Kodak Carousel 4200 Service Manual
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Kodak Carousel 4200 Service Manual

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© Eastman Kodak Company, 1999
{ServiceManual}{Production}{KodakServiceSupport}
Kodak Carousel PROJECTORS
Models 4200, 4200-J, 4200-KK, 4400, 4600,
4600-KK, 5600, 5600-J, and 5600-KK
A100_0029HA
SERVICE MANUAL
New Look PROJECTORS
Publication No. SM5440-1
18NOV97
Supersedes SM5440-1
13MAY97

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  • Page 1 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...

  • Page 2: Table Of Contents

    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.
  • Page 3 Adjusting the Focus Light Path - Auto Focus Models Adjustment Specification ........Adjusting the NULL.

  • Page 4: Replacements And Installations

    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.
  • Page 5 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.

  • Page 6: Installing The Fan Shaft Assembly

    SERVICE MANUAL [19] Lift and remove the FAN SHAFT ASSEMBLY. SCREW (2) SCREW RETAINER CLIP MOTOR BLOWER ASSEMBLY 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.

  • Page 7: Replacing The Motor

    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.

  • Page 8: Replacing The Worm Pulley And Mechanism Belt

    SERVICE MANUAL FAN BELT MECHANISM BELT A091_4015BCA 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.

  • Page 9: Installing The Worm Pulley And Mechanism Belt

    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.

  • Page 10: Replacing The Thermal Fuse Assembly

    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.

  • Page 11: Installing The Lamp Module Receptacle

    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.

  • Page 12: Replacing The Cycle Solenoid Assembly

    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.

  • Page 13: Replacing The Mechanism Assembly

    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.

  • Page 14: Replacing The Auto-Focus Bracket Assembly

    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.
  • Page 15 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.
  • Page 16 SERVICE MANUAL LIFT LEVER LIFT LEVER SHAFT SELECT LEVER E-RING BEARING SELECT LEVER SPRING E-RING CAM STACK A091_0010HCA BEARING A091_0010HA ASSEMBLY 18NOV97 – SM5440-1...

  • Page 17: Installing The Cam Stack Assembly And Cycle Lever Assembly

    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. E-RING (2) LEVER SPRING [23] Remove the HALF CYCLE SPRING between the CYCLE LEVER ASSEMBLY and the HALF CYCLE LEVER.

  • Page 18: Replacing The Lamp Socket Terminal Assembly

    SERVICE MANUAL Replacing the LAMP SOCKET TERMINAL ASSEMBLY Style 1 LAMP SOCKET TERMINAL ASSEMBLY Warning SCREW 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.

  • Page 19: Replacing The Lens Mount Assembly - Auto Focus Model

    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...

  • Page 20: Replacing The Lens Mount Assembly - Non Auto Focus Model

    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.

  • Page 21: Replacing The Auto-Focus Switch Assembly

    Replacements and Installations Replacing the AUTO-FOCUS SWITCH ASSEMBLY AUTO FOCUS Warning MOTOR BRACKET 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.
  • Page 22 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.

  • Page 23: Installing The Focus Shaft Assembly

    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.

  • Page 24: Installing The Focus Shaft Assembly

    SERVICE MANUAL Installing the FOCUS SHAFT ASSEMBLY [1] Do the replacement procedure for the FOCUS SHAFT ASSEMBLY in reverse order. 18NOV97 – SM5440-1...

  • Page 25: Adjustments

    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.

  • Page 26: Adjusting The Indexer Lever Assembly

    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.

  • Page 27: Adjusting The Slide Lift Lever Manual, With Mechanism Out

    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.

  • Page 28: Adjusting The Focus Light Path - Auto Focus Models

    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.

  • Page 29: Adjusting The Null

    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...

  • Page 30: Adjusting The Photocell

    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 AUTO-FOCUS CLAMP LEVER TARGET SLIDE A091_4031BCA A091_4031BA TL-3002 Adjustment Specification Use TL-3002 and FAN CAP 232729 to check the adjustment of the PHOTOCELL.
  • Page 31 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.
  • Page 32 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 CLAMP LEVER A091_4027BCA A091_4027BA...
  • Page 33 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.

  • Page 34: Adjusting The Clamp Pad Assembly

    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.
  • Page 35 Adjustments DARK SHUTTER PRESSURE A091_0013GCA A091_0013GA SM5440-1 – 18NOV97...

  • Page 36: Lubrication

    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 •...
  • Page 37 Lubrication A100_0020GA A091_0023HA SM5440-1 – 18NOV97...
  • Page 38 SERVICE MANUAL A091_0022DA 18NOV97 – SM5440-1...

  • Page 39: Tools

    Tools Section 4: Tools Tools 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 TL-3255 Torx DRIVER SET 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.

  • Page 40: Specifications

    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 400 W Dimensions •...
  • Page 41 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.

  • Page 42: Diagnostics

    SERVICE MANUAL Section 6: Diagnostics MAIN MOTOR Voltages 84.2 V brown LAMP VOLTAGE is white 74 V AC between brown and white for black LONG LIFE MODELS 117 V AC MOTOR A091_0006BCA A091_0006BA MAIN MOTOR PIN Colors Color brown violet yellow blue not used...

  • Page 43: Photocell Voltages

    PHOTOCELL Voltages PINS Voltage 14.5 V ac 14.5 V ac 29 V ac 5-PIN REMOTE CORD PLUG Voltages BLACK WHITE FOCUS YELLOW YELLOW KODAK EC-3 REMOTE CONTROL A100_0001BC_ 5-PIN REMOTE PLUG Voltages Description white Reverse Forward yellow Common brown RACK SOLENOID...

  • Page 44: Small Component Board Assembly 256809 Voltages

    SERVICE MANUAL SMALL COMPONENT BOARD ASSEMBLY 256809 Voltages W K R A V V O B Y SLIDE PROJECTOR BOARD A091_4034DC Description Component RED +, BLACK - Voltage TIMER Circuit + to - 32 V DC TIMER Circuit - G to + A 32 V DC TIMER Circuit - G to + K...

  • Page 45: Voltage Specifications - General Parts

    Diagnostics Voltage Specifications - General Parts Part Procedure Voltage FOCUS MOTOR ------ 6.7 V AC CYCLE SOLENOID Press the REVERSE 39 W, 10 V DC BUTTON. 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:...

  • Page 46: Slide Transport Malfunctions

    SERVICE MANUAL Slide Transport Malfunctions Malfunction Check Forward and reverse do not operate using the 1. Check that the secondary voltage on the FRONT PANEL BUTTONS or REMOTE MAIN MOTOR is correct. CONTROL. 2. Check that the W across the CYCLE SOLENOID COIL are correct.
  • Page 47 Diagnostics Malfunction Check The projector does not change cycles when 1. The CYCLE LEVER and the RATCHET using a DISSOLVE CONTROL; the REMOTE PLATE are dirty. CONTROL and CONTROL PANEL BUTTONS • Clean and apply lubricant SUPER operate correctly. LUBE TL-4276 to the CYCLE LEVER and RATCHET PLATE.

  • Page 48: Focus Malfunctions

    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.
  • Page 49 Diagnostics Malfunction Check No remote focus, RACK SOLENOID 1. Check that the REMOTE CORD operates ASSEMBLY operates (Auto Focus Models) 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.
  • Page 50 SERVICE MANUAL Malfunction Check 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: •...
  • Page 51 Kodak, Carousel, and Wratten are trademarks. Printed in U.S.A. • sm5440_1.fm EASTMAN KODAK COMPANY Rochester, NY 14650...

This manual is also suitable for:

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