Service Manual
Page 1
SM5440-1 18NOV97 Supersedes SM5440-1 13MAY97 SERVICE MANUAL Kodak Carousel PROJECTORS New Look PROJECTORS Kodak Home Page on Internet Models 4200, 4200-J, 4200-KK, 4400, 4600, 4600-KK, 5600, 5600-J, and 5600-KK Intranet Table of Contents © Eastman Kodak Company, 1999 A100_0029HA {ServiceManual}{Production}{KodakServiceSupport} Publication No.
SM5440-1 18NOV97 Supersedes SM5440-1 13MAY97 SERVICE MANUAL Kodak Carousel PROJECTORS New Look PROJECTORS Kodak Home Page on Internet Models 4200, 4200-J, 4200-KK, 4400, 4600, 4600-KK, 5600, 5600-J, and 5600-KK Intranet Table of Contents © Eastman Kodak Company, 1999 A100_0029HA {ServiceManual}{Production}{KodakServiceSupport} Publication No.
Service Manual
Page 18
... the LAMP MODULE DOOR. [6] Remove the LAMP DOOR PLATE ASSEMBLY. Caution Remove the CONDENSER LENS and HEAT ABSORBING GLASS and set on a cold surface; SM5440-1 PROJECTOR LAMP LAMP EJECTOR LAMP SOCKET TERMINAL ASSEMBLY Important The EXTRA BRIGHT LAMP MODULE does not have a HEAT ABSORBING GLASS and has a LABEL on the LAMP...
... the LAMP MODULE DOOR. [6] Remove the LAMP DOOR PLATE ASSEMBLY. Caution Remove the CONDENSER LENS and HEAT ABSORBING GLASS and set on a cold surface; SM5440-1 PROJECTOR LAMP LAMP EJECTOR LAMP SOCKET TERMINAL ASSEMBLY Important The EXTRA BRIGHT LAMP MODULE does not have a HEAT ABSORBING GLASS and has a LABEL on the LAMP...
Service Manual
Page 25
Adjusting the CYCLE SOLENOID Warning Dangerous Voltage [1] Connect the main power. 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 adjust the CYCLE SOLENOID. Section 2: Adjustments Adjustment Specification Use T-...
Adjusting the CYCLE SOLENOID Warning Dangerous Voltage [1] Connect the main power. 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 adjust the CYCLE SOLENOID. Section 2: Adjustments Adjustment Specification Use T-...
Service Manual
Page 28
... image on the GATE MECHANISM. 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 the image is necessary to bend the AUTO-FOCUS BRACKET...
... image on the GATE MECHANISM. 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 the image is necessary to bend the AUTO-FOCUS BRACKET...
Service Manual
Page 29
... the main power. [2] Do the removal for the NULL. [9] Bend the PHOTOCELL BRACKET to make a FAN COVER TOOL. 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 the image is necessary to move the NULL...
... the main power. [2] Do the removal for the NULL. [9] Bend the PHOTOCELL BRACKET to make a FAN COVER TOOL. 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 the image is necessary to move the NULL...
Service Manual
Page 31
Adjustments Warning Dangerous Voltage [4] Energize the projector. [5] Set the projector to pull the PHOTOCELL CIRCUIT BOARD up and off the PHOTOCELL HOUSING. If not, do the adjustment procedure for the FOCUS LIGHT PATH. Warning Dangerous ...
Adjustments Warning Dangerous Voltage [4] Energize the projector. [5] Set the projector to pull the PHOTOCELL CIRCUIT BOARD up and off the PHOTOCELL HOUSING. If not, do the adjustment procedure for the FOCUS LIGHT PATH. Warning Dangerous ...
Service Manual
Page 33
Adjustments [16] Set the projector to check that the CLAMP PAD ASSEMBLY moves forward and backward. A091_4030BCA A091_4030BA SM5440-1 - 18NOV97 33 the light path should be in the center of ...
Adjustments [16] Set the projector to check that the CLAMP PAD ASSEMBLY moves forward and backward. A091_4030BCA A091_4030BA SM5440-1 - 18NOV97 33 the light path should be in the center of ...
Service Manual
Page 36
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 18NOV97 - SERVICE MANUAL Section 3: Lubrication Apply lubricant SUPER LUBE TL-4276 to the following parts and areas of the projector; SM5440-1
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 18NOV97 - SERVICE MANUAL Section 3: Lubrication Apply lubricant SUPER LUBE TL-4276 to the following parts and areas of the projector; SM5440-1
Service Manual
Page 39
Cut here. FAN COVER TOOL 11.5 cm (4.5 in.) A091_0024GCA A091_0024GA SM5440-1 - 18NOV97 39 Section 4: Tools Tools TL-1744 TL-2264 TL-3002 TL-3003 TL-3005 TL-3255 TL-4276 Tool Description AUTO-FOCUS GAUGE FOCUS TEST (flat field) AUTO-FOCUS TARGET SLIDE ADJUSTMENT T-BAR ADJUSTMENT TOOL Torx DRIVER SET SUPER LUBE DIGITAL MULTIMETER 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.
Cut here. FAN COVER TOOL 11.5 cm (4.5 in.) A091_0024GCA A091_0024GA SM5440-1 - 18NOV97 39 Section 4: Tools Tools TL-1744 TL-2264 TL-3002 TL-3003 TL-3005 TL-3255 TL-4276 Tool Description AUTO-FOCUS GAUGE FOCUS TEST (flat field) AUTO-FOCUS TARGET SLIDE ADJUSTMENT T-BAR ADJUSTMENT TOOL Torx DRIVER SET SUPER LUBE DIGITAL MULTIMETER 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.
Service Manual
Page 40
...% 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 UL Complies with storage test specifications (TS 172) Complies with EXR lamp • EXTRA BRIGHT LAMP MODULE has a 30% increase in .) 1 second • EXR 82...
...% 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 UL Complies with storage test specifications (TS 172) Complies with EXR lamp • EXTRA BRIGHT LAMP MODULE has a 30% increase in .) 1 second • EXR 82...
Service Manual
Page 41
... CYCLE • PIN 4 - This focus adjustment will adjust for 2000 hours or 2,000,000 cycles. Brown, RACK SOLENOID • PIN 5 - The projector has a MTBF (mean time between the following times: • Fast = 3 1 second • Slow = 22 6 seconds 14 maximum front elevation assembly...4 7W 7-PIN PLUG 5Y 82 V AC 2 3 6N G O 0 V AC Common 24 V AC Unloaded A100_0023ACA A100_0023AA SM5440-1 - 18NOV97 41 The projector can operate for the difference in the slide position from the focus and reverse specifications by a qualified service person is inserted into the GATE. •...
... CYCLE • PIN 4 - This focus adjustment will adjust for 2000 hours or 2,000,000 cycles. Brown, RACK SOLENOID • PIN 5 - The projector has a MTBF (mean time between the following times: • Fast = 3 1 second • Slow = 22 6 seconds 14 maximum front elevation assembly...4 7W 7-PIN PLUG 5Y 82 V AC 2 3 6N G O 0 V AC Common 24 V AC Unloaded A100_0023ACA A100_0023AA SM5440-1 - 18NOV97 41 The projector can operate for the difference in the slide position from the focus and reverse specifications by a qualified service person is inserted into the GATE. •...
Service Manual
Page 44
... COMPONENT BOARD ASSEMBLY 256809 Voltages WWK R A V V O B Y B J1 R3 CR2 CR3 CR4 Q1 Q2 R6 R4 R5 C5 R17 C4 R Y G N R WW J2 F1 R7 CR5 SLIDE PROJECTOR BOARD Q3 C1 CR1 R12 ++ R11 R10 C3 C2 R13 R14 CR6 R15 Q4 Description TIMER Circuit TIMER Circuit TIMER Circuit CYCLE HOLD DOWN REVERSE...
... COMPONENT BOARD ASSEMBLY 256809 Voltages WWK R A V V O B Y B J1 R3 CR2 CR3 CR4 Q1 Q2 R6 R4 R5 C5 R17 C4 R Y G N R WW J2 F1 R7 CR5 SLIDE PROJECTOR BOARD Q3 C1 CR1 R12 ++ R11 R10 C3 C2 R13 R14 CR6 R15 Q4 Description TIMER Circuit TIMER Circuit TIMER Circuit CYCLE HOLD DOWN REVERSE...
Service Manual
Page 46
...DRIVE BELT. 2. Excessive lubrication and dirt can cause binds. 1. If there is a short•circuit causing the malfunction, the SOLENOID will not rotate. 4. Projector does not complete a cycle; Clean and lubricate the parts as necessary. Install a new CAM STACK ASSEMBLY; the malfunction is a bind in the wires: •... RATCHET LEVER. Check that the CAM SHAFT ASSEMBLY RATCHET SPRING is correct. 2. Check the CYCLE SOLENOID for the CYCLE LEVER. 2. Projector has continual cycle. Do the adjustment for a short•circuit in the CAM STACK, install a new CAM. 46 18NOV97 -
...DRIVE BELT. 2. Excessive lubrication and dirt can cause binds. 1. If there is a short•circuit causing the malfunction, the SOLENOID will not rotate. 4. Projector does not complete a cycle; Clean and lubricate the parts as necessary. Install a new CAM STACK ASSEMBLY; the malfunction is a bind in the wires: •... RATCHET LEVER. Check that the CAM SHAFT ASSEMBLY RATCHET SPRING is correct. 2. Check the CYCLE SOLENOID for the CYCLE LEVER. 2. Projector has continual cycle. Do the adjustment for a short•circuit in the CAM STACK, install a new CAM. 46 18NOV97 -
Service Manual
Page 47
... it should not be bent. • Check the height of the SLIDE LIFT LEVER; the REMOTE CONTROL and CONTROL PANEL BUTTONS operate correctly. The projector has power. If this does not correct the malfunction: • Install a new CAM SHAFT ASSEMBLY. 1. the lower corner of the LIFT LEVER ...RAMP is not correct, do the adjustment for correct alignment. 2. SLIDE TRAY advances when "REVERSE" is not bent. 2. Operate the projector in the forward direction. • Check that the LOCATOR LEVER moves correctly and is pressed. the lower corner of the LIFT LEVER RAMP is in...
... it should not be bent. • Check the height of the SLIDE LIFT LEVER; the REMOTE CONTROL and CONTROL PANEL BUTTONS operate correctly. The projector has power. If this does not correct the malfunction: • Install a new CAM SHAFT ASSEMBLY. 1. the lower corner of the LIFT LEVER ...RAMP is not correct, do the adjustment for correct alignment. 2. SLIDE TRAY advances when "REVERSE" is not bent. 2. Operate the projector in the forward direction. • Check that the LOCATOR LEVER moves correctly and is pressed. the lower corner of the LIFT LEVER RAMP is in...
Service Manual
Page 48
...not operate DARK SHUTTER SWITCH does not operate After the FOCUS MOTOR energizes and moves, the FOCUS MOTOR oscillates. Focus Malfunctions Check 1. Energize the projector and move the TIMER to check for changes in W. 3. Check the FOCUS SHAFT SPRING for damage; use a DVM to "S". •... and hold the REMOTE CONTROL. 3. Check that the voltage across the FOCUS MOTOR is correct, install a new FOCUS MOTOR. 4. SM5440-1 Energize the projector and release the DARK SHUTTER to close the DARK SHUTTER. 4. Check for damage and install a new part if necessary. 1. If this procedure does ...
...not operate DARK SHUTTER SWITCH does not operate After the FOCUS MOTOR energizes and moves, the FOCUS MOTOR oscillates. Focus Malfunctions Check 1. Energize the projector and move the TIMER to check for changes in W. 3. Check the FOCUS SHAFT SPRING for damage; use a DVM to "S". •... and hold the REMOTE CONTROL. 3. Check that the voltage across the FOCUS MOTOR is correct, install a new FOCUS MOTOR. 4. SM5440-1 Energize the projector and release the DARK SHUTTER to close the DARK SHUTTER. 4. Check for damage and install a new part if necessary. 1. If this procedure does ...