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{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
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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 o
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Adjusting the Focus Light Path - Auto Focus Models Adjustment Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Adjusting the NULL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Adjusting the PHOTOCELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Adjusting the CLAMP PAD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Adjusting the DARK SHU
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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 LAMP
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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
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SERVICE MANUAL [19] Lift and remove the FAN SHAFT ASSEMBLY. SCREW (2) SCREW RETAINER CLIP MOTOR BLOWER ASSEMBLY FAN SCREW (3) FAN PLATE 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 MECHANISM BELT A091_40
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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 t
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SERVICE MANUAL FAN BELT A091_4015BCA MECHANISM BELT A091_4015BA 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 18NOV9
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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 MECHANISM BELT A091_4015BA 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 LOWE
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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
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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 [5] Pull the SMALL CIRCUIT BOARD up. SOLENOID [6] Remove the Torx SCREW from the WORM PLUNGER PULLEY SHAFT. [7] Move the TAB on the WORM PULLEY ASSEMBLY ou
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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 [5] Pull the SMALL CIRCUIT BOARD up. ASSEMBLY [6] Disconnect all wires connected to the MECHANISM ASSEMBLY: • 1 yellow wire from CYCLE SWITCH • 1 orange wire f
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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 SCR
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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 LIFT LEVER (not shown) BEARING E-RING RETARD SPRING BEARING A100_0018HCA NUT A100_0018HA E-RING CAM STACK ASSEMBLY
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SERVICE MANUAL LIFT LEVER LIFT LEVER SHAFT SELECT LEVER E-RING BEARING SELECT LEVER SPRING E-RING NUT CAM STACK A091_0010HCA TAB BEARING A091_0010HA ASSEMBLY 16 18NOV97 – SM5440-1
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Replacements and Installations [20] Remove the 2 SCREWS from the CYCLE HALF-CYCLE SOLENOID. LEVER [21] Remove the CYCLE SOLENOID. [22] Slide the PLUNGER and PLUNGER SPRING off HALF-CYCLE the CYCLE LEVER. LEVER SPRING 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. CYCLE [26] Remove the 2 E-RINGS: LEVER • 1 on the CYCLE LEVER ASSEMBLY PLUNGER
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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
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Replacements and Installations Replacing the LENS MOUNT ASSEMBLY - Auto Focus Model SCREW (3) Warning LENS MOUNT Dangerous Voltage 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. A1
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SERVICE MANUAL Replacing the LENS MOUNT ASSEMBLY - Non Auto Focus Model SCREW (3) Warning LENS MOUNT Dangerous Voltage 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 rev
