Kodak Ektalite 500 Service Manual
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Kodak Ektalite 500 Service Manual

Kodak Ektalite 500 Service Manual

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© EASTMAN KODAK COMPANY, 2001
KODAK SERVICE AND SUPPORT
{ S er v i c e Manual } { P r o duc t i o n} { K odak S er v i c e Suppor t } { E x t e r n al }
Publication No. SM5766-1
23JUL01
Supersedes SM5766-1
13MAY97
Confidential

SERVICE MANUAL

for the
Kodak Ektalite 500 PROJECTOR
Kodak Ektalite 1000/1500/2000 SLIDE
PROJECTORS
Service Code: 5766
A091_4000BA

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  • Page 1: Service Manual

    © EASTMAN KODAK COMPANY, 2001 KODAK SERVICE AND SUPPORT { S er v i c e Manual } { P r o duc t i o n} { K odak S er v i c e Suppor t } { E x t e r n al } Publication No.

  • Page 2: Table Of Contents

    Kodak’s negligence or other fault. This equipment includes parts and assemblies sensitive to damage from electrostatic discharge.
  • Page 3 SERVICE MANUAL 23JUL01 Installation for the LAMP SOCKET TERMINAL ASSEMBLY ... SM5766-1 Removal for the LENS MOUNT ASSEMBLY - 1500 and Page 3 of 96 2000 PROJECTORS Only ........Installation for the LENS MOUNT ASSEMBLY - 1500 and 2000 PROJECTORS Only .
  • Page 4 SERVICE MANUAL 23JUL01 SMALL COMPONENT BOARD ASSEMBLY - Voltages, 1500 and 2000 SM5766-1 PROJECTORS ........... Page 4 of 96 MAIN COMPONENT BOARD ASSEMBLY - Voltages,...

  • Page 5: Removals And Installations

    SERVICE MANUAL Removals and Installations 23JUL01 Section 1: Removals and Installations SM5766-1 Page 5 of 96 WIRE ASSEMBLIES Important There are only 2 FUSES used in all Ektalite PROJECTORS. All FUSES are not available. When installing a new FUSE, install the same type FUSE (amp) that was installed previously. The color might vary among different PROJECTORS.

  • Page 6: Removal For The Lower Housing

    SERVICE MANUAL Removals and Installations 23JUL01 Removal for the LOWER HOUSING SM5766-1 Page 6 of 96 Warning Dangerous Voltage Disconnect the main power. Remove the PROJECTION LENS. Remove the LAMP MODULE. Remove the 6 Torx SCREWS from the LOWER HOUSING. Pull the LOWER HOUSING off the TOP HOUSING.

  • Page 7: Removal For The Fan Shaft Assembly

    SERVICE MANUAL Removals and Installations 23JUL01 Removal for the FAN SHAFT ASSEMBLY SM5766-1 Page 7 of 96 Warning Dangerous Voltage Disconnect the main power. Do the removal for the LOWER HOUSING. Lift the TRANSFORMER up. Lift the POWER MODULE up. Cut the 3 WIRE TIES: •...
  • Page 8 SERVICE MANUAL Removals and Installations 23JUL01 SM5766-1 Page TRANSFORMER 8 of 96 POWER MODULE WIRE TIE (2) (not shown) BLOWER COVER WIRE TIE SCREW (not shown) GRILLE ASSEMBLY LOWER LIGHT BAFFLE TAB A091_4011HCA SCREW A091_4011HA Remove the 2 long Torx SCREWS from the BLOWER COVER ASSEMBLY. Lift the BLOWER COVER ASSEMBLY up.
  • Page 9 SERVICE MANUAL Removals and Installations 23JUL01 SM5766-1 Page Caution 9 of 96 Move the MOTOR to allow access to the parts; wires are still connected to the MOTOR. Do not cause damage to the MOTOR wires. Remove the RETAINER CLIP from the FAN SHAFT. Pull the FAN up and off the FAN SHAFT to allow access to the FAN BELT.

  • Page 10: Installation For The Fan Shaft Assembly

    SERVICE MANUAL Removals and Installations 23JUL01 Installation for the FAN SHAFT ASSEMBLY SM5766-1 Page 10 of 96 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. Do the removal procedure for the FAN BELT and SHAFT in reverse order.

  • Page 11: Removal For The Motor

    SERVICE MANUAL Removals and Installations 23JUL01 Removal for the MOTOR SM5766-1 Page 11 of 96 Warning Dangerous Voltage Disconnect the main power. Do the removal for the LOWER HOUSING ASSEMBLY. Lift the TRANSFORMER up. Lift and remove the POWER MODULE. Cut the 2 WIRE TIES on the SMALL BOARD between the MOTOR and MECHANISM ASSEMBLY.
  • Page 12 SERVICE MANUAL Removals and Installations 23JUL01 Remove 3 Hex SCREWS - 1/4 in. from the MOTOR. SM5766-1 Page Lift the MOTOR up to allow access to the FAN and MECHANISM BELTS. 12 of 96 Remove the FAN and MECHANISM BELTS from the MOTOR PULLEY. Remove the MOTOR.

  • Page 13: Installation For The Motor

    SERVICE MANUAL Removals and Installations 23JUL01 Installation for the MOTOR SM5766-1 Page 13 of 96 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. Do the removal for the MOTOR in reverse order.

  • Page 14: Installation For The Worm Pulley And Mechanism Belt

    SERVICE MANUAL Removals and Installations 23JUL01 Move the TAB on the WORM PULLEY ASSEMBLY out. SM5766-1 Page Remove the WORM PULLEY ASSEMBLY and MECHANISM BELT. 14 of 96 WORM PULLEY SCREW MECHANISM BELT A091_4017GCA A091_4017GA Installation for 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.

  • Page 15: Removal For The Thermal Fuse Assembly

    SERVICE MANUAL Removals and Installations 23JUL01 SM5766-1 Page 15 of 96 FAN BELT MECHANISM BELT A091_4015BCA A091_4015BA Removal for the THERMAL FUSE ASSEMBLY Warning Dangerous Voltage Disconnect the main power. Do the removal for the LOWER HOUSING ASSEMBLY. Disconnect the 3 CONNECTORS on the MAIN BOARD. It is not necessary to disconnect the CONNECTOR next to the LOWER LIGHT BAFFLE ASSEMBLY.

  • Page 16: Installation For The Thermal Fuse Assembly

    SERVICE MANUAL Removals and Installations 23JUL01 Pull the THERMAL FUSE ASSEMBLY out of hole of the LOWER LIGHT BAFFLE SM5766-1 ASSEMBLY. Page 16 of 96 Installation for the THERMAL FUSE ASSEMBLY Do the removal for the THERMAL FUSE ASSEMBLY in reverse order. MAIN CIRCUIT BOARD SCREW PRE-HEAT...

  • Page 17: Removal For The Lamp Module Receptacle

    SERVICE MANUAL Removals and Installations 23JUL01 Removal for the LAMP MODULE RECEPTACLE SM5766-1 Page 17 of 96 Warning Dangerous Voltage Disconnect the main power. Do the removal for the LOWER HOUSING ASSEMBLY. Disconnect the 3 CONNECTORS on the MAIN BOARD. It is not necessary to disconnect the CONNECTORS next to the LOWER LIGHT BAFFLE ASSEMBLY.

  • Page 18: Installation For The Lamp Module Receptacle

    SERVICE MANUAL Removals and Installations 23JUL01 To remove the LAMP MODULE RECEPTACLE from the PREHEAT DUCT, compress the SM5766-1 2 TABS on the LAMP MODULE RECEPTACLE. Page 18 of 96 SCREW (2) SCREW (2) PRE-HEAT DUCT LOWER LIGHT BAFFLE LAMP MODULE RECEPTACLE BLOWER...

  • Page 19: Removal For The Cycle Solenoid Assembly

    SERVICE MANUAL Removals and Installations 23JUL01 Removal for the CYCLE SOLENOID ASSEMBLY SM5766-1 Page 19 of 96 Warning Dangerous Voltage SCREW (2) Disconnect the main power. Do the removals for the LOWER HOUSING ASSEMBLY and the MOTOR. CYCLE SOLENOID Disconnect the 3 CONNECTORS on the MAIN BOARD.

  • Page 20: Installation For The Cycle Solenoid Assembly

    SERVICE MANUAL Removals and Installations 23JUL01 Remove the 2 Hex SCREWS - SM5766-1 1/4 in. from the 2 CYCLE SOLENOID GROMMETS. Page 20 of 96 Pull the CYCLE SOLENOID ASSEMBLY up and out. If necessary, remove the CYCLE SOLENOID PLUNGER ASSEMBLY. Installation for the CYCLE SOLENOID ASSEMBLY Important Do the adjustment for the CYCLE SOLENOID ASSEMBLY.

  • Page 21: Removal For The Mechanism Assembly

    SERVICE MANUAL Removals and Installations 23JUL01 Removal for the MECHANISM ASSEMBLY SM5766-1 Page 21 of 96 SCREW SCREW (3) Warning DARK SHUTTER Dangerous Voltage LENS SWITCH MOUNT Disconnect the main power. Important The Models Style 2 1500 and 2000 have a MECHANISM DARK SHUTTER SWITCH and AUTO ASSEMBLY...

  • Page 22: Installation For The Mechanism Assembly

    SERVICE MANUAL Removals and Installations 23JUL01 SM5766-1 Disconnect all wires connected to the MECHANISM ASSEMBLY: Page 22 of 96 • 1 yellow wire from J105 • 1 orange wire from J105 • 1 green wire from POWER CORD • 2 green ground wires from the lower MECHANISM ASSEMBLY Remove the FOCUS KNOB from the FRONT PANEL.

  • Page 23: Removal For The Auto-Focus Bracket Assembly - 1500 And 2000 Projectors Only

    SERVICE MANUAL Removals and Installations 23JUL01 Removal for the AUTO-FOCUS BRACKET ASSEMBLY - 1500 and SM5766-1 Page 2000 PROJECTORS Only 23 of 96 Warning Dangerous Voltage Disconnect the main power. Important There is no AUTO-FOCUS BRACKET ASSEMBLY for the Model 1000. Do the removal for the LOWER HOUSING ASSEMBLY.

  • Page 24: Installation For The Auto-Focus Bracket Assembly - 1500 And 2000 Projectors Only

    SERVICE MANUAL Removals and Installations 23JUL01 SM5766-1 Page 24 of 96 SCREW SCREW (2) WORM PULLEY AUTO FOCUS SCREW CYCLE BRACKET A091_4023BCA SOLENOID A091_4023BA ASSEMBLY Installation for the AUTO-FOCUS BRACKET ASSEMBLY - 1500 and 2000 PROJECTORS Only Do the removal for the AUTO-FOCUS BRACKET ASSEMBLY in reverse order. Removal for the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY Warning Dangerous Voltage...
  • Page 25 SERVICE MANUAL Removals and Installations 23JUL01 Remove the DIRECTION LEVER LINK from the DIRECTION LEVER. SM5766-1 Page Remove the DIRECTION LEVER SPRING from the DIRECTION LEVER. 25 of 96 Disconnect the LIFT LEVER SPRING from LIFT LEVER on the TOP PLATE of the MECHANISM ASSEMBLY.
  • Page 26 SERVICE MANUAL Removals and Installations 23JUL01 SM5766-1 INDEXER TOP PLATE Page LEVER 26 of 96 SCREW (7) TOP LIGHT ASSEMBLY BAFFLE LIFT LEVER DIRECTION SPRING LEVER LINK DIRECTION LEVER LINK SPRING WORM PULLEY SELECT LEVER SPRING A091_0011DCA RETARD SPRING SCREW A091_0011DA Disconnect the SELECT LEVER SPRING from the SELECT LEVER.
  • Page 27 SERVICE MANUAL Removals and Installations 23JUL01 Remove the NUT from the LIFT LEVER SHAFT. SM5766-1 Page Remove the LIFT LEVER and SHAFT. 27 of 96 Remove the 2 E-RINGS from the 2 CAM SHAFT BEARINGS. Remove the 2 CAM SHAFT BEARINGS. Press and hold the SELECT LEVER down.
  • Page 28 SERVICE MANUAL Removals and Installations 23JUL01 Remove the 2 SCREWS from the SM5766-1 HALF-CYCLE Page CYCLE SOLENOID. LEVER 28 of 96 Remove the CYCLE SOLENOID. HALF-CYCLE Slide the PLUNGER and PLUNGER E-RING (2) LEVER SPRING SPRING off the CYCLE LEVER. Remove the HALF CYCLE SPRING between the CYCLE LEVER ASSEMBLY and the HALF CYCLE...

  • Page 29: Installation For The Cam Stack Assembly And Cycle Lever Assembly

    SERVICE MANUAL Removals and Installations 23JUL01 Installation for the CAM STACK ASSEMBLY and CYCLE LEVER SM5766-1 Page ASSEMBLY 29 of 96 Caution Keep both the CYCLE LEVER ASSEMBLY and the HALF CYCLE LEVER together and observe the orientation of both LEVERS. Do the removal for the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY in reverse order.

  • Page 30: Removal For The Style 2 Lamp Socket Terminal Assembly

    SERVICE MANUAL Removals and Installations 23JUL01 Removal for the Style 2 LAMP SOCKET TERMINAL ASSEMBLY SM5766-1 Page 30 of 96 SCREW Warning LAMP DOOR Dangerous Voltage PLATE ASSEMBLY 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 31: Installation For The Lamp Socket Terminal Assembly

    SERVICE MANUAL Removals and Installations 23JUL01 SM5766-1 Remove the LAMP DOOR PLATE ASSEMBLY. Page 31 of 96 Release the 2 TABS on the bottom side of the LAMP MODULE next to the LAMP MODULE DOOR. Caution Remove the CONDENSER LENS and HEAT ABSORBING GLASS and set the parts on a clean cloth.

  • Page 32: Removal For The Lens Mount Assembly - 1500 And 2000 Projectors Only

    SERVICE MANUAL Removals and Installations 23JUL01 Removal for the LENS MOUNT ASSEMBLY - 1500 and SM5766-1 Page 2000 PROJECTORS Only 32 of 96 SCREW (3) Warning Dangerous Voltage Disconnect the main power. Do the removal for the LOWER LENS HOUSING ASSEMBLY. MOUNT ASSEMBLY Disconnect the 3 CONNECTORS on...

  • Page 33: Installation For The Lens Mount Assembly - 1500 And 2000 Projectors Only

    SERVICE MANUAL Removals and Installations 23JUL01 Installation for the LENS MOUNT ASSEMBLY - 1500 and SM5766-1 Page 2000 PROJECTORS Only 33 of 96 Do the removal for the LENS MOUNT ASSEMBLY in reverse order. Removal for the LENS MOUNT ASSEMBLY - 500 and 1000 PROJECTORS Only SCREW (3) Warning...

  • Page 34: Installation For The Lens Mount Assembly - 500 And 1000 Projectors Only

    SERVICE MANUAL Removals and Installations 23JUL01 Installation for the LENS MOUNT ASSEMBLY - 500 and SM5766-1 Page 1000 PROJECTORS Only 34 of 96 Do the removal for the LENS MOUNT ASSEMBLY in reverse order. Removal for the AUTO-FOCUS SWITCH ASSEMBLY - Models 1500 and 2000 PROJECTORS Only AUTO FOCUS Warning...

  • Page 35: Installation For The Auto-Focus Switch Assembly - Models 500 And 2000 Projectors Only

    SERVICE MANUAL Removals and Installations 23JUL01 SM5766-1 Page Important 35 of 96 It is necessary to push the AUTO-FOCUS BRACKET backward and forward to allow access to the SCREWS on the LENS MOUNT ASSEMBLY. Remove the 3 SCREWS from the LENS MOUNT ASSEMBLY. Lift and remove the LENS MOUNT ASSEMBLY.

  • Page 36: Removal For The Focus Shaft Assembly - 1500 And 2000 Projectors Only

    SERVICE MANUAL Removals and Installations 23JUL01 Removal for the FOCUS SHAFT ASSEMBLY - 1500 and SM5766-1 Page 2000 PROJECTORS Only 36 of 96 Warning Dangerous Voltage Disconnect the main power. Do the removal for the LOWER HOUSING ASSEMBLY. Disconnect the 3 CONNECTORS on the MAIN BOARD. It is not necessary to disconnect the CONNECTOR next to the LOWER LIGHT BAFFLE ASSEMBLY.
  • Page 37 SERVICE MANUAL Removals and Installations 23JUL01 Remove the RACK SOLENOID ASSEMBLY and PLUNGER. SM5766-1 Page Remove the SCREW from the FOCUS MOTOR BRACKET ASSEMBLY. 37 of 96 Remove the FOCUS MOTOR BRACKET ASSEMBLY. Push the RACK LEVER away from the FOCUS SHAFT ASSEMBLY. Remove the FOCUS SHAFT ASSEMBLY.

  • Page 38: Installation For The Focus Shaft Assembly - 1500 And 2000 Projectors Only

    SERVICE MANUAL Removals and Installations 23JUL01 Installation for the FOCUS SHAFT ASSEMBLY - 1500 and SM5766-1 Page 2000 PROJECTORS Only 38 of 96 Important Do the adjustments for the PHOTOCELL NULL and AUTO-FOCUS CLAMP after installation. See the Adjustments section. Removal for the FOCUS SHAFT ASSEMBLY - 500 and 1000 PROJECTORS Only Warning...

  • Page 39: Installation For The Focus Shaft Assembly - 500 And 1000 Projectors Only

    SERVICE MANUAL Removals and Installations 23JUL01 Remove the FOCUS SHAFT ASSEMBLY. SM5766-1 Page 39 of 96 FOCUS SHAFT SCREW SPRING FOCUS SHAFT ASSEMBLY FOCUS MOTOR BRACKET SPACER LENS SUPPORT BRACKET A091_0020HCA E-RING SCREW A091_0020HA Installation for the FOCUS SHAFT ASSEMBLY - 500 and 1000 PROJECTORS Only Do the removal for the FOCUS SHAFT ASSEMBLY in reverse order.

  • Page 40: Adjustments

    SERVICE MANUAL Adjustments 23JUL01 Section 2: Adjustments SM5766-1 Page 40 of 96 CYCLE SOLENOID Warning Dangerous Voltage Connect the main power. Important • The CYCLE SOLENOID must operate correctly to do this adjustment. • The MECHANISM ASSEMBLY does not have to be removed to do this adjustment. Do the removal for the LOWER HOUSING ASSEMBLY.

  • Page 41: Indexer Lever Assembly

    SERVICE MANUAL Adjustments 23JUL01 SM5766-1 MECHANISM Page ASSEMBLY 41 of 96 T-BAR CYCLE TL-3003 A091_0007HCA A091_0007HA INDEXER LEVER ASSEMBLY Warning Dangerous Voltage Disconnect the main power. Do the removal for the MECHANISM ASSEMBLY. Place the MECHANISM ASSEMBLY on the MECHANISM RUNNING FIXTURE.
  • Page 42 SERVICE MANUAL Adjustments 23JUL01 Check the alignment of the INDEXER LEVER with the hole in the TOP PLATE SM5766-1 ASSEMBLY at Position 1. Page 42 of 96 Bend the INDEXER LEVER to the correct position. Check the travel of the INDEXER LEVER in the FORWARD position. When the INDEXER LEVER moves in the FORWARD position, the gate edge of the black plastic should be between the 2 holes at Position 2.

  • Page 43: Slide Lift Lever Manual

    SERVICE MANUAL Adjustments 23JUL01 SLIDE LIFT LEVER MANUAL SM5766-1 Page 43 of 96 Warning Dangerous Voltage Disconnect the main power. Do the removal for the MECHANISM ASSEMBLY. Place the MECHANISM ASSEMBLY on the MECHANISM RUNNING FIXTURE. Press and hold the SELECT LEVER down to move the SLIDE LIFT LEVER to the highest position.

  • Page 44: Slide Lift Lever Power

    SERVICE MANUAL Adjustments 23JUL01 SLIDE LIFT LEVER POWER SM5766-1 Page 44 of 96 Warning Dangerous Voltage Disconnect the main power. Do the removal for the MECHANISM ASSEMBLY. Place the MECHANISM ASSEMBLY on the MECHANISM RUNNING FIXTURE TL-3000. Energize the MECHANISM FIXTURE. Press and hold the SELECT LEVER down to move the SLIDE LIFT LEVER to the highest position.

  • Page 45: Zero Position Switch - 2000 Projector Only

    SERVICE MANUAL Adjustments 23JUL01 ZERO POSITION SWITCH - 2000 PROJECTOR Only SM5766-1 Page 45 of 96 Important It is necessary use make a 5/16 in. WRENCH to do this adjustment. Energize the projector. Connect the DIGITAL VOLT METER (DVM) between PINS B5 and B6 of the 12-PIN APPLICATION PLUG 12 PIN APPLICATIONS PLUG.

  • Page 46: Focus Light Path - 1500 And 2000 Projectors Only

    SERVICE MANUAL Adjustments 23JUL01 If the measurements are not within SM5766-1 ZERO POSITION Page specification, adjust the ZERO SWITCH 46 of 96 POSITION SWITCH ECCENTRIC to specification. A091_0017GCA A091_0017GA Focus Light Path - 1500 and 2000 PROJECTORS Only Warning Dangerous Voltage Disconnect the main power.
  • Page 47 SERVICE MANUAL Adjustments 23JUL01 Disconnect the MAIN BOARD from the 4 POSTS to allow access to the FOCUS LIGHT SM5766-1 PATH. Page 47 of 96 Important It is necessary to make a FAN COVER TOOL. See the Tools section. Install the FAN COVER TOOL over the FAN area and the LAMP MODULE. Energize the projector.
  • Page 48 SERVICE MANUAL Adjustments 23JUL01 Look through the PROJECTION LENS hole and observe the focus light path on the SM5766-1 AUTO-FOCUS TARGET SLIDE TL-3002. Page 48 of 96 Check the position of the image on the AUTO-FOCUS TARGET SLIDE TL-3002. Bend the AUTO-FOCUS BRACKET ASSEMBLY MIRROR until the image is within the target on the TARGET SLIDE.

  • Page 49: Null

    SERVICE MANUAL Adjustments 23JUL01 NULL SM5766-1 Page 49 of 96 Warning Dangerous Voltage Disconnect the main power. Do the removal for the LOWER HOUSING ASSEMBLY. Important It is necessary to use a FAN COVER TOOL. Install the FAN COVER TOOL over the FAN area and the LAMP MODULE. Energize the projector.
  • Page 50 SERVICE MANUAL Adjustments 23JUL01 SM5766-1 Page Important 50 of 96 If you cannot obtain the NULL position after doing the adjustment approximately 3 times, go to the adjustment for the PHOTOCELL. light path T-BAR TL-3003 NULL position PROJECTION LENS AUTO-FOCUS CLAMP LEVER TARGET SLIDE A091_4031BCA...

  • Page 51: Photocell

    SERVICE MANUAL Adjustments 23JUL01 PHOTOCELL SM5766-1 Page 51 of 96 PHOTOCELL Warning CIRCUIT BOARD Dangerous Voltage wratten FILTER (2) Disconnect the main power. Do the removal for the LOWER HOUSING ASSEMBLY. Important It is necessary to use a FAN COVER TOOL. Install the FAN COVER TOOL over the FAN area and the LAMP MODULE.
  • Page 52 SERVICE MANUAL Adjustments 23JUL01 Heat the 2 POSTS on the PHOTOCELL HOUSING to allow the POSTS to bend enough SM5766-1 to pull the PHOTOCELL BOARD up and off the PHOTOCELL HOUSING. Use a Page 52 of 96 SOLDERING IRON. Remove the 2 Wratten FILTERS and the PHOTOCELL MASK. Install the FAN CAP 232729 in the hole FAN CAP...
  • Page 53 SERVICE MANUAL Adjustments 23JUL01 SM5766-1 light path Page 53 of 96 NULL position CLAMP LEVER A091_4027BCA A091_4027BA Manually move the CLAMP PAD ASSEMBLY until the TAB is in the NULL position. Warning Dangerous Voltage Connect the main power. Important It is necessary to use a FAN COVER TOOL. Install the FAN COVER TOOL over the FAN area and the LAMP MODULE.
  • Page 54 SERVICE MANUAL Adjustments 23JUL01 Bend the CLAMP PAD ASSEMBLY until the image is in the center of the hole in the FAN SM5766-1 CAP. Page 54 of 96 Assemble the PHOTOCELL MASK, FILTERS and PHOTOCELL BOARD. hole T-BAR TL-3003 light image FAN CAP CLAMP PAD ASSEMBLY...

  • Page 55: Clamp Pad Assembly - 1500 And 2000 Projectors Only

    SERVICE MANUAL Adjustments 23JUL01 CLAMP PAD ASSEMBLY - 1500 and 2000 PROJECTORS Only SM5766-1 Page 55 of 96 Warning Dangerous Voltage Disconnect the main power. Do the removal for the LOWER HOUSING ASSEMBLY. Important SCREW It is necessary to use a FAN COVER TOOL. Install the FAN COVER TOOL over the FAN area and the LAMP MODULE.
  • Page 56 SERVICE MANUAL Adjustments Warning 23JUL01 Dangerous Voltage SM5766-1 Page 56 of 96 Connect the main power. Loosen the NUT on the CLAMP PAD ASSEMBLY. Energize the REMOTE FOCUS in either direction. Rotate the SCREW on the CLAMP PAD ASSEMBLY to adjust the pressure of the REMOTE FOCUS CLAMP on the CLAMP PAD ASSEMBLY until the CLAMP PAD ASSEMBLY does not move.

  • Page 57: Dark Shutter

    SERVICE MANUAL Adjustments 23JUL01 DARK SHUTTER SM5766-1 Page Do the removal for the LOWER HOUSING. 57 of 96 Insert a thin SLIDE into the GATE MECHANISM; the DARK SHUTTER should open. Check the PRESSURE PAD is correctly aligned with the DARK SHUTTER. Bend the PRESSURE PAD to adjust the alignment.

  • Page 58: Preventive Maintenance

    SERVICE MANUAL Preventive Maintenance 23JUL01 Section 3: Preventive Maintenance SM5766-1 Page 58 of 96 Apply SUPER LUBE TL-4276 to the following parts and areas of the PROJECTOR; see the illustrations. • • INDEXER LEVER and TOP PLATE • WORM PULLEY ASSEMBLY •...
  • Page 59 SERVICE MANUAL Preventive Maintenance 23JUL01 LENS MOUNT AY Figure 1 SM5766-1 Page 59 of 96 A091_4037GA...
  • Page 60 SERVICE MANUAL Preventive Maintenance 23JUL01 FAN AY Figure 2 SM5766-1 Page 60 of 96 A091_0021GA...
  • Page 61 SERVICE MANUAL Preventive Maintenance 23JUL01 INDEXER LEVER and TOP PLATE Figure 3 SM5766-1 Page 61 of 96 A091_0023HA...
  • Page 62 SERVICE MANUAL Preventive Maintenance 23JUL01 CYCLE LEVER and CAM STACK Figure 4 SM5766-1 Page 62 of 96 A091_0022DA...

  • Page 63: Special Tools

    SERVICE MANUAL Special Tools 23JUL01 Section 4: Special Tools SM5766-1 Page 63 of 96 Tool No. Description TL-1744 AUTO-FOCUS GAUGE TL-2264 FOCUS TEST (flat field) TL-2265 DIELECTRIC TESTER (optional) TL-3002 AUTO-FOCUS TARGET SLIDE TL-3003 ADJUSTMENT T-BAR TL-3005 ADJUSTMENT TOOL TL-3255 Torx DRIVER SET TL-4276 SUPER LUBE...
  • Page 64 SERVICE MANUAL Special Tools 23JUL01 SM5766-1 Page Important 64 of 96 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. COVER TOOL 11.5 cm (4.5 in.) A091_0024GCA...

  • Page 65: Specifications

    SERVICE MANUAL Specifications 23JUL01 Section 5: Specifications SM5766-1 Page 65 of 96 Electrical Supply, Modes 1000, 1500, 100, 115, 130, 220, 240 V, 50/60 HZ and 2000 Electrical Supply, Model 500 230 V, 50 HZ Power Consumption, All Models 400 W Dimensions •...
  • Page 66 SERVICE MANUAL Specifications 23JUL01 SM5766-1 Page Lumen Output • 900 minimum with EXR lamp 66 of 96 • Lowest corner to center ratio is 55% minimum • Test method • Ektagraphic • 102 mm, F/2.8 LENS aperture (24 x 36 mm), compatible with European specification DIN 19027 Operating temperature •...
  • Page 67 SERVICE MANUAL Specifications 23JUL01 SM5766-1 Page Safety • 3 GROUNDED POWER CORDS, 67 of 96 detachable • Heat sensitive interrupt fuses • 117 C ° LAMP THERMAL FUSE • 169 C ° MOTOR THERMAL FUSE • 150 C ° TRANSFORMER •...
  • Page 68 1500 hours of operation, or after 1 year. Warranty The projector has a warranty by Eastman Kodak Company to operate correctly for one year from the date of purchase. INT/EXT SWITCH Used for internal and external LAMP Model 2000 Only control.
  • Page 69 SERVICE MANUAL Specifications 23JUL01 SM5766-1 Page 6-PIN REMOTE CONTROL • PIN 1 - Connected to PIN 3 = 69 of 96 All Models Reverse • PIN 2 - Connected to PIN 3 - Forward • PIN 3 - 25.5 V AC when used with PIN 6 •...

  • Page 70: Diagnostics

    SERVICE MANUAL Diagnostics 23JUL01 Section 6: Diagnostics SM5766-1 Page 70 of 96 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...

  • Page 71: 12-Pin Applications Plug - Voltages, 2000 Projectors Only

    SERVICE MANUAL Diagnostics 23JUL01 MAIN MOTOR PIN - Voltages SM5766-1 Page 71 of 96 Voltage 50 V ac 25.5 V ac 10-11 14.5 V ac 11-12 14.5 V ac 10-12 29 V ac 12-PIN APPLICATIONS PLUG - Voltages, 2000 PROJECTORS Only 12-PIN APPLICATION PLUG A091_4021ACA A091_4021AA...
  • Page 72 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Color From Page orange J104 72 of 96 yellow J105 yellow J104 violet ZERO POSITION SWITCH violet ZERO POSITION SWITCH Voltages PINS Description Voltage A1 to B4 AC POWER SUPPLY 25.5 V ac, 500 mA A3 to A4 DISSOLVE CONTROL 25.5 V ac...

  • Page 73: Photocell - Voltages

    SERVICE MANUAL Diagnostics 23JUL01 PHOTOCELL - Voltages SM5766-1 Page 73 of 96 PHOTOCELL A091_4036ACA A091_4036AA Voltages PINS Voltage 14.5 V ac 14.5 V ac 29 V ac...

  • Page 74: 6-Pin Remote Plug - Voltages

    SERVICE MANUAL Diagnostics 23JUL01 6-PIN REMOTE PLUG - Voltages SM5766-1 Page 74 of 96 CABLE CONNECTOR GRAY FOCUS BLACK GREEN BLUE 2.7 K YELLOW 25.5 VOLTS AC A091_0001BA_ Voltages Description Reverse Forward Common - 25.5 V ac Focus - Forward Focus - Reverse RACK SOLENOID...
  • Page 75 SERVICE MANUAL Diagnostics 23JUL01 SMALL COMPONENT BOARD ASSEMBLY - Voltages, 1500 and SM5766-1 Page 2000 PROJECTORS 75 of 96 SLIDE PROJECTOR BOARD A091_4034DC...
  • Page 76 SERVICE MANUAL Diagnostics 23JUL01 Table 2 SMALL COMPONENT BOARD ASSEMBLY - Voltages, 1500 and SM5766-1 2000 PROJECTORS Page 76 of 96 Description Component Color - + TIMER Circuit Red (+) and Black 33.0 V dc TIMER Circuit Black, G (-) 33.0 V dc TIMER Circuit Red, A (+)
  • Page 77 SERVICE MANUAL Diagnostics 23JUL01 MAIN COMPONENT BOARD ASSEMBLY - Voltages, 1500 and SM5766-1 Page 2000 PROJECTORS 77 of 96 2000 BD. V101 CR16 CR15 CR17 CR14 CR13 CR12 S101 CR20 CR11 CR10 R 10 F101 A091_4039DA...
  • Page 78 SERVICE MANUAL Diagnostics 23JUL01 Table 3 MAIN COMPONENT BOARD ASSEMBLY - Voltages, 1500 and 2000 SM5766-1 PROJECTORS Page 78 of 96 Component Color Voltage J101 yellow 220 V ac J101 green 100 V ac J101 violet 117 V ac J101 130 V ac J101 white...

  • Page 79: Voltage Specifications - General Parts

    SERVICE MANUAL Diagnostics 23JUL01 Table 4 MAIN COMPONENT BOARD ASSEMBLY - Voltages, 1500 and SM5766-1 2000 PROJECTORS Page 79 of 96 FOCUS TRANSISTOR (EBC - EMITTER, BASE, COLLECTOR) TRANSISTOR Voltage E (+) B (-) 11.0 V dc (projector ON) E (+) B (-) 0.20 V dc (reverse focus)

  • Page 80: Power, Illumination, And Cooling Malfunctions

    SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Part Procedure Voltage Page LAMP RECEPTACLE ------ 82 V ac, approximately 80 of 96 85-86 V ac without a LAMP MODULE installed DROPPING RESISTOR Move to the LO LAMP 3.0 , 10.6 V ac drop position.
  • Page 81 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page There is excessive noise in the Check and remove obstructions 81 of 96 FAN. in the FAN area. Check that the tension is correct on the FAN BELT. Check that the FAN BELT is clean.
  • Page 82 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page The LAMP ASSEMBLY does not Check the LAMP ASSEMBLY for 82 of 96 operate. damage. Check the LAMP RECEPTACLE ASSEMBLY for damage. Manually actuate the INTERLOCK SWITCH, then check that the voltage is correct across the LAMP RECEPTACLE ASSEMBLY.
  • Page 83 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page The LO LAMP does not operate. Check that the W of the 83 of 96 DROPPING RESISTOR is 3 W. Check that the wire connections on the POWER SWITCH are correct. Check the POWER SWITCH for correct operation.

  • Page 84: Slide Transport Malfunctions

    SERVICE MANUAL Diagnostics 23JUL01 Slide Transport Malfunctions SM5766-1 Page 84 of 96 Malfunction Solution Forward and reverse do not operate Check that the secondary voltage using the FRONT PANEL BUTTONS on the MAIN MOTOR is correct. or REMOTE CONTROL. Check that the voltage across the CYCLE SOLENOID is correct.
  • Page 85 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page Projector does not complete a cycle; Check for a broken MECHANISM 85 of 96 FAN operates. DRIVE BELT. Check the CYCLE LEVER and RATCHET LEVER on the CAM SHAFT ASSEMBLY for the following: •...
  • Page 86 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page Projector has continual cycle. Check the CYCLE LEVER for 86 of 96 correct alignment. See the adjustment for the CYCLE LEVER. Check for damage to parts. Check for a short•circuit in the wires: •...
  • Page 87 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page SLIDE TRAY does not advance Check the SLIDE TRAY LATCH 87 of 96 smoothly. for correct alignment. Operate the projector in the forward direction. • Check that the INDEXER LEVER ASSEMBLY is in the correct alignment with the holes at positions A and B.
  • Page 88 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page SLIDE TRAY does not rotate freely Press and release the SELECT 88 of 96 when the SELECT BUTTON is BUTTON. pressed down. The projector has • Check that the LOCATOR power. LEVER moves correctly and is not bent.
  • Page 89 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page DARK SHUTTER SWITCH (Model Energize the projector and 89 of 96 2000 Only) does not operate release the DARK SHUTTER to allow projection. Check for continuity between PINS A6 and B1 on the 12-PIN DISSOLVE PLUG.
  • Page 90 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page ZERO POSITION SWITCH (Model De-energize the projector. 90 of 96 2000 only) does not operate Check for continuity between PIN B5 and B6 on the 12-PIN DISSOLVE PLUG. Install a SLIDE TRAY. Rotate the SLIDE TRAY to engage the ZERO POSITION SWITCH, the DVM should...

  • Page 91: Focus Malfunctions

    SERVICE MANUAL Diagnostics 23JUL01 Focus Malfunctions SM5766-1 Page 91 of 96 Malfunction Solution No manual focus Check the FOCUS SHAFT SPRING for the correct tension. Check the LENS SUPPORT SPRING for correct tension. Check the LENS DRIVE GEAR on the FOCUS SHAFT ASSEMBLY for damage and install a new part if necessary.
  • Page 92 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page No remote focus (Modes 1500 and Check that the REMOTE CORD 92 of 96 2000, RACK SOLENOID ASSEMBLY operates correctly; use a operates) REMOTE CORD you know is good. Actuate and hold the REMOTE CONTROL.
  • Page 93 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page No auto-focus (Models 1500 and Check that the AUTO-FOCUS 93 of 96 2000 Only) DEFEAT SWITCH is in the “ON” position. Check that the MAIN PROJECTION LAMP operates correctly. Insert the TARGET SLIDE TL- 3002 in the GATE MECHANISM.
  • Page 94 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page Slow auto-focus movement (Models Check that the alignment of the 94 of 96 1500 and 2000 only) FOCUS LIGHT PATH and NULL is correct. Check the resolution of the FOCUS LIGHT PATH. Clean the AUTO FOCUS MIRROR and BRACKET ASSEMBLY.
  • Page 95 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Malfunction Solution Page AUTO FOCUS MOTOR operates Install the TARGET SLIDE TL- 95 of 96 continually (Models 1500 and 2000 3002 in the GATE MECHANISM. Only) Check that the alignment of the TARGET and NULL is correct. If not, see the Adjustments section.
  • Page 96 SERVICE MANUAL Diagnostics 23JUL01 SM5766-1 Page 96 of 96 Kodak and Ektalite are trademarks. Printed in U.S.A. • sm5766_1.fm EASTMAN KODAK COMPANY Rochester, NY 14650...

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