Page 1 Kodak X-Omat Important The Kodak X-Omat 180 LP SORTER is designed for use on the Kodak X-Omat 180 LP PROCESSOR. Please insert this publication in the binder for the 180 LP PROCESSOR. If the PROCESSOR is a 180 LPS PROCESSOR, the binder already has this information, except for the Installation Instructions.
Page 2 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 of this information, even if loss or damage is caused by Kodak’s negligence or other fault.
Page 3: Table Of Contents
Table of Contents Description Page Installation ............. Special Tools Required .
Page 4 SERVICE MANUAL Theory of Operation ............Overview .
Page 5: Description Page
Installation Section 1: Installation Table of Contents Description Page Special Tools Required ..........Checking the Packing List.
Page 6: Checking The Packing List
SERVICE MANUAL Checking the Packing List [1] Unpack the SORTER. [2] Before installing the SORTER, check that you have all the parts listed on the packing list included with the SORTER. Identifying the PANELS on the PROCESSOR Figure 1–1 TOP COVER MAIN FEED SIDE DRYER SIDE...
Page 7: Before Starting The Installation Procedure
Installation Before Starting the Installation Procedure Important Do not proceed with this installation unless the 2180 LASER PRINTER has MCU Version 2.16 or higher software, and the 180 LP PROCESSOR has Version 2.22or higher operating software and boot Version 2.52 or higher software.
Page 8 SERVICE MANUAL Installation of the BOOT PROM U20 Figure 1–2 TL-4430 COVER of the ELECTRICAL keyed corner of PROM CAPTIVE SCREW keyed corner H127_2053BCA of SOCKET H127_2053BA [5] Rotate the CAPTIVE SCREW and release the COVER of the ELECTRICAL BOX. Possible damage from electrostatic discharge.
Page 9 Installation Connecting the INTERFACE CABLE Figure 1–4 [8] Connect the INTERFACE CABLE TL-4391 to TL-4391 to the PORTABLE COMPUTER the PORTABLE COMPUTER. [9] Energize the PROCESSOR and allow the PROCESSOR to operate for a minimum of 10 seconds. [10] Energize the PORTABLE COMPUTER. [11] Insert the DOWNLOAD DISKETTE into the A drive of the PORTABLE COMPUTER.
Page 10: Removing The Top Cover And The Hinge Plates
SERVICE MANUAL Removing the TOP COVER and the HINGE PLATES from the PROCESSOR Removal of the TOP COVER Figure 1–5 back HINGE PLATE TOP COVER CONNECTOR P/J25 4 SCREWS front non-drive side HINGE PLATE of processor 4 SCREWS 2 SCREWS drive side of processor 2 SCREWS...
Page 11 Installation [10] Remove and save the 2 SCREWS and the BRACKET from the processing TANK. Important For the SORTER to operate correctly, the PROCESSOR must be level. If you adjust the height of the PROCESSOR, it may be necessary to call the CESD Field Engineer to adjust the LASER PRINTER also. [11] Use the LEVEL, packed with the SORTER, to check the leveling of the PROCESSOR from side to side and from front to back.
Page 12: Installing The New Hinge Plates
SERVICE MANUAL Installing the New HINGE PLATES [1] Install the new front HINGE PLATE on the PROCESSOR. Use the 2 SCREWS from Step 10 on Page 1–7 and 4 SCREWS from Step 6 on Page 1–6. [2] Install CONNECTOR P/J33 on the front HINGE PLATE. Use the 2 SCREWS removed in Step 8 on Page 1–6. [3] Install the new back HINGE PLATE.
Page 13: Installing The Sorter On The Processor
Installation Installing the SORTER on the PROCESSOR Figure 1–10 Figure 1–11 Installation of the Back HINGE PIN Installation of the Front HINGE PIN back front HINGE PIN OUTER HINGE E-RING INNER E-RING INNER OUTER E-RING E-RING SPACER SORTER back FRAME HINGE SORTER PLATE...
Page 14 SERVICE MANUAL Warning The SORTER weighs 20 kg (45 lb). Hold the SORTER firmly until the GAS SPRING is installed. [4] Move the SORTER to the up position and continue holding it while you: (a) Press the GAS SPRING into the MOUNT on the SORTER. (b) Press the GAS SPRING into the MOUNT on the front HINGE PLATE.
Page 15 Installation Note If necessary, lift the back SPINDLE to allow adjustment of the front SPINDLE. ⁄ in.) ±1.3 mm (±0.050 (b) Adjust the front SPINDLE until the height of the SORTER is 8 cm (3.175 or 3 ⁄ in.). See Figure 1–13. (c) Observe Figure 1–13 carefully to check that you are measuring from the correct points.
Page 16: Installing The Encoder Wheel/Sprocket And Adjusting The Height Of The Drive Shaft On The Processor
SERVICE MANUAL Installing the ENCODER WHEEL/SPROCKET and Adjusting the Height of the DRIVE SHAFT on the PROCESSOR [1] Loosen the 2 SCREWS and remove the DRIVE CHAIN COVER. [2] Observe the color of the DRIVE CHAIN COVER. • .If the DRIVE CHAIN COVER is white, discard it. Use the black DRIVE CHAIN COVER provided with the SORTER.
Page 17 Installation Removal of the SPROCKET Figure 1–15 E-RING DRIVE dryer end SHAFT WASHER THRUST WASHER MAIN DRIVE SHAFT feed end SPROCKET SPROCKET PIN H127_0221BCA H127_0221BA [7] Remove the E-RING from the feed end of the MAIN DRIVE SHAFT. [8] Remove the DRIVE SHAFT WASHER from the MAIN DRIVE SHAFT. Note If necessary to release the MAIN DRIVE SHAFT, remove the RACKS from the PROCESSOR.
Page 18 SERVICE MANUAL Important For the correct transport and timing of films, install the new BEARING MOUNT on the PROCESSOR and carefully adjust the height of the DRIVE SHAFT. Removing the BEARING MOUNT Figure 1–16 [14] Remove the 2 SCREWS from the BEARING RETAINER.
Page 19 Installation [25] Temporarily hold the BEARING MOUNT in position by tightening the 2 SCREWS on the front of the BEARING MOUNT. [26] Insert a SHIM in the gap between the bottom of the TANK and the BEARING MOUNT. Note If the gap is too small to insert any SHIMS, advance to Step 30 and install 1 SHIM. Otherwise continue with Step 27. [27] Continue inserting SHIMS in the gap until no more SHIMS will fit.
Page 20 SERVICE MANUAL [42] Adjust the tension on the DRIVE CHAIN. See Figure 1–14 on Page 1–12. (a) With the 4 SCREWS on the MOTOR BRACKET loosened, press down on the DRIVE MOTOR. ⁄ (b) Allow 5 mm ( in.) deflection of the DRIVE CHAIN at the midpoint of the DRIVE CHAIN. (c) Tighten the 4 SCREWS.
Page 21: Installing The New Cover On The Electrical Box
Installation Installing the New COVER on the ELECTRICAL BOX Note Newer PROCESSORS have the ELECTRICAL BOX HARNESS for the SORTER installed at the factory. This can be determined by observing the ELECTRICAL BOX. If CONNECTOR P/J54 is installed on the side of the ELECTRICAL BOX, the ELECTRICAL BOX HARNESS was installed at the factory.
Page 22 SERVICE MANUAL Installation of the New COVER on the ELECTRICAL BOX Figure 1–21 2 GROUND STRAIN STRAPS RELIEF COVER SCREW STRAIN RELIEF CAPTIVE SCREW 3 SCREWS ELECTRICAL BOX CONNECTOR HARNESS H127_2021HCA H127_2021HA [2] Place the ELECTRICAL BOX on a table or work surface. Possible damage from electrostatic discharge.
Page 23: Installing The New Electrical Box Harness
Installation Installing the New ELECTRICAL BOX HARNESS Placing the New ELECTRICAL BOX HARNESS in Position The Correct Position of the ELECTRICAL BOX HARNESS Figure 1–22 STRAIN WIRES 50 and 53 RELIEF SCREW STRAIN RELIEF ELECTRICAL BOX HARNESS H127_2101DCA H127_2101DA [1] Place the ELECTRICAL BOX HARNESS in position. See Figure 1–22. 1C7833 –...
Page 24: Connecting The New Electrical Box Harness To J10 And Tb5
SERVICE MANUAL Connecting the New ELECTRICAL BOX HARNESS to J10 and TB5 Caution Connecting the wires to the wrong positions in the ELECTRICAL BOX can cause severe damage to the PROCESSOR. Check all connections before energizing the PROCESSOR. [1] Disconnect CONNECTOR J10 from the power supply. [2] Install wires 50, 51, and 55 to J10.
Page 25 Installation [3] Install the wires to TB5. See Figure 1–23 on Page 1–20 and the table below. (a) Install wire 53 to any available position on Level 4. (b) Install wire 50 to any available position on Level 2. To Any Available Connect Wire No.
Page 26: Connecting The New Electrical Box Harness To The 500 Board
SERVICE MANUAL Connecting the New ELECTRICAL BOX HARNESS to the 500 BOARD Caution Do not cause damage to the PINS. Check the positions on the CONNECTORS carefully before installing. [1] Disconnect CONNECTORS J504 and J505 from the 500 BOARD. See Figure 1–27 on Page 1–23. [2] Install the wires in tables below to the correct positions on the CONNECTORS J504 and J505.
Page 27 Installation Connecting the Wires to J504 and J505 Figure 1–27 J504 P504 P508 P507 P505 P506 J505 H127_2046HA Connecting Wires to CONNECTORS Figure 1–28 Removing Incorrectly Installed Wires Figure 1–29 J504 and J505 on the 500 BOARD from CONNECTORS J505 or J505 CONNECTOR CONNECTOR TL-4598...
Page 28 SERVICE MANUAL Installation of the Longer ZIPPER TUBING Figure 1–30 WIRE TIE ZIPPER WIRE TIE TUBING H127_2102HCA H127_2102HA Important The ZIPPER TUBING must be installed to meet safety approvals. [4] Remove the SCREW on the bottom of the ELECTRICAL BOX, that holds the existing STRAIN RELIEF. See Figure 1–22 on Page 1–19.
Page 29 Installation Figure 1–31 [7] Install the shorter piece of ZIPPER TUBING Installing the Shorter ZIPPER TUBING around the existing wires and wires 50 and 53 from the new ELECTRICAL BOX HARNESS. STRAIN Important RELIEF The STRAIN RELIEF should be higher than the ZIPPER TUBING.
Page 30 SERVICE MANUAL Installiation of the Wires in the HARNESS BRACKET Figure 1–32 ELECTRICAL BOX HARNESS 2 SCREWS 1 SCREW notch HARNESS BRACKET H127_2103DCA H127_2103DA [9] Place the HARNESS BRACKET in position on the floor of the ELECTRICAL BOX. See Figure 1–32. [10] Use the SCREW removed in Step 4 on Page 1–24 to fasten the HARNESS BRACKET to the bottom of the ELECTRICAL BOX.
Page 31: Modifications To The 500 Board
Installation Modifications to the 500 BOARD Moving JUMPER E1 Figure 1–33 +12V TP23 -12V TP32 PS_GND TP33 P502 P501 P508 P504 P507 TP10 MDTDRV TP16 C100 BT 501 TP27 XIRQ R/W- TP29 500 BD AD-REF P505 AD+REF MOTFB P509 AD_RUN P503 P506 BT 501...
Page 32: Installing The Sorter Harness
SERVICE MANUAL Installing the SORTER HARNESS Routing the SORTER HARNESS in PROCESSORS not Wired for the SORTER at the Factory Figure 1–34 SCREW STRAIN RELIEF front P/J33 HINGE PLATE SORTER HARNESS P/J52 front HINGE P/J53 PLATE SWITCH SORTER HARNESS STRAIN RELIEF SCREW SENSOR...
Page 33 Installation Routing the SORTER HARNESS in PROCESSORS Wired for the SORTER at the Factory Figure 1–35 STRAIN SCREW RELIEF P/J33 front HINGE PLATE SORTER HARNESS front P/J52 P/J53 HINGE PLATE SWITCH SORTER HARNESS STRAIN RELIEF SCREW SENSOR P/J54 ground wire STUD H127_2077ECA H127_2077EA...
Page 34 SERVICE MANUAL [1] For PROCESSORS that did not have the SORTER HARNESS installed at the factory, connect CONNECTOR P/J54 inside the ELECTRICAL BOX See Figure 1–34 on Page 1–28. For PROCESSORS that had the SORTER HARNESS installed at the factory, connect CONNECTOR P/J54 outside the ELECTRICAL BOX and skip Steps 2 through 4.
Page 35: Installing The Cover Extension
Installation Installing the COVER EXTENSION Aligning the COVER EXTENSION with the WET SECTION COVER Figure 36 COVER EXTENSION 3 FASTENERS WET SECTION COVER WET SECTION COVER H127_2094BCA H127_2094BC Note The WET SECTION COVER of later PROCESSORS may already have a COVER EXTENSION. If this PROCESSOR has the COVER EXTENSION, advance to Step 1 on Page 1–32.
Page 36: Installing The New Springs
SERVICE MANUAL Installing the New SPRINGS Figure 37 Note Installing the New SPRINGS in the CROSSOVERS The new SPRINGS are more resistant to corrosion than the old SPRINGS, and improve the reliability of the transport system. [1] Remove: (a) DEVELOPER/FIXER CROSSOVER (b) FIXER/WASH CROSSOVER (c) WASH RACK (d) DRYER RACK...
Page 37 Installation Figure 39 [4] Remove from both the LOWER and UPPER Installing the New SPRINGS in the WASH RACK IDLER GEARS on the WASH RACK: • SHOULDER SCREW 14 BEARINGS • BUSHING • IDLER GEAR UPPER IDLER [5] Remove and discard the 6 SPRINGS from the GEAR WASH RACK.
Page 38: Installing The Film Tray And The Top Cover Of The Sorter
SERVICE MANUAL Installing the FILM TRAY and the TOP COVER of the SORTER Installing the TOP COVER and the FILM TRAY Figure 1–41 TOP COVER ACCESS DOOR LATCH FILM RETAINING PLATE TRAY 2 SCREWS larger CUTOUT HINGE COVER H127_2035HCA 2 SCREWS H127_2035HA [1] Install the EXIT RACK.
Page 39: Final Checkout
Installation Final Checkout Checking the SWITCHES Note For instructions on connecting the PORTABLE COMPUTER and on using the DIAGNOSTICS DISKETTE 5B6278, see the User Instructions for the Software Diagnostics, Publication Part No. 699614, that is shipped with the DIAGNOSTICS DISKETTE. [1] Select “Specific Test Mode”.
Page 40 SERVICE MANUAL Installing the BIN Figure 1–43 [5] Close the TOP COVER and install the BIN. [6] Check that the PORTABLE COMPUTER displays “Bin Assembly Interlock ON”. [7] Remove the BIN, and check that the PORTABLE COMPUTER displays “Bin Assembly Interlock OFF”.
Page 41: Checking The Bin Sensors
Installation Checking the BIN SENSORS Figure 1–45 [1] Go to the “Sorter Sensor Test”. Checking the BIN SENSORS [2] Check that the 9 BIN SENSORS operate correctly, by blocking each BIN SENSOR with a piece of paper or film. If the BIN SENSORS do not operate correctly, see the diagnostic film procedures for the SORTER in Section 4.
Page 42: Checking The Diverters
SERVICE MANUAL Checking the DIVERTERS [1] Go to the “Sorter Component Test Mode” for the SORTER. [2] Using the PORTABLE COMPUTER, energize and de-energize DIVERTER No. 1. [3] Check that DIVERTER No.1 operates smoothly. [4] Check the other DIVERTERS. If the DIVERTERS do not operate correctly, see the diagnostic procedures for the SORTER in Section 4.
Page 43: Adjustments And Replacements
Adjustments and Replacements Section 2: Adjustments and Replacements Table of Contents Description Page Special Tools Required ..........Electrostatic Discharge .
Page 44: Electrostatic Discharge
SERVICE MANUAL Electrostatic Discharge Overview ESD, electrostatic discharge, is a primary source of: • product downtime • lost productivity • costly repairs While one cannot feel a static charge of less than 3,500 volts, as few as 30 volts can damage or destroy essential components in electronic equipment.
Page 45: Service Overview
Adjustments and Replacements Service Overview Position and Identification of Subassemblies Identifying the Sides of the SORTER Figure 2–1 right back left front H126_0730ACA H126_0730AA Figure 2–2 Identifying the MODULES MODULE NO. 9 MODULE NO. 1 front H127_2001GCA H127_2001GA 1C7833 – July 1995 2–3...
Page 46 SERVICE MANUAL Identifying the DIVERTERS Figure 2–3 DIVERTER NO. 1 H127_2087DCA H127_2087DA 2–4 July 1995 – 1C7833...
Page 47: De-Energizing And Energizing The Processor
Adjustments and Replacements De-energizing and Energizing the PROCESSOR For most of the service procedures on the SORTER, the MAIN CIRCUIT PROCESSOR must be de-energized. To de-energize BREAKER the PROCESSOR, move the MAIN CIRCUIT BREAKER CB1 on the front of the PROCESSOR to the “O”...
Page 48: General Access To The Sorter Or To The Processor
SERVICE MANUAL General Access to the SORTER or to the PROCESSOR Removal of the BIN Figure 2–4 [1] De-energize the PROCESSOR. See above procedure. [2] Remove any films from the BIN. [3] Lift and remove the BIN. [4] Lift the TOP COVER. [5] For access to the PROCESSOR, remove the FILM TRAY.
Page 49: Installing The Top Cover
Adjustments and Replacements Access to the SORTER or to the PROCESSOR Figure 2–5 TOP COVER ACCESS DOOR LATCH FILM TRAY RETAINING PLATE 2 SCREWS larger CUTOUT HINGE COVER H127_2035HCA H127_2035HA 2 SCREWS Caution The SORTER has many small parts, that can fall into the processing section, RACKS, and TANKS of the PROCESSOR.
Page 50: Replacement Of The Diverters Or The Bearings
SERVICE MANUAL Replacement of the DIVERTERS or the BEARINGS Note For replacement of the SOLENOIDS, see Page 2–9. [1] De-energize the PROCESSOR. See Page 2–5. [2] Do the General Access procedure on Page 2–6 as required. Possible damage from electrostatic discharge. [3] Disconnect the CONNECTOR for the SOLENOID from the 100 BOARD.
Page 51: Replacement Of A Solenoid
Adjustments and Replacements Replacement of a SOLENOID [1] Do Steps 1 - 4(b) on Page 2–8 to remove the DIVERTER. CONNECTOR Important The PLUNGER can fall out of the SOLENOID when you remove the SOLENOID from the SOLENOID BRACKET. PLUNGER [2] Remove the NUT, WASHER, and SOLENOID.
Page 52: Replacement Of The Interlock Switch
SERVICE MANUAL Replacement of the INTERLOCK SWITCH Figure 2–8 [1] De-energize the PROCESSOR. See Page 2–5. Replacement of the INTERLOCK SWITCH [2] Do the General Access procedure on Page 2–6 as required. INTERLOCK SWITCH SWITCH TABS [3] Remove the SCREW. [4] Remove the BRACKET from the SORTER.
Page 53: Replacement Of A Module
Adjustments and Replacements Replacement of a MODULE Caution • Do not allow the SCREWS or WASHERS to fall. You may want to place a cloth over the processing section to catch falling parts • This procedure is for removing and installing any MODULE: the TRANSPORT MODULE, the LEAD MODULE, or the MAIN MODULES.
Page 54: Replacement Of The Sensor On A Module
SERVICE MANUAL Replacement of the SENSOR on a MODULE Figure 2–10 Removing the PINS from the CONNECTOR Possible damage from electrostatic discharge. TL-4598 [1] Remove the MODULE. See Page 2–11. [2] Remove the 2 SCREWS. [3] Remove the CONNECTOR from the wires on the SENSOR: CONNECTOR (a) If the SENSOR will not be used again, cut...
Page 55 Adjustments and Replacements [5] To install a new SENSOR: (a) Feed the wires of the new SENSOR through the MODULE. (b) Connect the PINS from the new SENSOR to the new CONNECTOR. See Figure 2–12. (c) Check that the positions of the wires are correct. See Figure 2–13. Note For easier routing of the CONNECTOR through the MODULE, use tape to fasten a piece of stiff wire to the wire connected to the SENSOR...
Page 56: Replacement Of The Rollers On A Lead Or Main Module Or On The Access Door
SERVICE MANUAL Replacement of the ROLLERS on a LEAD or MAIN MODULE or on the ACCESS DOOR Important • Because you can easily cause damage to the O-RINGS, order new O-RINGS for this procedure. • This procedure does not apply to the TRANSPORT MODULE. •...
Page 57 Adjustments and Replacements Figure 2–15 [9] Install the O-RING. Using TWEEZERS to Install an O-RING Note For easier installation of the O-RING, use TWEEZERS SHAFT to stretch the O-RING over the SHAFT. See Figure 2–15. [10] For a MODULE, reverse the steps on Page 2–11 to install the MODULE in the SORTER.
Page 58: Replacement Of The Idler Rollers And Springs On A Module
SERVICE MANUAL Replacement of the IDLER ROLLERS and SPRINGS on a MODULE Replacement of the IDLER ROLLERS Figure 2–17 [1] Remove the MODULE. See Page 2–11. on a MODULE [2] Use a small SCREWDRIVER to press down on the SPRING to remove it from the groove in the SHAFT.
Page 59: Replacement Of The Bin Roller
Adjustments and Replacements Replacement of the BIN ROLLER Note For replacement of the BEARINGS or the GEAR on the BIN ROLLERS, see the procedure at the bottom of this page and the procedure on Page 2–18. [1] De-energize the PROCESSOR. See Page 2–5. [2] Do the General Access procedure on Page 2–6 as required.
Page 60: Replacement Of The Gear Or The Back Bearing
SERVICE MANUAL Replacement of the GEAR or the Back BEARING Figure 2–19 [1] Remove the BIN ROLLER. See Page 2–17. Removing the PIN from the BIN ROLLER [2] Use a ROLL PIN PUNCH TL-1387 to remove the PIN from the BIN ROLLER. [3] Remove from the BIN ROLLER: TL-1387 •...
Page 61: Replacement And Adjustment Of The Drive Belt
Adjustments and Replacements Replacement and Adjustment of the DRIVE BELT Adjusting the Tension on the DRIVE BELT Figure 2–21 6.4 mm (1/4 in.) DRIVE MOTOR 3 SCREWS DRIVE BELT DRIVE BELT H127_2028BCA H127_2028BA [1] De-energize the PROCESSOR. See Page 2–5. [2] Do the General Access procedure on Page 2–6 as required.
Page 62: Replacement Of The Drive Motor Or The Gearbox
SERVICE MANUAL Replacement of the DRIVE MOTOR or the GEARBOX Figure 2–22 Note Replacement of the DRIVE MOTOR If necessary, to more easily disconnect the CONNECTOR CONNECTOR, remove the BRACKET for the MOTOR CONTROLLER BOARD. See Page 2–24. DRIVE [1] Disconnect the CONNECTOR. MOTOR [2] Remove: •...
Page 63: Replacement Of The Main Drive Shaft
Adjustments and Replacements Replacement of the MAIN DRIVE SHAFT [1] De-energize the PROCESSOR. See Page 2–5. [2] Do the General Access procedure on Page 2–6 as required. [3] Loosen the 3 SCREWS that hold the DRIVE MOTOR. See Figure 2–21 on Page 2–19. [4] Remove: •...
Page 64: Replacement Of The Worm Gears
SERVICE MANUAL Replacement of the WORM GEARS Removal of a WORM GEAR Figure 2–25 TL-1387 SETSCREW PULLEY MAIN DRIVE GEAR SHAFT WORM GEAR WORM GEAR 2 THRUST WASHERS GEAR PIN E-RING BEARING H127_2034BCA THRUST BEARING H127_2034BA [1] Remove the MAIN DRIVE SHAFT. See Page 2–21. [2] Remove from the MAIN DRIVE SHAFT: •...
Page 65: Replacement Of The Gas Spring
Adjustments and Replacements Replacement of the GAS SPRING Replacement of the GAS SPRING Figure 2–26 [1] De-energize the PROCESSOR. See Page 2–5. [2] Do the General Access procedure on Page 2–6 as RELEASE required. CLIP [3] Lift the SORTER, and hold it with your left hand. 2 MOUNTS Warning The SORTER weighs 20 kg (45 lb).
Page 66: Replacement Of The 4000 Board Or Motor Controller Board
SERVICE MANUAL Replacement of the 4000 BOARD or MOTOR CONTROLLER BOARD Installation of a New BOARD Figure 2–27 MOTOR CONTROLLER BOARD 2 SCREWS P/J56 J4003 4000 BOARD J4002 2 SCREWS BRACKET ANCHOR J4001 H127_2030HCA H127_2030HA [1] De-energize the PROCESSOR. See Page 2–5. [2] Do the General Access procedure on Page 2–6 as required.
Page 67: Replacement Of The 100 Board
Adjustments and Replacements Replacement of the 100 BOARD Installation of a New 100 BOARD Figure 2–28 100 B0ARD ANCHOR SORTER FRAME J123 H127_2031HCA J112 H127_2031HA [1] De-energize the PROCESSOR. See Page 2–5. [2] Do the General Access procedure on Page 2–6 as required. Possible damage from electrostatic discharge.
Page 68 SERVICE MANUAL [9] Install the new 100 BOARD: (a) Place the new 100 BOARD in position. (b) Carefully press near an ANCHOR point on the 100 BOARD until the 100 BOARD snaps onto the ANCHOR. (c) Press near each of the other ANCHORS. (d) Connect all the CONNECTORS to the 100 BOARD.
Page 69: Replacement Of The Idler Gears
Adjustments and Replacements Replacement of the IDLER GEARS [1] De-energize the PROCESSOR. See Page 2–5. [2] Do the General Access procedure on Page 2–6 as required. Possible damage from electrostatic discharge. [3] Remove the 2 SCREWS from the BRACKET that holds the 4000 BOARD. See Figure 2–27 on Page 2–24. [4] For access to the 2 IDLER GEARS, move the BRACKET as necessary.
Page 70: Preventive Maintenance
SERVICE MANUAL Preventive Maintenance No preventive maintenance is necessary for the SORTER. Routine preventive maintenance on the PROCESSOR is, however, critical, especially cleaning the DRYER RACK and the EXIT RACK. RACKS that are not kept clean can cause delays in the transport of the film. Delays will affect the timing of when films are sensed by the SORTER and error codes E101 - E109.
Page 71: Theory Of Operation
Theory of Operation Section 3: Theory of Operation Table of Contents Description Page Overview ............Description .
Page 72: Overview
Overview Description The Kodak X-Omat 180 LP SORTER KIT allows the installation of a Kodak X-Omat 180 LP SORTER on a Kodak X-Omat 180 LP PROCESSOR in the field. The Kodak X-Omat 180 LPS PROCESSOR is a Kodak X-Omat 180 LP PROCESSOR with a SORTER installed at the factory.
Page 73 Theory of Operation MODULES, SENSORS, and DIVERTERS Figure 3–2 SENSOR DIVERTER SOLENOID LEAD MODULE ROLLER DIVERTER TRANSPORT MAIN TRANSPORT MODULE H127_2083DCA MODULE ROLLER H127_2083DA Each BIN is identified with a number and a customer-written label naming the modality assigned to it. Assignment of BINS is done through the DISPLAY SCREEN on the Kodak Ektascan 2180 LASER PRINTER.
Page 74 SERVICE MANUAL The film is then guided between MODULES where an optical infrared SENSOR in the upstream MODULE senses it. A drive BIN ROLLER engages the IDLER ROLLERS in the MODULE and feeds the film up at an angle into the BIN. The SORTER has 10 MODULES.
Page 75 Theory of Operation Driving the ROLLERS of the SORTER Figure 3–3 4000 BOARD DRIVE MOTOR INTERLOCK SWITCH MAIN DRIVE SHAFT SOLENOID MOTOR CONTROLLER BOARD ROLLER ENCODER WHEEL/SPROCKET PROCESSOR SENSOR MAIN DRIVE SHAFT H127_2088ECA H127_2088EA 1C7833 – July 1995 3–5...
Page 76: Operation Of The Boards
SERVICE MANUAL Operation of the BOARDS Control of the DIVERTER SOLENOIDS Note The following explanation is for DIVERTER No. 1. The other DIVERTERS are controlled in the same manner. The 500 BOARD provides the control signal on PIN 7 of CONNECTOR P/J506 (0 volts to turn the SOLENOID off or 5 volts to turn the SOLENOID on).
Page 77: Operation Of The Bin Sensors
Theory of Operation Operation of the BIN SENSORS Note This explanation follows the signal for BIN SENSOR No. 1. The others operate the same way. The 100 BOARD supplies a constant 5 volts to an infrared LED in the BIN SENSOR. The return for the LED is provided through a transistor that is enabled by a signal from the 500 BOARD.
Page 78: Operation Of The Interlock Board For The Top Cover
SERVICE MANUAL Operation of the INTERLOCK BOARD for the TOP COVER The INTERLOCK BOARD (the 4000 BOARD) disables the SORTER transport if the BIN is removed from the SORTER. The 4000 BOARD is a safety device. S20 is the INTERLOCK SWITCH for the BIN. When the BIN is in position, S20 is on. When S20 is on, the 24 volt return on PIN 4002 of CONNECTOR P4002 on the INTERLOCK BOARD is applied to PIN 1 of P4002 on the INTERLOCK BOARD through the S20 SWITCH.
Page 79: Operation Of The Sorter Transport
Theory of Operation Operation of the SORTER Transport The 100 BOARD powers an infrared LED on SENSOR U11 mounted next to an ENCODER WHEEL/ SPROCKET on the MAIN DRIVE SHAFT of the PROCESSOR. The ENCODER WHEEL/ SPROCKET has alternating holes and reflective material, which the infrared energy passes either through or reflects back to SENSOR U11.
Page 80: Explanation Of Error Codes
SERVICE MANUAL Explanation of Error Codes • Error 080 BIN Assembly not in position This warning will only occur if the BIN ASSEMBLY is removed from the SORTER. The MAIN DRIVE MOTOR on the SORTER will shut down, regardless whether film is present, until the BIN ASSEMBLY is put back in place.
Page 81: Diagnostics
Diagnostics Section 4: Diagnostics Table of Contents Description Page Error Codes ............Troubleshooting the BIN SENSORS .
Page 82 SERVICE MANUAL Error Code Error Description Possible Malfunction Action Speed of the 180 LP PROCESSOR transport Using the PORTABLE COMPUTER PROCESSOR is out of not operating diagnostics, energize the PROCESSOR E082 range transport. Check for nominal 230 V AC on the PROCESSOR B6 Motor CONNECTOR P/J22 PINS 2 and 3.
Page 83 Diagnostics Error Code Error Description Possible Malfunction Action Inoperative Transport 4000 BOARD Check that DS3 on the 4000 BOARD E083 in the SORTER (indicates 24 V is being supplied to the MOTOR CONTROLLER BOARD) is illuminated when the BIN INTERLOCK SWITCH is ON.
Page 84 SERVICE MANUAL Error Code Error Description Possible Malfunction Action Film did not arrive at This error may occur because the film did not arrive at the correct BIN at E091 - E099 BINS 1 - 9 (the last the expected time or because it arrived at the correct BIN but was not digit of the error code sensed.
Page 85: Troubleshooting The Bin Sensors
Diagnostics Troubleshooting the BIN SENSORS Checking the BIN SENSORS Figure 4–1 [1] Using the PORTABLE COMPUTER, go to the specific test mode, “Sorter Sensor Test”. The status of the BIN SENSORS will be displayed. With no film in the SENSOR area, “No Film film Detected”...
Page 86 SERVICE MANUAL Note Remain in the “Sorter Sensor Test” to keep the Enable Signal ON. • If no signal is present, install a new 500 BOARD. • If a signal is present at P/J508 PIN 14, check for a pulsed 5 V signal (OFF for 80 µseconds, ON for 100 mseconds) at P/J113 PIN 5 or TP15 on the 100 BOARD.
Page 87: Troubleshooting The Diverters
Diagnostics Troubleshooting the DIVERTERS [1] Using the PORTABLE COMPUTER, go to the specific test mode, “Sorter Component Test”. Activate the DIVERTERS to check that the DIVERTER is up when the DIVERTER is “OFF” and down when the DIVERTER is “ON”. Important A malfunction may be caused by a mechanical problem;...
Page 88 SERVICE MANUAL (b) Disconnect the adjacent CONNECTOR P/J104 (for BIN SENSOR No. 4) from the 100 BOARD, and connect it to P103 on the 100 BOARD. (c) Using the PORTABLE COMPUTER “Sorter Component Test”, energize DIVERTER SOLENOID No. 3. (d) If the interchanged SOLENOID works correctly, replace the malfunctioning DIVERTER SOLENIOD disconnected in Step (a).
Page 89: Component Locator
Component Locator Section 5: Component Locator Component Lists Connectors - P/J Page P/J50 Bin Interlock Switch 5–3 P/J52 Film Tray Sensor 5–3 P/J53 Processor Speed Sensor 5–3 P/J54 Electrical Box - Sorter 5–3 P/J55 5–3 P/J101 100 Board - Diverter 1 Solenoid 5–4 P/J102 100 Board - Diverter 2 Solenoid...
Page 90 SERVICE MANUAL Integrated Circuits - U Page U1 - U9 Bin Sensors 5–3 Spare Bin Sensor 5–3 Processor Speed Sensor 5–3 LED/Indicators - DS Page 4000 Board - Cover Interlock ON 5–4 4000 Board - Relay for Motor Controller Power ON 5–4 4000 Board - 24 Volts for Motor Controller ON 5–4...
Page 91 Component Locator Top View of the SORTER Figure 5–1 P/J55 P/J50 L2 L3 L4 4000 Bd 100 Bd P/J53 P/J52 P/J54 (LPS) P/J54 (Kit) H127_2068ECA H127_2068EA 1C7833 – July 1995 5–3...
Page 92 SERVICE MANUAL 4000 Board Figure 5–2 P4001 P4003 4000 INTERLOCK P4002 H127_2069BCA H127_2069BC 100 Board Figure 5–3 J110 J109 TP16 TP17 TP18 J123 J103 J105 J107 J108 J111 J101 J106 J102 J104 J112 TP19 TP20 TP11 TP13 TP15 J113 J114 J118 J119 J120...
Page 93: Diagrams
180 LP/LPS PROCESSOR ELECTRICAL BOX Wiring Diagram ....Note If you are installing a SORTER KIT on a Kodak X-Omat 180 LP PROCESSOR, remove Pages 6–5 through 6–8 from this section and insert them in the Diagram section of the 180 LP PROCESSOR service binder.
Page 94 SERVICE MANUAL 6–2 July 1995 – 1C7833...
Page 101: Illustrated Parts List
Illustrated Parts List Section 7: Illustrated Parts List Table of Contents Description Page Miscellaneous Hardware, 1 of 2 ..........Miscellaneous Hardware, 2 of 2 .
Page 102: Miscellaneous Hardware, 1 Of
SERVICE MANUAL Figure 7–1 Miscellaneous Hardware, 1 of 2 H127_2039ECA H127_2039EA 7–2 July 1995 – 1C7833...
Page 103 Illustrated Parts List Figure 7–1 Item Part No. Description 1C4089 Spring - Gas 1C4158 Pin - Hinge, front 188821 E-Ring 1C4171 Spacer 1C4160 Clip 1C4156 Plate - Hinge, Front 365159 Clamp 914599 Switch 1C4159 Pin - Hinge, Back 528291 Washer 188828 Lock Washer 532358...
Page 104: Miscellaneous Hardware, 2 Of
SERVICE MANUAL Figure 7–2 Miscellaneous Hardware, 2 of 2 H127_2041ECA H127_2041EA 7–4 July 1995 – 1C7833...
Page 105 Illustrated Parts List Figure 7–2 Item Part No. Description Notes 619599 Washer 1C7968 Spring 1C4243 Shaft - Pivot, Door 136224 E-Ring 1C7970 Roller 1C4199 O-Ring 1C4265 Door - Access Includes Items 5, 6, 8, & 9. 1C7969 Latch - Access Door Includes hardware.
Page 106: Bin, Top Cover, And Film Tray
SERVICE MANUAL Figure 7–3 Bin, Top Cover, and Film Tray H127_2095GCA H127_2095GA H127_2004HCB H127_2004HA 7–6 July 1995 – 1C7833...
Page 107 Illustrated Parts List Figure 7–3 Item Part No. Description Notes 1C7928 Includes Items 2, 3, & 4. 1C4224 Brush - Static 1C4181 Spring - Ground 4B4361 Rivet 1C7930 Cover - Top 852614 Washer 852653 Lock Washer 960860 Screw 852799 Washer 853086 Lock Washer 5B6861...
Page 108: Lower Transport Rollers, Diverters, And Idler Gears
SERVICE MANUAL Figure 7–4 Lower Transport Rollers, Diverters, and Idler Gears H127_2038DCA H127_2038DA 7–8 July 1995 – 1C7833...
Page 109 Illustrated Parts List Figure 7–4 Item Part No. Description Notes 129142 E-Ring 1C4236 Washer 1C7956 Bearing 5B6860 Solenoid Includes Plunger, Nut, and Washer. 1C4082 Bracket - Solenoid 5B6127 Spring - Diverter 151779 Bearing 5B6144 Screw 188828 Lock Washer 528291 Washer 1C4144 Diverter 1C4233...
Page 110 SERVICE MANUAL Figure 7–5 Drive Motor and Drive Shaft H127_2045DCA H127_2045DA 7–10 July 1995 – 1C7833...
Page 111 Illustrated Parts List Figure 7–5 Item Part No. Description Notes 1C7494 Motor - Drive 1C7496 Gearbox 1C4237 Bracket - Motor 1C4274 Pulley Includes Setscrew. 1C4272 Belt - Drive 1C4238 Setscrew 1C4273 Pulley 1C4236 Washer 1C7956 Bearing 129142 E-Ring 852611 Washer 853100 Lock Washer 5B6148...
Page 112 SERVICE MANUAL Figure 7–6 Encoder Wheel/Sprocket on the Processor H127_2040HCA H127_2040HA 7–12 July 1995 – 1C7833...
Page 113 Illustrated Parts List Figure 7–6 Item Part No. Description 918557 Sensor 532358 Screw 188828 Lock Washer 1C4223 Bracket - Sensor 852799 Washer 853086 Lock Washer 5B6141 Screw 365159 Clamp 1C4218 Encoder Wheel/Sprocket, 50 Hz 1C4219 Encoder Wheel/Sprocket, 60 Hz 914898 1C7833 –...
Page 114: Modules
SERVICE MANUAL Figure 7–7 Modules H127_2018DCA H127_2018DA 7–14 July 1995 – 1C7833...
Page 115 Illustrated Parts List Figure 7–7 Item Part No. Description Notes 5B6144 Screw 188828 Lock Washer 528291 Washer 1C7932 Module - Lead Complete Assembly 1C7934 Module - Transport Complete Assembly 535646 Pin - Gear 1C4226 Gear 129142 E-Ring 1C7956 Bearing 1C4236 Washer 1C4230 Roller - Bin...
Page 116: Main Module
SERVICE MANUAL Figure 7–8 Main Module H127_2071DCA H127_2071DA 7–16 July 1995 – 1C7833...
Page 117 Illustrated Parts List Figure 7–8 Item Part No. Description Notes 1C7933 Module - Main Complete Assembly. 532358 Screw 188828 Lock Washer 1C7510 Sensor - Bin Mod 1 must be installed to use this Sensor. 1C7963 Roller - Rubber 1C4199 O-Ring 1C4245 Shaft 1C4247...
Page 118: Lead Module
SERVICE MANUAL Figure 7–9 Lead Module H127_2079BCA H127_2079BA 7–18 July 1995 – 1C7833...
Page 119 Illustrated Parts List Figure 7–9 Item Part No. Description Notes 1C7932 Module - Lead Complete Assembly. 532358 Screw 188828 Lock Washer 1C7510 Sensor - Bin Mod 1 must be installed to use this Sensor. 1C7963 Roller - Rubber 1C4245 Shaft 1C4199 O-Ring 1C7833 –...
Page 120: Transport Module
SERVICE MANUAL Figure 7–10 Transport Module H127_2020DCA H127_2020DA 7–20 July 1995 – 1C7833...
Page 121 Illustrated Parts List Figure 7–10 Item Part No. Description Notes 1C7934 Module - Transport Complete Assembly. 1C4247 Spring 1C4244 Roller 1C4248 Shaft 1C7510 Sensor - Bin Mod 1 must be installed to use this Sensor. 532358 Screw 188828 Lock Washer 5B6108 Label - Transport Module 1C7963...
Page 122 SERVICE MANUAL Figure 7–11 Circuit Boards and Interlock Switch H127_2044ECA H127_2044EA 7–22 July 1995 – 1C7833...
Page 123 Illustrated Parts List Figure 7–11 Item Part No. Description 5B6148 Screw 853100 Lock Washer 852611 Washer 5B6144 Screw 188828 Lock Washer 528291 Washer 1C7495 Circuit Board - Motor Controller 1C4126 Bracket 1C7501 Circuit Board - 4000 322482 Switch - Interlock 5B6144 Screw 188828...
Page 124 SERVICE MANUAL 7–24 July 1995 – 1C7833...
Page 125: Numerical Parts Index
Numerical Parts Index Section 8: Numerical Parts Index Numerical Index Part No. Description Figure No. 129142 E-Ring 7–4, 7–5, 7–7 136224 E-Ring 7–2, 7–5 151779 Bearing 7–4 188821 E-Ring 7–1 188828 Lock Washer 7–1, 7–4, 7–6, 7–7, 7–8, 7–9, 7–10, 7–11 1C4082 Bracket - Solenoid 7–4...
Page 126 SERVICE MANUAL Numerical Index Part No. Description Figure No. 1C4272 Belt - Drive 7–5 1C4273 Pulley 7–5 1C4274 Pulley 7–5 1C7479 Circuit Board - 100 7–11 1C7494 Motor - Drive 7–5 1C7495 Circuit Board - Motor Controller 7–11 1C7496 Gearbox 7–5 1C7501 Circuit Board - 4000...
Page 127 Numerical Parts Index Numerical Index Part No. Description Figure No. 914599 Switch 7–1 914888 7–11 914898 7–6 914915 Spindle 7–1 918557 Sensor 7–6 960860 Screw 7–3 1C7833 – July 1995 8–3...
Page 128 SERVICE MANUAL 8–4 July 1995 – 1C7833...
Page 129: Alphabetical Parts Index
Alphabetical Parts Index Section 9: Alphabetical Parts Index Alphabetical Index Part No. Description Figure No. 151779 Bearing 7–4 1C4268 Bearing 7–4 1C7956 Bearing 7–4, 7–5, 7–7 1C4272 Belt - Drive 7–5 1C7928 7–3 1C4126 Bracket 7–11 1C4142 Bracket 7–11 1C7967 Bracket - Latch 7–2 1C4237...
Page 130 SERVICE MANUAL Alphabetical Index Part No. Description Figure No. 1C7934 Module - Transport 7–7, 7–10 1C7494 Motor - Drive 7–5 852624 7–1 1C4199 O-Ring 7–2, 7–8, 7–9 914898 7–6 535646 Pin - Gear 7–4, 7–5, 7–7 1C4159 Pin - Hinge, Back 7–1 1C4158 Pin - Hinge, front...
Page 131 Alphabetical Parts Index Alphabetical Index Part No. Description Figure No. 1C4236 Washer 7–4, 7–5, 7–7 528291 Washer 7–1, 7–4, 7–7, 7–11 619599 Washer 7–2 852611 Washer 7–2, 7–5, 7–11 852614 Washer 7–3 852799 Washer 7–3, 7–6 1C7833 – July 1995 9–3...
Page 132 SERVICE MANUAL 9–4 July 1995 – 1C7833...
Page 133: Publication History
Publication History Section 10: Publication History Print Date Pub. No. ECO No. Affected Pages Notes 13MAR95 1C7833 2468-008 all First printing. Filenames: sm3200_1.book (front_sorter .doc ii_sorter.doc ar_sorter.doc tg_sorter.doc dg_sorter.doc cl_sorter.doc di_sorter.doc ip_sorter.doc ni_sorter.doc ai_sorter.doc sorter.doc) July 1995 1C7833 2468-018 most Updated part numbers and minor design changes that occurred since March.
Page 134 Kodak, Ektascan, and X-Omat are trademarks. HEALTH SCIENCES DIVISION sorter3200_1_018. EASTMAN KODAK COMPANY ROCHESTER, N.Y. 14650...

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