Kodak Projector 4200 User Manual

{ServiceManual}{Production}{KodakServiceSupport}  
Publication No. SM5440-1  
18NOV97  
Supersedes SM5440-1  
13MAY97  
SERVICE MANUAL  
Kodak Carousel PROJECTORS  
New Look PROJECTORS  
Models 4200, 4200-J, 4200-KK, 4400, 4600,  
4600-KK, 5600, 5600-J, and 5600-KK  
Kodak Home Page  
on Internet  
Intranet  
Table of Contents  
A100_0029HA  
© Eastman Kodak Company, 1999  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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
4
Replacing the LOWER HOUSING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . .  
Installing the LOWER HOUSING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . .  
Replacing the FAN SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installing the FAN SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Replacing the MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installing the MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Replacing the WORM PULLEY and MECHANISM BELT . . . . . . . . . . . . . . . . .  
Installing the WORM PULLEY and MECHANISM BELT . . . . . . . . . . . . . . . . . .  
Replacing the THERMAL FUSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installing the THERMAL FUSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Replacing the LAMP MODULE RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . .  
Installing the LAMP MODULE RECEPTACLE. . . . . . . . . . . . . . . . . . . . . . . . . .  
Replacing the CYCLE SOLENOID ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .  
Installing the CYCLE SOLENOID ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .  
Replacing the MECHANISM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installing the MECHANISM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Replacing the AUTO-FOCUS BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . .  
Installing the AUTO-FOCUS BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . .  
Replacing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY . . .  
Installing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY . . . .  
Replacing the LAMP SOCKET TERMINAL ASSEMBLY . . . . . . . . . . . . . . . . . .  
Installing the LAMP SOCKET TERMINAL ASSEMBLY. . . . . . . . . . . . . . . . . . .  
Replacing the LENS MOUNT ASSEMBLY - Auto Focus Model . . . . . . . . . . . .  
Installing the LENS MOUNT ASSEMBLY - Auto Focus Models . . . . . . . . . . . .  
Replacing the LENS MOUNT ASSEMBLY - Non Auto Focus Model. . . . . . . . .  
Installing the LENS MOUNT ASSEMBLY - Non Auto Focus Model . . . . . . . . .  
Replacing the AUTO-FOCUS SWITCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . .  
Installing the AUTO-FOCUS SWITCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . . .  
Replacing the FOCUS SHAFT ASSEMBLY - Auto Focus Models. . . . . . . . . . .  
Installing the FOCUS SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Replacing the FOCUS SHAFT ASSEMBLY - Non Auto-Focus Models. . . . . . .  
Installing the FOCUS SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Adjusting the CYCLE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Adjusting the INDEXER LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .  
Adjusting the SLIDE LIFT LEVER MANUAL, with MECHANISM Out . . . . . . . .  
Adjusting the SLIDE LIFT LEVER POWER with Mechanism Out . . . . . . . . . . .  
4
4
6
7
7
8
9
10  
10  
10  
11  
12  
12  
13  
13  
14  
14  
14  
17  
18  
18  
19  
19  
20  
20  
21  
21  
21  
23  
23  
24  
25  
25  
26  
27  
27  
2
18NOV97 – SM5440-1  
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Adjusting the Focus Light Path - Auto Focus Models  
Adjustment Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Adjusting the NULL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Adjusting the PHOTOCELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Adjusting the CLAMP PAD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Adjusting the DARK SHUTTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
MAIN MOTOR Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
PHOTOCELL Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
5-PIN REMOTE CORD PLUG Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SMALL COMPONENT BOARD ASSEMBLY 256809 Voltages . . . . . . . . . . . . .  
Voltage Specifications - General Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Power, Illumination, and Cooling Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . .  
Slide Transport Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Focus Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
28  
29  
30  
34  
34  
36  
39  
40  
42  
42  
43  
43  
44  
45  
45  
46  
48  
SM5440-1 – 18NOV97  
3
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SERVICE MANUAL  
Section 1: Replacements and Installations  
Replacing the LOWER HOUSING ASSEMBLY  
Warning  
Dangerous Voltage  
[1] Disconnect the main power.  
[2] Remove the PROJECTION LENS.  
[3] Remove the LAMP MODULE ASSEMBLY.  
[4] Remove the 6 Torx SCREWS from the LOWER HOUSING ASSEMBLY.  
[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.  
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  
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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
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SERVICE MANUAL  
[19] Lift and remove the FAN SHAFT ASSEMBLY.  
SCREW (2)  
SCREW  
RETAINER CLIP  
FAN  
FAN PLATE  
MOTOR  
BLOWER ASSEMBLY  
SCREW (3)  
ASS4EMBLY  
FAN BELT  
MECHANISM BELT  
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  
A091_4015BCA  
A091_4015BA  
MECHANISM BELT  
6
18NOV97 – SM5440-1  
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Replacements and Installations  
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 Hex 1/4 in. SCREWS from the MOTOR.  
[9] Lift the MOTOR up to allow access to the FAN and MECHANISM BELTS.  
[10] Remove the FAN and MECHANISM BELTS from the MOTOR PULLEY.  
[11] Remove the MOTOR.  
SCREW (3)  
MOTOR  
A091_4016GCA  
A091_4016GA  
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
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SERVICE MANUAL  
FAN BELT  
A091_4015BCA  
A091_4015BA  
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 Torx SCREW from the WORM PULLEY ASSEMBLY.  
[5] Move the TAB on the WORM PULLEY ASSEMBLY out.  
[6] Remove the WORM PULLEY ASSEMBLY and MECHANISM BELT.  
8
18NOV97 – SM5440-1  
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Replacements and Installations  
WORM PULLEY  
SCREW  
MECHANISM  
BELT  
A091_4017GCA  
A091_4017GA  
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  
A091_4015BCA  
A091_4015BA  
MECHANISM BELT  
SM5440-1 – 18NOV97  
9
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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 Torx SCREW on the PREHEAT DUCT approximately half way.  
[7] Pull the THERMAL FUSE ASSEMBLY out of hole of the LOWER LIGHT BAFFLE ASSEMBLY.  
Installing the THERMAL FUSE ASSEMBLY  
[1] Do the replacement procedure for the THERMAL FUSE ASSEMBLY in reverse order.  
SCREW  
PRE-HEAT DUCT  
THERMAL FUSE  
A100_0015GCA  
POWER SWITCH  
A100_0015GA  
Replacing the LAMP MODULE RECEPTACLE  
Warning  
Dangerous Voltage  
[1] Disconnect the main power.  
[2] Do the replacement procedure for the LOWER HOUSING ASSEMBLY.  
[3] Cut and remove the necessary WIRE TIES.  
[4] Remove the 2 Torx SCREWS on the left side of the LOWER LIGHT BAFFLE ASSEMBLY.  
[5] Loosen the Torx SCREW on the right side of the LOWER LIGHT BAFFLE ASSEMBLY approximately 1/2 way.  
10  
18NOV97 – SM5440-1  
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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 the PREHEAT DUCT, compress the 2 TABS on the LAMP  
MODULE RECEPTACLE.  
PRE-HEAT DUCT  
SCREW (2)  
SCREW (2)  
LOWER LIGHT BAFFLE  
LAMP MODULE  
RECEPTACLE  
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  
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SERVICE MANUAL  
Replacing the CYCLE SOLENOID ASSEMBLY  
Warning  
Dangerous Voltage  
[1] Disconnect the main power.  
[2] Do the replacement procedures for the LOWER  
HOUSING ASSEMBLY and the MOTOR.  
CYCLE SOLENOID  
SCREW (2)  
[3] Cut and remove the necessary WIRE TIES.  
[4] Disconnect the 2 wires from the CYCLE  
SOLENOID on the SMALL CIRCUIT BOARD.  
CYCLE  
SOLENOID  
PLUNGER  
[5] Pull the SMALL CIRCUIT BOARD up.  
[6] Remove the Torx SCREW from the WORM  
PULLEY SHAFT.  
[7] Move the TAB on the WORM PULLEY  
ASSEMBLY out of the MECHANISM ASSEMBLY.  
[8] Lift and remove the WORM PULLEY ASSEMBLY.  
[9] Remove the 2 Hex 1/4 in. SCREWS from the 2  
CYCLE SOLENOID GROMMETS.  
[10] Pull the CYCLE SOLENOID ASSEMBLY up and  
out.  
[11] If necessary, remove the CYCLE SOLENOID  
PLUNGER ASSEMBLY.  
A100_0017GCA  
A100_0017GA  
Installing the CYCLE SOLENOID ASSEMBLY  
Important  
Do the adjustment for the CYCLE SOLENOID  
ASSEMBLY. See the Adjustments section.  
[1] Do the replacement procedure for the CYCLE  
SOLENOID ASSEMBLY in reverse order.  
12  
18NOV97 – SM5440-1  
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Replacements and Installations  
Replacing the MECHANISM ASSEMBLY  
SCREW (3)  
Warning  
Dangerous Voltage  
LENS  
MOUNT  
[1] Disconnect the main power.  
[2] Do the replacement procedure for the LOWER  
HOUSING ASSEMBLY.  
[3] Cut and remove the necessary WIRE TIES.  
[4] Disconnect the 2 wires from the CYCLE  
SOLENOID on the SMALL CIRCUIT BOARD.  
MECHANISM  
ASSEMBLY  
[5] Pull the SMALL CIRCUIT BOARD up.  
[6] Disconnect all wires connected to the  
MECHANISM ASSEMBLY:  
• 1 yellow wire from CYCLE SWITCH  
• 1 orange wire from WIRE NUT  
• 1 green wire from POWER CORD  
• 2 green ground wires from the lower  
MECHANISM ASSEMBLY  
[7] Remove the FOCUS KNOB from the FRONT  
PANEL.  
[8] Remove the 3 Torx SCREWS from the LENS  
SCREW  
MOUNT ASSEMBLY.  
[9] Lift and move the LENS MOUNT ASSEMBLY up.  
[10] Do the replacement procedure for the MOTOR.  
[11] Remove the 3 Torx SCREWS from the  
MECHANISM ASSEMBLY.  
[12] Loosen the SCREW on the STABILIZER WALL  
FOCUS KNOB  
approximately half way.  
Caution  
There might be a bind between the SELECT LEVER  
and the SELECT BUTTON when removing the  
MECHANISM ASSEMBLY. Do not use force; this  
might cause damage to the SELECT BUTTON.  
A091_4047CCA  
A091_4047CA  
[13] Remove the MECHANISM ASSEMBLY.  
Installing the MECHANISM ASSEMBLY  
Important  
To insert the SELECT BUTTON into the hole in the SELECT LEVER when installing the MECHANISM ASSEMBLY,  
hold the SELECT BUTTON completely down.  
[1] Do the removal procedure for the MECHANISM ASSEMBLY in reverse order.  
SM5440-1 – 18NOV97  
13  
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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 Torx SCREW from the WORM PULLEY.  
[8] Remove the WORM PULLEY.  
[9] Remove the 2 Hex SCREWS from the CYCLE SOLENOID.  
[10] Remove the CYCLE SOLENOID.  
[11] Remove the Phillips SCREW from the AUTO-FOCUS BRACKET ASSEMBLY.  
[12] Pull and remove the AUTO-FOCUS BRACKET ASSEMBLY through the hole where the CYCLE SOLENOID  
was.  
SCREW  
SCREW (2)  
WORM  
PULLEY  
AUTO  
FOCUS  
BRACKET  
SCREW  
CYCLE  
A091_4023BCA  
A091_4023BA  
SOLENOID  
ASSEMBLY  
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 Torx SCREW from the WORM PULLEY ASSEMBLY.  
[5] Remove the WORM PULLEY ASSEMBLY.  
[6] Remove the DIRECTION LEVER LINK from the DIRECTION LEVER.  
14  
18NOV97 – SM5440-1  
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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.  
LIFT LEVER SHAFT  
SELECT LEVER  
(not shown)  
LIFT LEVER  
BEARING  
E-RING  
RETARD  
SPRING  
BEARING  
A100_0018HCA  
A100_0018HA  
NUT  
E-RING  
CAM STACK ASSEMBLY  
[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.  
SM5440-1 – 18NOV97  
15  
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SERVICE MANUAL  
LIFT  
LEVER  
LIFT LEVER SHAFT  
SELECT LEVER  
E-RING  
BEARING  
SELECT LEVER  
SPRING  
E-RING  
NUT  
CAM STACK  
ASSEMBLY  
A091_0010HCA  
A091_0010HA  
TAB  
BEARING  
16  
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Replacements and Installations  
[20] Remove the 2 SCREWS from the CYCLE  
HALF-CYCLE  
LEVER  
SOLENOID.  
[21] Remove the CYCLE SOLENOID.  
[22] Slide the PLUNGER and PLUNGER SPRING off  
HALF-CYCLE  
LEVER SPRING  
the CYCLE LEVER.  
E-RING (2)  
[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:  
CYCLE  
LEVER  
• 1 on the CYCLE LEVER ASSEMBLY  
• 1 on the HALF CYCLE LEVER  
PLUNGER  
SPRING  
Caution  
Keep both the CYCLE LEVER ASSEMBLY and the  
HALF CYCLE LEVER together and observe the  
orientation of both LEVERS.  
PLUNGER  
[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  
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SERVICE MANUAL  
Replacing the LAMP SOCKET TERMINAL ASSEMBLY  
Style 1 LAMP SOCKET TERMINAL ASSEMBLY  
SCREW  
Warning  
LAMP DOOR  
Dangerous Voltage  
PLATE ASSEMBLY  
[1] Disconnect the main power.  
Important  
The EXTRA BRIGHT LAMP MODULE does not have a  
HEAT ABSORBING GLASS and has a LABEL on the  
LAMP DOOR.  
[2] Remove the LAMP MODULE.  
[3] Remove the PROJECTION LAMP from the LAMP  
MODULE.  
[4] Remove the SCREW from the LAMP DOOR  
PLATE ASSEMBLY.  
[5] Release the 2 TABS on the bottom side of the  
LAMP MODULE next to the LAMP MODULE  
DOOR.  
PROJECTOR  
LAMP  
[6] Remove the LAMP DOOR PLATE ASSEMBLY.  
LAMP  
EJECTOR  
Caution  
LAMP SOCKET  
TERMINAL  
ASSEMBLY  
Remove the CONDENSER LENS and HEAT  
ABSORBING GLASS and set the parts on a clean  
cloth. Do not set on a cold surface; this will cause  
damage to the parts.  
[7] Remove the LAMP EJECTOR.  
[8] Remove the LAMP SOCKET TERMINAL  
ASSEMBLY.  
CONDENSER  
LENS  
HEAT ABSORBING  
TAB (2)  
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.  
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Replacements and Installations  
Replacing the LENS MOUNT ASSEMBLY - Auto Focus Model  
SCREW (3)  
Warning  
Dangerous Voltage  
LENS MOUNT  
ASSEMBLY  
[1] Disconnect the main power.  
[2] Do the replacement procedure for the LOWER  
HOUSING ASSEMBLY.  
[3] Remove the FOCUS KNOB.  
Important  
It is necessary to push the AUTO-FOCUS BRACKET  
backward and forward to allow access to the SCREWS  
on the LENS MOUNT ASSEMBLY.  
[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 - Auto Focus Models  
[1] Do the replacement procedure for the LENS MOUNT ASSEMBLY in reverse order.  
SM5440-1 – 18NOV97  
19  
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SERVICE MANUAL  
Replacing the LENS MOUNT ASSEMBLY - Non Auto Focus Model  
SCREW (3)  
Warning  
Dangerous Voltage  
LENS MOUNT  
ASSEMBLY  
[1] Disconnect the main power.  
[2] Do the replacement procedure for the LOWER  
HOUSING ASSEMBLY.  
[3] Remove the FOCUS KNOB.  
[4] Remove the 3 SCREWS from the LENS MOUNT  
ASSEMBLY.  
[5] Lift and remove the LENS MOUNT ASSEMBLY.  
A100_0019GCA  
A100_0019GA  
Installing the LENS MOUNT ASSEMBLY - Non Auto Focus Model  
[1] Do the replacement procedure for the LENS MOUNT ASSEMBLY in reverse order.  
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Replacements and Installations  
Replacing the AUTO-FOCUS SWITCH ASSEMBLY  
AUTO FOCUS  
MOTOR BRACKET  
Warning  
Dangerous Voltage  
[1] Disconnect the main power.  
[2] Do the replacement procedure for the LOWER  
HOUSING ASSEMBLY.  
[3] Remove the FOCUS KNOB.  
[4] Remove the short, gray wire from the AUTO-  
FOCUS DEFEAT SWITCH.  
Important  
It is necessary to push the AUTO-FOCUS BRACKET  
backward and forward to allow access to the SCREWS  
on the LENS MOUNT ASSEMBLY.  
LOCKING  
TAB  
[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  
grey, red,  
and black  
wires  
AUTO FOCUS SWITCH ASSEMBLY.  
AUTO FOCUS  
SWITCH LEVER  
Important  
A091_4028GCA  
A091_4028GA  
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.  
AUTO FOCUS SWITCH ASSEMBLY  
[8] To disconnect and remove the AUTO FOCUS  
SWITCH, bend the LOCKING TAB on the FOCUS  
MOTOR BRACKET until it is aligned with the hole  
in the AUTO FOCUS SWITCH.  
Installing the AUTO-FOCUS SWITCH ASSEMBLY  
Important  
Align the 2 TABS on the AUTO-FOCUS SWITCH with the FOCUS MOTOR BRACKET, checking that the end of the  
AUTO-FOCUS LEVER engages with the CYCLE SOLENOID PLUNGER. After the AUTO-FOCUS SWITCH is in the  
correct position, bend the LOCKING TAB to hold the AUTO FOCUS SWITCH in place.  
[1] Do the replacement procedure for the AUTO-FOCUS SWITCH in reverse order.  
Replacing the FOCUS SHAFT ASSEMBLY - Auto Focus Models  
Warning  
Dangerous Voltage  
[1] Disconnect the main power.  
SM5440-1 – 18NOV97  
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SERVICE MANUAL  
[2] Do the replacement procedure for the LOWER HOUSING ASSEMBLY.  
[3] Remove the FOCUS KNOB.  
Important  
It is necessary to push the AUTO-FOCUS BRACKET backward and forward to allow access to the SCREWS 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.  
FOCUS SHAFT  
SPRING  
SCREW  
CLAMP LEVER  
SPRING  
RACK LEVER  
(not shown)  
FOCUS SHAFT  
SCREW  
FOCUS MOTOR  
BRACKET  
RACK  
SOLENOID  
SPACER  
E-RING  
PLUNGER  
LENS SUPPORT BRACKET  
PHOTOCELL  
BRACKET  
SPRING  
AUTO-FOCUS  
SWITCH  
ASSEMBLY  
SCREW  
A091_4029HCA  
A091_4029HA  
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Replacements and Installations  
Installing the FOCUS SHAFT ASSEMBLY  
Important  
Do the adjustments for the PHOTOCELL NULL and AUTO-FOCUS CLAMP after installation. See the Adjustments  
section.  
Replacing the FOCUS SHAFT ASSEMBLY - Non Auto-Focus Models  
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.  
FOCUS SHAFT  
SPRING  
SCREW  
FOCUS SHAFT  
ASSEMBLY  
FOCUS MOTOR  
BRACKET  
SPACER  
LENS SUPPORT  
BRACKET  
A091_0020HCA  
A091_0020HA  
E-RING  
SCREW  
SM5440-1 – 18NOV97  
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SERVICE MANUAL  
Installing the FOCUS SHAFT ASSEMBLY  
[1] Do the replacement procedure for the FOCUS SHAFT ASSEMBLY in reverse order.  
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Adjustments  
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.  
MECHANISM  
ASSEMBLY  
T-BAR  
TL-3003  
CYCLE  
BAR  
A091_0007HCA  
A091_0007HA  
SM5440-1 – 18NOV97  
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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  
TOP PLATE  
Bend  
here.  
MECHANISM  
RUNNING FIXTURE  
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  
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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 with the low surface of the SLIDE LIFT LEVER GAUGE TL-3001; the SLIDE LIFT  
LEVER should not make contact with the high surface of the SLIDE LIFT LEVER GAUGE TL-3001.  
[6] Bend the SLIDE LIFT LEVER until the adjustment is correct.  
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 with the low surface of the SLIDE LIFT LEVER GAUGE TL-3001; the SLIDE LIFT  
LEVER should not make contact with the high surface of the SLIDE LIFT LEVER GAUGE TL-3001.  
[7] Bend the SLIDE LIFT LEVER until the adjustment is correct.  
SM5440-1 – 18NOV97  
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SERVICE MANUAL  
SLIDE LIFT  
LEVER GUAGE  
TL-3001  
SLIDE LIFT  
LEVER  
SELECT  
LEVER  
(not shown)  
A091_0016BCA  
A091_0016BA  
Adjusting the Focus Light Path - Auto Focus Models  
Adjustment Specification  
Seat AUTO-FOCUS TARGET SLIDE TL-3002 on the GATE MECHANISM. Use TL-3005 or TL-1165 to bend the  
AUTO-FOCUS BRACKET ASSEMBLY MIRROR until the image is within the target of the TARGET SLIDE.  
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  
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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  
A091_4026HA  
AUTO-FOCUS TARGET SLIDE TL-3002  
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  
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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  
TAB  
AUTO-FOCUS  
TARGET SLIDE  
TL-3002  
CLAMP LEVER  
PAD  
A091_4031BCA  
A091_4031BA  
Adjustment Specification  
Use TL-3002 and FAN CAP 232729 to check the adjustment of the PHOTOCELL.  
Adjusting the PHOTOCELL  
PHOTOCELL  
CIRCUIT BOARD  
Warning  
Dangerous Voltage  
[1] Disconnect the main power.  
wratten  
FILTER (2)  
[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.  
PHOTOCELL  
MASK  
POST (2)  
PHOTOCELL  
A091_4032GCA  
A091_4032GA  
HOUSING  
30  
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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 in the GATE  
MECHANISM.  
[7] Look through the PROJECTION LENS hole and  
observe the focus light path on the AUTO-FOCUS  
TARGET SLIDE TL-3002. Check that the light  
path is correct. If not, do the adjustment  
procedure for the FOCUS LIGHT PATH.  
Warning  
Dangerous Voltage  
[8] Disconnect the main power.  
[9] Heat the 2 POSTS on the PHOTOCELL  
HOUSING to allow the POSTS to bend enough to  
pull the PHOTOCELL CIRCUIT BOARD up and  
off the PHOTOCELL HOUSING. Use a  
SOLDERING IRON.  
[10] Remove the 2 Wratten FILTERS and the  
PHOTOCELL MASK.  
SM5440-1 – 18NOV97  
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SERVICE MANUAL  
[11] Install the FAN CAP 232729 in the PHOTOCELL  
hole  
FAN CAP  
HOUSING.  
FAN CAP  
light image  
A091_4033GCA  
A091_4033GA  
[12] Manually move the CLAMP PAD ASSEMBLY until the TAB is in the NULL position.  
light path  
NULL position  
TAB  
CLAMP LEVER  
PAD  
A091_4027BCA  
A091_4027BA  
Warning  
Dangerous Voltage  
[13] Connect the main power.  
Important  
It is necessary to make a FAN COVER TOOL. See the Tools section.  
[14] Install the FAN COVER TOOL over the FAN area and the LAMP MODULE. See the Tools section.  
[15] Install and hold the AUTO FOCUS TARGET SLIDE TL-3002 until it is fully seated in the GATE MECHANISM.  
32  
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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.  
hole  
T-BAR TL-3003  
light image  
FAN CAP  
CLAMP PAD  
ASSEMBLY  
AUTO-FOCUS  
TARGET SLIDE  
TL-3002  
A091_4030BCA  
A091_4030BA  
Adjustment Specification  
Use TL-1744 to check that the CLAMP PAD ASSEMBLY moves forward and backward.  
SM5440-1 – 18NOV97  
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SERVICE MANUAL  
Adjusting the CLAMP PAD ASSEMBLY  
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] Connect the REMOTE CONTROL ASSEMBLY  
SCREW  
NUT  
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 in either direction.  
CLAMP PAD  
ASSEMBLY  
[8] Rotate the SCREW on the CLAMP PAD  
ASSEMBLY to adjust the pressure of the  
REMOTE FOCUS CLAMP on the CLAMP PAD  
ASSEMBLY until the CLAMP PAD ASSEMBLY  
does not move.  
A091_4041GCA  
A091_4041GA  
[9] Release the REMOTE FOCUS.  
[10] Tighten the NUT on the CLAMP PAD ASSEMBLY.  
[11] Install the AUTO-FOCUS GAUGE TL-1744 in the  
MECHANISM GATE. The CLAMP PAD  
ASSEMBLY should move forward and backward  
using TL-1744. If not, adjust the SCREW on the  
CLAMP PAD ASSEMBLY again; the CLAMP PAD  
ASSEMBLY adjustment is too tight and not  
correct.  
Adjustment Specification  
The PRESSURE PAD should be aligned with the DARK SHUTTER.  
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.  
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Adjustments  
DARK  
SHUTTER  
PRESSURE  
PAD  
A091_0013GCA  
A091_0013GA  
SM5440-1 – 18NOV97  
35  
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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  
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Lubrication  
A100_0020GA  
A091_0023HA  
SM5440-1 – 18NOV97  
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SERVICE MANUAL  
A091_0022DA  
38  
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Tools  
Section 4: Tools  
Tools  
Tool  
TL-1744  
Description  
AUTO-FOCUS GAUGE  
TL-2264  
FOCUS TEST (flat field)  
AUTO-FOCUS TARGET SLIDE  
ADJUSTMENT T-BAR  
ADJUSTMENT TOOL  
Torx DRIVER SET  
TL-3002  
TL-3003  
TL-3005  
TL-3255  
TL-4276  
SUPER LUBE  
DIGITAL MULTIMETER  
The LOWER HOUSING ASSEMBLY is a part of the cooling function. To operate the projector with the LOWER  
HOUSING removed, make a FAN COVER TOOL.  
Cut here.  
FAN  
COVER  
TOOL  
11.5 cm  
(4.5 in.)  
A091_0024GCA  
A091_0024GA  
SM5440-1 – 18NOV97  
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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  
Dimensions  
400 W  
• Height: 119 mm (4.69 in.) without TRAY  
• Width: 238 mm (12.93 in.)  
• Length: 295 mm (11.6 in.)  
35 mm, 50 x 50 mm (2 x 2 in.)  
1 second  
Slide size  
Slide change time  
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 102 mm, F/2.8 LENS  
aperture (24 x 36 mm), compatible with  
European specification DIN 19027  
Operating temperature  
Cooling  
• 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  
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  
Safety  
Complies with climactic test specifications (TS  
218)  
• 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.  
40  
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Specifications  
Item  
Desription  
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 1 second  
after the slide is inserted into the GATE.  
• The focus adjustment variation should not  
change from the focus and reverse  
specifications by more than 3 times the  
focus and reverse specifications.  
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  
Warranty  
Preventive maintenance by a qualified service  
person is recommended every 1500 hours of  
operation, or after 1 year.  
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  
REMOTE INLET  
7-PIN PLUG  
24 V AC  
24 V AC  
K
N
4
7
W
1
5
Y
82 V AC  
N
Unloaded  
2
3
6
G
O
0 V AC  
24 V AC  
Common  
A100_0023ACA  
A100_0023AA  
SM5440-1 – 18NOV97  
41  
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SERVICE MANUAL  
Section 6: Diagnostics  
MAIN MOTOR Voltages  
84.2 V  
1.6  
12  
11  
10  
9
brown  
white  
LAMP VOLTAGE is  
74 V AC  
between brown  
and white for  
LONG LIFE MODELS  
8
black  
7
117 V AC  
6.1  
MOTOR  
A091_0006BCA  
A091_0006BA  
MAIN MOTOR PIN Colors  
PIN  
Color  
12  
11  
10  
9
brown  
red  
violet  
yellow  
blue  
8
7
not used  
MAIN MOTOR PIN Voltages  
PIN  
Resistance  
Voltage  
8-9  
3.1 W  
24.4 V AC  
14.1 V AC  
14.1 V AC  
28.2 V AC  
10-11  
11-12  
10-12  
9-10  
4.3 W  
4.2 W  
8.0 W  
O.L.  
42  
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Diagnostics  
PHOTOCELL Voltages  
PHOTOCELL  
3
1
2
A091_4036ACA  
A091_4036AA  
PHOTOCELL Voltages  
PINS  
Voltage  
1-2  
2-3  
1-3  
14.5 V ac  
14.5 V ac  
29 V ac  
5-PIN REMOTE CORD PLUG Voltages  
BLACK  
FWD  
REV  
RED  
WHITE  
BRN  
FOCUS  
YELLOW  
YELLOW  
KODAK EC-3 REMOTE CONTROL  
A100_0001BC_  
5-PIN REMOTE PLUG Voltages  
PIN  
Description  
Reverse  
white  
red  
Forward  
yellow  
brown  
black  
Common  
RACK SOLENOID  
Focus - REMOTE  
SM5440-1 – 18NOV97  
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SERVICE MANUAL  
SMALL COMPONENT BOARD ASSEMBLY 256809 Voltages  
WWK R A V V O B Y B  
J1  
J2  
R3  
CR5  
CR3  
F1  
CR4  
CR2  
Q2  
R7  
C5  
Q1  
R6  
SLIDE PROJECTOR BOARD  
Q3  
R17  
R4  
R5  
C4  
CR1  
+
C1  
R12  
R11  
R10  
R13  
R14  
CR6  
R15  
+
C3  
C2  
Q4  
A091_4034DC  
Description  
TIMER Circuit  
Component  
RED +, BLACK -  
Voltage  
32 V DC  
CR3  
Q3  
+ to -  
TIMER Circuit  
TIMER Circuit  
- G to + A  
- G to + K  
+ to -  
32 V DC  
Q4  
18.1 V DC  
18.0 V DC  
CYCLE HOLD DOWN CR4  
REVERSE  
FOCUS  
CR2  
CR5  
+ to -  
+ to -  
28.0 V DC  
18.0 V DC  
FOCUS RACK USE  
REMOTE  
FOCUS  
FOCUS  
Q1  
Q2  
- B to + C  
- G to + A  
23.3 V DC  
28.0 V DC  
44  
18NOV97 – SM5440-1  
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Diagnostics  
Voltage Specifications - General Parts  
Part  
FOCUS MOTOR  
CYCLE SOLENOID  
Procedure  
Voltage  
------  
6.7 V AC  
Press the REVERSE  
BUTTON.  
39 W, 10 V DC  
RACK SOLENOID  
------  
------  
39 W, 10 V AC  
LAMP RECEPTACLE  
Standard Models:  
82 V AC, approximately 85-86  
V AC without a LAMP  
MODULE installed  
Long Life Models:  
74 V AC, 76 V AC without  
LAMP  
DROPPING RESISTOR  
Move to the LO LAMP  
position.  
3.0 W, 10.4 V AC drop across  
Power, Illumination, and Cooling Malfunctions  
Malfunction  
Check  
The MOTOR does not operate.  
1. Check the continuity across the THERMAL  
FUSE ASSEMBLY, and MOTOR FUSE.  
2. Check that the primary voltage on the MAIN  
MOTOR is correct.  
3. Check that the voltage on POWER  
SWITCH is correct.  
The FAN does not operate, MOTOR operates. 1. Check that the FAN BELT is not broken.  
2. Check and remove obstructions in the FAN  
area.  
There is excessive noise in the FAN.  
1. Check and remove obstructions in the FAN  
area.  
2. Check that the tension is correct on the  
FAN BELT.  
3. Check that the FAN BELT is clean.  
4. Check the condition of the BEARING in the  
FAN ASSEMBLY.  
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  
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SERVICE MANUAL  
Slide Transport Malfunctions  
Malfunction  
Check  
Forward and reverse do not operate using the  
FRONT PANEL BUTTONS or REMOTE  
CONTROL.  
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.  
Forward does not operate, reverse operates,  
voltages are 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.  
Reverse does not operate, forward operates,  
voltages are correct.  
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.  
Projector does not complete a cycle; FAN  
operates.  
1. Check for a broken MECHANISM DRIVE  
BELT.  
2. Check the CYCLE LEVER and RATCHET  
LEVER on the CAM SHAFT ASSEMBLY for  
the following:  
• correct alignment of the CYCLE LEVER  
• damage to parts  
• lubrication of the CYCLE LEVER (use  
SUPER LUBE TL-4276)  
3. Check the CYCLE SOLENOID for correct  
operation. See the Voltage chart.  
Projector has continual cycle.  
1. Check the CYCLE LEVER for correct  
alignment. See the adjustment for the  
CYCLE LEVER.  
2. Check for damage to parts.  
3. Check for a short•circuit in the wires:  
• Use a tool to hold the CYCLE LEVER  
down on the RATCHET LEVER. If  
there is a short•circuit causing the  
malfunction, the SOLENOID will be  
energized. If there is a bind, the CAM  
will not rotate.  
4. Check that the CAM SHAFT ASSEMBLY  
RATCHET SPRING is installed correctly.  
5. If there is a bind in the CAM STACK, install  
a new CAM.  
46  
18NOV97 – SM5440-1  
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Diagnostics  
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 new CAM SHAFT ASSEMBLY.  
SLIDE TRAY does not advance smoothly.  
1. Check the SLIDE TRAY LATCH for correct  
alignment.  
2. Operate the projector in the forward  
direction.  
• Check that the INDEXER LEVER  
ASSEMBLY is in the correct alignment  
with the holes at positions A and B.  
• Do the adjustment for the INDEXER  
LEVER ASSEMBLY.  
• Check the condition of the LOCATOR  
LEVER, it should not be bent.  
• Check the height of the SLIDE LIFT  
LEVER; the lower corner of the LIFT  
LEVER RAMP is parallel with the TOP  
HOUSING. If the height is not correct,  
do the adjustment for the MANUAL and  
POWER SLIDE LIFT LEVER  
ECCENTRICS.  
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.  
SM5440-1 – 18NOV97  
47  
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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 the projector and move the 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 for continuity between PINS 4 and 5  
on the SPECIAL APPLICATIONS PLUG.  
3. Press the “FORWARD” or “REVERSE”  
BUTTONS to close the DARK SHUTTER.  
4. In the closed position, the DVM should  
measure 0 W.  
5. If this procedure does not correct the  
malfunction, install a new DARK SHUTTER  
SWITCH.  
After the FOCUS MOTOR energizes and  
moves, the FOCUS MOTOR oscillates.  
1. Remove R3 and install a new 68K W 1/4 W  
RESISTOR (part 220040).  
2. If there is still a malfunction, install a new  
PHOTOCELL.  
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 and hold the REMOTE CONTROL.  
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  
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Diagnostics  
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 and hold the REMOTE CONTROL.  
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. Install a new  
FOCUS MOTOR.  
4. Check the AUTO FOCUS SWITCH  
ASSEMBLY for correct operation.  
5. Check the secondary voltages on the MAIN  
MOTOR.  
No auto-focus  
1. Check that the AUTO-FOCUS DEFEAT  
SWITCH is in the “ON” position.  
2. Check that the MAIN PROJECTION LAMP  
operates correctly.  
3. Insert the TARGET SLIDE TL-3002 in the  
GATE MECHANISM.  
• Check that the TARGET is correctly  
aligned. If not, see the Adjustment  
section.  
4. Check that the voltages across the  
PHOTOCELL are correct. The voltage  
from 1 to 2 is 13.8 V ac. The voltage from  
2 to 3 is 13.8 V ac. The voltage from 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 the resolution of the FOCUS LIGHT  
PATH. Clean the AUTO FOCUS MIRROR  
and BRACKET ASSEMBLY.  
3. Install a new PROJECTION LAMP if  
necessary.  
4. Install a new PHOTOCELL.  
5. Check the components on the CIRCUIT  
BOARD for damage.  
SM5440-1 – 18NOV97  
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SERVICE MANUAL  
Malfunction  
AUTO FOCUS MOTOR operates continually  
Check  
1. Install the TARGET SLIDE TL-3002 in the  
GATE MECHANISM.  
2. Check that the alignment of the TARGET  
and NULL is correct. If not, see the  
Adjustments section.  
3. Check for a light leak:  
• Install a different LAMP MODULE  
ASSEMBLY. If the FOCUS MOTOR  
stops operating continually, install a  
new LAMP MODULE ASSEMBLY.  
4. Check that the voltages across the  
PHOTOCELL are correct. The voltage  
from 1 to 2 is 13.8 V ac. The voltage from  
2 to 3 is 13.8 V ac. The voltage from 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 1. Check that the wires of the AUTO FOCUS  
forward only or reverse only and does not  
operate (stops) in the null position.  
MOTOR are in the correct position; the blue  
wire goes to the mark on the AUTO FOCUS  
MOTOR.  
AUTO FOCUS adjusts after REMOTE use  
1. Do the adjustment for the CLAMP LEVER  
ASSEMBLY.  
50  
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Kodak, Carousel, and Wratten are trademarks.  
Printed in U.S.A. • sm5440_1.fm  
EASTMAN KODAK COMPANY  
Rochester, NY 14650  
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