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Kodak 4200 manual

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Table of contents for the manual

  • Page 1

    Kodak Home Page on Internet Intranet Table of Contents © Eastman Kodak Company, 1999 {ServiceManual}{Production}{KodakServiceSupport} Publication No. SM5440-1 18NOV97 Supersedes SM5440-1 13MAY97 SERVICE MANUAL Kodak Carousel PROJECTORS l New Look PROJECTORS Models 4200, 4200-J, 4200-KK, 4400, 4600, 4600-KK, 5600, 5600-J, and 5600-KK A100_0029HA[...]

  • Page 2

    2 18NOV97 – SM5440-1 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,[...]

  • Page 3

    SM5440-1 – 18NOV97 3 Adjusting the Focus Light Path - Auto Focus Models Adjustment Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Adjusting the NULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Adjusting the PHOTOCELL . . . . . . . . . . . . . . [...]

  • Page 4

    SERVICE MANUAL 4 18NOV97 – SM5440-1 Section 1: Replacements and Installations Replacing the LO WER HOUSING ASSEMBL Y W arning Dangerous Voltage [1] Disconnect the main power . [2] Remov e the PROJECTION LENS. [3] Remov e the LAMP MODULE ASSEMBL Y . [4] Remov e the 6 T orx SCREWS from the LO WER HOUSING ASSEMBL Y . [5] Pull the LO WER HOUSING ASSE[...]

  • Page 5

    Replacements and Installations SM5440-1 – 18NOV97 5 [4] Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD . [5] Pull the SMALL CIRCUIT BOARD up . [6] Remov e the T orx SCREW from the BLO WER CO VER ASSEMBL Y . [7] Lift the GRILLE ASSEMBL Y in front of the BLOWER CO VER ASSEMBL Y up. [8] Loosen the T orx SCREW on the right [...]

  • Page 6

    SERVICE MANUAL 6 18NOV97 – SM5440-1 [19] Lift and remov e the F AN SHAFT ASSEMBL Y . Installing the F AN SHAFT ASSEMBL Y 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 remov al procedure for the F AN BEL T and SHAFT in rev erse ord[...]

  • Page 7

    Replacements and Installations SM5440-1 – 18NOV97 7 Replacing the MO T OR W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the replacement procedure f or the LO WER HOUSING ASSEMBL Y . [3] Disconnect all wires from the MO TOR. [4] Cut the 2 WIRE TIES on the SMALL CIRCUIT BOARD betw een the MO TOR and MECHANISM ASSEMBL Y . [5] Dis[...]

  • Page 8

    SERVICE MANUAL 8 18NOV97 – SM5440-1 Replacing the WORM PULLEY and MECHANISM BEL T W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the replacement procedure f or the LO WER HOUSING ASSEMBL Y . [3] Do the replacement procedure f or the MO TOR e xcept do not disconnect the wires from the MO T OR. [4] Remov e the T orx SCREW from th[...]

  • Page 9

    Replacements and Installations SM5440-1 – 18NOV97 9 Installing the WORM PULLEY and MECHANISM BEL T 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 f or the WORM PULLEY and MECHANISM BEL T in rev erse order . A0[...]

  • Page 10

    SERVICE MANUAL 10 18NOV97 – SM5440-1 Replacing the THERMAL FUSE ASSEMBL Y W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the replacement procedure f or the LO WER HOUSING ASSEMBL Y . [3] Cut and remov e the necessar y WIRE TIES. [4] Remov e the black wire from the THERMAL FUSE ASSEMBL Y on the PO WER SWITCH. [5] Remov e the gra[...]

  • Page 11

    Replacements and Installations SM5440-1 – 18NOV97 11 [6] Lift and remov e the LOWER LIGHT BAFFLE ASSEMBL Y . [7] Lift the GRILLE ASSEMBL Y up . [8] Remov e the 2 long T orx from the BLO WER CO VER ASSEMBL Y . [9] Lift the BLO WER CO VER ASSEMBL Y up. [10] Lift and mov e the PREHEA T DUCT up. [11] T o remov e the LAMP MODULE RECEPT ACLE from the P[...]

  • Page 12

    SERVICE MANUAL 12 18NOV97 – SM5440-1 Replacing the CYCLE SOLENOID ASSEMBL Y W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the replacement procedures f or the LO WER HOUSING ASSEMBL Y and the MO T OR. [3] Cut and remov e the necessar y WIRE TIES. [4] Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD . [5[...]

  • Page 13

    Replacements and Installations SM5440-1 – 18NOV97 13 Replacing the MECHANISM ASSEMBL Y W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the replacement procedure f or the LO WER HOUSING ASSEMBL Y . [3] Cut and remov e the necessar y WIRE TIES. [4] Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD . [5] Pul[...]

  • Page 14

    SERVICE MANUAL 14 18NOV97 – SM5440-1 Replacing the A UT O-FOCUS BRA CKET ASSEMBL Y W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the replacement procedure f or the LO WER HOUSING ASSEMBL Y . [3] Cut and remov e the necessar y WIRE TIES. [4] Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD . [5] Pull th[...]

  • Page 15

    Replacements and Installations SM5440-1 – 18NOV97 15 [7] Remov e the DIRECTION LEVER SPRING from the DIRECTION LEVER. [8] Disconnect the LIFT LEVER SPRING from LIFT LEVER on the T OP PLA TE of the MECHANISM ASSEMBL Y . [9] Remov e the RET ARD SPRING. [10] Remov e the 7 T orx SCREWS from the T OP PLA TE of the MECHANISM ASSEMBL Y . [11] Remov e th[...]

  • Page 16

    SERVICE MANUAL 16 18NOV97 – SM5440-1 A091_0010HA A091_0010HCA SELECT LEVER SPRING SELECT LEVER TAB LIFT LEVER BEARING NUT E-RING E-RING BEARING ASSEMBLY CAM STACK LIFT LEVER SHAFT[...]

  • Page 17

    Replacements and Installations SM5440-1 – 18NOV97 17 [20] Remov e the 2 SCREWS from the CYCLE SOLENOID . [21] Remov e the CYCLE SOLENOID . [22] Slide the PLUNGER and PLUNGER SPRING off the CYCLE LEVER. [23] Remov e the HALF CYCLE SPRING between the CYCLE LEVER ASSEMBL Y and the HALF CYCLE LEVER. [24] Disconnect the INDEX LEVER SPRING from the MEC[...]

  • Page 18

    SERVICE MANUAL 18 18NOV97 – SM5440-1 Replacing the LAMP SOCKET TERMINAL ASSEMBL Y Style 1 LAMP SOCKET TERMINAL ASSEMBLY W arning Dangerous Voltage [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] Remov e the LAMP MODULE. [3] Remov e the PROJECTION LAM[...]

  • Page 19

    Replacements and Installations SM5440-1 – 18NOV97 19 Replacing the LENS MOUNT ASSEMBL Y - A uto Focus Model W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the replacement procedure f or the LO WER HOUSING ASSEMBL Y . [3] Remov e the FOCUS KNOB. Important It is necessary to push the AUTO-FOCUS BRACKET backward and forward to all[...]

  • Page 20

    SERVICE MANUAL 20 18NOV97 – SM5440-1 Replacing the LENS MOUNT ASSEMBL Y - Non A uto Focus Model W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the replacement procedure f or the LO WER HOUSING ASSEMBL Y . [3] Remov e the FOCUS KNOB. [4] Remov e the 3 SCREWS from the LENS MOUNT ASSEMBL Y . [5] Lift and remov e the LENS MOUNT ASS[...]

  • Page 21

    Replacements and Installations SM5440-1 – 18NOV97 21 Replacing the A UT O-FOCUS SWITCH ASSEMBL Y W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the replacement procedure f or the LO WER HOUSING ASSEMBL Y . [3] Remov e the FOCUS KNOB. [4] Remov e the shor t, gra y wire from the A UT O- FOCUS DEFEA T SWITCH. Important It is neces[...]

  • Page 22

    SERVICE MANUAL 22 18NOV97 – SM5440-1 [2] Do the replacement procedure f or the LO WER HOUSING ASSEMBL Y . [3] Remov e 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] Remov e the 3 SCREWS from the LENS MOUNT ASSEMBL Y . [5] Lift and remov e [...]

  • Page 23

    Replacements and Installations SM5440-1 – 18NOV97 23 Installing the FOCUS SHAFT ASSEMBL Y Important Do the adjustments for the PHOTOCELL NULL and AUTO-FOCUS CLAMP after installation. See the Adjustments section. Replacing the FOCUS SHAFT ASSEMBL Y - Non A uto-Focus Models W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the repla[...]

  • Page 24

    SERVICE MANUAL 24 18NOV97 – SM5440-1 Installing the FOCUS SHAFT ASSEMBL Y [1] Do the replacement procedure f or the FOCUS SHAFT ASSEMBL Y in rev erse order .[...]

  • Page 25

    Adjustments SM5440-1 – 18NOV97 25 Section 2: Adjustments Adjustment Specification Use T-BAR TL-3003 to bend the CYCLE LEVER to adjust the CYCLE SOLENOID. Adjusting the CYCLE SOLENOID W arning Dangerous Voltage [1] Connect the main power . Important 1. The CYCLE SOLENOID must operate correctly to do this adjustment. 2. The MECHANISM ASSEMBLY does[...]

  • Page 26

    SERVICE MANUAL 26 18NOV97 – SM5440-1 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 ASSEMBL Y W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the remov al[...]

  • Page 27

    Adjustments SM5440-1 – 18NOV97 27 Adjusting the SLIDE LIFT LEVER MANU AL, with MECHANISM Out W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the remov al for the MECHANISM ASSEMBL Y . [3] Place the MECHANISM ASSEMBL Y on the MECHANISM R UNNING FIXTURE. [4] Press and hold the SELECT LEVER down to mo ve the SLIDE LIFT LEVER to the[...]

  • Page 28

    SERVICE MANUAL 28 18NOV97 – SM5440-1 Adjusting the Focus Light P ath - 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. W arning Dangerous Voltage [1] Disconnect the[...]

  • Page 29

    Adjustments SM5440-1 – 18NOV97 29 [10] Bend the A UT O-FOCUS BRA CKET ASSEMBL Y MIRROR until the image is within the target on the T ARGET SLIDE. Use ADJUSTMENT T OOL TL-3005 or the SPRING HOOK TL-1165. 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 [...]

  • Page 30

    SERVICE MANUAL 30 18NOV97 – SM5440-1 Important If you cannot obtain the NULL position after doing the adjustment approximately 3 times, go to the adjustment procedure for the PHOTOCELL. Adjustment Specification Use TL-3002 and FAN CAP 232729 to check the adjustment of the PHOTOCELL. Adjusting the PHO T OCELL W arning Dangerous Voltage [1] Discon[...]

  • Page 31

    Adjustments SM5440-1 – 18NOV97 31 W arning Dangerous Voltage [4] Energize the projector . [5] Set the projector to the LO-LAMP position. [6] Install and hold the A UT O FOCUS T ARGET SLIDE TL-3002 until it is fully seated in the GA TE MECHANISM. [7] Look through the PROJECTION LENS hole and obser ve the focus light path on the A UTO-FOCUS T ARGET[...]

  • Page 32

    SERVICE MANUAL 32 18NOV97 – SM5440-1 [11] Install the F AN CAP 232729 in the PHO T OCELL HOUSING. [12] Manually mov e the CLAMP P AD ASSEMBL Y until the T AB is in the NULL position. W arning Dangerous Voltage [13] Connect the main power . Important It is necessary to make a FAN COVER TOOL. See the Tools section. [14] Install the F AN CO VER TOOL[...]

  • Page 33

    Adjustments SM5440-1 – 18NOV97 33 [16] Set the projector to the LO-LAMP position. [17] Obser ve the image of the f ocus light path on the bottom of the F AN CAP; the light path should be in the center of the hole in the F AN CAP . [18] Bend the CLAMP P AD ASSEMBL Y until the image is in the center of the hole in the F AN CAP . [19] Assemble the P[...]

  • Page 34

    SERVICE MANUAL 34 18NOV97 – SM5440-1 Adjusting the CLAMP P AD ASSEMBL Y W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the remov al for the LO WER HOUSING ASSEMBL Y . Important It is necessary to make a FAN COVER TOOL. See the Tools section. [3] Install the F AN CO VER TOOL o ver the F AN area and the LAMP MODULE. See the T ool[...]

  • Page 35

    Adjustments SM5440-1 – 18NOV97 35 A091_0013GA SHUTTER DARK PAD PRESSURE A091_0013GCA[...]

  • Page 36

    SERVICE MANUAL 36 18NOV97 – SM5440-1 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[...]

  • Page 37

    Lubrication SM5440-1 – 18NOV97 37 A100_0020GA A091_0023HA[...]

  • Page 38

    SERVICE MANUAL 38 18NOV97 – SM5440-1 A091_0022DA[...]

  • Page 39

    Tools SM5440-1 – 18NOV97 39 Section 4: Tools T ools 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. Tool Description TL-1744 AUTO-FOCUS GAUGE TL-2264 FOCUS TEST (flat field) TL-3002 AUTO-FOCUS TARGET SLIDE TL-3003 ADJUSTMENT T-BAR TL-3005 ADJUSTMENT TOOL[...]

  • Page 40

    SERVICE MANUAL 40 18NOV97 – SM5440-1 Section 5: Specifications Item Desription Electrical Supply Standard U.S. Models: 110 - 125 V ac Japan J Models: 100 V AC, 60 Hz only Korea KK Models: 220 V AC, 60 Hz only Power Consumption 400 W Dimensions • Height: 119 mm (4.69 in.) without TRAY • Width: 238 mm (12.93 in.) • Length: 295 mm (11.6 in.) S[...]

  • Page 41

    Specifications SM5440-1 – 18NOV97 41 REMOTE INLET 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 sli[...]

  • Page 42

    SERVICE MANUAL 42 18NOV97 – SM5440-1 Section 6: Diagnostics MAIN MO T OR V oltages MAIN MO TOR PIN Color s MAIN MO TOR PIN V oltages PIN Color 12 brown 11 red 10 violet 9 yellow 8 blue 7 not used PIN Resistance Voltage 8-9 3.1 W 24.4 V AC 10-11 4.3 W 14.1 V AC 11-12 4.2 W 14.1 V AC 10-12 8.0 W 28.2 V AC 9-10 O.L. 12 11 10 9 8 7 A091_0006BA brown [...]

  • Page 43

    Diagnostics SM5440-1 – 18NOV97 43 PHO T OCELL V oltages PHO TOCELL V oltages 5-PIN REMO TE CORD PLUG V oltages 5-PIN REMO TE PLUG V oltages PINS Voltage 1-2 14.5 V ac 2-3 14.5 V ac 1-3 29 V ac PIN Description white Reverse red Forward yellow Common brown RACK SOLENOID black Focus - REMOTE 1 2 3 A091_4036AA A091_4036ACA PHOTOCELL A100_0001BC_ YELL[...]

  • Page 44

    SERVICE MANUAL 44 18NOV97 – SM5440-1 SMALL COMPONENT BO ARD ASSEMBL Y 256809 V oltages Description Component RED +, BLACK - Voltage TIMER Circuit CR3 + to - 32 V DC TIMER Circuit Q3 - G to + A 32 V DC TIMER Circuit Q4 - G to + K 18.1 V DC CYCLE HOLD DOWN REVERSE CR4 + to - 18.0 V DC FOCUS CR2 + to - 28.0 V DC FOCUS RACK USE REMOTE CR5 + to - 18.0[...]

  • Page 45

    Diagnostics SM5440-1 – 18NOV97 45 V oltage Specifications - General P ar ts P ower , Illumination, and Cooling Malfunctions Part Procedure Voltage FOCUS MOTOR ------ 6.7 V AC CYCLE SOLENOID 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 [...]

  • Page 46

    SERVICE MANUAL 46 18NOV97 – SM5440-1 Slide T ranspor t 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 SOLEN[...]

  • Page 47

    Diagnostics SM5440-1 – 18NOV97 47 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[...]

  • Page 48

    SERVICE MANUAL 48 18NOV97 – SM5440-1 Focus Malfunctions 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[...]

  • Page 49

    Diagnostics SM5440-1 – 18NOV97 49 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 [...]

  • Page 50

    SERVICE MANUAL 50 18NOV97 – SM5440-1 AUTO FOCUS MOTOR operates continually 1. Install the TARGET SLIDE TL-3002 in the GATE MECHANISM. 2. Check that the alignment of the TARGET and NULL is correct. If not, see the Adjustments section. 3. Check for a light leak: • Install a different LAMP MODULE ASSEMBLY. If the FOCUS MOTOR stops operating contin[...]

  • Page 51

    Printed in U.S.A. • sm5440_1.fm EASTMAN KODAK COMPANY Rochester, NY 14650 Kodak, Carousel, and Wratten are trademarks.[...]