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Kodak KKE PLUS 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. SM4530-1 30APR96 SERVICE MANUAL for the Kodak Ektagraphic III PAINTED and NON-PAINTED PROJECTORS Models A, KKA, JA, ATS, AM, AMT, JAMT, B, BR, E, E-PLUS SLIDE, J-E PLUS, and KKE PLUS A100_0001HA[...]

  • Page 2

    2 30APR96 – SM4530-1 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

    SM4530-1 – 30APR96 3 Adjusting the SLIDE LIFT LEVER POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Adjusting the ZERO POSITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Adjusting the Focus Light Path - Auto Focus Models . . . . . . . . . . . . . . . . . . . . . 31 Adjusting the NULL . . . . . . . . . [...]

  • Page 4

    SERVICE MANUAL 4 30APR96 – SM4530-1 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 (f or N.P . models) (or 6 Phillips SCREWS f or P ainted Models) from[...]

  • Page 5

    Replacements and Installations SM4530-1 – 30APR96 5 Replacing the F AN SHAFT 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 the 3 WIRE TIES: • 1 on BLOWER COVER wires • 2 on SMALL CIRCUIT BOARD between the MOTOR and MECHANISM ASSEMBLY [4] Discon[...]

  • Page 6

    SERVICE MANUAL 6 30APR96 – SM4530-1 [11] Lift the BLO WER CO VER ASSEMBL Y up. [12] Remov e the 3 He x 1/4 in. SCREWS from the MO TOR. [13] Lift the MO TOR until y ou obser ve the F AN BEL T and MECHANISM BEL T . [14] Remov e the F AN BEL T and MECHANISM BEL T off the MOT OR PULLEY . Use SPRING HOOK TL-1165. Caution Move the MOTOR to allow access[...]

  • Page 7

    Replacements and Installations SM4530-1 – 30APR96 7 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 order . Replacing the MO T OR W arni[...]

  • Page 8

    SERVICE MANUAL 8 30APR96 – SM4530-1 Installing the MO T OR 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 MO TOR in re verse order . Replacing the WORM PULLEY and MECHANISM BEL T W arning Dangerous Vo[...]

  • Page 9

    Replacements and Installations SM4530-1 – 30APR96 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 . Re[...]

  • Page 10

    SERVICE MANUAL 10 30APR96 – SM4530-1 Installing the THERMAL FUSE ASSEMBL Y [1] Do the replacement procedure f or the THERMAL FUSE ASSEMBL Y in rev erse order . A100_0015GA SCREW PRE-HEAT DUCT THERMAL FUSE POWER SWITCH A100_0015GCA[...]

  • Page 11

    Replacements and Installations SM4530-1 – 30APR96 11 Replacing the LAMP MODULE RECEPT A CLE 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 2 T orx SCREWS on the left side of the LO WER LIGHT BAFFLE ASSEMBL[...]

  • Page 12

    SERVICE MANUAL 12 30APR96 – SM4530-1 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 SM4530-1 – 30APR96 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 30APR96 – SM4530-1 Installing the MECHANISM ASSEMBL Y 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 remov al procedure for the MECHANISM ASSEMBL Y in re v erse order . Replacing the A UT O-FOCUS BRA CKET ASSEMBL Y[...]

  • Page 15

    Replacements and Installations SM4530-1 – 30APR96 15 Replacing the CAM ST A CK ASSEMBL Y and CYCLE LEVER ASSEMBL Y W arning Dangerous Voltage [1] Disconnect the main power . [2] Do the replacement procedure f or the MECHANISM ASSEMBL Y . [3] Remov e the INDEXER LEVER ASSEMBL Y from the T OP PLA TE of the MECHANISM ASSEMBL Y . [4] Remov e the T or[...]

  • Page 16

    SERVICE MANUAL 16 30APR96 – SM4530-1 [12] Remov e the LIGHT BAFFLE. [13] Remov e the NUT from the LIFT LEVER SHAFT . [14] Remov e the LIFT LEVER and SHAFT . [15] Remov e the 2 E-RINGS from the 2 CAM SHAFT BEARINGS. [16] Remov e the 2 CAM SHAFT BEARINGS. [17] Press and hold the SELECT LEVER down. [18] Remov e the CAM ST ACK ASSEMBL Y . [19] Discon[...]

  • Page 17

    Replacements and Installations SM4530-1 – 30APR96 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 30APR96 – SM4530-1 Replacing the LAMP SOCKET TERMINAL ASSEMBL Y , N.P . W arning Dangerous Voltage [1] Disconnect the main power . [2] Remov e the LAMP MODULE. [3] Remov e the PROJECTION LAMP from the LAMP MODULE. [4] Remov e the SCREW from the LAMP DOOR PLA TE ASSEMBL Y . [5] Release the 2 T ABS on the bottom side of the LAMP M[...]

  • Page 19

    Replacements and Installations SM4530-1 – 30APR96 19 Replacing the LAMP SOCKET TERMINAL ASSEMBL Y , Painted Models [1] Disconnect the main power . [2] Remov e: • LAMP MODULE • PROJECTION LAMP for the LAMP MODULE from the LAMP MODULE • SCREW and lift the CONDENSER LENS HOLDER up • CONDENSER LENS and HEAT GLASS • RETAINING RING • SPRING[...]

  • Page 20

    SERVICE MANUAL 20 30APR96 – SM4530-1 Caution The TABS could break. [3] Bend the 3 T ABS of the LAMP BRA CKET ASSEMBL Y . [4] Lift the top of the LAMP BRA CKET ASSEMBL Y up . [5] Rotate and push the LAMP TERMINAL ASSEMBL Y until it releases. [6] Remov e the LAMP TERMINAL ASSEMBL Y . Installing the LAMP SOCKET TERMINAL ASSEMBL Y , Painted Models [1[...]

  • Page 21

    Replacements and Installations SM4530-1 – 30APR96 21 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 th[...]

  • Page 22

    SERVICE MANUAL 22 30APR96 – SM4530-1 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 necessary to push[...]

  • Page 23

    Replacements and Installations SM4530-1 – 30APR96 23 Replacing the FOCUS SHAFT ASSEMBL Y - A uto Focus Models 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[...]

  • Page 24

    SERVICE MANUAL 24 30APR96 – SM4530-1 [17] Remov e the FOCUS MOT OR BRA CKET ASSEMBL Y . [18] Push the RA CK LEVER aw a y from the FOCUS SHAFT ASSEMBL Y . [19] Remov e the FOCUS SHAFT ASSEMBL Y . Installing the FOCUS SHAFT ASSEMBL Y Important Do the adjustments for the PHOTOCELL NULL and AUTO-FOCUS CLAMP after installation. See the Adjustments sec[...]

  • Page 25

    Replacements and Installations SM4530-1 – 30APR96 25 [12] Remov e the FOCUS MOT OR BRA CKET ASSEMBL Y . [13] Remov e the FOCUS SHAFT ASSEMBL Y . Installing the FOCUS SHAFT ASSEMBL Y [1] Do the replacement procedure f or the FOCUS SHAFT ASSEMBL Y in rev erse order .[...]

  • Page 26

    SERVICE MANUAL 26 30APR96 – SM4530-1 Section 2: Adjustments Adjustment Specification Use T-BAR TL-3003 to bend the CYCLE LEVER to adjust the CYCLE SOLENOID. Adjusting the CYCLE SOLENOID W arning Dangerous Voltage [1] Connect the main power . Important • The CYCLE SOLENOID must operate correctly to do this adjustment. • The MECHANISM ASSEMBLY[...]

  • Page 27

    Adjustments SM4530-1 – 30APR96 27 Adjustment Specification This adjustment adjusts the strobe and timing of the INDEXER LEVER. Use TL-3000. 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 th[...]

  • Page 28

    SERVICE MANUAL 28 30APR96 – SM4530-1 Adjusting the SLIDE LIFT LEVER MANU AL W arning Dangerous Voltage [1] Disconnect the main power . Important The older style MECHANISM SLIDE LIFT LEVER has an ECCENTRIC on it to do this adjustment. [2] Do the remov al for the MECHANISM ASSEMBL Y . [3] Place the MECHANISM ASSEMBL Y on the MECHANISM R UNNING FIXT[...]

  • Page 29

    Adjustments SM4530-1 – 30APR96 29 Adjusting the SLIDE LIFT LEVER PO WER W arning Dangerous Voltage [1] Disconnect the main power . Important The older style MECHANISM SLIDE LIFT LEVER has an ECCENTRIC on it to do this adjustment. [2] Do the remov al for the MECHANISM ASSEMBL Y . [3] Place the MECHANISM ASSEMBL Y on the MECHANISM R UNNING FIXTURE [...]

  • Page 30

    SERVICE MANUAL 30 30APR96 – SM4530-1 Adjusting the ZERO POSITION SWITCH Important It is necessary to make a 5/16 in. WRENCH to do this adjustment. See the Tools section. [1] Energize the projector . [2] Connect the DIGIT AL V OL T METER (D VM) between PINS 1 and 3 (ZER O POSITION SWITCH) of the SPECIAL APPLICA TIONS PLUG. [3] Without a TRA Y inst[...]

  • Page 31

    Adjustments SM4530-1 – 30APR96 31 Adjusting the Focus Light P ath - Auto Focus Models W arning Dangerous Voltage [1] Disconnect the main power . [2] Remov e the PROJECTION LENS. [3] 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. [4] Install the F AN CO VER TOOL o ver t[...]

  • Page 32

    SERVICE MANUAL 32 30APR96 – SM4530-1 Adjusting the NULL 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. • If you cannot obtain the NULL position after doing the adjustment approximately 3 times, go to [...]

  • Page 33

    Adjustments SM4530-1 – 30APR96 33 Adjusting the PHO T OCELL 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 ools section. [[...]

  • Page 34

    SERVICE MANUAL 34 30APR96 – SM4530-1 [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 o ver the F AN area and the LAMP MODULE. See the T ools sect[...]

  • Page 35

    Adjustments SM4530-1 – 30APR96 35 Adjustment Specification Use TL-1744 to check that the CLAMP PAD ASSEMBLY moves forward and backward. Adjusting the CLAMP P AD ASSEMBL Y W arning Dangerous Voltage [1] Disconnect the main power . Important • If the CLAMP ASSEMBLY has a COIL SPRING on the ADJUSTMENT SCREW, remove it. This will make the adjustme[...]

  • Page 36

    SERVICE MANUAL 36 30APR96 – SM4530-1 Adjusting the D ARK SHUTTER [1] Do the remov al for the LO WER HOUSING. [2] Inser t a thin SLIDE into the GA TE MECHANISM; the D ARK SHUTTER should open. [3] Check the the PRESSURE P AD is correctly aligned with the the D ARK SHUTTER. [4] Bend the PRESSURE P AD to adjust the alignment. A091_0013GA SHUTTER DARK[...]

  • Page 37

    Lubrication SM4530-1 – 30APR96 37 Section 3: Lubrication [1] Apply lubricant SUPER LUBE TL-4276 to the follo wing par ts 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 A100_00[...]

  • Page 38

    SERVICE MANUAL 38 30APR96 – SM4530-1 A091_0023HA[...]

  • Page 39

    Lubrication SM4530-1 – 30APR96 39 A091_0022DA[...]

  • Page 40

    SERVICE MANUAL 40 30APR96 – SM4530-1 Section 4: Tools 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 No. Description TL-1744 AUTO-FOCUS GAUGE TL-2264 FOCUS TEST (flat field) TL-3000 MECHANISM RUNNING FIXTURE (optional) TL-3002 AUTO-FOCUS TARGET SLI[...]

  • Page 41

    Specifications SM4530-1 – 30APR96 41 Section 5: Specifications Item Description 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.) [...]

  • Page 42

    SERVICE MANUAL 42 30APR96 – SM4530-1 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 foc[...]

  • Page 43

    Diagnostics SM4530-1 – 30APR96 43 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 Voltage 8-9 25.5 V ac 10-11 14.5 V ac 11-12 14.5 V ac 10-12 29 V ac 12 11 10 9 8 7 A091_0006BA brown white black 84.2 V 1.6 117 V AC 6.1 LAMP VOLTAGE i[...]

  • Page 44

    SERVICE MANUAL 44 30APR96 – SM4530-1 9-PIN SPECIAL APPLICA TION PLUG 9-PIN SPECIAL APPLICA TION PLUG PHO T OCELL V oltages PHO TOCELL V oltages PINS Description 1 and 3 ZERO POSITION SWITCH 4 and 5 SHUTTER SWITCH 7 and 8 LOWER VOLTAGE SUPPLY, 2.5 V AC, 500 mA, 1/2 Amp maximum 6 and 8 FORWARD TRAY CYCLE 2 and 8 REVERSE TRAY CYCLE and SHELL GROUND [...]

  • Page 45

    Diagnostics SM4530-1 – 30APR96 45 5-PIN REMO TE CORD PLUG V oltages 5-PIN REMO TE PLUG V oltages PIN Description white Reverse red Forward yellow Common brown RACK SOLENOID black Focus - REMOTE A100_0001BC_ YELLOW YELLOW FOCUS BRN REV WHITE BLACK RED FWD KODAK EC-3 REMOTE CONTROL[...]

  • Page 46

    SERVICE MANUAL 46 30APR96 – SM4530-1 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 47

    Diagnostics SM4530-1 – 30APR96 47 V oltage Specifications - General P ar ts P ower , Illumination, and Cooling Malfunctions Part Procedure Voltage FOCUS MOTOR None 8.5 V AC CYCLE SOLENOID Press the REVERSE BUTTON. 39 W, 18.7 V DC RACK SOLENOID None 39 W, 10 V AC LAMP RECEPTACLE None 82 V AC, approximately 85-86 V AC without a LAMP MODULE install[...]

  • Page 48

    SERVICE MANUAL 48 30APR96 – SM4530-1 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 49

    Diagnostics SM4530-1 – 30APR96 49 The projector does not change cycles when using a DISSOLVE CONTROL; the REMOTE CONTROL and CONTROL PANEl BUTTONS operate correctly. 1. If the CYCLE LEVER and the RATCHET PLATE are dirty. • Clean and apply lubricant SUPER LUBE TL-4276 to thE CYCLE LEVER and RATCHET PLATE. • If this does not correct the malfunc[...]

  • Page 50

    SERVICE MANUAL 50 30APR96 – SM4530-1 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 voltag[...]

  • Page 51

    Diagnostics SM4530-1 – 30APR96 51 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. Ch[...]

  • Page 52

    SERVICE MANUAL 52 30APR96 – SM4530-1 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 voltag[...]

  • Page 53

    Diagnostics SM4530-1 – 30APR96 53 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 continual[...]

  • Page 54

    Printed in U.S.A. • sm4530_1.fm EASTMAN KODAK COMPANY Rochester, NY 14650 Kodak, Ektagrphic, and Wratten are tradmarks.[...]