F3 Metal Mine Detector
Issue 1.4 4th February, 2005
Part No: 4904-0003
LEVEL 1 MAINTENANCE
FIELD SERVICE MANUAL
F3 Field Service Manual – Level 1 Maintenance
WARNING
THIS DOCUMENT CONTAINS MINELAB ELECTRONICS
LIMITED RIGHTS TECHNICAL DATA OR RESTRICTED
RIGHTS DATA OR BOTH.
Minelab Electronics
This work is copyright. Apart from any use as
permitted under the Copyright Act 1968, no part
may be reproduced by any process without written
permission from
Minelab Electronics
118 Hayward Avenue, Torrensville
South Australia.5031
Page 2
CONTENTS
SECTION PAGE
1. Introduction .....................................................................................................................4
1.1.
1.2.
2. Mechanical And Functional Testing Of The F3 ................................................................6
2.1.
2.2.
3. Disassembly And Reassembly Procedures ...................................................................12
3.1.
3.2.
3.3.
3.4.
3.5.
3.6.
3.7.
Levels Of Maintenance.............................................................................................4
How To Use This Manual .........................................................................................4
Level 1 Maintenance
Mechanical Testing...................................................................................................6
Functional Testing .................................................................................................... 7
Speaker Pod...........................................................................................................12
Handle.................................................................................................................... 15
Armrest...................................................................................................................18
Electronics Pack.....................................................................................................21
Coil .........................................................................................................................29
Shafts .....................................................................................................................34
Battery Pack ........................................................................................................... 44
4. Faultfinding Procedures ................................................................................................51
4.1.
4.2.
4.3.
4.4.
4.5.
4.6.
4.7.
Switch On Test Faultfinding....................................................................................51
Noise Cancel Faultfinding.......................................................................................51
Audio Reset Faultfinding......................................................................................... 51
Ground Balance Faultfinding ..................................................................................51
Test Piece Faultfinding ........................................................................................... 51
Alarm Tone Faultfinding ......................................................................................... 52
Earset Faultfinding..................................................................................................52
F3 Field Service Manual – Level 1 Maintenance
1. INTRODUCTION
This manual is intended to instruct service technicians in functional
verification and Level 1 maintenance of the F3 mine detector. All sub-assemblies of
the F3 can be replaced without the need for adjustment or calibration. This service
manual includes all Level 1 maintenance procedures, including functional testing and
troubleshooting.
1.1. LEVELS OF MAINTENANCE
Levels of maintenance for the F3 comprise:
Level 1:
and most minor components of the F3 detector. This level of maintenance can be
conducted at demining field sites or local depots if required. Level 1 maintenance
includes full functional testing of the detector and does not require any specialized
facilities but does require the F3 Service Tool Kit.
Level 2: Level 2 maintenance encompasses Level 1 maintenance plus repairs
to the earset earphone and coil socket replacement. This level of maintenance
requires electronic workshop facilities and the F3 Service Tool Kit.
Level 1 maintenance includes replacement of all major components
Level 3: Level 3 maintenance encompasses Level 1 and Level 2 maintenance,
plus electronics pack PCB repair. Level 3 repairs are only conducted at Minelab’s
repair workshops located in Australia, Ireland and the USA.
1.2. HOW TO USE THIS MANUAL
Section 2 for comprehensive mechanical and functional testing of the F3. If any
mechanical component (eg armrest, coil) of the F3 requires replacement, Section 3
details Disassembly and Reassembly Procedures. If any faults are found during
functional testing, references to faultfinding procedures in Section 4 are included.
If doubt exists as to the mechanical integrity or performance of the F3, turn to
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F3 Field Service Manual – Level 1 Maintenance
LEVEL 1 MAINTENANCE
Page 5
F3 Field Service Manual – Level 1 Maintenance
2. MECHANICAL AND FUNCTIONAL TESTING OF THE F3
This section details mechanical and functional testing of the F3. Section 2.1
lists all mechanical testing and directs the user to applicable Level 1 repair
procedures if any defects are found. Section 2.2 lists functional testing of the F3
and will refer the user to the applicable faultfinding procedure if a fault is found. A
defective component is confirmed using the substitution method, so a complete and
fully serviceable F3 should be on hand (or a range of serviceable spare parts). After
any repair to the F3, Section 2.2 Functional Testing must be repeated in full to
ensure the F3 is fully serviceable before being returned to operational use.
2.1. MECHANICAL TESTING
Confirm that all components are present in the hard case. Unpack and fully
assemble the F3 (as described in Section 2.3 of the F3 Operations Manual). Fit
known good batteries, and fully extend the shafts. During assembly:
•
•
•
•
•
•
•
found during the above procedures, refer to the Section 3 disassembly and
reassembly procedures and follow these procedures to the point where the faulty
part can be replaced.
Ensure that the Sensitivity Endcap is correctly positioned and in good
condition. (Replace Endcap in accordance with Section 2.5 of the F3
Operations Manual.)
Ensure that the Battery Pack lid O-ring is present, clean and in good
condition. Ensure that the tether attaching the BP lid to the BP is present
and in good condition.
Ensure that the coil can be tilted smoothly and holds its position without
drooping. Ensure that it rotates smoothly to its three positions.
Ensure that the skid plate is firmly attached and in good condition.
Ensure that the shafts extend smoothly to their full extension and that the
camlocks hold the coil and shafts in position.
Ensure that the earset dustcaps (on detector earset socket and earset) are in
good condition. Do not plug the earset in at this stage.
Unlock the armrest camlock and ensure that the armrest slides smoothly from
the handle to the endcap. Ensure that the armstrap is in good condition.
Mechanical testing is now complete. To replace any worn or damaged parts
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F3 Field Service Manual – Level 1 Maintenance
2.2. FUNCTIONAL TESTING
This section details functional testing of the F3. It should be used to confirm
serviceability of an F3 before it is returned to the field for use and whenever doubt
exists about the serviceability of an F3. The F3 must pass all these tests to be
considered serviceable. References to faultfinding procedures in Section 4 are
included for repair as required. If a repair is completed, the full functional test
should be repeated from Section 2.2.1.
A Ground Balance (GB) Test Piece is required to properly test the F3. This
Note:
is needed to simulate mineralised or “noisy” ground and ensure correct F3
Ground Balance operation. The GB Test Piece can be a local piece of
mineralised ground (hot rock or a fired tile) that produces a response from the
F3.
2.2.1. Switch On Test
•
•
Hold the coil at least 600mm (24ins) from the ground and away from any
metallic objects and switch on the F3.
Ensure that four or five rising tones taking 12 to 15 seconds are heard. A
steady threshold tone should be heard a few seconds after the rising tones
finish.
Figure 1 Switch On Procedure
•
If the correct tones are not heard, check that good batteries are being used
and that the batteries are fitted correctly.
•
If the correct tones are still not heard go to Section 4.1 for faultfinding
procedures.
2.2.2. Noise Cancel Test
•
Hold the coil stationary and at least 600mm (24ins) above the ground. Press
and immediately release the Noise Cancel button (black button located
behind the handle).
Note: The coil should not be moved during this procedure nor should metallic
objects be brought near the coil during this procedure.
Figure 2 Noise Cancel Procedure
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F3 Field Service Manual – Level 1 Maintenance
•
Noise Cancel will commence with two single beeps followed by 45 seconds of
sharp double beeps finishing with four single beeps.
•
During the 45 seconds, the detector scans the environment searching for the
source of any electrical interference. Once detected, the F3 will automatically
select a different operating frequency to eliminate or reduce the interference.
•
If the correct sequence of Noise Cancel beeps is not heard, go to Section 4.2
for faultfinding procedures.
2.2.3. Audio Reset Test
•
Hold the coil at least 600mm (24ins) off the ground and away from any
metallic objects.
Note: If the threshold seems to be at the correct volume, position the coil near a
piece of metal to conduct this procedure (If the coil is brought near a piece of
metal and the Audio reset Procedure is successfully completed, when the coil
is moved away from the piece of metal, another Audio Reset procedure will
need to be completed).
•
Press and immediately release the Ground Balance button (Green Button
located on top of the Handle (if the button is held too long, the detector will
begin to Ground Balance).
Figure 3 Audio Reset Procedure
•
•
Within two seconds the threshold tone will return to its correct level.
If the threshold tone does not return to the correct level, go to Section 4.3 for
faultfinding procedures.
2.2.4. Ground Balance Test
Note: Ensure the operator’s hands and arms are free of metallic objects (watches,
rings etc), and that no other metallic objects are near the coil.
a. If a Ground Balance Test Piece is being used:
•
Hold the ground balance button down for 3-4 seconds; this will reset the
detector internal ground balance setting.
•
Ensure that the coil is held stationary and away from any metal during this
procedure.
•
Move the Ground Balance Test Piece from approximately 150mm (6ins)
above the centre of the coil slowly towards the centre of the coil, a response
should be heard.
•
Press down and hold the green Ground Balance button whilst moving the
Ground Balance Test Piece from approximately 150mm (6ins) above the
centre of the coil slowly towards the centre of the coil (and touching the coil),
then out again approximately 150mm (6ins). Continue to move the Ground
Balance Test Piece slowly to and from the coil until the ‘Ground Balance OK’
tone is heard. (‘Ground Balance OK’ tone consists of a short high-pitched
double beep).
•
Release the Ground Balance button.
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F3 Field Service Manual – Level 1 Maintenance
•
Move the Ground Balance Test Piece from approximately 150mm (6ins)
above the centre of the coil slowly towards the centre of the coil, no response
should be heard.
•
If a response is still heard, repeat this procedure, if there is still a response,
go to Section 4.4 for faultfinding procedures.
b. If local ground is being used:
•
Ensure that this procedure is carried out on ground free of metal and hold the
coil about 150mm (6 ins) above the ground.
•
Press and hold the ground balance button down for 3-4 seconds, this will
reset the detector internal ground balance setting.
•
Slowly lower and raise the coil to the ground (touching the ground), a ground
response should be heard. If a response cannot be heard from the ground,
find an area of ground that produces a response when repeating the previous
step. If no ground can be found that produces a response from the detector,
a Ground Balance Test Piece must be used (Section 2.2.4.a).
•
Press down and hold the green Ground Balance button
and slowly lower the coil directly to the ground (touching the ground) then lift
the coil up again 150mm (6ins).
•
Continue to lower and raise the coil until the ‘Ground Balance OK’ tone is
heard. (‘Ground Balance OK’ tone consists of a short high-pitched double
beep).
Note: Movement of the coil during the entire Ground Balance procedure should be
slow, continuous and smooth and each down and up movement should take 3
to 4 seconds.
•
Release the Ground Balance button.
Figure 4 Ground Balance Procedure
•
Raise and lower the coil from the ground, no response from the ground
should be heard.
•
If the Ground Balance OK tone is not heard within 20 seconds of starting the
procedure, release the Ground Balance button and repeat this procedure.
•
If there is metal in the ground under the coil whilst Ground Balancing, the
detector will not ground balance correctly. Move the detector and repeat the
Ground Balance over ground that is free of any metallic objects.
•
If a response is still heard, repeat this procedure, if there is still a response
after repeating this procedure, go to Section 4.4 for faultfinding procedures.
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F3 Field Service Manual – Level 1 Maintenance
2.2.5. Test Piece Test
Note:
Ensure the operator’s hands and arms are free of metallic objects (watches,
rings etc), and that no other metallic objects are near the coil. Maximum sensitivity
is only available 30 seconds after the threshold tone is heard. Do not test the
detector with the Test Piece until 30 seconds after the threshold tone is heard.
a. Black Endcap.
•
Hold the Test Piece above the middle of the coil with the rounded end
(containing metallic target) away from the coil.
•
Move the Test Piece towards the centre of the coil until it lightly touches the
coil then move it sideways off the coil (the Test Piece should be moved slowly
and smoothly during this procedure). A faint but clear response (change in
threshold tone volume and pitch) should be heard indicating that the
sensitivity of the detector is correct.
•
If the correct response is not heard, go to Section 4.5 for faultfinding
procedures.
•
Turn the detector off.
b. Red Endcap.
•
•
•
Remove the black endcap and fit the red endcap.
Turn the detector on, wait for the start up procedure to finish.
Hold the Test Piece above the middle of the coil with the rounded end
(containing the metallic target) towards the coil.
•
Move the Test Piece towards the centre of the coil until it lightly touches the
coil then move it sideways off the coil (the Test Piece should be moved slowly
and smoothly during this procedure). A clear response (change in threshold
tone volume and pitch) should be heard indicating that the sensitivity of the
detector is correct.
•
If the correct response is not heard, go to Section 4.5 for faultfinding
procedures.
2.2.6. Alarm Tone Test
•
Remove the red endcap (with the detector switched on). A continuous
cycling alarm tone should now be heard.
•
•
•
•
If the alarm tone is not heard go to Section 4.6 for faultfinding procedures.
Turn the detector off.
Remove the red endcap and fit the black endcap.
Turn the detector on and repeat the black endcap Test Piece procedure
(Section 2.2.5).
Figure 5 Test Piece Procedure
Page 10
2.2.7. Earset Test
•
Plug the earset into the detector as follows:
o
Undo the dustcaps from the Earset plug and Earset socket on the
detector. As shown in the following figure, gently hold the Earset plug
by the collar, and align the plug (raised dot on plug should be
uppermost) to the Earset socket before firmly sliding the collar onto
the socket.
F3 Field Service Manual – Level 1 Maintenance
Figure 6 Fitting the Earset
•
•
Ensure that the threshold tone is audible at the earphone.
If an earset ‘speaker on’ (4523-0027) is being tested, ensure that the
threshold tones can still be heard from the detector loudspeaker.
•
If an earset ‘speaker off’ (4523-0025), green tubing on earset cable near
plug) is being tested, ensure that the threshold tones cannot be heard from
the detector loudspeaker.
•
If a volume control is fitted to the earset cable, ensure that it operates
correctly.
•
If any faults are found, go to Section 4.6 for faultfinding procedures, or
replace the earset.
•
Turn the detector off.
2.2.8. Battery Cable Test (if supplied)
•
•
Remove the battery pack from the detector.
Connect the battery pack to the detector using the battery pack extension
cable.
•
•
Turn the detector on and repeat the Test Piece test.
If the detector fails to function properly with the battery cable connected,
replace the battery cable as it is not repairable.
•
Turn the detector off, disconnect the battery pack extension cable and refit
the battery pack.
Functional testing has now been completed.
Remove the batteries from the battery pack.
Pack the detector and all accessories into the hard case.
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F3 Field Service Manual – Level 1 Maintenance
3. DISASSEMBLY AND REASSEMBLY PROCEDURES
Minelab F3 Tool Kit (Minelab Part No 3004-0018) is required for these
procedures. The kit comprises:
Minelab Part No Description
0005-0006 Silicon Grease (100g tube)
0005-0010 Silicon Sealant (75g tube)
8701-0009 Tubular Spanner 7/8”
8701-0010 F3 Coil Cable Pull through
8701-0011 Screwdriver Pozidrive No 1 250mm
8701-0012 M3 Hex T Driver
8701-0013 Flat blade screwdriver 6.5mm x 150mm
Note: Numbers in brackets on all figures refer to the item number from the
applicable figure.
3.1. Speaker Pod
3.1.1. Speaker Pod Disassembly:
•
Remove battery pack and sensitivity endcap from the detector.
3004-0017 SPKR/GB SW POD KIT SVC F3
1 SPEAKER POD – TOP HALF
2 SPEAKER POD – LOWER HALF
3 2701-0092 DECAL SPEAKER/HANDLE F3
4 4003-0083 SCREW M3X10 SS (not part of Kit)
5 4003-0084 SCREW NO 3X12 SS
•
Invert detector and lay speaker pod in sensitivity endcap to protect ground
balance/audio reset button (or use other means to protect ground
balance/audio reset button).
•
Remove 3 screws (5) on underside of speaker pod.
Figure 7 Speaker Pod Exploded View
Figure 8 Speaker Pod Parts List
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F3 Field Service Manual – Level 1 Maintenance
P0713
-A
•
Remove the top half of the speaker pod – lift the pod gently upward and
disconnect the speaker pod plug from the main wiring loom. Support the
main wiring loom socket against the lower half of the speaker pod when
disconnecting the speaker pod plug.
Note: Do not try and remove the loudspeaker, ground balance/audio reset button or
wiring from the upper half of the speaker pod, these components are
permanently sealed into the upper half of the speaker pod.
•
Remove the screw (4) which secures the lower half of the speaker pod to the
handle. (The nut for this screw sits in a recess between the two handle
halves).
Figure 9 Lower Speaker Pod showing screw securing Lower Speaker Pod to Handle
•
Remove the lower half of the speaker pod – lift the rear of the pod upwards
and remove the pod towards the front of the detector.
Note: The speaker pods halves should always be kept attached to each other
during storage and transportation to ensure that the loudspeaker and ground
balance/audio reset button seals are not damaged.
3.1.2. Speaker Pod Reassembly:
•
Ensure that the handle has been fully assembled (Section 3.2.2 Handle
Reassembly).
•
Peel back the shroud at the end of the speaker pod plug.
Figure 10 Peel back the shroud at the end of the Speaker Pod Plug
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F3 Field Service Manual – Level 1 Maintenance
P0716
-A
•
Refit the lower half of the speaker pod. The tongue at the front top of the
handle should be inserted into the recess in the lower half of the speaker pod.
Figure 11 Tongue at front top of Handle (red arrow), tongue recess (yellow arrow)
•
The main wiring loom plug should come through the larger rear hole of the
lower half of the speaker pod.
Figure 12 Correct position of Main Wiring Loom Plug (red arrow), screw securing
Pod to Handle (yellow arrow)
•
Note:
•
•
•
Refit the screw securing the pod to the handle.
Whilst refitting the speaker pod, care must be taken not to damage the seal
between the loudspeaker and ground balance/audio reset button to the pod
housing. Damaging this seal may allow water into either the loudspeaker or
switch.
If the plug and socket are dry, smear a small amount of silicon grease around
the shroud to ensure they will be waterproof. Plug the speaker pod plug into
the socket on the main wiring loom. Roll the speaker pod plug shroud back
over the socket. Push the upper half of the pod down towards the handle
until both halves of the pod are correctly mated. The plug/socket will go
down into the handle.
Invert the detector and lay speaker pod in a sensitivity endcap to protect
ground balance/audio reset button (or use other means to protect ground
balance/audio reset button). Refit the three screws which hold the pod
halves together.
Refit sensitivity endcap and battery pack.
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F3 Field Service Manual – Level 1 Maintenance
3.2. Handle
3.2.1. Handle Disassembly:
The noise cancel button and earset connector are an integral part of the main
Note:
wiring loom and this assembly is waterproof. Do not try to disassemble the
main wiring loom. It is not repairable.
•
Remove the speaker pod (Section 3.1.1 Speaker Pod Disassembly).
•
•
•
•
•
Note:
Figure 13 Handle Exploded View
8013-0001 HANDLE ASSEMBLY F3
1 4002-0039 NUT M4 HEX SS
2 3004-0016 RIGHT HANDLE HALF (part of HANDLE L+R KIT F3)
3 3004-0016 LEFT HANDLE HALF (part of HANDLE L+R KIT F3)
4 4002-0038 NUT STANDARD SS F3
5 4309-0037 DUSTCAP EARSET F3
6 8301-0031 SWITCH ASSY SLIDER F3
7 9511-0023 WIRING LOOM F3 SHAFT/HANDLE
8 4003-0082 BOLT M4X20 SKT SS
9 4003-0081 BOLT M4X10 SKT SS
Figure 14 Handle Parts List
Undo and remove the four bolts and nuts holding the handle halves together.
Carefully separate the left handle half from the upper shaft.
Remove the earset dustcap (5).
Remove the nut (4) that secures the lower speaker pod screw to the handle.
The main wiring loom (7) and on/off switch assy slider (6) can now be
removed from the right handle.
If the main wiring loom (7) needs to be replaced, carry out Section 3.4.1
Electronics Pack Removal. Then carefully pull the loom towards the front of
the detector until the loom comes out of the upper shaft. After replacing the
loom, refit the electronics pack (Section 3.4.4 Electronics Pack Refit) and
reassemble the Handle.
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F3 Field Service Manual – Level 1 Maintenance
3.2.2. Handle Reassembly:
•
•
Position the right handle half onto the upper shaft.
Locate the main wiring loom into the correct slots in the right handle half.
Starting from the main body of the main wiring loom, lay the cable into the
cable channels. Ensure that main wiring loom plug exits the top of the
handle in front of the upper screw boss (see figure below). Ensure that the
lower portion of the wiring loom cable sits under the rear handle screw boss.
There should be no excess cable at the bottom of the handle. Excess cable
should be carefully pulled through from the rear of the upper shaft.
•
Ensure that the on/off switch slider is correctly positioned.
Figure 15 Right Handle Half showing loom in cable channel (yellow, blue), on/off
switch slider (red), upper screw boss (orange), and cable under screw boss (green)
•
Place the nut (which secures the speaker pod assembly to the handle) into
the recess near the top of the handle. Care must be taken to ensure that
this nut stays in place during the following steps.
Figure 16 Handle Nut position
•
Fit the earset dustcap into the recess in the handle just forward of the earset
socket.
•
Carefully fit the left handle half to the right handle half and upper shaft.
Figure 17 Earset Dustcap position
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