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