EASTMAN Kodak X-Omat 180 LP User manual

HEALTH SCIENCES DIVISION
© Eastman Kodak Company
Publication No. 1C7833
July 1995
SERVICE MANUAL
for the
Kodak X-Omat 180 LP SORTER KIT
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. You may, therefore, want to save the installation section.

2July 1995 – 1C7833
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 of this information, even if loss or damage is caused by Kodak’s negligence or other fault.
This equipment includes parts and assemblies sensitive to damage from electrostatic
discharge. Use caution to prevent damage during all service procedures.

1C7833 – July 1995 –3
Description Page
Table of Contents
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Checking the Packing List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Before Starting the Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Removing the TOP COVER and the HINGE PLATES
from the PROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Installing the New HINGE PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Installing the SORTER on the PROCESSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Installing the ENCODER WHEEL/SPROCKET and Adjusting the Height of the
DRIVE SHAFT on the PROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Installing the New COVER on the ELECTRICAL BOX. . . . . . . . . . . . . . . . . . . . . . 1-15
Installing the New ELECTRICAL BOX HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Placing the New ELECTRICAL BOX HARNESS in Position . . . . . . . . . . . . . 1-17
Connecting the New ELECTRICAL BOX HARNESS to J10 and TB5 . . . . . . 1-18
Connecting the New ELECTRICAL BOX HARNESS to the 500 BOARD . . . 1-20
Modifications to the 500 BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Installing the SORTER HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Installing the COVER EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Installing the New SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Installing the FILM TRAY and the TOP COVER of the SORTER . . . . . . . . . . . . . . 1-32
Adjusting the Temperature of the DRYER in the PROCESSOR . . . . . . . . . . . . . . . . 1-32
Final Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Checking the SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Checking the BIN SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Checking the DIVERTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Installing the PANELS and Checking for Correct Operation of the SORTER . 1-36
Adjustments and Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Service Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Position and Identification of Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
De-energizing and Energizing the PROCESSOR . . . . . . . . . . . . . . . . . . . . . . . 2-5
General Access to the SORTER or to the PROCESSOR . . . . . . . . . . . . . . . . . 2-6
Installing the TOP COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Replacement of the DIVERTERS or the BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Replacement of a SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Replacement of the INTERLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Replacement of a MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Replacement of the SENSOR on a MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Replacement of the ROLLERS
on a LEAD or MAIN MODULE or on the ACCESS DOOR. . . . . . . . . . . . . . . . . 2-14
Replacement of the IDLER ROLLERS and SPRINGS on a MODULE . . . . . . . . . . 2-16
Replacement of the BIN ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Replacement of the Front BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Replacement of the GEAR or the Back BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Replacement and Adjustment of the DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Replacement of the DRIVE MOTOR or the GEARBOX. . . . . . . . . . . . . . . . . . . . . . 2-20
Replacement of the MAIN DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Replacement of the WORM GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Replacement of the GAS SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Replacement of the 4000 BOARD or MOTOR CONTROLLER BOARD . . . . . . . . 2-24
Replacement of the 100 BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Replacement of the IDLER GEARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

SERVICE MANUAL
–4 July1995 – 1C7833
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Operation of the BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Control of the DIVERTER SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Operation of the BIN SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Operation of the INTERLOCK BOARD for the TOP COVER. . . . . . . . . . . . . 3-8
Operation of the SORTER Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Explanation of Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Troubleshooting the BIN SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Troubleshooting the DIVERTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Component Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Numerical Parts Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Alphabetical Parts Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Publication History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Installation
1C7833 – July 1995 1–1
Section 1: Installation
Description Page
Table of Contents
Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Checking the Packing List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Before Starting the Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Removing the TOP COVER and the HINGE PLATES
from the PROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Installing the New HINGE PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Installing the SORTER on the PROCESSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Installing the ENCODER WHEEL/SPROCKET and Adjusting the Height of the
DRIVE SHAFT on the PROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Installing the New COVER on the ELECTRICAL BOX. . . . . . . . . . . . . . . . . . . . . . 1-17
Installing the New ELECTRICAL BOX HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Placing the New ELECTRICAL BOX HARNESS in Position . . . . . . . . . . . . . 1-19
Connecting the New ELECTRICAL BOX HARNESS to J10 and TB5 . . . . . . 1-20
Connecting the New ELECTRICAL BOX HARNESS to the 500 BOARD . . . 1-22
Modifications to the 500 BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Installing the SORTER HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Installing the COVER EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Installing the New SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Installing the FILM TRAY and the TOP COVER of the SORTER . . . . . . . . . . . . . . 1-34
Adjusting the Temperature of the DRYER in the PROCESSOR . . . . . . . . . . . . . . . . 1-34
Final Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Checking the SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Checking the BIN SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
Checking the DIVERTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Installing the PANELS and Checking for Correct Operation of the SORTER . 1-38
Special Tools Required
-- PORTABLE COMPUTER, IBM compatible with MS-DOS version 3.0 or
higher on the hard drive, 720 KB 31⁄2in. disk drive, and a serial port
configured as COM1.
5B6278 DIAGNOSTICS DISKETTE
TL-4390 SCALE
TL-4391 INTERFACE CABLE
TL-4430 PROM EXTRACTION TOOL
TL-4598 PIN EXTRACTION TOOL

SERVICE MANUAL
1–2 July 1995 – 1C7833
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.
Figure 1–1 Identifying the PANELS on the PROCESSOR
H127_0022DA
TOP COVER
MAIN
CIRCUIT
BREAKER
DRIVE SIDE
PANEL
FEED SIDE
PANEL
NON-DRIVE SIDE
PANEL
DRYER SIDE
PANEL
H127_0022DCC

Installation
1C7833 – July 1995 1–3
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.
[1] Determine the version of software by pressing:
(a) F4 while in the “CONTROL PRINTER” screen on the LASER PRINTER.
(b) F5 for “Show More Functions”.
(c) F2 for “Show Printer Info”.
(d) F2 for “Show Versions”.
The MCU version of the software on the LASER PRINTER and the version of the operating software on
the PROCESSOR will be displayed.
If the software on the LASER PRINTER is not 2.16 or higher, ask the CESD Field Engineer to install
Mod 21 on the 2180 LASER PRINTER.
Note
If necessary, use the PORTABLE COMPUTER and DIAGNOSTIC DISKETTE 5B6278 to determine the boot
software version on the PROCESSOR. See the instructions 699614, packed with the DIAGNOSTIC DISKETTE.
[2] If the PROCESSOR does not have 2.22 or higher operating software and 2.52 or higher boot. Follow Steps 3 -
15. Otherwise, proceed to Page 1–6.
Important
You may experience difficulty if you try to download the new software after the SORTER is installed. Install the
new boot PROM and download the new software first.
[3] De-energize the PROCESSOR.
[4] Remove the DRIVE SIDE PANEL from the PROCESSOR. See Figure 1–1 on Page 1–2.

SERVICE MANUAL
1–4 July 1995 – 1C7833
Figure 1–2 Installation of the BOOT PROM U20
[5] Rotate the CAPTIVE SCREW and release the COVER of the ELECTRICAL BOX.
Possible damage from electrostatic discharge.
ESD
Caution
To prevent damage during installation, correctly align the keyed corners of the BOOT PROM U20 and the SOCKET.
[6] Install the new BOOT PROM U20.
(a) Use the PROM EXTRACTION TOOL TL-4430 to remove the existing BOOT PROM U20.
(b) Place the new BOOT PROM U20 carefully on the SOCKET.
(c) Check that the keyed corners are aligned.
(d) Press U20 firmly into the SOCKET.
(e) Close the COVER of the ELECTRICAL BOX.
[7] Connect the INTERFACE CABLE TL-4391 to the ELECTRICAL BOX.
Figure 1–3 Connecting TL-4391 to the ELECTRICAL BOX
H127_2053BA
BOX
ELECTRICAL
COVER of the
CAPTIVE SCREW
TL-4430
keyed corner
of PROM
of SOCKET
keyed corner
U20
H127_2053BCA
H127_0077BA
H127_0077BCA
INTERFACE CABLE
ELECTRICAL BOX

Installation
1C7833 – July 1995 1–5
Figure 1–4 Connecting the INTERFACE CABLE
TL-4391 to the PORTABLE COMPUTER [8] Connect the INTERFACE CABLE TL-4391 to
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.
[12] At C:> type A: and press [ Enter ] .
[13] At A:> type DOWNLOAD and press [ Enter ] .
[14] Follow the instructions on the screen of the
PORTABLE COMPUTER.
[15] Wait approximately 3 minutes until loading is
complete.
H108_0205AA
INTERFACE
CABLE
H108_0205ACA

SERVICE MANUAL
1–6 July 1995 – 1C7833
Removing the TOP COVER and the HINGE PLATES
from the PROCESSOR
Figure 1–5 Removal of the TOP COVER
[1] De-energize the PROCESSOR:
(a) Move the MAIN CIRCUIT BREAKER on the front of the PROCESSOR to the “O” position.
(b) Move the wall CIRCUIT BREAKER to the “OFF” position.
[2] Lift the TOP COVER of the PROCESSOR.
[3] Remove from the PROCESSOR: See Figure 1–1 on Page 1–2.
• the front, DRIVE SIDE PANEL
• the back, NON-DRIVE SIDE PANEL
• the left, DRYER SIDE PANEL
[4] Disconnect CONNECTOR P/J25 on the back of the PROCESSOR.
[5] Close the TOP COVER.
[6] Remove:
• 4 SCREWS from the existing front HINGE PLATE, and save the SCREWS
• 4 SCREWS from the existing back HINGE PLATE, and save the SCREWS
• TOP COVER from the PROCESSOR
Note
The TOP COVER and the HINGE PLATES of the PROCESSOR will not be used with the SORTER installed.
[7] Disconnect CONNECTOR P/J33. See Figure 1–5.
[8] Remove and save the 2 SCREWS and CONNECTOR P/J33 from the BRACKET.
[9] Cut the STRAIN RELIEF, and remove it from the wire.
H127_2015HA
RELIEF
STRAIN
H127_2015HCA
P/J33
front
2 SCREWS
2 SCREWS
HINGE PLATE
back
of processor
non-drive side
CONNECTOR
4 SCREWS
of processor
drive side
RACK
EXIT
BRACKET
CONNECTOR
4 SCREWS
HINGE PLATE
TOP COVER
P/J25
CONNECTOR
P/J33