Text preview for : ektagraphic_sm.pdf part of Kodak Ektagraphic III SERVICE MANUAL
for the
Kodak Ektagraphic III
Painted and Non-Painted PROJECTORS
Models A, KKA, JA, ATS, AM, AMT, JAMT, B, BR, E,
E-PLUS SLIDE, J-E PLUS, and KKE PLUS
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{ServiceManual}{Production}{KodakServiceSupport}
Publication No. SM4530-1 30APR96
SERVICE MANUAL for the Kodak Ektagraphic III Painted and Non-Painted PROJECTORS Models A, KKA, JA, ATS, AM, AMT, JAMT, B, BR, E, E-PLUS SLIDE, J-E PLUS, and KKE PLUS
Kodak Home Page on Internet
Intranet Table of Contents
A100_0001HA
© Eastman Kodak Company, 1999
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. 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 Replacements and Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the LOWER HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . Installing the LOWER HOUSING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the FAN SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the FAN SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the WORM PULLEY and MECHANISM BELT . . . . . . . . . . . . . . . . . Installing the WORM PULLEY and MECHANISM BELT . . . . . . . . . . . . . . . . . . Replacing the THERMAL FUSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the THERMAL FUSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the LAMP MODULE RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . Installing the LAMP MODULE RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the CYCLE SOLENOID ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . Installing the CYCLE SOLENOID ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the MECHANISM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the MECHANISM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the AUTO-FOCUS BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . Installing the AUTO-FOCUS BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . Replacing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY . . . Installing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY . . . . Replacing the LAMP SOCKET TERMINAL ASSEMBLY, N.P. . . . . . . . . . . . . . Installing the LAMP SOCKET TERMINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . Replacing the LAMP SOCKET TERMINAL ASSEMBLY, Painted Models . . . . Installing the LAMP SOCKET TERMINAL ASSEMBLY, Painted Models . . . . . Replacing the LENS MOUNT ASSEMBLY - Auto Focus Model . . . . . . . . . . . . Installing the LENS MOUNT ASSEMBLY - Auto Focus Models . . . . . . . . . . . . Replacing the LENS MOUNT ASSEMBLY - Non Auto Focus Model. . . . . . . . . Installing the LENS MOUNT ASSEMBLY - Non Auto Focus Model . . . . . . . . . Replacing the AUTO-FOCUS SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . Installing the AUTO-FOCUS SWITCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . Replacing the FOCUS SHAFT ASSEMBLY - Auto Focus Models. . . . . . . . . . . Installing the FOCUS SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the FOCUS SHAFT ASSEMBLY - Non Auto-Focus Models. . . . . . . Installing the FOCUS SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the CYCLE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the INDEXER LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the SLIDE LIFT LEVER MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Page 4 4 4 5 7 7 8 8 9 9 10 11 11 12 12 13 14 14 14 15 17 18 18 19 20 20 20 21 21 22 22 23 24 24 25 26 26 27 28
30APR96 SM4530-1
Adjusting the SLIDE LIFT LEVER POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the ZERO POSITION SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Focus Light Path - Auto Focus Models . . . . . . . . . . . . . . . . . . . . . Adjusting the NULL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the PHOTOCELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the CLAMP PAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the DARK SHUTTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN MOTOR Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-PIN SPECIAL APPLICATION PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PHOTOCELL Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-PIN REMOTE CORD PLUG Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SMALL COMPONENT BOARD ASSEMBLY 256809 Voltages . . . . . . . . . . . . . Voltage Specifications - General Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power, Illumination, and Cooling Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . Slide Transport Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Focus Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 30 31 32 33 35 36 37 40 41 43 43 44 44 45 46 47 47 48 51
SM4530-1 30APR96
3
SERVICE MANUAL
Section 1: Replacements and Installations
Replacing the LOWER HOUSING ASSEMBLY
Warning
Dangerous Voltage [1] Disconnect the main power. [2] Remove the PROJECTION LENS. [3] Remove the LAMP MODULE ASSEMBLY. [4] Remove the 6 Torx SCREWS (for N.P. models) (or 6 Phillips SCREWS for Painted Models) from the LOWER HOUSING ASSEMBLY. [5] Pull the LOWER HOUSING ASSEMBLY off the TOP HOUSING.
Installing the LOWER HOUSING ASSEMBLY
LOWER HOUSING SCREW (6)
A100_0012HCA A100_0012HA
LAMP MODULE
[1] Do the replacement procedure for the LOWER HOUSING ASSEMBLY in reverse order.
4
30APR96 SM4530-1
Replacements and Installations
Replacing the FAN SHAFT ASSEMBLY
WIRE TIE (not shown)
BR and KK models
BLOWER COVER WIRE TIE
GRILLE ASSEMBLY
A100_0013HCA A100_0013HA
Warning
Dangerous Voltage [1] Disconnect the main power. [2] Do the replacement procedure for the LOWER HOUSING ASSEMBLY. [3] Cut the 3 WIRE TIES: · 1 on BLOWER COVER wires · 2 on SMALL CIRCUIT BOARD between the MOTOR and MECHANISM ASSEMBLY [4] Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD. [5] Pull the SMALL CIRCUIT 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. [10] Remove the 2 long Torx SCREWS from the BLOWER COVER ASSEMBLY.
SM4530-1 30APR96
5
SERVICE MANUAL
MOTOR
SCREW RETAINER CLIP FAN PLATE ASSEMBLY FAN BELT
FAN FAN CAP E-RING SPRING SCREW (3) FAN BLOWER ASSEMBLY SCREW WASHER CORK WASHER WASHER
MECHANISM BELT
FAN PLATE Painted PROJECTOR
A008_0172HCA A008_0172HA
[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 SPRING 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] N.P. only: Remove the RETAINER CLIP from the FAN SHAFT. [16] Painted Models only: Remove the FAN CAP, E-RING, SPRING, and WASHER. [17] Pull the FAN up and off the FAN SHAFT to allow access to the FAN BELT. [18] Remove the FAN BELT. [19] N.P. only: Remove the 3 Torx SCREWS from the FAN SHAFT ASSEMBLY. [20] Lift and remove the FAN SHAFT ASSEMBLY.
6
30APR96 SM4530-1
Replacements and Installations
Installing the FAN SHAFT ASSEMBLY
FAN BELT
MECHANISM BELT
A091_4015BCA A091_4015BA
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.
Replacing the MOTOR
SCREW (3)
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.
A091_4016GCA A091_4016GA
MOTOR
SM4530-1 30APR96
7
SERVICE MANUAL
Installing the MOTOR
FAN BELT
MECHANISM BELT
A091_4015BCA A091_4015BA
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.
Replacing the WORM PULLEY and MECHANISM BELT
Warning
Dangerous Voltage
WORM PULLEY SCREW
[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 (on N.P. models) (or Hex SCREW on Painted Models) from the WORM PULLEY ASSEMBLY. [5] Move the TAB on the WORM PULLEY ASSEMBLY out.
MECHANISM BELT
[6] Remove the WORM PULLEY ASSEMBLY and MECHANISM BELT.
A091_4017GCA A091_4017GA
8
30APR96 SM4530-1
Replacements and Installations
Installing the WORM PULLEY and MECHANISM BELT
FAN BELT
MECHANISM BELT
A091_4015BCA A091_4015BA
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.
Replacing the THERMAL FUSE ASSEMBLY
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 Torx SCREW on the PREHEAT DUCT approximately half way. [7] Pull the THERMAL FUSE ASSEMBLY out of hole of the LOWER LIGHT BAFFLE ASSEMBLY.
SM4530-1 30APR96
9
SERVICE MANUAL
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
10
30APR96 SM4530-1
Replacements and Installations
Replacing the LAMP MODULE RECEPTACLE
SCREW (2) LOWER LIGHT BAFFLE PRE-HEAT DUCT SCREW (2)
LAMP MODULE RECEPTACLE BLOWER COVER ASSEMBLY
A100_0016HCA A100_0016HA
SCREW (not shown)
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. [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.
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.
SM4530-1 30APR96
11
SERVICE MANUAL
Replacing the CYCLE SOLENOID ASSEMBLY
Warning
Dangerous Voltage [1] Disconnect the main power. [2] Do the replacement procedures for the LOWER HOUSING ASSEMBLY and the MOTOR.
CYCLE SOLENOID SCREW (2)
[3] Cut and remove the necessary WIRE TIES. [4] Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD.
CYCLE SOLENOID PLUNGER
[5] Pull the SMALL CIRCUIT BOARD up. [6] Remove the Torx SCREW (for N.P. models) (or Hex SCREW for Painted Models) from the WORM PULLEY SHAFT. [7] Move the TAB on the WORM PULLEY ASSEMBLY out of the MECHANISM ASSEMBLY. [8] Lift and remove the WORM PULLEY ASSEMBLY. [9] Remove the 2 Torx 1/4 in. SCREWS from the 2 CYCLE SOLENOID GROMMETS. [10] Pull the CYCLE SOLENOID ASSEMBLY up and out. [11] If necessary, remove the CYCLE SOLENOID PLUNGER ASSEMBLY.
A100_0017GCA A100_0017GA
Installing the CYCLE SOLENOID ASSEMBLY
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.
12
30APR96 SM4530-1
Replacements and Installations
Replacing the MECHANISM ASSEMBLY
SCREW (3) LENS MOUNT SCREW DARK SHUTTER SWITCH
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] Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD.
MECHANISM ASSEMBLY
[5] Pull the SMALL CIRCUIT BOARD up. [6] 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 [7] Remove the FOCUS KNOB from the FRONT PANEL.
SCREW
Important
For Auto-Focus models only, disconnect the short, gray wire connected to the AUTO-FOCUS DEFEAT SWITCH.
FOCUS KNOB
[8] Remove the 3 Torx SCREWS from the LENS MOUNT ASSEMBLY. [9] Lift and move the LENS MOUNT ASSEMBLY up. [10] Do the replacement procedure for the MOTOR. [11] Remove the 3 Torx SCREWS from the MECHANISM ASSEMBLY.
AUTO FOCUS DEFEAT SWITCH (not shown)
[12] Loosen the SCREW on the STABILIZER WALL approximately half way. [13] Remove the SCREW from the DARK SHUTTER SWITCH and remove the SWITCH.
A091_4022CCA A091_4022CA
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. [14] Remove the MECHANISM ASSEMBLY.
SM4530-1 30APR96
13
SERVICE MANUAL
Installing the MECHANISM ASSEMBLY
Important
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.
Replacing the AUTO-FOCUS BRACKET ASSEMBLY
SCREW
SCREW (2) WORM PULLEY
CYCLE SOLENOID
AUTO FOCUS BRACKET ASSEMBLY
SCREW
A091_4023BCA A091_4023BA
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] Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD. [5] Pull the SMALL CIRCUIT BOARD up. [6] Do the replacement procedure for the MECHANISM ASSEMBLY. [7] Remove the Torx SCREW (on N.P. models) (or Hex SCREW on Painted Models) from the WORM PULLEY. [8] Remove the WORM PULLEY. [9] 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.
Installing the AUTO-FOCUS BRACKET ASSEMBLY
[1] Do the replacement procedure for the AUTO-FOCUS BRACKET ASSEMBLY in reverse order.
14
30APR96 SM4530-1
Replacements and Installations
Replacing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY
LIFT LEVER SHAFT LIFT LEVER
STYLE 1 RETARD SPRING
E-RING BEARING
STYLE 2 RETARD SPRING
BEARING
NUT CAM STACK ASSEMBLY E-RING
A008_0173HCA A008_0173HA
Warning
Dangerous Voltage [1] Disconnect the main power. [2] Do the replacement procedure for the MECHANISM ASSEMBLY. [3] Remove the INDEXER LEVER ASSEMBLY from the TOP PLATE of the MECHANISM ASSEMBLY. [4] Remove the Torx SCREW (on N.P. models) (or Hex SCREW on Painted Models) from the WORM PULLEY ASSEMBLY. [5] Remove the WORM PULLEY ASSEMBLY. [6] Remove the DIRECTION LEVER LINK from the DIRECTION LEVER. [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 (on N.P. models) (or Hex SCREWS on Painted Models) from the TOP PLATE of the MECHANISM ASSEMBLY. [11] Remove the TOP PLATE.
SM4530-1 30APR96
15
SERVICE MANUAL
[12] Remove the LIGHT BAFFLE.
LIFT LEVER SHAFT SELECT LEVER LIFT LEVER
E-RING
BEARING SELECT LEVER SPRING
BEARING
NUT CAM STACK ASSEMBLY TAB E-RING
A008_0174HCA A008_0174HA
[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.
16
30APR96 SM4530-1
Replacements and Installations
HALF-CYCLE LEVER HALF-CYCLE LEVER SPRING
[20] Remove the 2 SCREWS from the CYCLE SOLENOID. [21] Remove the CYCLE SOLENOID.
E-RING (2)
[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.
CYCLE LEVER PLUNGER SPRING
[26] Remove the 2 E-RINGS: · 1 on the CYCLE LEVER ASSEMBLY · 1 on the HALF CYCLE LEVER
Caution
PLUNGER
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.
CYCLE SOLENOID SCREW (2) INDEX LEVER and SPRING (not shown)
A091_0009CCA 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.
SM4530-1 30APR96
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SERVICE MANUAL
Replacing the LAMP SOCKET TERMINAL ASSEMBLY, N.P.
SCREW LAMP DOOR PLATE ASSEMBLY
Warning
Dangerous Voltage [1] Disconnect the main power. [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
PROJECTOR LAMP LAMP EJECTOR LAMP SOCKET TERMINAL ASSEMBLY
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. [8] Remove the LAMP SOCKET TERMINAL ASSEMBLY.
CONDENSER LENS TAB (2) HEAT ABSORBING GLASS A091_0018CCA
A091_0018CA
Installing the LAMP SOCKET TERMINAL ASSEMBLY
[1] Do the replacement procedure for the LAMP SOCKET TERMINAL ASSEMBLY in reverse order.
18
30APR96 SM4530-1
Replacements and Installations
Replacing the LAMP SOCKET TERMINAL ASSEMBLY, Painted Models
E-RING SPRING WASHER
PROJECTOR LAMP LAMP EJECTOR 6 TABS CONDENSER HOLDER
SOCKET PIN
SCREW
LAMP SOCKET
TOP PLATE
CONDENSER LENS LAMP BRACKET HEAT GLASS
A008_0171DCA A008_0171DA
[1] Disconnect the main power. [2] Remove: · LAMP MODULE · PROJECTION LAMP for the LAMP MODULE from the LAMP MODULE · SCREW and lift the CONDENSER LENS HOLDER up · CONDENSER LENS and HEAT GLASS · RETAINING RING · SPRING WASHER · SOCKET PIN
SM4530-1 30APR96
19
SERVICE MANUAL
Caution
The TABS could break. [3] Bend the 3 TABS of the LAMP BRACKET ASSEMBLY. [4] Lift the top of the LAMP BRACKET ASSEMBLY up. [5] Rotate and push the LAMP TERMINAL ASSEMBLY until it releases. [6] Remove the LAMP TERMINAL ASSEMBLY.
Installing the LAMP SOCKET TERMINAL ASSEMBLY, Painted Models
[1] Do the replacement procedure for the LAMP SOCKET TERMINAL ASSEMBLY in reverse order and check the following during installation: · Check that the LAMP EJECTOR is aligned correctly before you install the LAMP TERMINAL ASSEMBLY. · Check that the LAMP TERMINAL ASSEMBLY wires are aligned correctly. · Bend the 3 TABS down until they are flush with the top of the LAMP BRACKET ASSEMBLY. If the TABS break, use TOP PLATE SCREW 785130 to install a new TAB.
Replacing the LENS MOUNT ASSEMBLY - Auto Focus Model
SCREW (3) LENS MOUNT ASSEMBLY
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 short, gray wire connected to the AUTO-FOCUS DEFEAT SWITCH.
Important
It is necessary to push the AUTO-FOCUS BRACKET backward and forward to allow access to the SCREWS on the LENS MOUNT ASSEMBLY. [5] Remove the 3 SCREWS from the LENS MOUNT ASSEMBLY. [6] Lift and remove the LENS MOUNT ASSEMBLY.
A100_0019GCA A100_0019GA
Installing the LENS MOUNT ASSEMBLY - Auto Focus Models
[1] Do the replacement procedure for the LENS MOUNT ASSEMBLY in reverse order.
20
30APR96 SM4530-1
Replacements and Installations
Replacing the LENS MOUNT ASSEMBLY - Non Auto Focus Model
SCREW (3) LENS MOUNT ASSEMBLY
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.
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.
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SERVICE MANUAL
Replacing the AUTO-FOCUS SWITCH ASSEMBLY
AUTO FOCUS MOTOR BRACKET
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 short, gray wire from the AUTOFOCUS DEFEAT SWITCH.
Important
LOCKING TAB
· It is necessary to push the AUTO-FOCUS BRACKET backward and forward to allow access to the SCREWS on the LENS MOUNT ASSEMBLY. · Keep the AUTO-FOCUS SWITCH LEVER that is connected to the AUTO FOCUS SWITCH so you can install it on the new AUTO FOCUS SWITCH. [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 AUTO FOCUS SWITCH ASSEMBLY. [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.
AUTO FOCUS SWITCH LEVER
grey, red, and black wires
A091_4028GCA A091_4028GA
AUTO FOCUS SWITCH ASSEMBLY
Installing the AUTO-FOCUS SWITCH ASSEMBLY
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.
22
30APR96 SM4530-1
Replacements and Installations
Replacing the FOCUS SHAFT ASSEMBLY - Auto Focus Models
CLAMP LEVER SPRING RACK LEVER (not shown) SCREW FOCUS SHAFT SPRING
FOCUS SHAFT
SCREW
FOCUS MOTOR BRACKET
RACK SOLENOID SPACER E-RING LENS SUPPORT BRACKET PHOTOCELL AUTO-FOCUS BRACKET SWITCH SPRING ASSEMBLY PLUNGER
SCREW
A091_4029HCA A091_4029HA
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 short, gray wire from the AUTO-FOCUS DEFEAT SWITCH.
Important
It is necessary to push the AUTO-FOCUS BRACKET backward and forward to allow access to the SCREWS on the LENS MOUNT ASSEMBLY. [5] Remove the 3 SCREWS from the LENS MOUNT ASSEMBLY. [6] Lift and remove the LENS MOUNT ASSEMBLY. [7] Remove the FOCUS SHAFT SPRING from the LENS MOUNT BRACKET. [8] Remote models only: Remove the SPRING from the CLAMP LEVER on the LENS MOUNT BRACKET. [9] Remove the SPRING from the PHOTOCELL BRACKET. [10] Remove the E-RING and SPACER from the FOCUS SHAFT ASSEMBLY. [11] Remove the SCREW from the LENS SUPPORT BRACKET. [12] Lift and remove the LENS SUPPORT BRACKET. [13] Remote models: Remove the AUTO-FOCUS SWITCH ASSEMBLY. [14] Remote models: Remove the SCREW from the RACK SOLENOID ASSEMBLY. [15] Remote models: Remove the RACK SOLENOID ASSEMBLY and PLUNGER. [16] Remote models: Remove the SCREW from the FOCUS MOTOR BRACKET ASSEMBLY.
SM4530-1 30APR96 23
SERVICE MANUAL
[17] Remove the FOCUS MOTOR BRACKET ASSEMBLY. [18] Push the RACK LEVER away from the FOCUS SHAFT ASSEMBLY. [19] Remove the FOCUS SHAFT ASSEMBLY.
Installing the FOCUS SHAFT ASSEMBLY
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-Focus Models
SCREW FOCUS SHAFT ASSEMBLY FOCUS SHAFT SPRING
FOCUS MOTOR BRACKET
SPACER
LENS SUPPORT BRACKET
E-RING
SCREW
A091_0020HCA A091_0020HA
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.
24 30APR96 SM4530-1
Replacements and Installations
[12] Remove the FOCUS MOTOR BRACKET ASSEMBLY. [13] Remove the FOCUS SHAFT ASSEMBLY.
Installing the FOCUS SHAFT ASSEMBLY
[1] Do the replacement procedure for the FOCUS SHAFT ASSEMBLY in reverse order.
SM4530-1 30APR96
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SERVICE MANUAL
Section 2: Adjustments
Adjustment Specification
Use T-BAR TL-3003 to bend the CYCLE LEVER to adjust the CYCLE SOLENOID.
Adjusting the CYCLE SOLENOID
MECHANISM ASSEMBLY
T-BAR TL-3003
CYCLE BAR
A091_0007HCA A091_0007HA
Warning
Dangerous Voltage [1] Connect the main power.
Important
· The CYCLE SOLENOID must operate correctly to do this adjustment. · The MECHANISM ASSEMBLY does not have to be removed to do this adjustment. [2] Do the removal for the LOWER HOUSING ASSEMBLY. [3] Bend the CYCLE LEVER up or 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.
26
30APR96 SM4530-1
Adjustments
Adjustment Specification
This adjustment adjusts the strobe and timing of the INDEXER LEVER. Use TL-3000. 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
MECHANISM ASSEMBLY TOP PLATE
Bend here.
MECHANISM RUNNING FIXTURE
position 1
position 2
A091_0008HCA A091_0008HA
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 TL-3000. [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.
Adjustment Specification
Use TL-3000 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.
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SERVICE MANUAL
Adjusting the SLIDE LIFT LEVER MANUAL
SLIDE LIFT LEVER GUAGE TL-3001
SLIDE LIFT LEVER
SELECT LEVER (not shown)
A091_0016BCA A091_0016BA
Warning
Dangerous Voltage [1] Disconnect the main power.
Important
The older style MECHANISM SLIDE LIFT LEVER has an ECCENTRIC on it to do this adjustment. [2] Do the removal for the MECHANISM ASSEMBLY. [3] Place the MECHANISM ASSEMBLY on the MECHANISM RUNNING FIXTURE TL-3000. [4] Press and hold the SELECT LEVER down to move the SLIDE LIFT LEVER to the highest position. [5] 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. [6] Bend the SLIDE LIFT LEVER until the adjustment is correct.
Adjustment Specification
Use TL-3000 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.
28
30APR96 SM4530-1
Adjustments
Adjusting the SLIDE LIFT LEVER POWER
SLIDE LIFT LEVER GUAGE TL-3001
SLIDE LIFT LEVER
SELECT LEVER (not shown)
A091_0016BCA A091_0016BA
Warning
Dangerous Voltage [1] Disconnect the main power.
Important
The older style MECHANISM SLIDE LIFT LEVER has an ECCENTRIC on it to do this adjustment. [2] Do the removal for the MECHANISM ASSEMBLY. [3] Place the MECHANISM ASSEMBLY on the MECHANISM RUNNING FIXTURE TL-3000. [4] Energize the MECHANISM FIXTURE. [5] Press and hold the SELECT LEVER down to move the SLIDE LIFT LEVER to the highest position. [6] 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 TL3001. [7] Bend the SLIDE LIFT LEVER until the adjustment is correct.
Adjustment Specification
Make a 5/16 in WRENCH to do this adjustment (see the Tools section). Connect a DIGITAL VOLT METER betweens PINS 1 and 3 (ZERO POSITION SWITCH). The DVM should measure · without a TRAY and 0 W with a TRAY installed.
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SERVICE MANUAL
Adjusting the ZERO POSITION SWITCH
SPECIAL APPLICATIONS PLUG
Important
It is necessary to make a 5/16 in. WRENCH to do this adjustment. See the Tools section.
1
4 2
[1] Energize the projector. [2] Connect the DIGITAL VOLT METER (DVM) between PINS 1 and 3 (ZERO POSITION SWITCH) of the SPECIAL APPLICATIONS PLUG. [3] Without a TRAY installed, the DVM should measure ·. [4] Install a TRAY. [5] To move the TRAY out of the zero position, press the "FORWARD" or "REVERSE" BUTTONS; the DVM should measure 0 W.
7 6 3 8
5
A100_0022ACA A100_0022AA
ZERO POSITION SWITCH NUT
[6] If the measurements are not within specification, adjust the ZERO POSITION SWITCH ECCENTRIC to specification.
A091_0017GCA A091_0017GA
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.
30
30APR96 SM4530-1
Adjustments
Adjusting the Focus Light Path - Auto Focus Models
ADJUSTMENT TOOL TL-3005 or SPRING HOOK TL-1165 AUTO FOCUS BRACKET ASSEMBLY
light path image
AUTO-FOCUS TARGET SLIDE TL-3002
A091_4026HCA A091_4026HA
Warning
Dangerous Voltage [1] Disconnect the main power. [2] Remove the PROJECTION LENS. [3] Do the removal for the LOWER HOUSING ASSEMBLY.
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. [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 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.
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SERVICE MANUAL
Adjusting the NULL
light path T-BAR TL-3003
NULL position
PROJECTION LENS
TAB
A091_4031BCA A091_4031BA
AUTO-FOCUS TARGET SLIDE TL-3002
CLAMP LEVER PAD
Warning
Dangerous Voltage [1] Disconnect the main power. [2] Do the removal for the LOWER HOUSING ASSEMBLY.
Important
· It is necessary to make a FAN COVER TOOL. See the Tools section. · If you cannot obtain the NULL position after doing the adjustment approximately 3 times, go to the adjustment procedure for the PHOTOCELL. [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.
Adjustment Specification
Use TL-3002 and FAN CAP 232729 to check the adjustment of the PHOTOCELL.
32
30APR96 SM4530-1
Adjustments
Adjusting the PHOTOCELL
PHOTOCELL CIRCUIT BOARD wratten FILTER (2)
Warning
Dangerous Voltage [1] Disconnect the main power. [2] Do the removal for the LOWER HOUSING ASSEMBLY.
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. [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. [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.
FAN CAP light image
POST (2) PHOTOCELL HOUSING hole FAN CAP
PHOTOCELL MASK
A091_4032GCA A091_4032GA
[11] Install the FAN CAP 232729 in the PHOTOCELL HOUSING.
A091_4033GCA A091_4033GA
SM4530-1 30APR96
33
SERVICE MANUAL
light path
NULL position
TAB
A091_4027BCA A091_4027BA
CLAMP LEVER PAD
[12] Manually move the CLAMP PAD ASSEMBLY until the TAB is in the NULL position.
T-BAR TL-3003 hole
FAN CAP
light image
AUTO-FOCUS TARGET SLIDE TL-3002
CLAMP PAD ASSEMBLY
A091_4030BCA A091_4030BA
Warning
Dangerous Voltage [13] Connect the main power.
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. [16] Set the projector to the LO-LAMP position. [17] Observe the image of the focus light path on the bottom of the FAN CAP; 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.
34
30APR96 SM4530-1
Adjustments
Adjustment Specification
Use TL-1744 to check that the CLAMP PAD ASSEMBLY moves forward and backward.
Adjusting the CLAMP PAD ASSEMBLY
Warning
Dangerous Voltage [1] Disconnect the main power.
Important
· If the CLAMP ASSEMBLY has a COIL SPRING on the ADJUSTMENT SCREW, remove it. This will make the adjustment easier. · It is necessary to make a FAN COVER TOOL. See the Tools section.
SCREW NUT
[2] Do the removal for the LOWER HOUSING ASSEMBLY. [3] Install the FAN 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. [5] Connect the main power. [6] Loosen the NUT on the CLAMP PAD ASSEMBLY. [7] Energize the REMOTE FOCUS in either direction.
A091_4041GCA A091_4041GA
CLAMP PAD ASSEMBLY
[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.
Adjustment Specification
The PRESSURE PAD should be aligned with the DARK SHUTTER.
SM4530-1 30APR96
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SERVICE MANUAL
Adjusting the DARK SHUTTER
[1] Do the removal for the LOWER HOUSING.
DARK SHUTTER
[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.
PRESSURE PAD
A091_0013GCA A091_0013GA
36
30APR96 SM4530-1
Lubrication
Section 3: Lubrication
[1] Apply lubricant SUPER LUBE TL-4276 to the following parts and areas of the projector; see the illustrations: · FAN · INDEXER LEVER and TOP PLATE · WORM PULLEY ASSEMBLY · CAM STACK ASSEMBLY · CYCLE LEVERS · PIVOT SHAFT and LEVERS · LENS MOUNT ASSEMBLY
A091_4037GA
A100_0020GA
SM4530-1 30APR96
37
SERVICE MANUAL
A091_0023HA
38
30APR96 SM4530-1
Lubrication
A091_0022DA
SM4530-1 30APR96
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SERVICE MANUAL
Section 4: Tools
Tool No. TL-1744 TL-2264 TL-3000 TL-3002 TL-3003 TL-3005 TL-3255 TL-4276 Description AUTO-FOCUS GAUGE FOCUS TEST (flat field) MECHANISM RUNNING FIXTURE (optional) AUTO-FOCUS TARGET SLIDE ADJUSTMENT T-BAR ADJUSTMENT TOOL Torx DRIVER SET 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.
FAN COVER TOOL
11.5 cm (4.5 in.)
A091_0024GCA A091_0024GA
40
30APR96 SM4530-1
Specifications
Section 5: Specifications
Item Electrical Supply Description Standard U.S. Models: 110 - 125 V ac Japan J Models: 100 V AC, 60 Hz only Korea KK Models: 220 V AC, 60 Hz only 400 W · Height: 119 mm (4.69 in.) without TRAY · Width: 238 mm (12.93 in.) Slide size Slide change time Lamp (in LO position) · Length: 295 mm (11.6 in.) 35 mm, 50 x 50 mm (2 x 2 in.) 1 second · 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 Lumen Output · EXY 82 V, 300 W, 200 hours average life · 900 minimum with EXR lamp · Lowest corner to center ratio is 55% minimum · Test method: Ektagraphic 102 mm, F/2.8 LENS aperture (24 x 36 mm), compatible with European specification DIN 19027 · 4.5 C (40 F), 15% humidity in low · 49 C (120 F), 15% humidity in high Cooling Approvals Environmental storage Environmental operation Safety · 21 - 27 C (70 - 80 F), 20 - 60% humidity optimum Fan speed is 2780 or 3000 RPMs, 1360 BTUs per hour to cool projector UL Complies with storage test specifications (TS 172) Complies with climactic test specifications (TS 218) · 3 GROUNDED POWER CORDS, detachable · Heat sensitive interrupt fuses · 109 C power to motor (lamp fuse) Dielectric strength Automatic Timer · 171 C MOTOR Apply 1200 V AC, 60 Hz for 1 second; maximum leakage current is 2.5 mA. Operates between the following times: · Fast = 3 1 second · Slow = 22 6 seconds 14 maximum front elevation assembly.
Power Consumption Dimensions
Operating temperature
Elevation
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SERVICE MANUAL
Item Auto Focus System
Description · After the initial focus adjustment, 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. 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. Preventive maintenance by a qualified service person is recommended every 1500 hours of operation, or after 1 year. See the owner's manual. · PIN 1 - Black, REMOTE FOCUS · 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 6 - White, LAMP CONTROL · PINS 1 and 3 - ZERO POSITION SWITCH · PINS 4 and 5 - SHUTTER SWITCH · PINS 7 and 8 - LOW VOLTAGE SUPPLY, 25.5 V AC, 500 mA, 1/2 Amp Maximum · PINS 6 and 8 - FORWARD TRAY CYCLE · PINS 2 and 8 - REVERSE TRAY CYCLE and SHELL PLUG GROUND
Reliability
Maintenance Warranty 7-PIN REMOTE CONTROL (See illustration below.)
9-PIN SPECIAL APPLICATIONS (See illustration below.)
SPECIAL APPLICATIONS PLUG
7-PIN PLUG 24 V AC K
1 5 2 4
24 V AC N
7
1 4 2
W
7
Y
3 6
82 V AC N
Unloaded
6 3 8
5
G 0 V AC
A100_0023ACA A100_0023AA
O Common 24 V AC
A100_0022ACA A100_0022AA
42
30APR96 SM4530-1
Diagnostics
Section 6: Diagnostics
MAIN MOTOR Voltages
12 11 10 9 8 7 black brown white
84.2 V 1.6
LAMP VOLTAGE is 74 V AC between brown and white for LONG LIFE MODELS
MOTOR
117 V AC 6.1
A091_0006BCA A091_0006BA
MAIN MOTOR PIN Colors PIN 12 11 10 9 8 7 MAIN MOTOR PIN Voltages PIN 8-9 10-11 11-12 10-12 25.5 V ac 14.5 V ac 14.5 V ac 29 V ac Voltage brown red violet yellow blue not used Color
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SERVICE MANUAL
9-PIN SPECIAL APPLICATION PLUG
SPECIAL APPLICATIONS PLUG
1
4 2
7 6 3 8
5
A100_0022ACA A100_0022AA
9-PIN SPECIAL APPLICATION PLUG PINS 1 and 3 4 and 5 7 and 8 6 and 8 2 and 8 Description ZERO POSITION SWITCH SHUTTER SWITCH LOWER VOLTAGE SUPPLY, 2.5 V AC, 500 mA, 1/2 Amp maximum FORWARD TRAY CYCLE REVERSE TRAY CYCLE and SHELL GROUND
PHOTOCELL Voltages
PHOTOCELL
3
1
2
A091_4036ACA A091_4036AA
PHOTOCELL Voltages PINS 1-2 2-3 1-3
44
Voltage 14.5 V ac 14.5 V ac 29 V ac
30APR96 SM4530-1
Diagnostics
5-PIN REMOTE CORD PLUG Voltages
BLACK FWD REV
RED
WHITE BRN FOCUS YELLOW YELLOW
A100_0001BC_
KODAK EC-3 REMOTE CONTROL
5-PIN REMOTE PLUG Voltages PIN white red yellow brown black Description Reverse Forward Common RACK SOLENOID Focus - REMOTE
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SERVICE MANUAL
SMALL COMPONENT BOARD ASSEMBLY 256809 Voltages
WWK R A V V O B Y B J1 R3 CR3 CR2 CR4
RY GN R W W
J2 CR5 F1 R7
Q1 Q2 R4 C1 CR1 + C3 + C2 R6 R5 C4
C5 R17 SLIDE PROJECTOR BOARD Q3
R12 R11 R10
R13 R14 CR6 R15
Q4
A091_4034DC
Description TIMER Circuit TIMER Circuit TIMER Circuit CYCLE HOLD DOWN REVERSE FOCUS FOCUS RACK USE REMOTE FOCUS FOCUS
Component CR3 Q3 Q4 CR4 CR2 CR5 Q1 Q2
RED +, BLACK + to - G to + A - G to + K + to + to + to - B to + C - G to + A
Voltage 32 V DC 32 V DC 18.1 V DC 18.0 V DC 28.0 V DC 18.0 V DC 23.3 V DC 28.0 V DC
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30APR96 SM4530-1
Diagnostics
Voltage Specifications - General Parts
Part FOCUS MOTOR CYCLE SOLENOID RACK SOLENOID LAMP RECEPTACLE DROPPING RESISTOR Procedure None Press the REVERSE BUTTON. None None Move to the LO LAMP position. Voltage 8.5 V AC 39 W, 18.7 V DC 39 W, 10 V AC 82 V AC, approximately 85-86 V AC without a LAMP MODULE installed 3.0 W, 10.6 V AC drop across
Power, Illumination, and Cooling Malfunctions
Malfunction The MOTOR does not operate. Check 1. Check the continuity across the THERMAL FUSE ASSEMBLY, and MOTOR FUSE. 2. Check that the primary voltage on the MAIN MOTOR is correct. 3. Check that the voltage on POWER SWITCH is correct. 1. Check that the FAN BELT is not broken. 2. Check and remove obstructions in the FAN area. 1. Check and remove obstructions in the FAN area. 2. 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. 1. Check the LAMP for damage. 2. Check the LAMP RECEPTACLE ASSEMBLY for damage and correct voltage. 3. Check the LAMP TERMINAL ASSEMBLY in the LAMP MODULE ASSEMBLY for damage. 1. Check that the W of the DROPPING RESISTOR is 3 W. 2. Check that the wire connections on the POWER SWITCH are correct. 3. Check the POWER SWITCH for correct operation. 1. Check the DARK SHUTTER for correct operation. See the adjustment for the DARK SHUTTER. 2. Check the LIGHT BAFFLE in the MECHANISM for damage; it should not cause a jam in the SHUTTER.
The FAN does not operate, MOTOR operates.
There is excessive noise in the FAN.
The LAMP does not operate.
The LO LAMP does not operate.
There is an obstruction in the light path.
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SERVICE MANUAL
Slide Transport Malfunctions
Malfunction Forward and reverse do not operate using the FRONT PANEL BUTTONS or REMOTE CONTROL. Check 1. Check that the secondary voltage on the MAIN MOTOR is correct. 2. Check that the W across the CYCLE SOLENOID COIL are correct. 3. Check that the voltage across the CYCLE SOLENOID is correct. 1. Check that the CYCLE LEVER and RATCHET PLATE are clean. Clean and lubricate the parts as necessary. Use SUPER LUBE TL-4276. 2. Install a new CAM STACK ASSEMBLY; the malfunction is within the CAM. 1. Do the adjustment for the CYCLE SOLENOID. 2. Check that the DIRECTION LEVER SPRING is on the DIRECTION LEVER. 3. Check the DIRECTION LEVER for binds. Excessive lubrication and dirt can cause binds. 1. Check for a broken MECHANISM DRIVE BELT. 2. Check the CYCLE LEVER and RATCHET LEVER on the 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) 3. Check the CYCLE SOLENOID for correct operation. See the Voltage chart. 1. Check the CYCLE LEVER for correct alignment. See the adjustment for the CYCLE LEVER. 2. Check for damage to parts. 3. Check for a short·circuit in the wires: · Use a tool to hold the CYCLE LEVER down on the RATCHET LEVER. If there is a short·circuit causing the malfunction, the SOLENOID will be energized. If there is a bind, the CAM will not rotate. 4. Check that the CAM SHAFT ASSEMBLY RATCHET SPRING is installed correctly. 5. If there is a bind in the CAM STACK, install a new CAM.
Forward does not operate, reverse 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.
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30APR96 SM4530-1
Diagnostics
Malfunction The projector does not change cycles when using a DISSOLVE CONTROL; the REMOTE CONTROL and CONTROL PANEl BUTTONS operate correctly.
Check 1. If 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, install a new CAM SHAFT ASSEMBLY. 1. Check the SLIDE TRAY LATCH for correct alignment. 2. 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. 1. Do the adjustment for the CYCLE SOLENOID. 2. Check that the SPRING is on the DIRECTION LEVER. 3. Check for a bind in the DIRECTION LEVER ASSEMBLY. 4. Check that the DIRECTION LEVER LINK is in the correct position. 1. Press and release the SELECT BUTTON. · Check that the LOCATOR LEVER moves correctly and is not bent. 2. Press and hold the SELECT BUTTON down. · Check the SLIDE LIFT LEVER RAMP for damage. 3. 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.
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.
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SERVICE MANUAL
Malfunction TIMER does not operate
Check 1. Check the VARIABLE RESISTOR for correct operation and install a new part if necessary. 2. Move the TIMER BUTTON forward and backward; use a DVM to check for changes in W. 3. Energize the projector and move the TIMER to "S". · Check the voltages on CR3, Q3, and Q4, see the voltage table. 1. Energize the projector and release the DARK SHUTTER to allow projection. 2. Check for continuity between PINS 4 and 5 on the SPECIAL APPLICATIONS PLUG. 3. Press the "FORWARD" or "REVERSE" BUTTONS to close the DARK SHUTTER. 4. In the closed position, the DVM should measure 0 W. 5. If this procedure does not correct the malfunction, install a new DARK SHUTTER SWITCH. 1. Deenergize the projector. 2. Check for continuity between PINS 1 and 3 on the SPECIAL APPLICATIONS PLUG. 3. Install a SLIDE TRAY. 4. Rotate the SLIDE TRAY to engage the ZERO POSITION SWITCH, the DVM should measure 0 W. 5. If the W measurement is not correct, see the adjustment for the ZERO POSITION SWITCH. Install a new ZERO POSITION SWITCH if necessary. 1. Remove R3 and install a new 68K W 1/4 W RESISTOR (part 220040). 2. If there is still a malfunction, install a new PHOTOCELL.
DARK SHUTTER SWITCH does not operate
ZERO POSITION SWITCH does not operate
After the FOCUS MOTOR energizes and moves, the FOCUS MOTOR oscillates.
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30APR96 SM4530-1
Diagnostics
Focus Malfunctions
Malfunction No manual focus Check 1. Check the FOCUS SHAFT SPRING for the correct tension. 2. Check the LENS SUPPORT SPRING for correct tension. 3. Check the LENS DRIVE GEAR on the FOCUS SHAFT ASSEMBLY for damage and install a new part if necessary. 1. 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 8.5 V AC. If the voltage is correct, install a new FOCUS MOTOR. Check that the secondary voltage on the MAIN MOTOR is correct. 1. 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 8.5 V AC. If the voltage is correct, install a new FOCUS MOTOR. 4. Check the AUTO FOCUS SWITCH ASSEMBLY for correct operation. 5. Check the secondary voltages on the MAIN MOTOR.
No remote focus (Non Auto Focus models)
No remote focus, RACK SOLENOID ASSEMBLY operates (Auto Focus Models)
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SERVICE MANUAL
Malfunction No auto-focus
Check 1. Check that the AUTO-FOCUS DEFEAT SWITCH is in the "ON" position. 2. Check that the MAIN PROJECTION LAMP operates correctly. 3. Insert the TARGET SLIDE TL-3002 in the GATE MECHANISM. · Check that the TARGET is correctly aligned. If not, see the Adjustment section. 4. Check that the voltages across the PHOTOCELL are correct. The voltage from 1 to 2 is 14.5 V ac. The voltage from 2 to 3 is 14.5 V ac. The voltage from 1 to 3 is 29 V ac. 5. Make a short· between 1 and 2; the FOCUS MOTOR should rotate. 6. Make a short·circuit between 2 and 3; the FOCUS MOTOR should rotate in the reverse direction. 7. 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. 1. Check that the alignment of the FOCUS LIGHT PATH and NULL is correct. 2. Check the resolution of the FOCUS LIGHT PATH. Clean the AUTO FOCUS MIRROR and BRACKET ASSEMBLY. 3. Install a new PROJECTION LAMP if necessary. 4. Install a new PHOTOCELL. 5. Check the components on the CIRCUIT BOARD for damage.
Slow auto-focus movement
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30APR96 SM4530-1
Diagnostics
Malfunction AUTO FOCUS MOTOR operates continually
Check 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. 3. Check for a light leak: · Install a different LAMP MODULE ASSEMBLY. If the FOCUS MOTOR stops operating continually, install a new LAMP MODULE ASSEMBLY. 4. Check that the voltages across the PHOTOCELL are correct. The voltage from 1 to 2 is 14.5 V ac. The voltage from 2 to 3 is 14.5 V ac. The voltage from 1 to 3 is 29 V ac. 5. Check that the PHOTOCELL HOUSING has 2 FILTERS. 6. Install a new PHOTOCELL. 7. Check the components on the CIRCUIT BOARD for damage. 1. Check that the wires of the AUTO FOCUS MOTOR are in the correct position; the blue wire goes to the mark on the AUTO FOCUS MOTOR. 1. Do the adjustment for the CLAMP LEVER ASSEMBLY.
AUTO FOCUS MOTOR operates continually in forward only or reverse only and does not operate (stops) in the null position. AUTO FOCUS adjusts after REMOTE use
SM4530-1 30APR96
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Kodak, Ektagrphic, and Wratten are tradmarks.
Printed in U.S.A. · sm4530_1.fm
EASTMAN KODAK COMPANY Rochester, NY 14650