLY 10 Installing the THERMAL FUSE ASSEMBLY 10 Replacing the LAMP MODULE 10 Installing the LAMP MODULE 11 Replacing the CYCLE SOLENOID ASSEMBLY 12 Installing the CYCLE SOLENOID ASSEMBLY 12 Replacing the MECHANISM ASSEMBLY 13 Installing the MECHANISM ASSEMBLY 13 Replacing the AUTO FOCUS BRACKET ASSEMBLY 14 Installing the AUTO FOCUS BRACKET ASSEMBLY 14 Replacing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY 14 Installing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY 17 Replacing the LAMP SOCKET TERMINAL ASSEMBLY 18 Installing the LAMP SOCKET TERMINAL ASSEMBLY 18 Replacing the LENS MOUNT ASSEMBLY Auto Focus Model 19 Installing the LENS MOUNT ASSEMBLY Auto Focus Models 19 Replacing the LENS MOUNT ASSEMBLY Non Auto Focus Model 2
18. LL VoltageS desde hoe yox CR do a kk NR y 5 PIN REMOTE CORD PLUG 5 SMALL COMPONENT BOARD ASSEMBLY 256809 Voltages Voltage Specifications General Power Illumination and Cooling 5 Slide Transport Malfunctions Focus 5 SERVICE MANUAL Section 1 Replacements and Installations Replacing the LOWER HOUSING ASSEMBLY A Warning Dangerous Voltage 1 Disconnect the main power 2 Remove the PROJECTION LENS 3 Remove the LAMP MODULE ASSEMBLY 4 Remove the 6 Jorx SCREWS from the LOWER HOUSING ASSEMBLY 5 Pull the LOWER HOUSING ASSEMBLY off the TOP HOUSING Installing the LOWER HOUSING ASSEMBLY 1 Do the replacement procedure for the LOWER HOUSING ASSEMBLY in reverse order LOWER HOUSING oe LAMP MODULE Replacing the FAN SHAFT ASSEMBLY Warning Dangerous Voltage 1 Disconnect the main power 2 Do the replacement procedure for the LOWER HOUSING ASSEMBLY 3 Cut the 3 WIRE TIES 1on BLOWER COVER wires e 2 SMALL CIRCUIT BOARD between the MOTOR and MECHANISM ASSEMBLY 4 18NOV97 SM5440 1 Replacements and Installations 4 Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD 5 Pull the SMALL CIR
19. LS c Ls 117 V AC 6 10 MOTOR C lt M A091 0006BCA A091 0006BA MAIN MOTOR PIN Colors MAIN MOTOR PIN Voltages Resistance Voltage o pauw 42 18NOV97 SM5440 1 PHOTOCELL Voltages PHOTOCELL A091 4036ACA A091 4036AA PHOTOCELL Voltages PINS Voltage 5 PIN REMOTE CORD PLUG Voltages BLACK YELLOW YELLOW KODAK EC 3 REMOTE CONTROL A100_0001BC_ 5 PIN REMOTE PLUG Voltages _ yellow Common bom RACKSOLENOID SM5440 1 18NOV97 Diagnostics 43 SERVICE MANUAL SMALL COMPONENT BOARD ASSEMBLY 256809 Voltages IWWK RA VV OB Ry O INR O 7 CR5 CR4 F1 0 bou R7 ai Q2 R6 R17 SLIDE PROJECTOR BOARD Pat eg C1 R12 R13 R11 R14 R10 CR6 C3 C2 R15 91_4034 TIMER Circuit 32 V DC TIMER Circuit 32 V DC C YCLE HOLD DOWN CR4 10 18 0 V DC REVERSE FOCUS 28 0 DC FOCUS RACK USE CR5 10 18 0 V DC FOCUS 253 D0 FOCUS 28 0 VDO 44 18NOV97 SM5440 1 Diagnostics Voltage Specifications General Parts voltage FOCUS MOTOR MOTOR 6 7 NN SOLENOID Press the RIsSeREVERSE 39 W 10 V DC BUTTON RACK SOLENOID ______ 39 W 10 V AC LAMP
20. PRING is on the DIRECTION LEVER Check for a bind in the DIRECTION LEVER ASSEMBLY Check that the DIRECTION LEVER LINK is in the correct position Press and release the SELECT BUTTON Check that the LOCATOR LEVER moves correctly and is not bent Press and hold the SELECT BUTTON down Check the SLIDE LIFT LEVER RAMP for damage Check the height of the SLIDE LIFT LEVER the lower corner of the LIFT LEVER RAMP is parallel with the TOP HOUSING If the height is not correct do the adjustment for the MANUAL and POWER SLIDE LIFT LEVER ECCENTRICS 47 SERVICE MANUAL TIMER does not operate DARK SHUTTER SWITCH does not operate After the FOCUS MOTOR energizes and moves the FOCUS MOTOR oscillates Focus Malfunctions No manual focus No remote focus Non Auto Focus models 48 Check the VARIABLE RESISTOR for correct operation and install a new part if necessary Move the TIMER BUTTON forward and backward use a DVM to check for changes in W Energize the projector and move the TIMER to S Check the voltages on CR3 Q3 and Q4 see the voltage table Energize the projector and release the DARK SHUTTER to allow projection Check for continuity between PINS 4 and 5 on the SPECIAL APPLICATIONS PLUG Press the FORWARD or REVERSE BUTTONS to close the DARK SHUTTER In the closed position the DVM should measure 0 W If this
21. R The LEVER should make contact with the low surface of TL 3001 The LEVER should not make contact with the high surface of TL 3001 Adjusting the SLIDE LIFT LEVER POWER with Mechanism Out Warning Dangerous Voltage 1 2 3 4 5 6 7 Disconnect the main power Do the removal for the MECHANISM ASSEMBLY Place the MECHANISM ASSEMBLY on the MECHANISM RUNNING FIXTURE TL 3000 Energize the MECHANISM FIXTURE Press and hold the SELECT LEVER down to move the SLIDE LIFT LEVER to the highest position Measure the height of the SLIDE LIFT LEVER Use SLIDE LIFT LEVER GAUGE TL 3001 The SLIDE LIFT LEVER should make contact with the low surface of the SLIDE LIFT LEVER GAUGE TL 3001 the SLIDE LIFT LEVER should not make contact with the high surface of the SLIDE LIFT LEVER GAUGE TL 3001 Bend the SLIDE LIFT LEVER until the adjustment is correct SM5440 1 18NOV97 27 SERVICE MANUAL SLIDE LIFT LEVER GUAGE TL 3001 SLIDE LIFT LEVER SELECT LEVER not shown A091 0016BCA A091 0016BA Adjusting the Focus Light Path Auto Focus Models Adjustment Specification Seat AUTO FOCUS TARGET SLIDE TL 3002 on the GATE MECHANISM Use TL 3005 or TL 1165 to bend the AUTO FOCUS BRACKET ASSEMBLY MIRROR until the image is within the target of the TARGET SLIDE Warn
22. ROJECTION LAMP operates correctly Insert the TARGET SLIDE TL 3002 in the GATE MECHANISM Check that the TARGET is correctly aligned If not see the Adjustment section Check that the voltages across the PHOTOCELL are correct The voltage from 1 to 2 is 13 8 V ac The voltage from 2 to 315 13 8 V ac The voltage from 1 to is 28 V ac Make a shorts between 1 and 2 the FOCUS MOTOR should rotate Make a shortecircuit between 2 and 3 the FOCUS MOTOR should rotate in the reverse direction If the FOCUS MOTOR operates correctly install a new PHOTOCELL If the FOCUS MOTOR does not operate correctly measure the voltages on the CIRCUIT BOARD Check that the alignment of the FOCUS LIGHT PATH and NULL is correct Check the resolution of the FOCUS LIGHT PATH Clean the AUTO FOCUS MIRROR and BRACKET ASSEMBLY Install a new PROJECTION LAMP if necessary Install a new PHOTOCELL Check the components on the CIRCUIT BOARD for damage 49 SERVICE MANUAL AUTO FOCUS MOTOR operates continually 1 Install the TARGET SLIDE TL 3002 in the GATE MECHANISM 2 Check that the alignment of the TARGET and NULL is correct If not see the Adjustments section Check for a light leak Install a different LAMP MODULE ASSEMBLY If the FOCUS MOTOR stops operating continually install a new LAMP MODULE ASSEMBLY Check that the voltages across the PHOTOCELL are correct The volta
23. SEMBLY Installing the LENS MOUNT ASSEMBLY Auto Focus Models 1 Do the replacement procedure for the LENS MOUNT ASSEMBLY in reverse order SM5440 1 18NOV97 19 SERVICE MANUAL Replacing the LENS MOUNT ASSEMBLY Non Auto Focus Model Warning Dangerous Voltage 1 Disconnect the main power 2 Do the replacement procedure for the LOWER HOUSING ASSEMBLY c SCREW 3 LENS MOUNT ASSEMBLY is n Te 3 Remove the FOCUS KNOB 4 Remove the 3 SCREWS from the LENS MOUNT po ue ASSEMBLY M 5 Lift and remove the LENS MOUNT ASSEMBLY AO e fe E SN 2 n d x AN Y v A100 0019GCA A100 0019GA Installing the LENS MOUNT ASSEMBLY Non Auto Focus Model 1 Do the replacement procedure for the LENS MOUNT ASSEMBLY in reverse order 20 18NOV97 SM5440 1 Replacements and Installations Replacing the AUTO FOCUS SWITCH ASSEMBLY AUTO FOCUS A Dan ave e EX uA d BEDS SiS LAA 1 Disconnect the main power 2 Do the replacement procedure for the LOWER Ss HOUSING ASSEMBLY 3 Remove the FOCUS KNOB 4 Remove the short gray wire from the AUTO Y FOCUS DEFEAT SWITCH Ta j Important gt 3 It is necessary to push the AUTO FOCUS BRACKET backward and forward to allow access to the SCREWS LOCKING on the LENS
24. SEMBLY Installing the THERMAL FUSE ASSEMBLY 1 Do the replacement procedure for the THERMAL FUSE ASSEMBLY in reverse order SCREW PRE HEAT DUCT THERMAL FUSE A100 0015GCA A100 0015GA POWER SWITCH Replacing the LAMP MODULE RECEPTACLE A Warning Dangerous Voltage 1 Disconnect the main power 2 Do the replacement procedure for the LOWER HOUSING ASSEMBLY 3 Cut and remove the necessary WIRE TIES 4 Remove the 2 Torx SCREWS on the left side of the LOWER LIGHT BAFFLE ASSEMBLY 5 Loosen the Torx SCREW on the right side of the LOWER LIGHT BAFFLE ASSEMBLY approximately 1 2 way 10 18NOV97 SM5440 1 Replacements and Installations 6 Lift and remove the LOWER LIGHT BAFFLE ASSEMBLY 7 Lift the GRILLE ASSEMBLY up 8 Remove the 2 long Torx from the BLOWER COVER ASSEMBLY 9 Lift the BLOWER COVER ASSEMBLY up 10 Lift and move the PREHEAT DUCT up 11 To remove the LAMP MODULE RECEPTACLE from the PREHEAT DUCT compress the 2 TABS on the LAMP MODULE RECEPTACLE SCREW 2 U LOWER LIGHT BAFFLE PRE HEAT DUCT 8 LAMP MODULE RECEPTACLE BLOWERCOVER lt ASSEMBLY A100_0032HCA A100_0032HA SCREW not shown Installing the LAMP MODULE RECEPTACLE Warning Dangerous Voltage 1 Disconnect the main power 2 Do the replacement procedure for the LAMP MODULE RECEPTACLE in reverse order SM5
25. SHAFT ASSEMBLY amp Important When installing the FAN and MECHANISM BELTS install the MECHANISM BELT on the small MOTOR PULLEY and the FAN BELT on the large MOTOR PULLEY 1 Do the removal procedure for the FAN BELT and SHAFT in reverse order FAN BELT MECHANISM BELT A091 4015 A091 4015BA 6 18NOV97 SM5440 1 Replacements and Installations Replacing the MOTOR Warning Dangerous Voltage 1 Disconnect the main power 2 Do the replacement procedure for the LOWER HOUSING ASSEMBLY 3 Disconnect all wires from the MOTOR 4 Cut the 2 WIRE TIES on the SMALL CIRCUIT BOARD between the MOTOR and MECHANISM ASSEMBLY 5 Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD 6 Pull the SMALL CIRCUIT BOARD up 7 Disconnect all wires on the MOTOR 8 Remove 3 Hex 1 4 in SCREWS from the MOTOR 9 Lift the MOTOR up to allow access to the FAN and MECHANISM BELTS 10 Remove the FAN and MECHANISM BELTS from the MOTOR PULLEY 11 Remove the MOTOR SCREW 3 SS 25 co MOTOR A091 4016GCA A091 4016GA Installing the MOTOR amp Important When installing the FAN and MECHANISM BELTS install the MECHANISM BELT on the small MOTOR PULLEY and the FAN BELT on the large MOTOR PULLEY 1 Do the replacement procedure for the MOTOR in reverse order SM5440 1 18NOV97 7 SERVICE MANUAL A091 4015BCA A091 4015BA
26. Service amp Support Q Kodak Home Page on Internet Q Intranet Q Table of Contents Eastman Kodak Company 1999 A100_0029HA Publication No SM5440 1 18NOV97 Supersedes SM5440 1 13MAY97 SERVICE MANUAL Kodak Carousel PROJECTORS New Look PROJECTORS Models 4200 4200 J 4200 KK 4400 4600 4600 KK 5600 5600 J and 5600 KK PLEASE NOTE The information contained herein is based on the experience and knowledge relating to the subject matter gained by Eastman Kodak Company prior to publication No patent license is granted by this information Eastman Kodak Company reserves the right to change this information without notice and makes no warranty express or implied with respect to this information Kodak shall not be liable for any loss or damage including consequential or special damages resulting from any use of this information even if loss or damage is caused by Kodak s negligence or other fault af This equipment includes parts and assemblies sensitive to damage from electrostatic discharge Use caution to prevent damage during all service procedures Table of Contents Description U Replacements Installations Replacing the LOWER HOUSING 5 Installing the LOWER HOUSING 5 Replacing the FAN SHAFT ASSEMBLY
27. Warning Dangerous Voltage 1 Disconnect the main power Important The EXTRA BRIGHT LAMP MODULE does not have a HEAT ABSORBING GLASS and has a LABEL on the LAMP DOOR 2 Remove the LAMP MODULE 3 Remove the PROJECTION LAMP from the LAMP MODULE 4 Remove the SCREW from the LAMP DOOR PLATE ASSEMBLY 5 Release the 2 TABS on the bottom side of the LAMP MODULE next to the LAMP MODULE DOOR 6 Remove the LAMP DOOR PLATE ASSEMBLY Caution Remove the CONDENSER LENS and HEAT ABSORBING GLASS and set the parts on a clean cloth Do not set on a cold surface this will cause damage to the parts 7 Remove the LAMP EJECTOR B Remove the LAMP SOCKET TERMINAL ASSEMBLY Installing the LAMP SOCKET TERMINAL ASSEMBLY 1 Do the replacement procedure for the LAMP SOCKET TERMINAL ASSEMBLY in reverse order 18 18NOV97 SM5440 1 Replacements and Installations Replacing the LENS MOUNT ASSEMBLY Auto Focus Model LENS MOUNT ASSEMBLY A100 0019GCA A100 0019GA SCREW 3 Warning Dangerous Voltage 1 Disconnect the main power 2 Do the replacement procedure for the LOWER HOUSING ASSEMBLY 3 Remove the FOCUS KNOB amp Important It is necessary to push the AUTO FOCUS BRACKET backward and forward to allow access to the SCREWS on the LENS MOUNT ASSEMBLY 4 Remove the 3 SCREWS from the LENS MOUNT ASSEMBLY 5 Lift and remove the LENS MOUNT AS
28. amp Important It is necessary to make FAN COVER TOOL See the Tools section 3 Install the FAN COVER TOOL over the FAN area and the LAMP MODULE See the Tools section 4 Energize the projector 5 Set the projector to the LO LAMP position 6 Install and hold the AUTO FOCUS TARGET SLIDE TL 3002 until it is fully seated in the GATE MECHANISM 7 Look through the PROJECTION LENS hole and observe the focus light path on the AUTO FOCUS TARGET SLIDE TL 3002 Check that the light image is correct If not do the Adjusting the FOCUS LIGHT PATH 8 Check that the TAB on the CLAMP PAD ASSEMBLY is in the NULL position If the TAB is not in the correct position do the adjustment procedure for the NULL 9 Bend the PHOTOCELL BRACKET to move the NULL in the center use T BAR TL 3003 SM5440 1 18NOV97 29 SERVICE MANUAL amp Important If you cannot obtain the NULL position after doing the adjustment approximately 3 times go to the adjustment procedure for the PHOTOCELL light path T BAR TL 3003 N b NULL position E Cf fre AUTO FOCUS CLAMP LEVER A091 4031BCA TARGET SLIDE PAD A091 4031BA TL 3002 Adjustment Specification Use TL 3002 and FAN CAP 232729 to check the adjustment of the PHOTOCELL Adjusting the PHOTOCELL PHOTOCELL A Warning CIRCUIT BOARD Dangerous Voltage wratten 1 Disconnect the main power FILTER 2 2 Do the
29. e energized If there is a bind the CAM will not rotate Check that the CAM SHAFT ASSEMBLY RATCHET SPRING is installed correctly If there is a bind in the CAM STACK install a new CAM 18NOV97 SM5440 1 The projector does not change cycles when using a DISSOLVE CONTROL the REMOTE CONTROL and CONTROL PANEL BUTTONS operate correctly SLIDE TRAY does not advance smoothly SLIDE TRAY advances when REVERSE is pressed SLIDE TRAY does not rotate freely when the SELECT BUTTON is pressed down The projector has power SM5440 1 18NOV97 Diagnostics Check 1 The CYCLE LEVER and the RATCHET PLATE are dirty Clean and apply lubricant SUPER LUBE TL 4276 to the CYCLE LEVER and RATCHET PLATE If this does not correct the malfunction e Install a new CAM SHAFT ASSEMBLY Check the SLIDE TRAY LATCH for correct alignment Operate the projector in the forward direction Check that the INDEXER LEVER ASSEMBLY is in the correct alignment with the holes at positions A and B Do the adjustment for the INDEXER LEVER ASSEMBLY Check the condition of the LOCATOR LEVER it should not be bent Check the height of the SLIDE LIFT LEVER the lower corner of the LIFT LEVER RAMP is parallel with the TOP HOUSING If the height is not correct do the adjustment for the MANUAL and POWER SLIDE LIFT LEVER ECCENTRICS Do the adjustment for the CYCLE SOLENOID Check that the S
30. ge from 1 to 2 is 13 8 V ac The voltage from 210 315 13 8 V ac The voltage from 1 to 3 is 28 V ac Check that the PHOTOCELL HOUSING has 2 FILTERS Install a new PHOTOCELL Check the components on the CIRCUIT BOARD for damage AUTO FOCUS MOTOR operates continually in 1 Check that the wires of the AUTO FOCUS forward only or reverse only and does not MOTOR are in the correct position the blue operate stops in the null position wire goes to the mark on the AUTO FOCUS MOTOR AUTO FOCUS adjusts after REMOTE use 1 Do the adjustment for the CLAMP LEVER ASSEMBLY 50 18NOV97 SM5440 1 Kodak Carousel and Wratten are trademarks Printed in U S A sm5440 1 fm EASTMAN KODAK COMPANY Rochester NY 14650 Kodak Service amp Support
31. ing Dangerous Voltage 1 Disconnect the main power 2 Remove the PROJECTION LENS 3 Do the removal for the LOWER HOUSING ASSEMBLY amp Important It is necessary to make a FAN COVER TOOL See the Tools section 4 Install the FAN COVER TOOL over the FAN area and the LAMP MODULE 5 Energize the projector 6 Set the projector to the LOW LAMP position 7 Install the AUTO FOCUS TARGET SLIDE TL 3002 until it is fully seated in the GATE MECHANISM 8 Look through the PROJECTION LENS hole and observe the focus light path on the AUTO FOCUS TARGET SLIDE TL 3002 9 Check the position of the image on the AUTO FOCUS TARGET SLIDE TL 3002 28 18NOV97 SM5440 1 Adjustments 10 Bend the AUTO FOCUS BRACKET ASSEMBLY MIRROR until the image is within the target on the TARGET SLIDE Use ADJUSTMENT TOOL TL 3005 or the SPRING HOOK TL 1165 ADJUSTMENT TOOL TL 3005 or SPRING HOOK TL 1165 sS AUTO FOCUS LE y BRACKET d Ec ASSEMBLY v light path amp image E A091 4026HCA AUTO FOCUS TARGET SLIDE TL 3002 A091 4026HA Adjustment Specification Use TL 3002 to observe the focus light path and check the light image Use T BAR TL 3003 to bend the PHOTOCELL BRACKET to move the NULL in the center if necessary Adjusting the NULL Warning Dangerous Voltage 1 Disconnect the main power 2 Do the removal for the LOWER HOUSING ASSEMBLY
32. nts and Installations 7 Remove the DIRECTION LEVER SPRING from the DIRECTION LEVER 8 Disconnect the LIFT LEVER SPRING from LIFT LEVER on the TOP PLATE of the MECHANISM ASSEMBLY 9 Remove the RETARD SPRING 10 Remove the 7 Torx SCREWS from the TOP PLATE of the MECHANISM ASSEMBLY 11 Remove the TOP PLATE 12 Remove the LIGHT BAFFLE LIFT LEVER SHAFT LIFT LEVER SELECT LEVER not shown OWNER 5 1 CUS A d p o A100 0018HCA A100 0018HA CAM STACK ASSEMBLY 13 Remove the NUT from the LIFT LEVER SHAFT 14 Remove the LIFT LEVER and SHAFT 15 Remove the 2 E RINGS from the 2 CAM SHAFT BEARINGS 16 Remove the 2 CAM SHAFT BEARINGS 17 Press and hold the SELECT LEVER down 18 Remove the CAM STACK ASSEMBLY 19 Disconnect the SELECT LEVER SPRING from the TAB and remove the SELECT LEVER SM5440 1 18NOV97 15 SERVICE MANUAL SELECT LEVER by cU E RING zl M d UN Pt x E TI un E seLeCT LEVER BEARING SPRING C 8j S m 07 EN XS 2 gt CO Eo X N 2 a C S3 26 LA Ae x fcc d Ps A 7 _ NUT BEARING TDI 18NOV97 SM5440 1 16 Replacements and Installations 20 Remove the 2 SCREWS from the CYCLE HAL
33. procedure does not correct the malfunction install a new DARK SHUTTER SWITCH Remove and install a new 68K W 1 4 W RESISTOR part 220040 there is still a malfunction install a new PHOTOCELL Check the FOCUS SHAFT SPRING for the correct tension Check the LENS SUPPORT SPRING for correct tension Check the LENS DRIVE GEAR on the FOCUS SHAFT ASSEMBLY for damage and install a new part if necessary Check the REMOTE CORD for damage use a REMOTE CORD that has no damage 2 Actuate and hold the REMOTE CONTROL 3 Check that the voltage across the FOCUS MOTOR is 6 7 V AC If the voltage is correct install a new FOCUS MOTOR Check that the secondary voltage on the MAIN MOTOR is correct 18NOV97 SM5440 1 No remote focus RACK SOLENOID ASSEMBLY operates Auto Focus Models No auto focus Slow auto focus movement SM5440 1 18NOV97 Diagnostics Check Check that the REMOTE CORD operates correctly use a REMOTE CORD you know is good EC 3 2 Actuate and hold the REMOTE CONTROL 3 Check that the voltage across the FOCUS MOTOR is 6 7 V AC If the voltage is correct on the FOCUS MOTOR the FOCUS MOTOR is defective Install a new FOCUS MOTOR Check the AUTO FOCUS SWITCH ASSEMBLY for correct operation Checkthe secondary voltages on the MAIN MOTOR Check that the AUTO FOCUS DEFEAT SWITCH is in the ON position Check that the MAIN P
34. removal for the LOWER HOUSING ASSEMBLY amp Important It is necessary to make a FAN COVER TOOL See the Tools section 3 Install the FAN COVER TOOL over the FAN area and the LAMP MODULE See the Tools section POST 2 PHOTOCELL MASK PHOTOCELL HOUSING A091 4032GCA A091 4032GA 30 18NOV97 SM5440 1 SM5440 1 18NOV97 Adjustments Warning Dangerous Voltage 4 Energize the projector 5 Set the projector to the LO LAMP position 6 Install and hold the AUTO FOCUS TARGET SLIDE TL 3002 until it is fully seated in the GATE MECHANISM 7 Look through the PROJECTION LENS hole and observe the focus light path on the AUTO FOCUS TARGET SLIDE TL 3002 Check that the light path is correct If not do the adjustment procedure for the FOCUS LIGHT PATH Warning Dangerous Voltage 8 Disconnect the main power 9 Heat the 2 POSTS on the PHOTOCELL HOUSING to allow the POSTS to bend enough to pull the PHOTOCELL CIRCUIT BOARD up and off the PHOTOCELL HOUSING Use a SOLDERING IRON 10 Remove the 2 Wratten FILTERS and the PHOTOCELL MASK 31 SERVICE MANUAL 11 Install the FAN CAP 232729 in the PHOTOCELL hole FAN CAP HOUSING FAN CAP light image A091 4033GCA A091 4033GA 12 Manually move the CLAMP PAD ASSEMBLY until the TAB is in the NULL position light path b NULL position CLAMP LEVER A091
35. se operates voltages are correct Reverse does not operate forward operates voltages are correct Projector does not complete a cycle FAN operates Projector has continual cycle 46 Check that the secondary voltage on the MAIN MOTOR is correct Check that the W across the CYCLE SOLENOID COIL are correct Check that the voltage across the CYCLE SOLENOID is correct Check that the CYCLE LEVER and RATCHET PLATE are clean Clean and lubricate the parts as necessary Use SUPER LUBE TL 4276 Install a new CAM STACK ASSEMBLY the malfunction is within the CAM Do the adjustment for the CYCLE SOLENOID Check that the DIRECTION LEVER SPRING is on the DIRECTION LEVER Check the DIRECTION LEVER for binds Excessive lubrication and dirt can cause binds Check for a broken MECHANISM DRIVE BELT Check the CYCLE LEVER and RATCHET LEVER CAM SHAFT ASSEMBLY for the following correct alignment of the CYCLE LEVER damage to parts lubrication of the CYCLE LEVER use SUPER LUBE TL 4276 Check the CYCLE SOLENOID for correct operation See the Voltage chart Check the CYCLE LEVER for correct alignment See the adjustment for the CYCLE LEVER 2 Check for damage to parts 3 Check for a shortecircuit in the wires Usea tool to hold the CYCLE LEVER down on the RATCHET LEVER If there is a shortecircuit causing the malfunction the SOLENOID will b
36. stment 2 Do the removal for the LOWER HOUSING ASSEMBLY 3 Bend the CYCLE LEVER up down Use T BAR TL 3003 4 Energize the projector 5 Press the FORWARD BUTTON to check for correct operation 6 Press the REVERSE BUTTON to check for correct operation 7 Do the steps above until the FORWARD and REVERSE functions operates correctly MECHANISM ASSEMBLY TL 3003 A091 0007HCA A091 0007HA SM5440 1 18NOV97 25 SERVICE MANUAL Adjustment Specification This adjustment adjusts the strobe and timing of the INDEXER LEVER The gate edge of the black plastic of the INDEXER LEVER should be between the 2 holes at position 2 Adjusting the INDEXER LEVER ASSEMBLY A Warning Dangerous Voltage 1 Disconnect the main power 2 Do the removal for the MECHANISM ASSEMBLY 3 Place the MECHANISM ASSEMBLY on the MECHANISM RUNNING FIXTURE 4 Check the alignment of the INDEXER LEVER with the hole in the TOP PLATE ASSEMBLY at Position 1 5 Bend the INDEXER LEVER to the correct position 6 Check the travel of the INDEXER LEVER in the FORWARD position When the INDEXER LEVER moves in the FORWARD position the gate edge of the black plastic should be between the 2 holes at Position 2 7 Bend the INDEXER LEVER until you reach the correct position MECHANISM TOP PLATE ASSEMBLY
37. stment the auto focus system will adjust for the difference in the slide position from slide to slide This focus adjustment will occur within 1 second after the slide is inserted into the GATE The focus adjustment variation should not change from the focus and reverse specifications by more than 3 times the focus and reverse specifications Reliability The projector can operate for 2000 hours or 2 000 000 cycles The projector has a MTBF mean time between failures of 7500 operation hours Maintenance Preventive maintenance by a qualified service person is recommended every 1500 hours of operation or after 1 year Warranty See the owner s manual 7 PIN REMOTE CONTROL PIN 1 Black REMOTE FOCUS See illustration on next PIN 2 Green FORWARD TRAY CYCLE PIN 3 Orange REVERSE TRAY CYCLE PIN 4 Brown RACK SOLENOID PIN 5 Yellow COMMON PIN 6 Brown LAMP CONTROL PIN 7 White LAMP CONTROL REMOTE INLET 7 PIN PLUG 24 V AC 24 V AC N 4 7 OW Y 82 V AC Unloaded 30 6C N O V AC 24 V AC Common A100 0023ACA A100 0023AA SM5440 1 18NOV97 41 SERVICE MANUAL Section 6 Diagnostics MAIN MOTOR Voltages M 10 brown LAMP VOLTAGE is 9 white 74 V between brown 8 and white for 7 l black Y LONG LIFE MODE
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