Kodak Miniloader 1 User manual

I!!!!
Publication number SM 3211/3212
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,.: .,.,.,. .: .,./ :.:.. .,
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SERVICE MANUAL
SM 321113212
KODAK LIMITED
September 1990

CONTENTS
Preventative maintenance procedures
Technical feedback codes
Adjustments
Cassette pick-up suckers
Vacuum and cassette opener mechanism
Supply magazine separation
Separation ratchet and magazine suckers
Supply magazine sucker adjustment
Photocells and photocell amplifiers
Photocells FC1 &FC2
Photocell FC3
Photocell FC4
Photocell FC5
Photocell FC6 & FC7
Photocell FC7 & FC8
Removals
Fuses
Switches
Microswitches
Photocells
Photocells and Timers-
Timers-adjustment (Serial Number 1101 to 1161)
Timers-adjustment (Serial Number 1162 to 1216)
Photocells-adjustment (Serial Number 1127 and up)
PCB’s -Serial number 1101 to 1161
List of PCB’s fitted
PCB 101
PCB 102
PCB 103
PCB 1038
PCB 104
PCB 105
PCB 106
PCB107
PCB 108
SM4
Slid 5-7
SM &25
SM 8-10
SM 11-12
SM 13-15
SM 16
SM 17-18
SM 19-25
SM 20
SM 21
SM 22
SM 23
SM 24
SM 25
SM 26-28
SM 29-30
SM 31
SM 32
SM33
SM 34-38
SM 34-35
SM 36-37
SM 38
SM 39-59
SM 41
SM 42-43
SM 44-45
SM 46-47
SM 48-49
SM 50-51
SM 52-53
SM 54-55
SM 56
SM 57
Miniloader Service Manual - contents
SM2 9-l-90

CONTENTS
I
__
PCB’s -Serial number 1162 to 1217 SM 58-79
PCB 101A SM
58-59
PCB 102A
SM 60-61
PCB 103A
SM 62-63
PCB 104A
SM 64-65
PCB 105A SM 66-67
PCB 1058
SM 68-69
PCB 106A SM 70
PCB 106B SM 71
PCB107A
SM 72
PCB 108A
SM 73-75
Solenoid valve settings SM 76
Air nozzles system SM77
Cassette patching SM 78-80
Fault-finding charts
SM 81-86
Miniloader Service Manual - contents
SM3
9-l -90

Miniloader Service Manual Publication Number SM 321
l/321 2
PREVENTATIVE MAINTENANCE PROCEDURE FOR MINILOADER 1
REMINDER- Remember that all labour for fitting parts and carrying out repairs etc. is NOT part of the
PREVENTATIVE MAINTENANCE visit and must be fed back as separate tasks, irrespective of the
Contract held by the customer.
1)
2)
3)
4)
5)
6)
7)
3)
9)
Discuss recent performance of the MINILOADER with the customer, check recently processed
FILMS for artifacts and examine recent entries in the equipment LOG BOOK. Check modification
status.
Withdraw the MAGAZINE/S. Remove the TOP COVER and both SIDE PANELS from the
MINILOADER. Fit a new AIR FILTER element. Using a BRUSH and a VACUUM CLEANER,
remove all dust and debris from inside the MINILOADER. Polish the TUNNEL on PROCESSOR
INTERFACE versions.
_
Check the condition of all HOSES and SUCKERS and replace if damaged. Check the VACUUM to
the SUCKERS ( 150 - 200 millibars ). Check the COMPRESSOR reaches a minimum pressure of
2.5 bar. Take necessary action to correct.
Check CHAIN tensions, and adjust and lubricate as necessary.
Check condition and tension of CONVEYOR BELT and clean or adjust if necessary.
Check PHOTOCELL REFLECTORS for security and cleanliness.
Check CASSETTE REFLECTOR patches and replace if necessary.
Lubricate the TILT PIVOTS every visit. Annually lubricate PUSH ROD ends and other moving parts.
Check general security of PUSH RODS and MOTORS etc. Check the PRINTED CIRCUIT
BOARDS are correctly installed.
10) Load the SUPPLY MAGAZINE with TEST FILM and run some test cycles paying particular
attention to FILM SEPARATION, TILT action, correct positioning of new FILM in the CASSETTE,
CASSETTE INJECTOR action and correct release of FILM into RECEIVING MAGAZINE on
STAND ALONE versions. Check MAGAZINE NEARLY EMPTY signal and MAGAZINE EMPTY
signal. Adjust as necessary.
11) Note reading on cycle COUNTER. Remove TEST FILM, replace all COVERS and if possible
process some film to check for artifacts. Fill in the equipment LOG BOOK.
Miniloader Service Manual
SM 3211/3212 Version 1
SM4
9-l-90

Miniloader Service Manual Publication Number SM 321
l/321 2
TECHNICAL FEEDBACK SPECIAL PURPOSE CODES.
KODAK MINILOADER 1 STAND ALONE
SERVICE CODE 3211
KODAK MINILOADER 1 PROCESSOR INTERFACE SERVICE CODE 3212
CASSETTE did not open
FILM not removed from CASSETTE
FILM jammed in TUNNEL /RECEIVING
MAGAZINE
CASSETTE failed to eject
Multiple FILM bad
New FILM not picked up
MAGAZINE blocked by FILM
CAM SYSTEM malfunction
Loss of pressure /vacuum
Cycle time incorrect
221
Scratches on FILM
222 Static marks on FILM
223 Lines on FILM
225 Light leak marks on FILM
226 Pressure marks on FILM
227
MAGAZINE repair
226 CASSETTE preparation and repair
229 FILM not entering CASSETTE correctly
230 Unable to power up.
231
Unable to enter CASSETTE
232 SERIAL MODE malfunctions
For Kodak Personnel use only
CESD AUGUST 1990
Page1 of6
TECHNICAL FEEDBACK REMEDY CODES.
KODAK MINILOADER 1 STAND ALONE
SERVICE CODE 3211
KODAK MINILOADER 1 PROCESSOR INTERFACE SERVICE CODE 3212
1
2
3
4
5
6
7
6
9
A
R
S
Adjust I Align I Setup
Clean
Instruct Operator /Customer
Lubricate
Reinstall /Repair
Replace /Send out for repair
Reset / Reprogram
Rewire /Resolder / Rebond /Crimp
No remedy required / Product problem
Unable to duplicate problem
Reseat / retighten
Recommend site improvements
I
For Kodak Personnel use only
CESD AUGUST 1990
Page2oft
SM 321113212 Version 1
Miniloader Service Manual
SM5 9-l-90

Miniloader Service Manual Publication Number SM
3211/3212
MS1
MS2
MS3
MS4
MS5
MS6
MS7
MS8
MS9
TECHNICAL FEEDBACK SUBSYSTEM CODES.
KODAK MINILOADER 1 STAND ALONE
SERVICE CODE 3211
I
KODAK MINILOADER 1 PROCESSOR INTERFACE SERVICE CODE 3212
MICROSWITCHES SWITCHES MOTORS.
CAM home MS10 INTERLOCK CBl Main CIRCUIT
Ml
COMPRESSOR MOTOR
CAM position MS11
INTERLOCK
BREAKER
M2 CASSETTE vacuum
CAM p&ion
MS12 INTERLOCK S16 JOG SWITCH PUMP
CAM position
MS13 TILT s17
CAM position
MS14 TILT
S18
CAM position MS15 TILT s19
CAM position MS16
CAM p&lion
MS17
CAM position Ey
CAM position
INTERLOCK
S22
S23
S24
s25
S26
S27
UNLOAD only
M3
MAGAZINE vawum
SERIAL MODE start
PUMP
SERl& MODE intIXU@
M4 FAN MOTOR
Reset CAMS
M5 TILT MOTOR
CASSETTE eject
Cyde lime
M6 CASSETTE CONVEYOR
TlMER T9 inhibit MOTOR
KN SWlTCH
(HTERLOCK inhibit)
Top COVER INTERLOCK
Front DOOR NTERLOCK
Rear DOOR INTERLOCK
L
I
‘or Kodak Personnel use only
CESD AUGUST 1990
Page 3 of i
FCl
FC2
FC3
FC4
FC5
FC6
FC7
FC8
TECHNICAL FEEDBACK SUBSYSTEhI CODES.
I
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1
3. :
KODAK MINILOADER 1 STAND ALONE
KODAK MINILOADER 1 PROCESSOR INTERFACE
SERVICE CODE 3211
SERVICE CODE 3212
PHOTOCELLS
SOLENOID VALVES
CASSElTE at endstop / FILM in SVl
CASSEITE INJECTOR
CASSEllE
sv2 MAGAZINE INJECTOR
CASSEITE entered sv3
CASSE’ITE (unload)
CASSETTE opened
vacuum
FILM stuck on screen
sv4 MAGAZINE (bad) vacuum
MAGAZINE nearly empty sv5
COMPRESSOR
MAGAZINE empty
FILM jammed in tunnel /MAGAZINE
full
Multiple FILM load
Fl
F2
F3
F4
F5
F6
F7
F8
F9
FUSES.
COMPRESSOR
CASSETTE vacuum
MAGAZINE vacuum
FAN
TILT MOTOR
CUNVNOR MOTOR
CAM MOTOR
TRANSFORMER primary
TRANSFORMER secondary
stabilii
‘r
DC 12 VOLT stabilised
DC 12 VOLT MOTORS
FlO
Fll
For Kodak Personnel use only
CESD AUGUST 1990 Page 4 of 6 ~~
SM 3211/3212 Version 1
Miniloader Service Manual
SM6
9-I -90

Miniloader Service Manual Publication Number SM 3211/3212
Al
A2
A3
A4
A6
A6
A7
A8
TECHNICAL FEEDBACK SUBSYSTEh4 CODES.
KODAK MINILOADER 1 STAND ALONE SERVICE CODE 3211
KODAK MINILOADER 1 PROCESSOR INTERFACE SERVICE CODE 3212
PRINTED CIRCUIT BOARDS
PCB 101 / 101A
PCB 102 / 102A
PCB 103/103A/103B
PCB lO41104A
PCB 105 / 105AllOSB
PCB 106/106A/ 106B
PCB 107 / 107A
PcB 108 1 10aA
221
222
223
225
226
227
228
22A
228
22c
22D
22F
22G
22H
MECHANICAL
FRAME
MAGAZINE CARRIER
MAGAZINE opening mechanism
CASSElTE transport
CASSEl-l-E CENTERING
CASSElTE OPENER mechanism
CASSElTE unload mechanism
TUNNEL
DOORS
COMPRESSOR SYSTEM
VACUUM SYSTEM
CASSETTE
FILM SEPERATION
PUSHROD
:orKodakPmonnduseody CESD AUGUST 1990
Page 5 of 6
TECHNICAL FEEDBACK COMPONENT CODES.
KODAK MINILOADER 1 STAND ALONE SERVICE CODE 3211
KODAK MINILOADER 1 PROCESSOR INTERFACE SERVICE CODE
3212
51
49
50
319
55
46
29
75
43
55
ELECTRtCAL
BUZER
tz&Tm
ctRaJrrBmRD
CIRCUIT BREAWI
CONNECTOR
COUNTER
DmE
FAN
FUSE
s
POTENTIOMETER
U
PowEASuPPLY
75 RECTFIEFI
U
REGULATOR
45 RELAY
59
RESISTDR
45
SDLENOID
41 SW!TcH
56 TRANSFORMER
49
WIRE
MECHANICAL I PNEUMATIC.
24
AR REGULATOR
59 ARM
5
BEARING
12
BELT
21
BRACKET
a
CAM/CAM FOLLOWER
32 CASSETTE
91
CATCH / LATCH
12
CHAIN
31
CLAMP
11
aurai
66
67
20
16
66
7
GASKET I SEAL
GAUGE
GEARISPROXfT
/PULLEY
GUIDE
LIGHT LOCK
PNEUMATC
FITTING
PEFLtCTOR I
MIRROR
ROLLER
OTHER ELECTRKX
6
COLIAR I COUPLER 28
SHAFT
39 CONNECTING ROD
9d
SPACER
33
COVER/PANEL/
26
SPRING
COOR 36 SUCKER
31
FASTENER 37 OTHER MECHANICAL
/
25
FILTER PNEUMATC
21
FRAME
_-n
43
46
INTEGRATED
CIRCLJIT
MOTOR
PHOTOCELL
79
For Kodak Personnel use only CESD NOVEMBER
1990
Page 6 of 6
SM 321113212 Version 2
Miniloader Service Manual
SM7
11-l-90

Miniloader Service Manual
Publication Number SM 321113212
ADJUSTMENTS -
ADJUSTING UNLOAD (CASSETTE PICK-UP) SUCKERS.
SERIAL NUMBERS BELOW 1162
These MINILOADERS are fitted with solid unload SUCKERS (part number 30012181). There should also
be a SPACER (part number 30012238) fitted above the SUCKER at the free end of the SUCKER BAR,
figure 1A. The later collapsible SUCKERS should not be fitted unless the spigots on the SUCKER BAR
are shortened. Also, without the STOP SCREW no advantage is gained from the collapsible SUCKERS.
1 To begin the adjustment, position the PUSH ROD END in the centre of the slot in the CAM FOLLOWER,
(figure 1 C).
2 Using the JOG SWITCH (S16 on PCB 106/A/B) jog the CAM MOTOR until the CASSETTE SUCKERS
-
are at their lowest point. Adjust the angle of the SUCKER BAR by loosening the two GRUB SCREWS
and set the SUCKERS parallel to the BELT. After the PUSH ROD length (Figure C) so the SUCKERS
just touch the BELT.
3 Using TEST FILM enter a loaded CASSElTE. Observe the release point of the unloaded FILM. On
PROCESSOR INTERFACE versions this is not criiical, but on STAND ALONE versions the leading edge
of the FILM should just touch the rear edge of the RECEIVING MAGAZINE. If the FILM lands short or
stubs on the MAGAZINE alter the position of the PUSH ROD END in the SLOT in the CAM
FOLLOWER.
4 Repeat steps 2 and 3 until the settings are correct.
Spacer 30012238 d
_ ~xj==&;W;; 30012181
Conveyor
Figure 1 A
SM 321113212 Version 1
Miniloader Service
SM8
Manual
9-l-90

Miniloader Service Manual Publication Number SM
3211/3212
ADJUSTING UNLOAD (CASSEmE PICK-UP) SUCKERS.
SERIAL NUMBERS ABOVE 1162
These MINILOADERS are fitted with collapsible unload SUCKERS (part no.30012299). There should also
be a SPACER (part number 30012238) fitted above the SUCKER at the free end of the SUCKER BAR,
figure 1B.
To commence the adjustment, position the PUSH ROD END in the centre of the slot in the CAM
FOLLOWER, (figure 1 C).
Using the JOG SWITCH (SlS on PCB 106/kVB) jog the CAM MOTOR until the CASSETTE SUCKERS
are at their lowest point. Screw in the STOP SCREW (see figure 1 B) so it is clear of its REST. Adjust the
angle of the SUCKER BAR by loosening the two GRUB SCREWS and set the SUCKERS parallel to the
BELT Alter the PUSH ROD length so the SUCKERS just touch the BELT.
Fii the STEP BY STEP SWITCH (see page SM 70). Using TEST FILM enter a loaded CASSETTE.
Observe the release point of the unloaded FILM. On PROCESSOR INTERFACE versions this is not
critical, but on STAND ALONE versions the leading edge of the FILM should just touch the rear edge of
the RECEIVING MAGAZINE. If the FILM lands short or stubs on the MAGAZINE alter the position of the
PUSH ROD END in the SLOT in the CAM FOLLOWER.
4) Repeat steps 2 and 3 until the settings are correct.
5) Enter a loaded CASSETTE and stop the MINILOADER when the SUCKERS are at their lowest point.
Adjust the STOP SCREW so the SUCKERS press on the FILM and collapse by 1 mm.
Spacer 30012238
Cassette -b
Stop screw
Rest
Conveyor
Figure 1 B
SM 3211/3212 Version 1
Miniloader Service Manual
SM9
9-I-90

I
Miniloader Service Manual 1
Publication Number SM 3211/3212
ADJUSTING UNLOAD (CASSETTE PICK-UP) SUCKERS.
Push
Cam
Unload sucker bar
Push rod
(adjust length using the
. Push rod ends
Sudters
Rgure 1C
Miniloader Service Manual
SM 10
9-l-90
SM 321113212 Version 1