{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
HALF-CYCLE
LEVER SPRING
CYCLE
LEVER
PLUNGER
SPRING
HALF-CYCLE
LEVER
PLUNGER
E-RING (2)
Replacements and Installations
[20] Remove the 2 SCREWS from the CYCLE
SOLENOID.
[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:
• 1 on the CYCLE LEVER ASSEMBLY
• 1 on the 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.
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.
SM5440-1 – 18NOV97 17
SERVICE MANUAL
Replacing the LAMP SOCKET TERMINAL ASSEMBLY
Style 1 LAMP SOCKET TERMINAL ASSEMBLY
SCREW
LAMP DOOR
PLATE ASSEMBLY
PROJECTOR
LAMP
LAMP
EJECTOR
LAMP SOCKET
TERMINAL
ASSEMBLY
Warning
Dangerous Voltage
[1] Disconnect the main power.
Important
The EXTRA BRIGHT LAMP MODULEdoes nothave a
HEAT ABSORBING GLASS and has a LABEL on the
LAMP DOOR.
[2] Remove the LAMP MODULE.
[3] Remove the PROJECTIONLAMP 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.
[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 18NOV97 – SM5440-1
Replacing the LENS MOUNT ASSEMBLY - Auto Focus Model
SCREW (3)
LENS MOUNT
ASSEMBLY
Dangerous Voltage
It is necessary to push the AUTO-FOCUS BRACKET
backward and forward to allowaccess tothe SCREWS
on the LENS MOUNT ASSEMBLY.
Warning
[1] Disconnect the main power.
[2] Do the replacement procedure for the LOWER
HOUSING ASSEMBLY.
[3] Remove the FOCUS KNOB.
Important
[4] Remove the 3 SCREWS from the LENS MOUNT
ASSEMBLY.
[5] Lift and remove the LENS MOUNT ASSEMBLY.
Replacements and Installations
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.
SM5440-1 – 18NOV97 19
SERVICE MANUAL
Replacing the LENS MOUNT ASSEMBLY - Non Auto Focus Model
SCREW (3)
LENS MOUNT
ASSEMBLY
Dangerous Voltage
Warning
[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.
20 18NOV97 – SM5440-1
Replacing the AUTO-FOCUS SWITCH ASSEMBLY
Replacements and Installations
AUTO FOCUS
MOTOR BRACKET
LOCKING
TAB
AUTO FOCUS
SWITCH LEVER
AUTO FOCUS SWITCH ASSEMBLY
grey, red,
and black
wires
A091_4028GCA
A091_4028GA
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 allowaccess tothe 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 gray, red, and black wires from the
AUTO FOCUS SWITCH ASSEMBLY.
Important
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.
[8] To disconnect and remove the AUTO FOCUS
SWITCH,bendthe LOCKING TAB on the FOCUS
MOTOR BRACKET untilit isaligned withthe hole
in the AUTO FOCUS SWITCH.
Installing the AUTO-FOCUS SWITCH ASSEMBLY
Important
Align the 2TABS onthe AUTO-FOCUS SWITCH with the FOCUS MOTORBRACKET, checking that the endof the
AUTO-FOCUSLEVERengageswiththe CYCLE SOLENOID PLUNGER. After theAUTO-FOCUSSWITCHisinthe
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] Do the replacement procedure for the LOWER HOUSING ASSEMBLY.
[3] Remove the FOCUS KNOB.
Important
It is necessary topush the AUTO-FOCUS BRACKETbackward and forward toallow access to theSCREWS on the
LENS MOUNT ASSEMBLY.
[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] Remote models only: Remove the SPRING from the CLAMP LEVER on the LENS MOUNT BRACKET.
[8] Remove the SPRING from the PHOTOCELL BRACKET.
[9] Remove the E-RING and SPACER from the FOCUS SHAFT ASSEMBLY.
[10] Remove the SCREW from the LENS SUPPORT BRACKET.
[11] Lift and remove the LENS SUPPORT BRACKET.
[12] Remote models: Remove the AUTO-FOCUS SWITCH ASSEMBLY.
[13] Remote models: Remove the SCREW from the RACK SOLENOID ASSEMBLY.
[14] Remote models: Remove the RACK SOLENOID ASSEMBLY and PLUNGER.
[15] Remote models: Remove the SCREW from the FOCUS MOTOR BRACKET ASSEMBLY.
[16] Remove the FOCUS MOTOR BRACKET ASSEMBLY.
[17] Push the RACK LEVER away from the FOCUS SHAFT ASSEMBLY.
[18] Remove the FOCUS SHAFT ASSEMBLY.
CLAMP LEVER
SPRING
SCREW
FOCUS SHAFT
SPRING
RACK LEVER
(not shown)
FOCUS SHAFT
FOCUS MOTOR
BRACKET
SPACER
E-RING
PHOTOCELL
BRACKET
SPRING
AUTO-FOCUS
SWITCH
ASSEMBLY
SCREW
SCREW
RACK
SOLENOID
PLUNGER
LENS SUPPORT BRACKET
A091_4029HCA
A091_4029HA
22 18NOV97 – SM5440-1
Replacements and Installations
Installing the FOCUS SHAFT ASSEMBLY
Important
Do the adjustments for thePHOTOCELL NULL and AUTO-FOCUS CLAMP after installation. See the Adjustments
section.
Replacing the FOCUS SHAFT ASSEMBLY - Non Auto-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
ASSEMBLY
FOCUS SHAFT
SPRING
FOCUS MOTOR
BRACKET
SPACER
E-RING
SM5440-1 – 18NOV97 23
SCREW
LENS SUPPORT
BRACKET
A091_0020HCA
A091_0020HA
SERVICE MANUAL
Installing the FOCUS SHAFT ASSEMBLY
[1] Do the replacement procedure for the FOCUS SHAFT ASSEMBLY in reverse order.
24 18NOV97 – SM5440-1
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.
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 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.
Adjustments
T-BAR
TL-3003
MECHANISM
ASSEMBLY
CYCLE
BAR
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
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
ASSEMBLY
MECHANISM
RUNNING FIXTURE
TOP PLATE
Bend
here.
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] Disconnect the main power.
[2] Do the removal for the MECHANISM ASSEMBLY.
[3] Place the MECHANISM ASSEMBLY on the MECHANISM RUNNING FIXTURE.
[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 withthe lowsurface of theSLIDE LIFTLEVER GAUGE TL-3001; theSLIDE 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.
SLIDE LIFT
LEVER GUAGE
TL-3001
SLIDE LIFT
LEVER
SELECT
LEVER
(not shown)
A091_0016BCA
A091_0016BA
Adjustment Specification
Use 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.
Adjusting the SLIDE LIFT LEVER POWER with Mechanism Out
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] 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 withthe lowsurface of theSLIDE LIFTLEVER GAUGE TL-3001; theSLIDE LIFT
LEVER should not make contact with the high surface of the SLIDE LIFT LEVER GAUGE TL-3001.
[7] Bend the SLIDE LIFT LEVER until the adjustment is correct.
SM5440-1 – 18NOV97 27
SERVICE MANUAL
SLIDE LIFT
LEVER GUAGE
TL-3001
Adjusting the Focus Light Path - Auto Focus Models
Adjustment Specification
SLIDE LIFT
LEVER
SELECT
LEVER
(not shown)
A091_0016BCA
A091_0016BA
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.
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.
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
AUTO FOCUS
BRACKET
ASSEMBLY
light path
image
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.
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 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
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
NULL position
PROJECTION
LENS
AUTO-FOCUS
A091_4031BCA
A091_4031BA
TARGET SLIDE
TL-3002
Adjustment Specification
Use TL-3002 and FAN CAP 232729 to check the adjustment of the PHOTOCELL.
Adjusting the PHOTOCELL
PHOTOCELL
CIRCUIT BOARD
wratten
FILTER (2)
Dangerous Voltage
It is necessary to makea FANCOVER TOOL. Seethe
Tools section.
Warning
[1] Disconnect the main power.
[2] Do the removal for the LOWER HOUSING
ASSEMBLY.
Important
[3] Install the FAN COVER TOOL over the FAN area
and the LAMP MODULE. See the Tools section.
TAB
CLAMP LEVER
PAD
POST (2)
PHOTOCELL
HOUSING
30 18NOV97 – SM5440-1
PHOTOCELL
MASK
A091_4032GCA
A091_4032GA
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 inthe GATE
MECHANISM.
[7] Look through the PROJECTION LENS hole and
observe the focuslight 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 enoughto
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.
SM5440-1 – 18NOV97 31
SERVICE MANUAL
hole
light image
FAN CAP
[11] Install the FAN CAP 232729 in the PHOTOCELL
HOUSING.
FAN CAP
A091_4033GCA
A091_4033GA
[12] Manually move the CLAMP PAD ASSEMBLY until the TAB is in the NULL position.
light path
NULL position
A091_4027BCA
A091_4027BA
Warning
Dangerous Voltage
[13] Connect the main power.
TAB
CLAMP LEVER
PAD
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 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.
T-BAR TL-3003
CLAMP PAD
AUTO-FOCUS
ASSEMBLY
TARGET SLIDE
TL-3002
Adjustment Specification
Use TL-1744 to check that the CLAMP PAD ASSEMBLY moves forward and backward.
FAN CAP
hole
light image
A091_4030BCA
A091_4030BA
SM5440-1 – 18NOV97 33
SERVICE MANUAL
Adjusting the CLAMP PAD ASSEMBLY
SCREW
NUT
CLAMP PAD
ASSEMBLY
A091_4041GCA
A091_4041GA
Warning
Dangerous Voltage
[1] Disconnect the main power.
[2] Do the removal for the LOWER HOUSING
ASSEMBLY.
Important
It is necessary to makea FANCOVER TOOL. Seethe
Tools section.
[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.
Warning
Dangerous Voltage
[5] Connect the main power.
[6] Loosen the NUT on the CLAMP PAD ASSEMBLY.
[7] Energize the REMOTE FOCUS ineither 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 theCLAMP PAD ASSEMBLY.
[11] Install the AUTO-FOCUS GAUGETL-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 CLAMPPAD
ASSEMBLY adjustment is too tight and not
correct.
Adjustment Specification
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
Adjustments
A091_0013GA
SHUTTER
DARK
PAD
PRESSURE
A091_0013GCA
SM5440-1 – 18NOV97 35
SERVICE MANUAL
Section 3: Lubrication
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
36 18NOV97 – SM5440-1
Lubrication
A100_0020GA
A091_0023HA
SM5440-1 – 18NOV97 37
SERVICE MANUAL
A091_0022DA
38 18NOV97 – SM5440-1
Tools
11.5 cm
(4.5 in.)
A091_0024GA
TOOL
A091_0024GCA
COVER
FAN
Cut here.
Section 4: Tools
Tools
Tool Description
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
TL-4276 SUPER LUBE
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.
Torx
DRIVER SET
DIGITAL MULTIMETER
SM5440-1 – 18NOV97 39
SERVICE MANUAL
Section 5: Specifications
Item Desription
Electrical Supply 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
Power Consumption 400 W
Dimensions • Height: 119 mm (4.69 in.) without TRAY
• Width: 238 mm (12.93 in.)
• Length: 295 mm (11.6 in.)
Slide size 35 mm, 50 x 50 mm (2 x 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 EXR lamp
• EXTRA BRIGHT LAMP MODULE has a
30% increase in lumen output
• Lowest corner to center ratio is 55%
minimum
• Test method:
–
Ektagraphic
aperture (24 x 36 mm), compatiblewith
European specification DIN 19027
Operating temperature • 4.5 C (40 F), 15% 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
Approvals UL
Environmental storage Complies with storage test specifications (TS
172)
Environmental operation Complies with climactic test specifications (TS
218)
Safety • 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.
102 mm, F/2.8 LENS
40 18NOV97 – SM5440-1
Item Desription
1
2
3
4
5
6
7
A100_0023AA
Y
W
N
O
G
N
K
7-PIN PLUG
A100_0023ACA
24 V AC
24 V AC
24 V AC
0 V AC
Common
Unloaded
82
V AC
Automatic Timer Operates between the following times:
• Fast = 3 1 second
• Slow = 22 6 seconds
Elevation 14 maximum front elevation assembly.
Auto Focus System • 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 1second
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
(See illustration on next page.)
• 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 7 - White, LAMP CONTROL
Specifications
REMOTE INLET
SM5440-1 – 18NOV97 41
SERVICE MANUAL
Section 6: Diagnostics
MAIN MOTOR Voltages
12
11
10
9
8
7
MOTOR
MAIN MOTOR PIN Colors
PIN Color
12 brown
11 red
10 violet
9 yellow
8 blue
7 not used
brown
white
black
84.2 V
1.6
117 V AC
6.1
LAMP VOLTAGE is
74 V AC
between brown
and white for
LONG LIFE MODELS
A091_0006BCA
A091_0006BA
MAIN MOTOR PIN Voltages
PIN Resistance Voltage
8-9 3.1 W 24.4 V AC
10-11 4.3 W 14.1 V AC
11-12 4.2 W 14.1 V AC
10-12 8.0 W 28.2 V AC
9-10 O.L.
42 18NOV97 – SM5440-1
PHOTOCELL Voltages
1
2
3
A091_4036AA
A091_4036ACA
PHOTOCELL
PHOTOCELL Voltages
Diagnostics
PINS Voltage
1-2 14.5 V ac
2-3 14.5 V ac
1-3 29 V ac
5-PIN REMOTE CORD PLUG Voltages
REV
WHITE
KODAK
EC-3 REMOTE CONTROL
A100_0001BC_
FWD
RED
BLACK
BRN
FOCUS
YELLOWYELLOW
5-PIN REMOTE PLUG Voltages
PIN Description
white Reverse
red Forward
yellow Common
brown RACK SOLENOID
black Focus - REMOTE
SM5440-1 – 18NOV97 43
SERVICE MANUAL
SMALL COMPONENT BOARD ASSEMBLY 256809 Voltages
WBWK R A V V O B Y
CR2
Q2
R3
R4
Q1
R6
CR3
R5
J1
C4
CR4
C5
R17
SLIDE PROJECTOR BOARD
J2
F1
R7
Q3
WWRNGYR
CR5
C1
CR1
++
C3
C2
R12
R11
R10
R13
R14
CR6
R15
Q4
Description Component RED +, BLACK - Voltage
TIMER Circuit CR3 + to - 32 V DC
TIMER Circuit Q3 - G to + A 32 V DC
TIMER Circuit Q4 - G to + K 18.1 V DC
CYCLE HOLD DOWN
CR4 + to - 18.0 V DC
REVERSE
FOCUS CR2 + to - 28.0 V DC
FOCUS RACK USE
CR5 + to - 18.0 V DC
REMOTE
FOCUS Q1 - B to + C 23.3 V DC
FOCUS Q2 - G to + A 28.0 V DC
A091_4034DC
44 18NOV97 – SM5440-1
Voltage Specifications - General Parts
Part Procedure Voltage
FOCUS MOTOR ------ 6.7 V AC
CYCLE SOLENOID Press the REVERSE
BUTTON.
RACK SOLENOID ------ 39 W, 10 V AC
LAMP RECEPTACLE ------ Standard Models:
DROPPING RESISTOR Move to the LO LAMP
position.
39 W, 10 V DC
82 V AC, approximately 85-86
V AC without a LAMP
MODULE installed
Long Life Models:
74 V AC, 76 V AC without
LAMP
3.0 W, 10.4 V AC drop across
Power, Illumination, and Cooling Malfunctions
Diagnostics
Malfunction Check
The MOTOR does not operate. 1. Check thecontinuity across theTHERMAL
FUSE ASSEMBLY, and MOTOR FUSE.
2. Check that the primary voltageonthe MAIN
MOTOR is correct.
3. Check that the voltage on POWER
SWITCH is correct.
The FAN does not operate, MOTOR operates. 1. Check that the FAN BELT is not broken.
2. Check andremove obstructionsin theFAN
area.
There is excessive noise in the FAN. 1. Check andremove obstructionsin theFAN
area.
2. Check that the tension is correct on the
FAN BELT.
3. Check that the FAN BELT is clean.
4. Check thecondition ofthe BEARING in the
FAN ASSEMBLY.
The LAMP does not operate. 1. 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. 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.
SM5440-1 – 18NOV97 45
SERVICE MANUAL
Slide Transport Malfunctions
Malfunction Check
Forward and reverse do not operate using the
FRONT PANEL BUTTONS or REMOTE
CONTROL.
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. 1. Check the CYCLE LEVER for correct
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
LEVERon theCAM SHAFTASSEMBLYfor
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.
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.
46 18NOV97 – SM5440-1
Malfunction Check
The projector does not change cycles when
using a DISSOLVE CONTROL; the REMOTE
CONTROL and CONTROL PANEL BUTTONS
operate correctly.
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.
2. If this does not correct the malfunction:
• Install a newCAM SHAFT ASSEMBLY.
SLIDE TRAY does not advance smoothly. 1. Check the SLIDE TRAYLATCH 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.
SLIDE TRAY advances when “REVERSE” is
pressed.
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.
SLIDE TRAY does not rotate freely when the
SELECT BUTTON is pressed down. The
projector has power.
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.
Diagnostics
SM5440-1 – 18NOV97 47
SERVICE MANUAL
Malfunction Check
TIMER does not operate 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 theprojector andmovethe TIMER
to “S”.
• Check the voltages on CR3, Q3, and
Q4, see the voltage table.
DARK SHUTTER SWITCH does not operate 1. Energize the projector and release the
DARK SHUTTER to allow projection.
2. Check forcontinuity between PINS4 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,installanewDARKSHUTTER
SWITCH.
After the FOCUS MOTOR energizes and
moves, the FOCUS MOTOR oscillates.
1. Remove R3and install a new 68K W1/4 W
RESISTOR (part 220040).
2. If there is still a malfunction, install a new
PHOTOCELL.
Focus Malfunctions
Malfunction Check
No manual focus 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.
No remote focus (Non Auto Focus models) 1. Check the REMOTE CORD for damage;
use a REMOTE CORD that has no
damage.
2. Actuate andhold the REMOTECONTROL.
3. Check that the voltage across the FOCUS
MOTOR is 6.7 V AC. If the voltage is
correct, install a new FOCUS MOTOR.
4. Check that the secondary voltage on the
MAIN MOTOR is correct.
48 18NOV97 – SM5440-1
Malfunction Check
No remote focus, RACK SOLENOID
ASSEMBLY operates (Auto Focus Models)
1. Check that the REMOTE CORD operates
correctly; use a REMOTE CORD you know
is good (EC 3).
2. Actuate andhold the REMOTECONTROL.
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. Installa new
FOCUS MOTOR.
4. Check the AUTO FOCUS SWITCH
ASSEMBLY for correct operation.
5. Check the secondary voltagesonthe MAIN
MOTOR.
No auto-focus 1. Check that the AUTO-FOCUS DEFEAT
SWITCH is in the “ON” position.
2. Check thatthe MAIN PROJECTIONLAMP
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 13.8 V ac. The voltage from
2 to 3is 13.8V ac. The voltagefrom 1 to 3
is 28 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.
Slow auto-focus movement 1. Check that the alignment of the FOCUS
LIGHT PATH and NULL is correct.
2. Check theresolution of the FOCUS LIGHT
PATH. Clean the AUTO FOCUSMIRROR
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.
Diagnostics
SM5440-1 – 18NOV97 49
SERVICE MANUAL
Malfunction Check
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.
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 13.8 V ac. The voltage from
2 to 3is 13.8V ac. The voltagefrom 1 to 3
is 28 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.
AUTO FOCUS MOTOR operates continually in
forward only or reverse only and does not
operate (stops) in the null position.
1. Check that the wires of the AUTO FOCUS
MOTORare in the correctposition; the blue
wiregoes to themarkon the AUTOFOCUS
MOTOR.
AUTO FOCUS adjusts after REMOTE use 1. Do the adjustment for the CLAMP LEVER
ASSEMBLY.
50 18NOV97 – SM5440-1
Printed in U.S.A. • sm5440_1.fm
EASTMAN KODAK COMPANY
Rochester, NY 14650
Kodak, Carousel,
and
Wratten
are trademarks.
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