Kodak 4200-J, 5600 User Manual
{ServiceManual}{Production}{KodakServiceSupport}
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,
Kodak Home Page
on Internet
Intranet
Table of Contents
4600-KK, 5600, 5600-J, and 5600-KK
© Eastman Kodak Company, 1999
A100_0029HA
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 Page
Replacements and Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacing the LOWER HOUSING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 4
Installing the LOWER HOUSING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacing the FAN SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installing the FAN SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacing the MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installing the MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Replacing the WORM PULLEY and MECHANISM BELT . . . . . . . . . . . . . . . . . 8
Installing the WORM PULLEY and MECHANISM BELT . . . . . . . . . . . . . . . . . . 9
Replacing the THERMAL FUSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installing the THERMAL FUSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Replacing the LAMP MODULE RECEPTACLE. . . . . . . . . . . . . . . . . . . . . . . . . 10
Installing the LAMP MODULE RECEPTACLE. . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . 20
Installing the LENS MOUNT ASSEMBLY - Non Auto Focus Model . . . . . . . . . 20
Replacing the AUTO-FOCUS SWITCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 21
Installing the AUTO-FOCUS SWITCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . 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
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Adjusting the CYCLE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Out . . . . . . . . . . . 27
2 18NOV97 – SM5440-1
Adjusting the Focus Light Path - Auto Focus Models
Adjustment Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Adjusting the NULL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Adjusting the PHOTOCELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Adjusting the CLAMP PAD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Adjusting the DARK SHUTTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
MAIN MOTOR Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
PHOTOCELL Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5-PIN REMOTE CORD PLUG Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SMALL COMPONENT BOARD ASSEMBLY 256809 Voltages . . . . . . . . . . . . . 44
Voltage Specifications - General Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Power, Illumination, and Cooling Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . 45
Slide Transport Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Focus Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SM5440-1 – 18NOV97 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
[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.
Torx
SCREWS from the LOWER HOUSING ASSEMBLY.
LOWER HOUSING
SCREW (6)
A100_0030HCA
A100_0030HA
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:
• 1 on BLOWER COVER wires
• 2 on 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 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.
WIRE TIE (not shown)
KK models
BLOWER COVER WIRE TIE
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 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] 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.
MOTOR
SCREW
RETAINER CLIP
FAN
SCREW (2)
BLOWER ASSEMBLY
MECHANISM BELT
FAN PLATE
ASS4EMBLY
FAN BELT
SCREW (3)
A100_0014HCA
A100_0014HA
Installing the FAN SHAFT ASSEMBLY
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
6 18NOV97 – SM5440-1
MECHANISM BELT
A091_4015BCA
A091_4015BA
Replacements and Installations
A091_4016GA
MOTOR
SCREW (3)
A091_4016GCA
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
[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.
Hex
1/4 in. SCREWS from the MOTOR.
Installing the MOTOR
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
FAN BELT
MECHANISM BELT
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
[5] Move the TAB on the WORM PULLEY ASSEMBLY out.
[6] Remove the WORM PULLEY ASSEMBLY and MECHANISM BELT.
Torx
SCREW from the WORM PULLEY ASSEMBLY.
A091_4015BCA
A091_4015BA
8 18NOV97 – SM5440-1
Replacements and Installations
A091_4017GA
WORM PULLEY
BELT
MECHANISM
A091_4017GCA
SCREW
Installing the WORM PULLEY and MECHANISM BELT
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.
FAN BELT
MECHANISM BELT
A091_4015BCA
A091_4015BA
SM5440-1 – 18NOV97 9
SERVICE MANUAL
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
[7] Pull the THERMAL FUSE ASSEMBLY out of hole of the LOWER LIGHT BAFFLE ASSEMBLY.
Torx
SCREW on the PREHEAT DUCT approximately half way.
Installing the THERMAL FUSE ASSEMBLY
[1] Do the replacement procedure for the THERMAL FUSE ASSEMBLY in reverse order.
SCREW
A100_0015GCA
A100_0015GA
POWER SWITCH
Replacing the LAMP MODULE RECEPTACLE
PRE-HEAT DUCT
THERMAL FUSE
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
[5] Loosen the
10 18NOV97 – SM5440-1
Torx
SCREWS on the left side of the LOWER LIGHT BAFFLE ASSEMBLY.
Torx
SCREW on the right side of the LOWER LIGHT BAFFLE ASSEMBLY approximately 1/2 way.
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 thePREHEAT DUCT, compressthe 2 TABS on the LAMP
MODULE RECEPTACLE.
SCREW (2)
LOWER LIGHT BAFFLE
LAMP MODULE
RECEPTACLE
PRE-HEAT DUCT
SCREW (2)
BLOWER COVER
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.
SM5440-1 – 18NOV97 11
SERVICE MANUAL
Replacing the CYCLE SOLENOID ASSEMBLY
CYCLE SOLENOID
CYCLE
SOLENOID
PLUNGER
SCREW (2)
Warning
Dangerous Voltage
[1] Disconnect the main power.
[2] Do the replacement procedures for the LOWER
HOUSING ASSEMBLY and the MOTOR.
[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] Remove the
PULLEY SHAFT.
[7] Move the TAB on the WORM PULLEY
ASSEMBLY out of the MECHANISM ASSEMBLY.
[8] Lift andremove the WORM PULLEY ASSEMBLY.
[9] Remove the 2
CYCLE SOLENOID GROMMETS.
[10] Pull the CYCLE SOLENOID ASSEMBLY up and
out.
[11] If necessary, remove the CYCLE SOLENOID
PLUNGER ASSEMBLY.
Torx
SCREW from the WORM
Hex
1/4 in. SCREWS from the 2
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 18NOV97 – SM5440-1
Replacing the MECHANISM ASSEMBLY
Replacements and Installations
LENS
MOUNT
SCREW
FOCUS KNOB
SCREW (3)
MECHANISM
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] Disconnect the 2 wires from the CYCLE
SOLENOID on the SMALL CIRCUIT BOARD.
[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.
[8] Remove the 3
MOUNT ASSEMBLY.
[9] Lift and move the LENS MOUNT ASSEMBLY up.
[10] Do the replacement procedure for the MOTOR.
[11] Remove the 3
MECHANISM ASSEMBLY.
[12] Loosen the SCREW on the STABILIZER WALL
approximately half way.
Torx
SCREWS from the LENS
Torx
SCREWS from the
Caution
There might be a bind between the SELECT LEVER
and the SELECT BUTTON when removing the
MECHANISM ASSEMBLY. Do not use force; this
A091_4047CCA
A091_4047CA
might cause damage to the SELECT BUTTON.
[13] Remove the MECHANISM ASSEMBLY.
Installing the MECHANISM ASSEMBLY
Important
To insert the SELECTBUTTON into the holein the SELECT LEVERwhen 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
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
[8] Remove the WORM PULLEY.
[9] Remove the 2
[10] Remove the CYCLE SOLENOID.
[11] Remove the
[12] Pull and remove the AUTO-FOCUS BRACKET ASSEMBLY through the hole where the CYCLE SOLENOID
was.
Torx
SCREW from the WORM PULLEY.
Hex
SCREWS from the CYCLE SOLENOID.
Phillips
SCREW from the AUTO-FOCUS BRACKET ASSEMBLY.
SCREW
CYCLE
SOLENOID
AUTO
FOCUS
BRACKET
ASSEMBLY
SCREW
SCREW (2)
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] 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
[5] Remove the WORM PULLEY ASSEMBLY.
[6] Remove the DIRECTION LEVER LINK from the DIRECTION LEVER.
Torx
SCREW from the WORM PULLEY ASSEMBLY.
WORM
PULLEY
A091_4023BCA
A091_4023BA
14 18NOV97 – SM5440-1
Replacements 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.
A100_0018HCA
A100_0018HA
E-RING
RETARD
SPRING
LIFT LEVER SHAFT
BEARING
CAM STACK ASSEMBLY
LIFT LEVER
NUT
E-RING
SELECT LEVER
(not shown)
[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.
BEARING
SM5440-1 – 18NOV97 15
SERVICE MANUAL
LIFT
LEVER
SELECT LEVER
SELECT LEVER
SPRING
CAM STACK
ASSEMBLY
E-RING
BEARING
LIFT LEVER SHAFT
TAB
NUT
BEARING
E-RING
A091_0010HCA
A091_0010HA
16 18NOV97 – SM5440-1
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