Kodak X-Omat MULTILOADER 300 Service Manual

supersedes SM 3058-5 from 12/97

SERVICE MANUAL

for the

Publication No. SM 3058-6

9/98

SM 3058-4 from 1/96 SM 3058-2 from 7/93

SM 3058 from 3/93 SM 3058 from 2/91

Kodak X-Omat

MULTILOADER 300 / 300 Plus

PLEASE NOTE

The information contained herein is based on the experience and knowledge

relating to the subject matter gained by Kodak prior to publication.No patent license

is granted by this information.Kodak 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 the use of this information, even if

loss or damage is caused by Kodak’s negligence or other fault.

SERVICEMANUAL SM3058-6

While we cannot even feel a static charge of less than 3,500 volts, a s few as 30 volts can damage or destroy essential components in t he electronic eq uipment upon which you rely. As technology continues to advance, these advanced components will be even more vulnerable to ESD destruction. The conclusion is clear. To tak e charge of p roductivity and p rofitability, you must take care of ESD, now. Effective ESD control requires the following things.

AWARENESS

Everyone in your organisa tion needs to b e aware of ESD , because p artial ESD control is no ESD control at all. Ev eryone needs to remember that:

· ESD is a primary source of frustrating equipment failures and intermittent malfunc tions.

ESD affects productivity and profitability. ESD can be co ntrolled.

ACTION

To take charge of ESD , you must take action. And that mean s everyone from senior management to the evening security crew. If you repair and maintain electronic equipment, it means always w earing grounding straps and working at ESD- protected sites. If you ever work around electronic eq uipment, it means keeping static gener ators like plas tic trash bags away from sensitive components. For everyone, taking charge of ESD means maling the simple ESD controls a way of life. (See the following sec tions for sp ecial tips).

EFFECTIVE ESD CONTROL IS EVERYONE’S RESPONSIBILITY.

EVERY DAY

1. Put trash in its place. A nd that place is away from static-sensitive equipment. Plastic

materials, like trashcan liners and plastic foam cups, generate t he static elec tricity that damages or destroys e lectronic components .

2. Look for the label. Static-sensitive components are marked with bright graphic labels. Look for these labels. Follow label directions.

3. Sp ray the carpe t. ESD that is generated when yo u walk over ca rpet is a ma jor culprit in component destruction. In some cases, especially in low-humidity environments, you may need to periodically spray carpets with an anti-static preparation, available at loca l stores.

KODAK AG, Stuttgart V 9/98

SM 3058-6 ESD

DURING MAINTENANCE AND REPAIR

· Wear a grounding strap when you deal with static -sensitive components . Always mak e

certain that the clip is attached to a properly grounded, unpainted surface.

· Use a portable grounding mat if you cannot r epair components at an ESD-protected

workstation. (Kodak’s Customer Equipment Services Division can assist you in setting up ESD-protected workstations .)

· Use protective pack aging when y ou transport components from one area to another.

Transparent anti static bags , available from a variety of manufactures , shield your just-repaired components from further damage.

SAFETY WARNINGS

· BE CAREFUL WHEN WORKING IN THE CASSETTE OPENER AREA. THE OPENER

MOTOR AND THE OPENER MECHANISM ARE VERY STRONG. THEY CANNOT BE MOVED MANUALLY. THEY MAY SQUEEZE YOUR HAND AND TRAP YOU IF YOU TRY TO STOP THEM MANUALLY. NEVER START THE CASSETTE OPENER MOTOR WHEN SOMEONE’S HANDS ARE IN THE CASSETTE AREA.

· DISCONNECT THE POWER WHEN TAKING OUT OR INSTALLING THE POWER

SUPPLY. IT IS POSSIBLE TO TOUCH THE MAINS VOLTAGE.

· IF YOU TAKE OUT SAFETY COVERS OR WIRE TIES TO HAVE EASIER ACCESS TO

PARTS, INSTALL THEM B EFORE YOU MOUNT THE SIDE PANELS WHEN THE SERVICE CALL OR THE PM IS FINISHED.

· BE CAREFUL WHEN WORKING ON CIRCUIT BOARDS A4 AND A8. THERE ARE 120

VAC ON THOSE BOARDS. BE ESPECIALLY CARE FUL WHEN MEASURING ON THE REAR SIDE OF THE CIRCUIT BOARDS OR WHE N A4 IS PIVOTED OUT OR A8 IS PIVOTED UP. AN ELECTRIC SHOCK MAY RESULT.

· WHEN WORKING IN THE AREA OF PCB A4, COVER THE VENTING HOLE AT THE

TOP OF THE POWER SUPPLY SO THAT NOTHING MAY FALL INTO IT. TAKE THIS COVER OFF BEFORE MOUNTING THE SIDE PANELS TO AVOID OVERHEATING OF THE SYSTEM.

9/98 VI KODAK AG, Stuttgart

TOOLS SM 3058-6

1. SPECIAL TOOLS

VERNIER CALIPER ......................................................................................................TL 1727

GREASE...........................................................................................................................TL 2247

TEMPLATE CASSETTE TYPE 2 ................................................................................9194501

METRIC ALLEN SET.....................................................................................................TL 2764

METRIC ALLEN SET BALL ENDED...........................................................................TL 3789

METRIC OPEN END WRENCH SET ..........................................................................TL 2765

METRIC OPEN END WRENCH 5.5mm......................................................................TL 1936

ESD KIT ...........................................................................................................................TL 3346

DENTIST MIRROR.........................................................................................................TL 2753

LOGIC PEN.....................................................................................................................TL 3008

EXTRACTION TOOL ......................................................................................................TL 1580

EXTRACTION TOOL ......................................................................................................TL 1654

THICKNESS GAUGE .....................................................................................................TL 2372

LAPTOP DATA CABLE .................................................................................................TL 4391

TORX WRENCH SET ....................................................................................................TL 3261

BLOW PIPE POSITIONER CASSETTE ......................................................................TL 4830

BLOW PIPE POSITIONER MAGAZINE......................................................................TL 4582

CES SERVICE SOFTWARE..............................................................G9904537 / TL4462 ***

LAPTOP COMPUTER, has to be bought locally.

*** Always use the lates t software vers ion available.

KODAK AG, Stuttgart 1-1 9/98

SM 3058-6 TOOLS

9/98 1-2 KODAK AG, Stuttgart

REPLACEMENTS SM 3058-6

2. REPLACEMENTS INTRODUCTION

In this section it is very often explained how to use the CES SERVICE SOFTWARE. The first line tells always what should be performed. In the next lines it is explained how to reach this goal. These additional explanations are printed italic and can be skipped if you are experienced w ith the CES SERVICE SOFTW ARE.

EXAMPLE:

1. Start the CASSETTE INPUT FLAP MOTOR M1

Start the SERVICE PROGRAM.

Select SERVICE MODE from the GLOBAL MENU....................................... press ENTER

ENTER SERVICE MODE MESSAGE is displayed............................................press ENTER

UNIT DATA are displayed ...............................................................................press ENTER

Select COMPONENT TEST from the MAIN MENU.......................................press ENTER

Select CASSETTE MOTORS ...............................................................................press ENTER

Select INPUT FLAP MOT M1.............................................................................press ENTER

Select CLOSE/OPEN.......................................................................................... press ENTER

CASSETTE TRANSPORT

REPLACEMENT OF CASSETTE INPUT FLAP MOTOR.

1. Switch off the ML300.

2. Take off the PANELS.

3. Take off the MOTOR CAM.

MOUNTING SCREW (4)

GUIDE BRACKET

NUT

CAM

figure 2-1

KODAK AG, Stuttgart 2-1 9/98

SM 3058-6 REPLACEMENTS

4. Take out the 2 MOUNTING SCREWS of the GUIDE BRACKET.

5. Remove the NUT.

6. Take off the GUIDE BRACKET.

7. Take off the INPUT FLAP.

8. Take out the 4 MOUNTING SCREWS of the MOTOR INPUT FLAP.

9. Install the new MOTOR.

FUNCTION TEST

1. Start the CASSETTE INPUT FLAP MOTOR M1

Start the SERVICE PROGRAM.

Select SERVICE MODE from the GLOBAL MENU....................................... press ENTER

ENTER SERVICE MODE MESSAGE is displayed............................................press ENTER

UNIT DATA are displayed ...............................................................................press ENTER

Select COMPONENT TEST from the MAIN MENU.......................................press ENTER

Select CASSETTE MOTORS ...............................................................................press ENTER

Select INPUT FLAP MOT M1.............................................................................press ENTER

Select CLOSE/OPEN.......................................................................................... press ENTER

2. Make sure that the MOTOR CAM turns clockwise. If it turns counter-clockwise

interchange PIN 1 and 3 at the MOTOR C ONNECTOR.

3. Exit the SERVICE PROGRAM

Press 3 times BACKSPACE.

Select LEAVE COMPONENT TEST ...................................................................press ENTER

Select QUIT ML300 SERVICE MODE............................................................... press ENTER

Select Quit the program................................................................................. press ENTER

9/98 2-2 KODAK AG, Stuttgart

REPLACEMENTS SM 3058-6

REPLACEMENT OF THE SHORT TRANSPORT ROLLERS.

1. Switch off ML300.

2. Take off the PANELS.

3. Remove the COVE R PLATE .

REAR

COVER PLATE

MOTOR INPUT FLAP

FRONT

MOUNTING SCREW (6)

figure 2-2

KODAK AG, Stuttgart 2-3 9/98

SM 3058-6 REPLACEMENTS

Note

There is a SPACER between the 2 BALL B EARINGS of the BELT TENS IONER.

4. Remove the FRONT BELT TENSIONER and take off the DRIVE BELT.

BELT

TENSIONER

SPACER

BALL

BEARING

figure 2-3

9/98 2-4 KODAK AG, Stuttgart

REPLACEMENTS SM 3058-6

5. Take off the C-RING at the DRIVE PULLEY.

C-RING

C-RING DRIVE PULLEY DOWEL PIN C-RING BALL BEARING

figure 2-4

KODAK AG, Stuttgart 2-5 9/98

SM 3058-6 REPLACEMENTS

6. Take out the DRIVE PU LLEY with the DOW EL PIN.

7. Take off the C-RING of the BALL BEARING.

8. Take off the BALL BEARING.

9. Lift the ROLLER END with the PLASTIC BEARING and pull out the TRANSPORT

ROLLER.

Note

Make sure that all PLASTIC BEARINGS are installed as shown in the figure below.

10. Install the new TRANS PORT ROLLER.

This side of all PLASTIC BEAR-

INGS must show up

figure 2-5

FUNCTION TEST

1. Check that a CASSETTE is transported correctly forward and backward.

9/98 2-6 KODAK AG, Stuttgart

REPLACEMENTS SM 3058-6

REPLACEMENT OF THE LONG TRANSPORT ROLLER.

1. Switch off the ML300.

2. Take off the PANELS.

3. Remove the COVER PLATE of the HOLDING FINGER ASSEMBLY.

COVER PLATE

REAR

figure 2-6

FRONT

4. Loosen the MOUNTING SCREWS of the CASSETTE TRANSPORT MOTOR to take

off the TIMING BELT tension.

REAR

SMALL DRIVE

PULLEY

TRANSPORT MOTOR

FRONT

CASSETTE

TIMING BELT

MOUNTING

MOUNTING SCREW

figure 2-7

SCREWS

5. Take off the small DRIVE PULLEY with the TIMING BELT.

KODAK AG, Stuttgart 2-7 9/98

SM 3058-6 REPLACEMENTS

6. Take off the DOWEL PIN and the BEARING.

DOWEL PIN

BEARING

C-RING

DOWEL PIN

PLASTIC DRIVE

PULLEY

BEARING

figure 2-8

SMALL DRIVE PULLEY

7. TakeofftheleftsideDRIVEBELT.

8. Take off the C-RING, WASHER and the DOWEL PIN of the PLASTIC DRIVE

PULLEY.

9. Take off the TRANSPORT ROLLER DRIVE BELT on the right side.

10. Remove the right-hand CENTRING BAR from the MOUNTING BRACKET. To do

so take out the 2 MOUNTING SCREW S and lift up the right-hand TRANS PORT ROLLERS with their BEARING SIDE.

11. Take off the right-hand PLASTIC PULLEY and BEARING of the TRANSPORT

ROLLER.

12. Shift the TRANSPORT ROLLER fully to the left until it stops.

13. Lift the right end of the TRAN SPORT ROLLER up and slide it out to the right.

14. Install new the TRANSPORT ROLLER.

9/98 2-8 KODAK AG, Stuttgart

REPLACEMENTS SM 3058-6

FUNCTION TEST.

1. Check that a CASSETTE is transported correctly forward and backward.

REPLACEMENT OF THE CASSETTE WIDTH TIMING BELT.

1. Switch off the ML300.

2. Open the TOP COVER.

3. Remove the COVE R PLATE .

COVER PLATE

REAR

4. Take out the left GUID E.

FRONT

figure 2-9

REAR

MOUNTING

LEFT GUIDE

figure 2-10

KODAK AG, Stuttgart 2-9 9/98

SCREWS

HOLDING

FINGER

SM 3058-6 REPLACEMENTS

5. Loosen the MOUNTING SCREWS of the HOLDING FINGER.

6. Take out the HOLDING FINGER.

7. Take out BOARD A10 (ODOMETER CASSETTE WIDTH).

PCB A10

figure 2-11

8. Take out the right C-RINGS of the 2 CASSE TTE TIMING BELT SHAFTS.

FRONT

TIMING BELT

SHAFT

C-RING

SET SCREW

CLUTCH

figure 2-12

REAR

C-RING

TIMING BELT

SHAFT

9. Loosen the CLUTCH SE T SCREWS and take out the PIN.

9/98 2-10 KODAK AG, Stuttgart

REPLACEMENTS SM 3058-6

10. Lift out the short TRANSPORT ROLLER near to the ODOMETER.

short TRANSPORT

ODOMETER

ROLLER

figure 2-13

11. Shift both CA SSETTE TIMING BELT SHAFTS to the left.

12. Replace the TIMING BELT.

13. When installing the HOLDING FINGER, make sure that the TIMING BELT is

centred before you tighten the MOUNTING SCREWS.

14. The ODOMETER (PCB A10) has to be positioned as shown.

CODE DISC

On this side of the CODE DISC

is an imprinted number

21.3 ± 0.5 mm

PCB A10

This corner is cut at an angle

1.2 mm max. for new style PCBs

0.5 mm max. for old style PCBs

0.1 mm min. for both styles.

figure 2-14

KODAK AG, Stuttgart 2-11 9/98

SM 3058-6 REPLACEMENTS

15. If the distance of 21.3mm is not correct, loosen the MOUNTING SCREW of the

PCB HOLDER and move it as required.

Note

Not all PCB A10 are working correctly when the gap is set to 1 .2 mm. Espec ially with the old style PCBs the g ap should not be bigger than 0.5 mm.

16. If the distance of 1mm is not correct, loosen the MOUNTING SCREWS of PCBA10

and move it as re quired.

17. If the PCB cannot be moved fa r enough, take it out and elongate the MOUNTING

SCREW HOLES with a small file.

FUNCTION TEST

1. FeedinaCASSETTE.

2. Check that the HOLDING FINGER transports the CASSETTE up to the CASSETTE

END STOP.

3. Check that the correct CASSETTE SIZE is detected.

9/98 2-12 KODAK AG, Stuttgart

REPLACEMENTS SM 3058-6

REPLACEMENT OF THE CASSETTE TRANSPORT MOTOR M2.

Note

Always order MOTOR PN 9228010 and RETAINING RING PN 450016

1. Switch off the ML300.

2. Take off the PANELS.

Note

THE DOWEL PIN MAY FALL DOWN

3. Take off the DRIVE PULLEY with the D OWEL PIN and the TIMING B ELT.

SCREW 3

SCREW 1 SCREW 2 TIMING BELT SCREW 4 SCREW 5

PCB A9

MOUNTING

SCREW (3)

DRIVE PULLEY WITH

DOWEL PIN

RETAINING RING

figure 2-15

KODAK AG, Stuttgart 2-13 9/98

SM 3058-6 REPLACEMENTS

4. Loosen SCREWS 1, 2 and 3. Se e figure 2-15.

5. Take out SCREWS 4 and 5. See figures 2-15.

Note

The SPACERS between the MOTOR and the MOUNTING BRACKET may fall down.

6. Take out the MOUNTING SCREWS of the CA SSETTE TRANSPORT MOTOR.

MOUNTING SCREW

MOUNTING

SCREW

figure 2-16

7. Take out the CASSETTE TRANSPORT MOTOR.

8. Install the new MOTOR.

9/98 2-14 KODAK AG, Stuttgart

REPLACEMENTS SM 3058-6

FUNCTION TEST.

1. Start the CASSETTE TRANSPORT MOTOR M2

Start the SERVICE PROGRAM

Select SERVICE MODE from the GLOBAL MENU....................................... press ENTER

ENTER SERVICE MODE MESSAGE is displayed............................................press ENTER

UNIT Data are displayed ...............................................................................press ENTER

Select COMPONENT TEST from the MAIN MENU.......................................press ENTER

Select CASSETTE MOTORS ...............................................................................press ENTER

Select CASSETTE TRANSPORT M2 ...................................................................press ENTER

2. Check that the MOTOR is running forward/backward.

Select FORWARD/BACKWARD

3. Exit the SERVICE PROGRAM

Press 3 times BACKSPACE

Select LEAVE COMPONENT TEST ...................................................................press ENTER

Select QUIT ML300 SERVICE MODE............................................................... press ENTER

Select Quit the program................................................................................. press ENTER

KODAK AG, Stuttgart 2-15 9/98

SM 3058-6 REPLACEMENTS

REPLACEMENT OF THE CASSETTE OPENER MOTOR M5

1. Switch off the ML300.

2. Remove the PANE LS.

3. Take off the ACTUATOR

MOUNTING SCREW (3) CASSETTE OPENER MOTOR

OPENER

STOP PLATE

MOUNTING SCREW (3) OPENER STOP PLATE

PCB A9

SENSOR B15

DRIVE GEAR

ACTUATOR

figure 2-17

4. Take out MOUNTING SCREWS of CASSETTE OPENER MOTOR.

5. Mark the position of the OPENER STOP PLATE.

6. Take out the MOUNTING SCREWS of the OPENER STOP PLATE.

7. Take out the DOWEL PIN of the MOTOR SHAFT.

8. Take out the STOP PLATE .

9/98 2-16 KODAK AG, Stuttgart

REPLACEMENTS SM 3058-6

Warning

Hold with one hand the CASSETTE OPENER MECHANISM. As soon as you take off the CHAIN, the mechanism moves down and may squeeze in your fingers . When the t he GEAR is off lower the CASSETTE OPENER MECHANISM to its bottom position.

9. Take off the DRIVE GEAR with the CHAIN.

10. TakeoutSCREW1to5.

SCREW 1 2 3 4

SCREW 5

PCB A9

CASSETTE OPENER MOTOR

figure 2-18

11. Pull the MOUNTING PLATE forward a s far as possible.

Note

The MOTOR comes off with a THREAD P LATE. This THREAD PLATE must be inserted again with the new MOTOR. It holds the OP ENER STOP PLA TE.

12. Take out the CASSETTE OPENER MOTOR.

13. Insert the new CASSETTE OPENER MOTOR together with the THREAD PLATE.

KODAK AG, Stuttgart 2-17 9/98

SM 3058-6 REPLACEMENTS

14. Insert and fasten SCREW 1 to 5.

15. Insert the 3 MOTOR MOUNTING SCRE WS. Do not fasten them. Mount SENSOR

B15/C_OP_EO.

16. Mount the OPENER STOP PLATE. Use the marks made in step 5 as reference.

Tighten the MOUNTING SCREWS just a bit, that the STOP PLATE can s till be moved.

Warning

BE CAREFUL WHEN WORKING IN THE CASSETTE OPENER AREA. THE OPENER MOTOR AND THE OPENER MECHANISM ARE VERY STRONG. THEY CANNOT BE MOVED MANUALLY. THEY MAY SQUEEZE YOUR HAND AND TRAP YOU IF YOU TRY TO STOP THEM MANUALLY. NEVER START THE CASSETTE OPE NER MOTOR WHEN SOMEONE’S HANDS ARE IN THE CASSETTE AREA.

17. Switch on the ML300

DOWEL PIN should be

in a horizontal position

DOWEL PIN GROOVE

figure 2-19

18. To mount the MOTOR D RIVE GEAR the D OWEL PIN has to be in the correct

position in relation to the STOP BOLTS of the STOP PLATE.

To rotate the MOTOR SHAFT use the SERVICE PROGRAM. Switch on the CASSETTE OPENER MOTOR M5 until the DOWEL PIN is in a horizontal position.

9/98 2-18 KODAK AG, Stuttgart

+ 214 hidden pages

Kodak X-Omat MULTILOADER 300 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

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