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1. NOTE DRIVE MOTOR MUST REMOVED SO WEIGHT CAN SWING FREE Figure Adjusting Fit of Shuttle Arms to Pull Down Cam 23 SERVICE INSTRUCT IONS NOTE If adjustment of framer knob does not per mit movement of pointer G as specified it may be necessary to rotate the camshaft slightly to bring cam into proper position 3 Carefully tighten upper bearing support sembly F while observing alignment of pointer G with witness mark H The in stant that pointer G starts to move upward stop turning support assembly F This is the proper adjustment CAUTION Do not tighten shuttle arms more than is specified in an attempt to remove cam noise Exces Sive tightening of shuttle arms for the purpose of re ducing other noises will reduce life of cam and cam shoes d Checking Shuttle Stroke Normal shuttle stroke vertical travel of shuttle teeth is 0 3025 inches Fig ure F The most convenient means of measuring the stroke is to usethe projector as an optical comparitor The step on the stroke gage item 6 Figure A is the length of the nominal stroke When itis inserted in the aperture and projected itprovides a reference dimen sion with which the actual stroke can be compared A sketch of a target is shown in Figure J The A to B section is a 100 to 1 enlargement of the gage The C and D lines represent 100 to 1 enlargements of the limits of tolerance STROKE GAGE TOP TOOTH OF SHUTTLE we
2. a _ PLATE TOOTH AT BOT TOM OF STROKE an gt cea 5 rm e 1 Procedure for Measuring Shuttle Stroke see Figure J a Remove pressure plate assembly from the lens carrier b Set the framer knob at the mid point of its over all travel c Suspend the target approximately 18 feet from the projector with center of target on same horizontal line as op tical axis of projector If room ar rangement necessitates tilting projector target must also be tilted so that angle between target and optical axisis 90 de grees If this is not done Keystone error will be produced d Open the lens carrier and turn the pro jector mechanism by hand until shuttle is at bottom of stroke and shutter just clears aperture e insert stroke gage 550 5 N2 in the aperture plate and lightly press it down against the top tooth of the claw Close the lens carrier TARGET AS SEEN FROM PROJECTOR STROKE LIMITS ee am a LIMITS OF GAGE IMAGE TOOTH AT TOP oF STROKE ADJUST THROW SO THAT IMAGE OF GAGE EXACTLY MATCHES GAGE LIMIT MARKS Figure J Checking and Adjusting Shuttle Stroke with Target 24 f Turn on the projector lamp and focus the image of the shuttle slot on the tar get Move projecto
3. l Insufficient clearance between sound 1 Readjust all guides per para head threading guides 4 and 5 Fig graph 44 ure R Soundhead loose or improperly 2 Reposition per paragraph positioned 41 step 5 Obstruction or burr in lower take up Jj Remove obstruction remove sprocket guard burr with crocus cloth Film guide 4 Figure 9 improperly 4 Reposition guide positioned _ nr IY Obstruction or burr in lower take up 1 Remove obstruction remove Film sticks in or is ejected from lower take up sprocket guard G3 Autothread lever 11 Figure 11 9 sprocket guard burr with crocus cloth Sprocket guard sticking 2 Clean sprocket guard pivot Broken sprocket guard spring 3 Replace spring 30 Figure 10 Sprocket guard and sprocket mis 4 Realign aligned laterally Reposition or straighten bent or improperly positioned lever Film piles up ahead of idler roller 11C Figure 11 or is ejected from this area l 2 Autothread lever 11 Figure 11 bent or improperly positioned 1 Reposition or straighten lever Idler roller sticking or roller stud loose or bent 2 Remedy sticking condition replace autothread lever 11 Figure 11 41 SERVICE INSTRUCTIONS TROUBLE PROBABLE CAUSE REMEDY System will not lock 1 Autothread lever 11F Figure 11 1 Repair or replace lever binding
4. NOTE Items 3 1 through 3 11 are not applicable to Model 1585CX 1592CX and 1592CSX projectors Transformer Assembly P N 077631 item 3 14 is used and is secured the projector base with four hex head screws P N 30815 item 1 13 Replacement transformers are pre wired and ready for installation Items 3 24 Strain Relief and 3 25 Line Cord Assembly The Models 1585CX 1592CX 1592 5 do not require the strain relief item 3 24 since they are provided with a separate line cord P N 710318 which plugs into a receptacle that is mounted to the cord wrap and socket assembly see Figure A of this Supplement Item 3 27 Motor Pulley All motor pulleys are color coded and if badly worn or damaged must be replaced with a pulley of the same color as that on the projector being repaired Pulleys used on Models 1585CX 1592 and 1592 5 can be ordered under P N 709524 709549 or 709550 Item 3 29 Motor Clamp Bracket Assembly For Models 1585CX 1592CX and 1592CSX use Bracket Assembly P N 016947 Item 3 29A Fuse and Sleeve Assembly For Mod els 1585CX 1592CX and 1592CSX use Fuse and Sleeve Assembly P N 077632 Item 3 31 Motor Assembly 50 60 Hz For els 1585CX 1592 and 1592CSX use Motor Assembly P N 016495 preferred or 709107 Replacement motors are pre wired and ready for installation Item 3 32 Main Fuse For Models 1585CX 1592CX and 1592CSX use 4 amp 250 volt Slo Blo fuse P N 117172
5. 15A and washers 15B and disassemble the rollers 15 and 15D from the stabilizer arm roller shafts The removal of screws 15E will free the torsion spring 15G and stabilizer arms 15 15H and 15d e Remove two screws 16 and disassemble the lamp contact assembly 17 and lamp release ring 18 from the soundhead casting f Loosen the setscrew 19 which bears against the light pipe and photocell retainer 22 Then re move the two screws 20 and carefully withdraw the sound drum assembly 21 retainer 22 and photocell assembly 23 as a group from the sound head casting Wrap the sound drum and photocell in tissue paper to protect them from damage Do not remove the edge guide screw 24 g To remove the stabilizer tension adjuster remove the retaining ring 25 from the adjuster 27 and unscrew the adjuster from the tapped hole in the spring retainer 28 Be careful not to lose the friction washer 26 located at the lower end of the adjuster 11 DISASSEMBLING THE MECHANISM Figure 10 Remove parts as necessary in their indexed order of disassembly noting the following special pre cautions a To remove the lens carrier assembly 5 pry out the hinge pins 1 and 2 with a wire cutter or similar tool and lift the lens carrier from the me chanism Note that the spring washer 3 is used with the upper pin and the flat washer 4 with the lower pin To disassemble the lens carrier remove the
6. 2 Release spring 10 Figure 11 dis 2 Engage spring with locking engaged or broken lever or replace spring 3 Eccentric bushing 12 Figure 3 Readjust bushing per para improperly adjusted graph 44 step i Loop restorer cycles 1 Restorer out of adjustment 1 Adjust per paragraph 45 continuously 2 Shuttle retractor pin 29 Figure 12 2 Clean and lubricate pin sticking 3 Pressure plate 5B Figure 10 binding 3 Realign pressure plate on aperture plate edge guide Slack film in soundhead 1 Sprocket guards sticking 1 Clean sprocket shoe pivots area 2 Take up jerking 2 Check take up torque and check for binding in take up reel arm 3 Jockey rollers soundhead sticking 3 Clean and lubricate 4 Soundhead improperly positioned 4 Reposition per paragraph 41 step g 5 Dirt or obstruction between sound 5 Remove obstruction drum and exciter lamp cover Film scratches 1 Caked emulsion on film path parts 1 Clean film path 2 Film chips in sprocket guards 2 Remove film chips 3 Scratches or burrs on film guides 3 Polish with crocus cloth or guards aperture or pressure plate replace 4 Jockey rollers soundhead sticking 4 Clean and lubricate Perforations checked 1 Shuttle not retracting 1 Adjust per paragraph 44 step f 2 Pressure plate not lifting from 2 Adjust per paragraph 44 aperture plate step g 3 Excessive feed or take up tension 3 Adjust tension Film dimpled between 1 Sprocket shoe
7. 37 Assemble the gear rack 39 and worm gear 44 into the base holding the worm gear between the two formed ears of the base with all gear teeth worm gear gearshaft and tilt rack engaged Secure the worm gear with a new spring pin 43 Position the tilt ad apter 38 so that the gear rack does not bind in the rectangular cut out and tighten the screw 37 securely b Assemble the rubber feet 31 and flat washer 32 to the base with the four screws 30 ble the tilt bar 28 to the lower end of the gear rack 39 with the screw 26 and lock washer 27 The short leg of the tilt bar must be toward the front operating side of the base New rubber feet 29 are cemented to the tilt bar F LMOSOUND PROJECTORS MODELS 1585 1590 1592 c Assemble the voiume and tone control assem bly 25 into the base and secure with the four Screws 24 Check to make certain that the con trol knobs are not binding in the cut outs of the base before tightening the four screws Do not install the cover 23 until all wiring connections and adjustments have been made d Assemble the edge connector 18 to the amp liter 20 and position these components within the base The two spacers 21 are positioned between the amplifier and base at the end furthest from the tilt bar Loosely assemble the two amplifier screws 19 then install the two edge connector screws 17 and tighten all screws securely Do not install the co
8. 9 Bo o OO PB 3 Adjusting the Animation Clutch 1592 Models Adjusting the Fire Shutter 1592 Models Adjusting the Reel Arms and Rewind Clutch Adjusting the Soundhead Projector Speed Checks w lt a C D pg B B 5 84 e e 9 gt a q Co y Auto Load System Adjustments General Adjusting the Loading Guides EE EEN Checking and Adjusting Loop Restorer Timing the Sprockets ee Checking the Exciter Lamp Cover Gear Shift Tension Adjustment Idler Gear Backlash Adjustment TROUBLE SHOOTING w ee RECOMMENDED SPARE PARTS LIST FOR AUTOLOAD FILMosouND 16MM PROJECTOR MODEL 1592C REFERENCE SERVICE MANUAL NO 74404 MAY 1978 THE FOLLOWING IS A RECOMMENDED SPARE PARTS LIST FOR REPAIR OF 50 PROJECTORS C2 C E PART DESCRIPTION QTY PART NO DESCRIPTION 17639 Ring Retaining 12 44459 Belt Dive s soara e Je 21736 Ring Retaining 12 45682 Cover Rear arm 24047 Belt Take up 12 45692 Capacitor Start o4 30166 Screw Binding head 24 47431 La
9. 1585 1590 and 1592 Design speci fications are listed in the Feature Description List on the preceding page An illustrated Parts Catalog is included at the rear of the manual to identify replacement parts and to aid the serviceman in the disassembly and reassembly of the projector DESCRIPTION With the exception of the 1585ML and MLS all projectors covered in these instructions are versions of the basic projector models 1585C 1590C and 1592 The additional suffix letters are used to identify variations of the basic models as follows The suffix letter 5 signifies a basic or model equipped with a front cover and speaker assembly Parts Catalog Figure 15 rather than the standard front cover Parts Catalog Figure 1 item 1 The suffix letter H signifies a basic model wired for 50 60Hz operation rather than 60Hz only The Models 1585ML and MLS are militarized versions of the 1585CH and CHS and also are de signed for 50 60Hz operation Except for the above variations the CS CH CHS ML and MLS versions are identical with the basic models and almost all components are interchangeable The most notable physical differ ence in the 1585 models are the ML and MLS pro jectors the top covers of which are provided with two five amp Slo blo fuses Part number differ ences between models are indicated by the use of code letters in the Usable on Code column of the parts lists The coding system is e
10. 5F Install and tighten the two screws 54 d Slip the adjustment plate with pressure plate assembled into place within the lens carrier and loosely install the two screws 5G Insert the lens plug Figure A into the lens bore of the carrier with the rectangular boss of the plug fitted into the open ing in the pressure plate Tighten screws 5G curely and withdraw the lens plug e Clean the nameplate area of the lens carrier with a cloth dampened with solvent Remove the back ing from the nameplate 5J and activate the adhesive as instructed in paragraph 18 step c Assemble the nameplate to the lens carrier and wipe away excess adhesive with a soft cloth dampened with solvent 24 REASSEMBLING THE MECHANISM Figure 10 Reassemble Figure 10 parts as outlined in the follow ing paragraphs a Rotate and hold the lower loopform 13 Figure 11 fully counterclockwise and assemble the filter exit guide 32 Figure 10 to the mechanism housing with the screw 31 b Assemble the sprocket guards 27 and 28 rollers 29 and torsion springs 30 to the tapped mounting posts of the guard mounting plates The rollers must be assembled as shown in the inset of Figure 10 The inner bent end of each spring is inserted into small spring holes in the mounting plates adjacent to the tapped posts The outer bent end of each spring hooks over the outer edge of each sprocket guard 27 and 28 The springs should tend to rota
11. Clean film path components SERVICE INSTRUCTIONS 53 SOUND SYSTEM TROUBLES AND REMEDIES TROUBLE PROBABLE CAUSE REMEDY Projector runs no voltage 1 Loose connection 1 Repair connection at P C board 2 Amplifier switch damaged 2 Replace switch Projector runs voltage 1 Exciter lamp cable disconnected 1 Connect cable at P C board but ex citer lamp does not light 2 Wrong exciter lamp used 2 Replace with correct lamp 3 Projector main switch open or leads 3 Replace main switch or disconnected connect leads Voltage at P C board 1 Speaker jack disconnected or speaker 1 Connect leads Repair or exciter lamp lights but jack switch open replace jack no sound 2 Photocell cable disconnected or leads 2 Connect cable Connect leads reversed to proper terminals 3 Photocell out of line 3 Realign paragraph 41 step b 4 Dirt on end of photocell 4 Clean photocell 5 Wrong exciter lamp used 5 Replace with correct lamp Low volume 1 Trouble in printed circuit board 1 Check out the circuit board 2 Wrong exciter lamp used 2 Replace with correct lamp 3 Photocell out of line 3 Realign paragraph 41 step b 4 Dirt on photocell or slit 4 Clean photocell and slit 5 Slit misaligned 5 Realign paragraph 41 step e 6 Buzz track misaligned 6 Realign paragraph 41 step 1 Distortion at all volume 1 Wrong exciter lamp used 1 Replace with correct lamp levels 2 Trouble in printed
12. If one of the teeth cannot be brought into tolerance by the above method it may be necessary to loosen the screws which at tach the in out bracket Figure G and shift the bracket slightly Tighten the mounting Screws securely and check and adjust shut tle tooth height as outlined above c Checking Fit of Shuttle Arms to Pull Down Cam see Figure H Remove rear cover and the projection lamp NOTE If projector has just been lubricated run for two or three minutes before proceeding with this adjustment 1 Open film gate and turn projector mechan ism by hand until shuttle teeth are retrac ted and have moved downward to approxi mately the center ofthe stroke center tooth approximately on horizontal center line of aperture Slip the guide bars of tool 5 552 4 N1 over casting to which shuttle mounting plate is attached Figure H When tool A is positioned so that stud B can bear on shuttle arm C tighten thumbscrew D just enough to hold tool in position Engage hook of tool 552 4 N2 in the slot of stud B as shown and allow weight E to swing down ward Tilt projector if required so that the weight does not rub on any stationary parts 2 Loosen upper bearing support assembly F approximately one turn Rotate projector framer knob sothat pointer G moves above witness mark Then turn framer knob in the opposite direction until pointer G moves back down in line with mark H WE IGHT 5 552 4
13. Item 3 34 Animation Switch Not used on Models 1585CX 1592CX and 1592CSX Item 3 35 Rotary Switch and Bracket Assembly Not used on Models 1585CX 1592CX and 1592CSX see item 3 39 Item 3 39 Rotary Switch Assembly For Models 1585CX 1592CX and 1592CSX use Rotary Switch Assembly P N 077655 This switch is pre wired and ready for installation Items 3 40 through 3 47 These items notused on Mode1 1585CX 1592 and 1592 5 projectors NOTE Parts which peculiar only to the Models 1585CX 1592 1592 5 the amplifier fuses and fuse board mounted near the drive motor These parts are shown in Figure B of this Supplement PARTS CATALOG FIGURE 4 All uncoded and code parts apply to Model 1585CX all uncoded and code parts apply to Models 1592CX and 1592C Sx PARTS CATALOG FIGURE 5 Only items 5 22 through 5 29 apply to Model 1585CX all listed items apply to Models 1592CX and 1592C5X b 1590 Models Only These projectors equipped with only a power transformer 14 which is secured to the base with four screws 13 The mounting brackets 14C and 14D can be replaced by drilling out the rivets 14 However if the transformer itself is faulty replace the complete transformer and bracket assembly 14 c The drive motor and blower components must be removed as a unit to permit belt replacement or motor and blower repairs This is accomplished by removing the four mo
14. N If the kickplate does not release the arm of the hub assembly 13 is not striking the hood 9 Figure P properly The hood can be moved slightly and the hub assembly should be ad justed accordingly When the auto thread system is activated and the kickplate does not lock in position loosen the screw 12 Figure N holding the hub as sembly to locking pawl and adjust the hub assem bly until the tip of the bracket touches the upper curved surface of the loop former This will lock kickplate in position e Again depress the loop form assembly 4 Fig ure N and check to make certain that there is 0 012 to 0 015 inch clearance between the top surface of the lower loop form 4 Figure N and the bottom surface of the kickplate 8 Figure P To adjust remove the two screws which attach the hood 9 Loosen two setscrews 10 and rotate kickplate 8 to obtain de sired clearance Tighten setscrews and reinstall hood Before tightening hood retaining screws press hood toward rear of the projector TORSION SPRING LOCKING THREAD I NG LEVER Figure Threading Lever Clearance Adjustment 32 f With the auto load system locked and film gate open check to make certain that the shuttle teeth do not protrude through the slot in the aperture plate If shuttle teeth protrude loosen screw 6 Figure N and carefully raise the shuttle retractor 7 until teeth are retracted then tighten screw 6 securely CAUTION The top e
15. accomplished by removing the four motor mounting screws 15 and the four blower housing screws 16 If the drive belt 23 is in need of replacement it can be cut with a sharp knife If the belt is in good condition slip it edgewise down between the mechanism pulley and the casting Lift the assembled motor and blower from the base Remove three screws 17 and dis assemble the fan housing 19 from the housing cover 22 Loosen the setscrew 20 and disassemble the fan and hub assembly 21 and cover 22 from the motor shaft d Loosen the screws in the top ears of the motor clamps 28 and disassemble the clamps and mounting brackets 30 from the motor end bells Note the difference in motor clamp brackets 29 as used in earlier models and in the more current designs as well as the addition of the coil like thermal fuse 29A e 1592 Models Onlv Remove the twoscrews 33 and disassemble the animation switch and bracket assembly 34 and rotary switch and bracket assem blv 35 from the projector mainplate Disassemble as necessary for repair or parts replacement f 1585 and 1590 Models Only Remove the nut 36 lockwasher 37 and rotary switch 38 trom the mainplate Remove the screw 40 and the fuse holder 41 5 REMOVAL OF GEARS REEL ARMS AND SOUND HEAD Figure 4 Remove parts as necessary in their indexed order of disassembly noting the fol lowing special precautions a To remove the rear reel arm
16. assembly 29 for repair or replacement disassemble the retaining ring 1 washer 3 spur gear 4 and a second re taining ring 1 from the end of the reel arm shaft Note the manner in which the reel arm disc 27 is positioned before disassembling the screws 26 and disc 27 from the mainplate then carefully with draw the reel arm assembly catching the lock button 30 and spring 31 as they pop free b To remove the front reel arm assembly 28 for repair or replacement disassemble the gear and clutch parts 15 through 19 from the end of the reel arm shaft Note the manner in which the reel arm disc 27 is positioned before disassembling the screws 26 and disc 27 from the mainplate Careful withdraw the reel arm assembly catching the lock button 30 and spring 31 as they pop free R F LMOS OUND PROJECTORS MODELS 1585 1590 1592 To remove the soundhead assembly 40 for repair or replacement it first is necessary to re move the amplifier cover item 16 Figure 6 so that the soundhead leads can be unsoldered from the edge connector terminals refer to appropriate wiring dia gram Assuming that the transformer assembly has already been removed paragraph 4 referto Figure 4 and disassemble the retaining ring 32 flywheel 35 and washers 33 and 34 from the end of the sound drum shaft Then remove three screws 36 and washers 37 and carefully lift the soundhead as sembly from the mainplat
17. circuit board 2 Check out the circuit board Crackling noises 1 Broken ground lead to main frame 1 Replace defective lead 2 Buzz track out of line 2 Realign paragraph 41 step f 3 Broken cable shield 3 Repair shield or replace cable Wow or flutter 1 Soundhead stabilizer guide roller 1 Clean roller and roller shaft sticking 2 Stabilizer guide spring broken 2 Repair or replace spring unhooked lost 3 Film edge guide soundhead out of 3 Realign paragraph 41 step f line 4 Loose flywheel 4 Tighten flywheel 5 Damaged sound drum bearing 5 Replace sound drum FILMOSOUND PROJECTORS MODELS 1585 1590 1592 53 SOUND SYSTEM TROUBLES AND REMEDIES CONT D TROUBLE Wow or flutter Cont d bearing to bind PROBABLE CAUSE REMEDY 6 Dirt causing guide roller arm pivot 6 Clean and polish 7 Photocell or exciter cable rubbing 7 Reposition cables against flywheel 8 Chips or dirt in take up sprocket 8 Remove and clean sprocket gear teeth gear 9 Loop restorer stroke is too short or 9 Adiust paragraph 45 restorer set too low Clicking noises 1 Dirt on sound drum 1 Clean sound drum 2 Broken ground lead to main frame 2 Replace lead High frequencies fade 1 Warped film 1 Recondition or replace film jumps focus 2 Film edge guide soundhead out 2 Realign paragraph 41 step f of line Dirt on sound drum Hum 1 Grou
18. end of the tilt gear rack 39 Remove two screws 37 and disassemble the adapter 38 and gear rack 39 from the base Remove the retaining ring 40 and lift out the tilt gearshaft 41 and spring tension washer 42 Drive out the spring pin 43 and lift out the tilt worm gear 44 8 DISASSEMBLING THE FRONT REEL ARM Fig ure 7 Disassemble the front reel arm in the fol lowing manner noting any special precautions a Remove the two screws 1 and lift the reel arm cover 2 from the front arm 22 Note the shim washers 3 located between the cover and reel arm mounting bosses b Remove the screw 4 and disassemble the feed spindle assembly 5 from the front reel arm If spindle parts are damaged loosen the setscrews 5A and remove the gear 5B and washer 5C from the spindle 5D c Remove the retaining ring 7 from the spring post in the reel arm to free the end of the torsion spring 10 Loosen the setscrews 8 and 8A and lift the gear 9 and torsion spring 10 from the reel arm shaft 14 H damaged disassemble the plastic sleeve 9 from the gear hub d Remove the two retaining rings 11 and dis assemble the reel arm shaft 14 and washers 12 and 13 from the reel arm e Remove the retaining ring 15 and withdraw the upper spur gear 16 from the gearshaft 20 Remove the two gear retaining clips 17 the washer 18 and the lower spur gear 19 and slide the gear shaft 20 from the
19. for Mod els 1585CX 1592CX and 1592CSX are included at the end of this Supplement 3 PARTS CATALOG DIFFERENCES Since the Models 1585CX 1592CX and 1592CSX are simply modified versions of the Models 1585C 1592C and 1592CS respectively all replacement parts listed for the basic models suffix C and CS will apply to the CX and CSX models except as noted herein In other words parts listed for the Model 1585C coded in th Usable on Code column will apply to the Model 1585 parts listed for the Models 1592C and 1592CS coded E will apply to the Models 1592CX and 1592CSX Differences are as follows PARTS CATALOG FIGURE 1 Item 1 1 Front Cover and Speakers Assembly P N 016507 Applicable to Model 1592 5 Item 1 1 Front Cover Assembly P N 016527 Applicable to Models 1585CX and 1592CX Item 1 1A Instruction Plate For 1585CX 1592 and 1592CSX use P N 708200 Item 1 2 Front Cover Nameplate P N 48058 Used on all models except those with Front Cover and Speakers Assembly see Parts Catalog Figure 15 Item 1 4 Line Cord Retainer Bracket Models 1585CX 1592CX and 1592CSX use Cord Wrap and Socket Assembly P N 077607 in place of this bracket Replacement parts for the Cord Wrap and Socket Assembly are shown in Figure A of this Supplement Item 1 5 Control Panel Cover Plate This plate is not used on Models 1585CX 1592CX and 1592CSX projectors Item 1 7 Rear Cover Models 1585CX 1592CX and 1592C
20. from its socket Do not rock or twist the lamp during removal or the lamp pins may be damaged The lamp shield 14 and lampholder 18 are secured to the mainplate with two screws 13 4 REMOVAL OF ELECTRICAL PARTS Figure 3 Before removing electrical components notethe man ner in which the leadwires are routed and tied The pictorial wiring diagrams at the rear of the Parts Catalog will assist in the proper reconnection of ieadwires 1585 and 1592 Models Only lf only the power transformer 4 is to be replaced remove the two hex nuts 1 screws 2 and lockwashers 3 at upper ends of the brackets 7 and 8 Export models also require spacers 3A which are located between the bracket 8 brace 8A and transformer If the lamp transformer 10E is to be replaced the entire transformer group items 1 through 10 must be removed from the base In order to gain access to the two screws the amplifier cover item 16 Figure 6 must also be removed b 1590 Models Only These projectors are equipped with only a power transformer 14 which is secured to the base with four screws 13 The mounting brackets 14C and 14D can be replaced by drilling out the rivets 14 However if the transformer itself is faulty replace the complete transformer and bracket assembly 14 The drive motor and blower components must be removed as a unit to permit belt replacement or motor and blower repairs This is
21. in use On one the track spacing exceeds the length of the scanning beam This track can be positioned so that little or no signal is reproduced On the other type of track spacing is less than the length of the beam This track should be positioned so that both tones are reproduced at approximately the same vol ume level If after adjustment of guide rollerpo sition signal levels cannot be balanced or elimin ated on wide track or level of tones fluctuates ad just edge guide screw 24 to clear up the condition If the edge guide screw is far out of adjustment turn it clockwise until it clears the edge of film adjust rollers andthen setguide screw to stop weave of film g Positioning the Soundhead 1 Lock the autoload system in the load posi tion and loosen the three soundhead mount ing screws 36 Figure 4 just enough to permit the soundhead to be shifted 2 Hold the soundhead locating gage Figure A by its handle and insert the gage carefully between the sound drum and take up sprocket as shown in Figure M The gage must be between the sound drum threading guides Position the gage so that one end bears against the supporting ribs for the sound track edge of the film and with the round body of the gage in contact with the rear sprocket flange as shown LOCAT ING GAGE SPROCKET Figure M Positioning the Soundhead FILMOSOUND PROJECTORS MODELS 1585 1590 1592 3 Tilt the gage so that it lie
22. long leg of the spring in the V like notch along the left edge of the lever 11 m Assemble the torsion spring 5 and threading arm 4 to the stud in the lower right hand corner of the mounting plate 21 Engage the legs of the spring 13 SERVICE INSTRUCTIONS so that they tend to pivot the threading arm clock wise Install the retaining ring 3 to secure the arm to the stud n Install the rollers 2 on their respective studs and secure them with the screws 1 23 REASSEMBLING THE LENS CARRIER Figure 10 Reassemble the lens carrier assembly as out lined in the following paragraphs a Lightly grease the gear teeth of the pinion as sembly 5M the pinion slots of the carrier 5N and the notches of the pinion spring 5L b Assemble the spring 5L into the two grooves of the pinion assembly 5M and assemble the pinion into the grooves of the carrier 5N Fasten the spring securely with the two screws 5K Check to make certain that the knob rotates smoothly c Place the pressure plate 5B on the work sur face polished surface down and the forked end of the plate to the left Assemble the pressure plate lever SF to the pressure plate with the small extrusion of the lever fitted into the corresponding hole in the pressure plate Assemble the flat washers 5D into the springs 5E and assemble these parts and the adjustment plate 5H to the pressure plate with the shorter bushing located at the lever
23. loop restorer para restorer roller stud bent graph 45 replace damaged parts 4 Obstruction or burr in take up 4 Clean remove burr with sprocket upper guard crocus cloth 5 Sprockets out of time 5 Time sprockets per para graph 46 40 TROUBLE Film not threading over take up sprocket Sprocket guard mounting plate 1 Take up sprocket shaft loose in gear 4 F LMOSOUND PROJECTORS MODELS 1585 1590 1592 PROBABLE CAUSE REMEDY Reposition per paragraph 21 Figure 11 out of position 44 step b Obstruction in upper sprocket guard 2 Remove obstruction Sprocket guard spring 30 Figure 10 3 Replace spring broken Retime sprockets paragraph 46 and tighten setscrews 11 Figure iQ 13 Figure 10 EE Film piles up ahead of KL sound drum 1 Not enough clearance between sound Edge guide adjusting screw 24 Fig Insufficient clearance between sound head threading guides 4 and 5 Fig 1 Readjust all guides per paragraph 44 ure Back up bracket 16 Figure 11 bent 2 Straighten bracket downward Exciter lamp cover loose 3 Tighten cover retaining screw Obstruction in gap between sound 4 Remove obstruction drum and exciter lamp cover 5 Check clearance per drum and cover graph 47 6 Adjust per paragraph 41 ure 9 out too far step f E Film ejects ahead of lower take up sprocket Shoe or piles up in this area
24. press the bearing through the bearing assembly 23 and into the worm gear d Insert the end of the camshaft 30 with ball bearing 29 assembled through the bearing hole in the right hand cast arm of the mechanism hous ing To the shaft assemble the loop restorer cam 27 shim washer 26 and the assembled worm gear group Assemble the torsion spring 14 over the hub of the driven clutch 15 spreading the legs of the spring so that they straddle the bent ear at the top of the clutch Insert the hub of the driver clutch 13 through the hub of the driven clutch spreading the legs of the torsion spring still further until one of the lugs of the driver clutch is also straddled by the spring legs Install the washer 17 and the as sembled clutches on the camshaft When installed the bent ear of the driven clutch 15 must be par allel with the camshaft flat for the loop restorer cam 27 e Slide the camshaft all the way in place in serting the end of the camshaft into bearing 12 while seating the large bearing 29 in the bearing hole of the cast arm Assemble the two retaining rings 16 to the camshaft one between washer 26 and loop restorer cam 27 the other between washer 17 and clutch 15 Clutch and loop restorer adjust ments will be made after reassembly has been completed f Fasten the bearing loading spring 10 to the cast arm of the mechanism housing with two screws 9 Assemble the large retaining
25. rotation add to design speed to obtain true speed If pattern drifts against rotation subtractfrom design speed to obtain true speed 5 Timed Loop Make loop of exactly 120 frames At sound speed splice will pass aperture 12times per minute plus or minus the permissible variation in speed and the timing error b Speeds at 120 Volts AC 60 Hz 1 Sound Speed 24 FPS 2 Shutter 1440 RPM 2 Sprocket 102 86 RPM 2 2 Silent Speed 18 FPS 5 Shutter 1080 RPM 5 Sprocket 77 1 RPM 5 29 SERVICE INSTRUCTIONS 1 Sprocket guard 2 Guard retaining screw 3 Lower sprocket hub 4 Upper sprocket hub ear 5 Actuating assembly 6 Shuttle retractor serew T Shuttle retractor 8 Pressure plate lift off 9 Connecting link ear 10 Film guide screw 11 Film guide 12 Escape hub screw 13 Film escape hub 14 Loopformer Figure N Autoload System Adjustments View I 43 AUTO LOAD SYSTEM ADJUSTMENTS GENERAL a The auto load system consists of a series of guides and rollers which when the system is in the load position are so located as to guide the film through the threading path When the system is in the open position the guides and rollers clear the film path b When the system is in the open position the lo cation of the guiding parts is not critical Therefore adjustments to assure proper location of the guiding parts are made with the system in the load position c The gu
26. should be inspected The end of the leader must be properly trimmed and free from sharp bends All sprocket holes in the first 18 inches of leader must be in good condition Splices must be properly registered and in good condition Sprocket holes re stricted by cement or splicing tape must be cleared or the splice remade The repairman is cautioned that it would be a waste of time to adjust or attempt to adjust the autoload system to autothread a film which is in such poor condition as to be incapable of being the source of an uninterrupted film presen tation of acceptable quality c Autoload Trouble Shooting Chart 39 SERVICE INSTRUCTION TROUBLE PROBABLE CAUSE REMEDY Film cannot be inserted into 1 Obstruction below roller of channe1 1 Remove obstruction feed sprocket 16C Figure 10 2 Roller channel 16C Figure 10 bent 2 Straighten or replace or binding assembly 3 Excessive pressure on leaf spring 3 Adjust 1 spring paragraph 26 Figure 11 44 step Film will not pull between 1 Entrance guide 11 Figure N 1 Realign per paragraph 44 feed sprocket and sprocket misaligned step h shoe 2 Feed sprocket guard sticking 2 Clean sprocket shoe pivot 3 Feed sprocket guard spring 30 3 Replace spring Figure 10 broken 4 Caked emulsion or burr on sprocket 4 Clean remove burr with shoe film rails crocus cloth Film comes out the side 1 Obstruction in sprocket guard 1 Remove
27. so that the nylon face of the cam follower 21A rides against the polished surface of the cam indicated by the dash arrow in 11 SERVICE NST RUCT FONS Figure 12 Install this assembled group over the end of the camshaft and secure the cam bracket as sembly to the cast arm of the mechanism housing with the two screws 19 d At this point refer to Figure 11 and install the assembled aperture plate 65 with screws 64 Then return to Figure 12 and continue with reas sembly as follows e Make certain that the shuttle link bearings 17A are firmly pressed into the notches at the front end of each shuttle arm 17 and that the cam followers 17B are assembled into the center notched section of each arm see Figure B Insert the lubricated cam wiper wick 15 into the coils of the extension spring 13 Assemble the lubri cated felt wiper 14 and the extension spring 13 to the shuttle arms as shown in Figure B Assem ble the ball and stud assemblies 12 to the ends of the arms with the hex nuts 11 tightening the nuts only fingertight Carefully insert the front ends of the shuttle arms between the guides of the in out bracket assembly 21 Assemble the shuttle 16 to the front ends of the shuttle arm so that the shuttle teeth extend through the shuttle slot in the aperture plate and face in toward the mechanism housing Rotate the in out cam 20 until the tongue protruding from the unpolished face of the cam rests d
28. spring 7 and the film tension rail 6 to the aperture plate The ends of the spring should engage the notches in the film tension rail and the center of the spring Should bear against the staked pin in the aper ture plate Assemble the spacer bushings 5 and spring retaining cover 4 to the aperture plate and install the two screws 3 c Attach the film guide rail 2 to the aper ture plate with the two screws 1 tightening the screws securely Refer to paragraph 20 step d for installation instructions 20 REASSEMBLING THE MECHANISM Figure 13 Reassemble Figure 13 parts as outlined in the following paragraphs NOTE When reassembling 1592 model projectors use only steps a through g following When reas sembling 1585 and 1590 model projectors refer to steps h and j only a Assemble the strike 7K to the clutch slide bar assembly 7G with the screw 7H and washer 7J Insert the shaft 7C part wav through the right hand arm of the mounting bracket assem bly 7L and install the bumper 7D on the end of the shaft Hold the slide bar assembly 7G in position between the arms of the bracket as sembly and continue to insert the shaft assem bling the flat washer 7E and the spring 7F on the shaft before it is inserted through the left hand arms Install the three retaining rings 7B with the center ring to the right of the spring and washer The setscrew 7A must be adjusted at final assembly to limit slid
29. the tilt bar 28 from the lower end of the tilt gear rack 39 Remove two screws 37 and disassemble the adapter 38 and gear rack 39 from the base Remove the retaining ring 40 and lift out the tilt gearshaft 41 and spring tension washer 42 Drive out the spring pin 43 and lift out the tilt worm gear 44 8 DISASSEMBLING THE FRONT REEL ARM Fig ure 7 Disassemble the front reel arm in the fol lowing manner noting any special precautions a Remove the two screws 1 and lift the reel arm cover 2 from the front arm 22 Note the shim washers 3 located between the cover and reel arm mounting bosses b Remove the screw 4 and disassemble the feed spindle assembly 5 from the front reel arm H spindle parts are damaged loosen the setscrews SA and remove the gear 5B and washer 5C from the spindle 5D c Remove the retaining ring 7 from the spring post in the reel arm to free the end of the torsion spring 10 Loosen the setscrews 8 and 8A and lift the gear 9 and torsion spring 10 from the reel arm shaft 14 If damaged disassemble the plastic sleeve 9A from the gear hub d Remove the two retaining rings 11 and dis assemble the reel arm shaft 14 and washers 12 and 13 from the reel arm e Remove the retaining ring 15 and withdraw the upper spur gear 16 from the gearshaft 20 Remove the two gear retaining clips 17 the washer 18 and the lower spur gear 19 and slide
30. the upper loop former assembly 31 Remove the connecting link and stud assembly 35 f The hex head screw 36 is used to adjust the lens carrier and should not be disturbed Do not re move the lens carrier catch SR unless damaged and in need of replacement g Remove two screws 40 and the upper guard mounting plate assembly 41 Note the manner in which the legs of the torsion spring 44 are engaged Loosen two setscrews 42 and disassemble the shaft and link assembly 43 torsion spring 44 flat washer 45 and the loopformer and lock pawi as sembly 46 from the mechanism housing Do not disassemble the loopformer and lock pawl assembly unless parts are damaged and obviously in need of replacement SERVICE INSTRUCT IONS h Remove the screw 49 and flat washer 50 and disengage and remove the tension spring 51 Remove the screw 52 and flat washer 53 and lift out the cam follower and support assembly 54 Do not disassemble unless parts are dam aged and in need of replacement Loosen the hex head locking screw 55 and disassemble the arm assembly 56 flat washer 57 and the lever and shaft assembly 58 from the mechanism housing i Remove the two screws 60 lock washers 61 and flat washers 62 which secure the self centering assembly 63 to the mechanism hous ing The self centering device is furnished only as an assembly j Remove screws 64 and the aperture plate assembly 65 Refer t
31. two base to end cap mounting screws 3 finger tight then install two screws 4 through the mainplate and into the speed nuts on the front mounting ears of the cap Tighten all four screws securely Install the rear end cap assembly 7 in the same manner f Assemble the tilt knob 2 to the protruding end of the tilt shaft and tighten the setscrew 1 securely Rotate the tilt knob to check the tilting mechanism g Refer to the appropriate wiring diagram at the end of the Parts Catalog section for proper wiring connections 33 REASSEMBLING LAMPHOUSE AND COVERS Figure 1 No special instructions are necessary for the reassembly of the lamphouse or cover com ponents These items need not be installed until after all adjustments have been made see the fol lowing section F LMOSOUND PROJECTORS MODELS 1585 1590 1592 pedjustments 34 GENERAL INSTRUCTIONS The alignment and adjustments covered in this section are necessary to the proper operation of the projector Even though the projector may not have under gone complete overhual and repair it is recommendedthat all the adjustments be checked as a routine measure Routine adjustments such as those applicable to sliding fits clearances and end play have been covered in the reassembly pro cedures and are not repeated in this section except where they directly affect other adjustments or alignments All special tools and fixtures required to per form the a
32. two screws 5 and remove the pressure plate 58 flat washers 5D springs 5E and pressure plate lever SF The adjustment plate 5H need not be removed Pry up the nameplate 5J with a knife biade Remove two screws 5K and disas semble the spring 5L and the knob and pinion as sembly 5M from the lens carrier 5N b Remove the retaining ring 6 and withdraw the actuating lever 7 from the animation switch actuating rod Remove the two screws 9 and the hood 10 c Loosen two setscrews 11 in each sprocket gear 12 and 13 and remove the gears tension washers 14 and flat washers 14 from the sprocket shafts Remove two screws 15 andthe upper sprocket guard assembly 16 and withdraw the upper sprocket assembly 17 its thrust washer 18 fromthe me chanism housing Disassemble the lower sprocket assembly 19 flange 20 and thrust washer 21 from the mechanism housing d Remove the retaining ring 22 from the lower end of the rewind button shaft and lift the rewind button 23 and its spring 24 from the top of the mechanism housing FILMOSOUND PROJECTORS MODELS 1585 1590 1592 e When removing sprocket guards 27 and 28 note the manner in which the torsion springs 30 are assembled so that they may be properly re installed f 1592 Models Only Loosen the setscrew 34 and disassemble the animation switch lever assem bly 35 and switch lever crank 37 from the mec
33. until the pencil alignment mark ap pears in the center of the timing plate peep hole Tighten the gear setscrews securely without retain ing the gear or the sprocket 34 ADJUSTMENT BRACKET M BRACKET S CREW O GEAR REW ND CLUTCH IDLER GEAR amp ARM ASSY BOWED WASHER Figure S Adjusting Gear Shift Tension and Backlash 47 CHECKING THE EXCITER LAMP COVER CLEARANCE Since the film must pass between the sound drum and exciter lamp cover the clearance between these two items should be checked Insert a 77 drill or a straight piece of 25 wire into the chan nel between the drum and cover Gage shouid enter channel with slight friction but without forcing If clearance is inadequate straighten the exciter cover locating pins to obtain proper clearance 48 GEAR SHIFT TENSION ADJUSTMENT When shifting from forward to rewind or vice versa the idler gear arm Figure S should pivot smoothly to effect the engagement of the idler gear with gear or gear B This can be checked by rotating the drive belt pulley manually first in one direction and then the other H the pivoting action seems hesitant in crease the tension on the arm assembly by pressing the retaining ring more firmly on the spur gear shaft until the bowed washer Figure S is flattened against the face of the gear 49 IDLER GEARBACKLASH ADJUSTMENT Inboth the forward and rewind positions there must be a per ceptible amount of ba
34. with the screw 32 lock washer 33 and flat washer 33A Assemble the upper loopformer assembly 31 to the upper end of the connecting link 35 and install the re taining ring 30 Slip the pin end of the threading F FLMOSOU ROJECTORS MODELS 1585 1590 1592 lever 28 up behind the link 43 engaging the pin with the rectangular slot in the link Insert the shaft of the loopformer assembly through the mounting plate 41 and mechanism housing and into the hub of the threading lever 28 Tighten the hex head locking screw 27 securely Attach the leaf spring 26 to the upper loopform with two screws 25 h Assemble the small hole in the film guide 24 over the pin in the lower sprocket guard mounting plate 21 and hold the film guide in place while in serting the shaft of the toggle lever assembly 23 through the guard plate The forked end of the toggle lever must straddle the film guide mount ing pin Secure the toggle lever to the mounting plate with the retaining ring 22 Engage the re maining forked end of the toggle lever with the pin at the lower end of the connecting link 35 and se cure the lower mounting plate 21 to the mechanism housing with the two screws 20 The film guide 24 must be lifted slightly during this operation so that its large pivot hole slides over the sprocket shaft bearing in the housing i Assemble one large washer 18 and the lower film guide 19 over the lower s
35. 13 45 CHECKING AND ADJUSTING LOOP RESTORER The automatic response of the loop restorer should be checked by means of two test film strips TFS D550 NX1 and TFS D550 NX5 The first provides a test for damaged perforations the second for elong ated perforations Run each test strip through the projector in forward and observe the reaction of the loop restorer as the damaged and elongated perforations pass through the film gate The lower loop should be automatically restored within five or six frames To adjust the loop restorer refer to Figure R View B and proceed as follows a Slip the loop restorer position tool Figure A over the loop restorer roller 1 Figure R with the flat on the tool facing the guide roller at the rear end of the upper sprocket shoe 6 Figure R The flat of the tool should just touch the guide roller lightly To adjust spacing between loop restorer roller and guide roller loosen the mounting screws in the self centering assembly inset B Figure R and raise or lower that assembly until the proper spacing is obtained Then tighten the mounting 2 di Ma M M n ve LOOP CAM SETSCREW HE BELOW CAMSHAFT CAM FOLLOWER SUPPORT TENS ION SPRING SELF CENTER ING ASSEMBLY LOCKING S CR EW RESTORER ARM 55 Y F LMOSOUND P ROJECTORS MODELS 15055 1590 1592 EXE 8 8 eg Sg F WI lt 1 Loop restorer ro
36. 20 or 240 volts separate lamp transformer is not included Unlike the 1592 models coveredinthe basic service manual the 1592CX and 1592C 5X are not provided with the animation feature The Model 1585CX is not provided with the still feature 2 REPAIR AND ADJUSTMENT PROCEDURES NOTE Except as noted in the following paragraphs all repair and adjustment information contained in Service Manual No 74404 will apply to Models 1585C X 1592CX and 15922 SX projectors If electrical repairs are necessary refer to the and schematic diagrams included with this Supplement The most prominent physical differences are referencedto parts catalog illustrations in the basic manual and for the most part require no detailed repair instructions REPAIR OF FIGURE 1 ITEMS The disassembly reassembly procedures for Mod els 1585CX 1592CX and 1592CSX are the same except for the cord wrap and socket assembly Figure A This assembly is removed the same manner as the line cord retainer bracket item 1 4 butis withdrawn only as far as necessary to expose the leadwire con nections to the input connector and voltage selector Switch REPAIR OF FIGURE 2 ITEMS The disassembly reassembly procedures for Mod els 1585CX 1592CX and 1592C SX are the same as those in the basic service manual REPAIR OF FIGURE 3 ITEMS Except as follows the disassembly reassembly procedures for Models 1585CX 1592CX and 15922 SX are t
37. 5 and the spacers 26 f Hold the mechanism assembly 29 securely while removing the four screws 27 and the idler gear adjustment bracket 28 Carefully withdraw the mechanism assembly from the mainplate 7 REMOVAL OF BASE COMPONENTS Figure 6 Remove parts as necessary in their indexed order of disassembly noting the following special pre cautions a The lever stop and pin 5 has been carefully adjusted to insure the proper advance of film and SERVICE INSTRUCTIONS then secured with screw 4 Do not disturb these items unless obvious damage indicates a need for replacement b Remove the adapter shaft 7 and lift out the film guide roller 8 Remove the screw 9 and lift the sliding film guide assembly 10 from the flanges on the base Disassemble if necessary for replace ment of damaged parts c To expose the amplifier assembly 20 and edge connector assembly 18 remove the screws 15 and the cover 16 Remove the four screws 17 and 19 and lift out both assemblies When separating the edge connector from the amplifier pull them straight apart without wriggling or twist ing them and thus distorting the pins Note the spacers 21 located beneath the amplifier d Remove the four screws 22 and the cover 23 to expose the volume and tone control as sembly 25 Four screws 24 secure the control assemblv into the base e Remove the screw 26 and lockwasher 27 and disassemble
38. 92CSX PROJECTORS 1 GENERAL INFORMATION This Supplement has been prepared to provide the necessary information for the maintenance repair and adjustment of the Models 1585 1592CX and 1592CSX Automatic Threading 16mm Sound Projectors These three projectors are modified versions of related models already covered in the basic service manual Part No 74404 dated May 1978 Modifications con sist primarily of manufacturing changes necessary to adapt these units to meet foreign electrical require ments as noted by the wiring diagrams included with this Supplement Most of the physical differences consist in changes of part numbers see paragraph 3 Basically the Model 1585CX is the modified version of the Model 1985C whose replacement parts are coded in the parts catalog of manual No 74404 In like manner the Models 1592CX and 1592CSX are the modified versions Modeis 1592C and 1592CS respectively which are coded in the basic parts catalog The most Obvious phySical differences are as follows All modeis covered in the basic service manual are provided with an integrated line cord which plugs into any convenient 120 volt outlet The Models 1585CX 1592CX and 1592 5 are provided with a separate line cord which must be connected between a socket located at the rear of the projector see Figure A this Supplement and the outlet A voltage selector switch is included so that incoming voltage can be set at 120 2
39. Adjustment is made by loosening the face gear setscrews 5 8 and 8A and reposi tioning the face gears 5B and 9 as necessary b Rear Reel Arm Adjustment See Figure 8 Adjust end play of the shaft 31 to 0 008 inch 0 003 inch by positioning retaining ring 28 against an 0 008 inch shim The backlash for both face gears should be between 0 005 inch minimum and 0 018 inch maximum The upper gear 27 is adjusted by F ILMOSOUND PROJECTORS MODELS 1585 1590 1592 loosening its setscrew 26 and repositioning the gear as necessary The lower gear 14 is adjusted by loosening the setscrew 13 in the tapped hole of the arm and shifting the shaft 16 in and out as necessary c Rewind Clutch Adjustment The rewind clutch system must be adjusted to produce a supply spindle torque of 5 1 2 to 6 inch ounces when the rewind but ton is pressed during operation Install an empty reel on the supply spindle and wrap several turns of aten inch film strip around the reel hub Hook a spring scale to the free end of the film strip Turn on the projector rotate the Motor Lamp switch to verse and press and release the rewind button at the top of the mechanism housing The spring scale must register between 2 5 and 4 5 in lbs When the rewind clutch system begins to slip Take up torque is adjusted by means of the take up clutch assembly item 18 Figure 4 Grip the flats on the inner face of the clutch with a wrench w
40. FILM TECH THE INFORMATION CONTAINED IN THIS ADOBE ACROBAT PDF FILE IS PROVIDED AT YOUR OWN RISK AND GOOD JUDGMENT THESE MANUALS ARE DESIGNED TO FACILITATE THE EXCHANGE OF INFORMATION RELATED TO CINEMA PROJECTION AND FILM HANDLING WITH NO WARRANTIES NOR OBLIGATIONS FROM THE AUTHORS FOR QUALIFIED FIELD SERVICE ENGINEERS IF YOU ARE NOT A QUALIFIED TECHNICIAN PLEASE MAKE NO ADJUSTMENTS TO ANYTHING YOU MAY READ ABOUT IN THESE ADOBE MANUAL DOWNLOADS WWW FILM TECH COM SERVICE INSTRUCTIONS AUTOLOAD FILMOSOUND 16mm PROJECTOR AUTOMATIC THREADING MODELS EEN CS 1585CH CHS 1592C CS 1585ML MLS 1592CH CHS 1978 Bell amp Howell Company All Rights reserved F BELL INTERNATIONAL SERVICE DEPT PART NO 74404 MAY 1978 INTRODUCTION y E G GF P DISASSEMBI Y PROCEDURE 3333 Ss I Na d d REASSEMBLY PROCEDURE ADJUSTMENTS 54 General Instructions Optical Alignment ge gg o pa e c gt 3 gt w y E gt m 3 8 y y m w 4 m en ep e e se 5 Adjusting the Intermittent Mechanism Lens Carrier Adjustment 9
41. LY rr e 16MM SOUND PROJECTORS vn 8 BLK YEL BLK AMP BOARD e ER G _ O w j p NEUE ES MN 8 4 gt 4 uidi A E 4 e2o v 120 V Fos pos amp POS 6 ULL CCW DIODE IODE Mic JACK CIRCUIT MODEL 1565 ONLY Figure C Schematic Diagram Models 1585CX 1592 1592 5 1585CXU YEL f GRD LEADS EECH EE TO PROJ BASE pep GREEN BLACK Lee n NOTOK ASSEM 016495 YELLOW CAPACITOR 708457 z P VER c wHT TRANS FORMER ASSEM TINY 7763 BLK UM PIE iim BLK YEL SPEAKER 20894 C 16 SOUND PROJECTORS SEE INSET 305792 3 2 0 AMP 125 I TORC EXC LAME PIN m a II aaa a 29070 RESISTOR JACK CIRCUIT MODEL 1585 CXU ONLY Figure D Diagram Models 1585CX 1592 1592CSX 1585CXU
42. Pressure plate spring lost 4 Replace spring 5 Pressure mounting plate screws 5 Tighten mounting screws 1 6 Sprocket guards not closing 6 Clean or adjust 3 7 Sprocket drive gear loose shatt 7 Retime paragraph 46 and tighten setscrews 8 In out bracket spring broken 8 Replace spring ES Lower loop not 1 Loop restorer stroke too short 1 Adjust paragraph 45 restored 2 Loop restorer does not engage 2 Adjust paragraph 45 restorer cam Film rubs on loop 1 Restorer arm out of position 1 Reposition paragraph 45 restorer roller 2 Loop restorer does not engage 2 Adjust paragraph 45 restorer cam Excessive film slap 1 Damaged film 1 Recondition or replace 2 Green film 2 Age or buff film 3 Dirty pressure plate 3 Clean pressure plate 4 Pressure plate rubbing on aperture 4 Realign pressure plate plate guide rails 5 Incorrect shuttle stroke 5 Adjust paragraph 36 step d Animation clutch does not 1 Open in animation clutch circuit 1 Repair circuit operate 1592 Models Only 2 Solenoid plunger set too high or 2 Adjust solenoid plunger too low paragraph 38 step c 3 Stop pawl clearance excessive 3 Adjust paragraph 38 step a Animation clutch stops 1 Insufficient shuttle retraction 1 Adjust paragraph 38 step b sprocket but shuttle pulls film 1592 Models Only Splices jam in sprocket 1 Bad splices 1 Replace splices SS shoes 2 Emulsion build up 2
43. S b Photocell Alignment Figure 9 1 Loosen the setscrew 19 and the two hous ing screws 20 Remove the exciter lamp 8 and the optical slit 11 2 Insert the sound drum alignment tool into the optical slit opening as shown in Fig ure L 3 Press the sound drum in until its inner face just makes contact with the first step or bearing surface of the alignment tool and maintain this contact while tight ening the two screws 20 securely 4 Withdraw the alignment tool and while looking into the optical slit mounting hole shift the photocell until its forward tip is flush with the inner face of the sound drum Maintain this position while tightening the setscrew 19 c Roller Tension Adjustment Figure C The roler arms are linked by a torsion spring and therefore will move as a pair The counterbalance spring must be adjusted to offset the weight of the rolers and roiler arms Place the soundhead on a level surface and move the roller arms as a set to various positions H the roller arms fail to remain in the set positions engage the slotted head of the tension adjuster with a screwdriver and turn the adjuster clockwise or counterclockwise until proper counterbalance is obtained NOTE The following adjustments must be made with the soundhead installed and the projector threaded with special test film d Soundhead Installation 1 Carefully assemble the soundhead assembly to the project
44. SX use Rear Cover P N 710065 Item 1 9 Top Cover Assembly Models 1585CX 1592CX and 1592CSX use Top Cover Assembly P N 077472 This assembly includes items 1 9A 1 9B 1 9C 1 9H 1 9J and 1 9K aslistedinthe basic Parts Catalog The top cover less preceding parts can be ordered under part number 016534 Item 1 14 Air Deflector Modeis 1585CX 1592CX and 1592CSX use Air Deflector P N 707447 Item 1 16 Lamp Type Label Models 1585CX 1592CX and 1592C SX use Lamp Type Label P N 49112 Item 1 18 50 60 Hz Label Models 1585CX 1592CX and 1592 5 use 50 60 Hz Label P N 44490 PARTS CATALOG FIGURE 2 Item 2 6 Front End Cap Assembly Models 1585CX 1592CX and 1592C SX use Front End Cap Assembly P N 077461 Components of this assembly are Tinnerman nuts P N 45102 item 2 6A 8 ohm speaker P N 708994 item 2 6B and front end cap P N 710063 item 2 6C plus six speed nuts P N 709218 item 2 5 Item 2 7 Rear End Cap Assembly Models 1585CX 1592CX and 1592CSK use Rear End Cap Assembly P N 077473 Components of this assembly include only the following items the receptacle opening cover P N 48066 item 2 7G the rear end cap P N 710064 item 2 7H the hex locking nut P N 19010 item 2 8 the auxiliary speaker jack P N 43878 item 2 9 and the insulating washer P N 25368 plus six speed nuts P N 709218 item 2 5 Item 2 11A Still Run Lever P N 709040 This lever is not used on Model 1585CX projectors PARTS CATALOG FIGURE 3
45. TFL 55 NXI1 Project film and turn framing knob from one limit to the other If at one limit a frame line is not visible loosen nut on the framing eccentric located at top of shuttle arm plate assembly Figure B and turn eccentric until the frame line appears Hold eccentric while tighten ing nut Check adjustment by again turning framing knob from limit tolimit while observing picture When the eccentric is properly adjusted either frame line can be projected and movement of film should be ap proximately equal at top and bottom of framer travel 57 LENS CARRIER ADJUSTMENT Angular rela tionship between the lens carrier and the aperture plateis controlled by lens mount stop screw item 36 Figure 11 Thread projector with roll title or target F LMOSOUND PROJECTORS MODELS 1585 1590 1592 film having sharp images corners and projectapic ture approximately 30 inches high onto a matte sur face The projector must be square with the screen Focus the picture and compare resolution of the two sides ofthe image when viewed from a distance of ap proximately twice the width of the picture one side appears to be soft refocus to sharpen that edge of the picture and note whether the lens is moved toward or away from the aperture For example if image at right hand edge of screen is soft until lens is moved toward aperture then lens stop screw is set too far forward and should be turned clockwise CAUTION This adjustment i
46. adjuster 27 through the hole in the top of the sound head casting Assemble the spring retainer 28 to the adjuster threading it approximately midway in the threaded area Before inserting pin end of ad juster into the small hole at the bottom of the casting assemble the friction washer 26 bowed face up to the end of the adjuster Assemble the retaining ring 25 into the groove at the upper end of the ad juster Hook the tension spring 12 between the end of the lower stabilizer arm 15H and the hole in the spring retainer 28 install the exciter lamp 8 Refer to paragraph 40 for soundhead adjustments i Reassemble the exciter lamp cover as follows Remove the cloth backing from the light shield 6 and assemble the light shield to the left hand inside upper wall of the lamp cover 7 so that it is flush with the outer edge of the cover Remove any excess or overlap with a sharp knife or razor blade As semble the cover screw 2 to the cover and install the retaining ring 1 Press the hole plug 5 into the hole in the cover Position the film guide 4 over the tapped holes in the cover with the flange of the guide wrapped around the front of the cover and loosely install the screws 3 Insert a 0 020 inch spacer between the guide flange and the cover press the flange against the spacer and tighten the screws 3 securely Remove the spacer 26 REASSEMBLING THE REAR REEL ARM AS SEMBLY Figure 8 Reassemble the
47. ame as those in the basic service manual REPAIR OF FIGURE 6 ITEMS The disassembly reassembly procedures for Mod els 1585CX 1592CX and 1592 5 are the same as those in the basic service manual REPAIR OF FIGURE 7 ITEMS The disassembly reassembly procedures for Mod els 1585CX 1592CX and 1592CSX are the same as those in the basic service manual with one exception The face gear item 7 5B has been altered new part number 709806 and is now being used in current production models of all projectors covered by this Supplement and the basic service manual The newly designed face gear eliminates the need for the flat washer item 7 5B If it should be necessary to re place the face gear in earlier model projectors the new gear should be installed and the washer item 1 5B discarded REPAIR OF PARTS IN FIGURES 8 THROUGH 14 The disassembly reassembly procedures for Mod els 1585CX 1592CX and 1592CSX are the same as those in the basic service manual Be sureto remem ber that all uncoded and code parts apply to Model 1585CX and that all uncoded and code E parts apply to Models 1592CX and 1592C SX REPAIR OF FIGURE 15 PARTS The disassembly reassembly procedures for Mod el 1592CSX are the same as thoseinthe basic service manual 16MM SOUND PROJECTORS 1 AMP FUSE P N 38019 STAND OFF 4 P N 740177 FUSE BOARD P N 077143 Figure B Amplifier Fuse Board and Fuses NOTE Pictorial and schematic diagrams
48. ance from the edge of the shuttle slot to the inner end of the shuttle tooth nearest the aper ture opening shouid be 0 007 inch minimum From the edge of the shuttle slot to the outer end of the shuttle tooth the distance should be 0 050 inch max inum Check these clearances at both the upper tooth and lower tooth If the clearances vary at the upper and lower teeth and inner clearance is less than 0 007 inch at either end the following possi ble causes should be checked and corrected 1 Aperture plate out of alignment See para graph 35 step a Aligning the Aperture Plate 2 Shuttle stroke incorrect See paragraph 36 step d Shuttle Stroke Adjustment 3 Link bearing missing from end of shuttle arm Partial disassembly required to re move shuttle arm and replace link bearing refer to Disassembly section 4 Ball and stud assembly loose on shuttle arm Reposition ball and stud assembly Figure B and tighten stud nut securely 0 050 MAX 0 007 MIN 0 3025 0 0005 IN TOTAL TRAVEL OF CENTER TOOTH Figure F Aperture Plate and Shuttle Tooth Clearance b Checking Shuttle Tooth Height Swing open the lens carrierandadvance the mechanism manually un til the shuttle is at the center o its stroke as shown in Figure F Hold the shuttle tooth height gage Fig ure by its knurled handle and place it against the aperture plate between the rails The center ears on either side of the gage handle are the h
49. asure shuttle stroke Figure F 7 S 09701 35N2 Shuttle Height Check shuttle protrusion Figure G 8 S 552 2 N1 Restorer Positioning Tool Adjusting the loop restorer Figure R 9 5 2552 4 1 Shuttle Tension Adjusting shuttle tension Figure H 10 5 552 4 Weight for Shuttle Tension Gage Adjusting shuttle tension Figure H 11 5 552 1 1 Timing and Alignment Plate Timing the sprockets Figure R 12 S 552 5 N1 Soundhead Locating Gage Positioning the soundhead Figure M 13 S 550 8 N1 Alignment Tool Aligning sound drum and photocell Figure L S 550 5 N1 Shuttle Stroke Target Measuring shuttle stroke Figure 4 14 Shop made fewind torque reel use Torque adjustments P N 014570 Purchase Push Pull Scale Torque adjustments chatillon LP 72 Master Gage C0 Chicago 60622 Figure A Special Service Tools SERVICE INSTRUCTIONS Disassembly Procedurs 1 GENERAL PRECAUTIONS a Be sure to use the proper size tools for dis assembly and reassembly procedures After remov ing attaching parts screws nuts etc loosely re install these parts to the removed part or tapped holes to prevent loss b Cemented or adhesive backed parts aresonoted in the parts lists and can be removed by prying up one edge with a knife blade Be careful not to scratch surrounding areas and remove traces of old adhe sive with solvent c When unsoldering is required to remove elec trical parts it is advisable to tag leadwires
50. bearing posts of the reel arm Inspect the nylon bearings 21 and if damaged press them from the bearing posts 9 DISASSEMBLING THE REAR REEL ARM Figure 8 Disassemble the rear reel arm in the following manner noting any special precautions a Remove the two screws 1 and lift the reel arm cover 2 from the rear arm 32 Note the shim washers 3 located between the cover and the reel arm mounting bosses b Press the take up arm against the reel arm casting and slip the take up belt 4 from the pulleys Release the take up arm slowly and catch the tension spring 5 as it drops free Remove the screw 6 and disassemble the take up spindle and pulley assembly 7 and shim washer 8 from the take up arm The take up arm and rear reel arm are replace able only as an assembly 32 c Remove the retaining ring 10 and large flat washer 11 from the end of the gearshaft 16 Re move the rubber sleeve 12 from the hub of the gear 14 Loosen the gear setscrew 13 and disassemble the gear 14 the shim washer 15 and the gearshaft 16 from the reel arm d Remove the retaining ring 17 from the spring post in the reel arm to free the end of the torsion spring 18 and lift the torsion spring from the hub of the upper face gear 27 e Remove the retaining ring 19 and slide the upper spur gear 20 toward the upper face gear 27 until the upper gear retaining clip 21 can be removed Move the gearshait 24 dow
51. ch is obtained between stop pawl Figure K for the following adjustment procedure finger and tip of trigger Tighten collar 1 Rotate the mechanism by hand until the finger of the setscrew stop pawl is centered at the tip of the trigger as shown in Figure K View A and place Still Run 2 With the tip of an appropriate spring gage knob in Run press down on upper collar 2 until gage indicates a spring pre load of 5 ounces then 1 Refer to Figure K View E Loosen set tighten upper collar setscrew screws in collars 1 and 2 and press lower collar 1 up against the underside 3 Loosen setscrews in collars 3 and 4 Use of the stop pawl until a clearance of 0 010 a suitable clamp to hold the solenoid plunger 26 up to its seat then raise lower collar 3 until it just touches the stop pawl and tighten the collar setscrew Position the upper col lar 4 so that there is 1 16 to 1 8 inch clearance between collar and stop pawl and tighten upper collar setscrew d Checking Still Run Linkage Referto Figure View E in this section for the following adjustment procedure 1 Rotate the projector Still Run knob to the Run position so that the still run rod 5 moves downward in the limit of its travel 2 Rotate the mechanism knob and check to make certain that the ear of the stop pawl clears the trigger as shown in View A Figure 3 Operate the projector and switch from Run to Still position The s
52. chanism until the op erator has had an opportunity to stop the projector SPECIAL MAINTENANCE PRECAUTIONS The removal and installation of most projec tor parts can be accomplished with tools normally available in photo equipment repair shops A pencil type soldering gun should be available for elec trical repairs and the Bristol wrenches listed in the following chart will also be required Special tools and gages necessary for projector alignments and adjustments are illustrated and listed in Fig ure and its accompanying chart BRISTOL SETSCREW WRENCHES REQUIRED FOR MAINTENANCE B amp H Part No No of No 4 40 G1271 Fl No 6 32 STK3852 B STK3863 B 8 32 NOTE Wrench G165 F3 is needed to tighten setscrew in tool handles CLEANING film path areas must be kept free from emulsion build up or film jamming will take place during the automatic threading operation Use Toluol and or an orange stick to remove emulsion from SERVICE INSTRUCTIONS the film path areas being careful not to scratch the surfaces Pay particular attention to the film path parts of the soundhead cover and soundhead Do not use trichloroethylene solvents to clean plastic parts Use a naphtha base cleaning fluid and be sure that grease is NOT wiped off critical areas of lubrication Do not use solvents on these critical areas especially in the auto threading linkage since lubrication is applied during assembly and it would be d
53. cket damaged 1 Replace sprocket Feed spindle does not rotate 1 Dirt in reverse take up clutch 1 Clean clutch Gate will not lock 1 Laten spring set too close to lens 1 Adjust latch spring mount stop 2 Pressure plate out of line 2 Realign pressure plate ns _ _ __ Shuttle runs but sprockets 1 Animation clutch spring broken 1 Replace spring do not revolve or lost 1592 Models Only U s E Short lamp life 1 Line voltage in excess of lamp 1 Use lamp of correct voltage voltage rating 2 Drive belt broken or disengaged 2 Replace or re engage belt 3 Dirt and lint clogging blower housing 3 Clean Projector speed slow 1 Binding in the mechanism 1 Free binding condition 2 Belt slipping 2 Clean or replace belt SS Runs at speed between 1 Pulleys out of line 1 Realign pulleys 2 Belt shifter bent 2 Straighten belt shifter 3 Improper power line frequency 3 Use proper voltage and frequency 35 SERVICE INSTRUCTIONS 51 PICTURE TROUBLES AND REMEDIES TROUBLE PROBABLE CAUSE REMEDY Film jump 1 Damaged film 1 Repair or replace 2 Loose shuttle 2 Adjust and tighten paragraph 36 step c 3 Dirty film aperture 3 Clean film aperture 4 Damaged or lost pressure plate 4 Replace spring spring 5 Pressure plate misaligned 5 Realign pressure plate 6 Incorrect shuttle stroke 6 Ad
54. cklash between the idler gear and gears A and B Figure S As the idler arm pivots a stop pin protruding at the upper end of the arm rides the slightly curved rim of the adjustment bracket from one limit stop to the other Check gear backlash at both limit stops If there is no backlash at one stop and too much at the other loosen the ad justment bracket screws and shift the bracket slightly to balance the backlash in both positions FILMOSOUND PROJECTORS MODELS 1585 1590 1592 Trouble Shooting 50 MISCELLANEOUS TROUBLES AND REMEDIES TROUBLE PROBABLE CAUSE REMEDY Nothing runs 1 Defective On Off switch 1 Replace switch 2 Damaged power cable 2 Repair or replace cable 3 Loose connections 3 Repair connections Motor hums but does 1 Starting circuit open or shorted 1 Repair loose or transposed not run i connections replace defec tive capacitor and or relay Motor runs but mechanism 1 Damaged switch 1 Replace switch does not run 2 Transposed leads on main switch 2 Connect leads to proper terminals 3 Drive belt broken or unhooked from 3 Replace or reinstall pulley drive belt 4 Motor pulley loose on shaft 4 Position pulley and tighten setscrews 5 Animation clutch spring broken 5 Replace spring 1592 Models Only Rewind does not operate 1 Rewind clutch not engaging or 1 Adjust paragraph 40 step c clutch slipping Take up does not operate 1 Take up spro
55. djustment procedures are listed and il lustrated in Figure A In addition special test films SOCKET MOUNTING LAMP PLUG APERTURE PLUG and electronic test equipment vacuum tube volt meter voltohmmeter oscillator and tachometer or Strobotac are needed to check and adjust the sound system of the projector The test films are listed in the Introduction section Many of the procedures listed in this sec tion require operation with the rear tor cover removed To avoid shock haz ards disconnect the power and discharge the motor starting capacitor when not required LENS PLUG i SPR NG P N 6124 ALIGNMENT ROD 2 Figure E Aligning the Optical System SERVICE INSTRUCTIONS 35 OPTICAL ALIGNMENT It is important that these alignments be per formed in the following listed sequence steps a through d All special tools and fixtures required for optical alignment are shown in Figure A These items are shown installed in the projector in Fig ure E Be sure to turn the mechanism manually until the shutter blade is clear of the aperture opening before inserting alignment tools a Aligning the Aperture Plate 1 Remove the projection lens from the lens carrier Open the lamphouse and remove the projection lamp and the condensing lens assembly 2 Swing the lens carrier tully open and dis assemble the pressure plate from the lens Garrier 3 Loosen the two aperture plate mountin
56. don the tapped boss of the mainplate Insert the spacer 19 between the link assembly and the tapped boss and install the pivot screw 15 Secure the shaft of the link 18 with the washer 17 and retaining ring 16 d Engage the remaining loop of the torsion spring 20 with the pin at the lower end of the sliding link assembly 13 while assembling the spacers 14 and sliding link to the projector mainplate Install and tighten the two shoulder screws 12 Assemble a retaining ring 9 into the ring groove closest to the slotted end of the switch shaft tube 11 and insert the short end of the tube through the mainplate from the front Assemble the run still arm assembly 10 over the protruding end of the tube 11 engaging the key lugs of the arm in the slot of the tube and the slot in the end of the arm with the staked pin at the upper end of the sliding link assembly 15 Install the second retaining ring 9 into the ring groove at the end of the tube 11 Insert the long straight end of the fire shutter rod 8 down behind the pivoting link assembly 18 and through the hole in the bent ear of the link En gage the upper end of the rod with the hole in the fire shutter filter arm Assemble the spring 7 and collar 6 small diameter up to the lower end of the rod and tighten the collar setscrew 5 5 Assemble a collar 2 small diameter up to the still run rod 4 Insert the straight end of the still ru
57. e d No special instructions are required for re moval of the drive gearing in Figure 4 except to note in which direction the gear hubs are facing Inspect all gears for chipped or broken teeth and replace if necessary Clean and re lubricate all reusable gears 6 REMOVAL OF RUN STILL LINKAGE AND ME CHANISM ASSEMBLY Figure 5 Remove parts ag necessary in their indexed order of disassembly noting the following special precautions NOTE The disassembly procedures in steps a through d following apply only to the 1592 model projectors Steps e and apply to all models a Loosen the setscrews 1 in the collars 2 then disengage the lower end of the still run rod 4 from the pivoting link assembly 18 and dis assemble the rod collars and spring 3 from the stop pawl b Loosen the setscrew 5 and remove the collar 6 and spring 7 from the Iower end of the fire shut ter rod Disengage the upper end of the rod from the fire shutter and remove the rod 8 c Disassemble the still run lever 9 from the mainplate d Remove the two shoulder screws 12 and lift the sliding link assembly 13 and the two spacers 14 from the mainplate Remove the pivot screw 15 and disassemble the pivoting link assembly 18 spacer 19 torsion spring 20 and flat washer 21 from the mainplate e Remove two retaining rings 22 and lift out the torsion spring 23 Remove the shoulder studs 24 belt shifter bracket 2
58. e top cover assembly d Remove three screws 11 and 12 and disas semble the lamphouse assembly 13 from the main plate The lower screw also attaches the air deflector 1S 14 The Still Run knob 13F is used only on the 1592 models The lower end of the still run lever en gages the pin on the crank lever item 11 Figure 2 3 REMOVAL OF END CAPS AND LAMP Figure 2 Remove parts as necessary in their indexed order of disassembly noting the following special pre cautions a Loosen the setscrew 1 and disassemble the tilt knob assembly 2 from the tilt shaft b Replacement of the speaker 6B starting cap acitor 7C and receptacle 7F can be accomplished without disassembling the end caps 6 and 7 from the projector However if the end caps are damaged and in need of replacement proceed as follows Tilt the projector so that the four screws 3 and one spacer 3A which secure the end caps 6 and 7 to the base can be removed Then set the pro jector upright and remove the remaining four screws 4 which are inserted through the front side of the mainplate Be careful not to lose the speed nuts 5 assembled to the mounting bosses of the end caps The 1592 models use a single knob 11 for Fwd Rev Lamp control plus a crank lever 11 to provide for the Still Run control operation d To remove the projection lamp 12 press down the lamp retaining spring and pull the lamp straight out
59. e bar travel As semble the complete clutch bracket assembly 7 to the mechanism housing with the two screws 4 and 5 and lock washers 6 and press down firmly on the bracket while tightening the screws As the adjustment bracket 3 to the end of the longer screw 5 and install the washer 2 and the round nut 1 tightening the nut finger tight b Lightly grease both bearing openings in the cast arms of the mechanism housing Press the ball bearing 12 into its bearing opening until fully seated Assemble the large bearing 29 to the camshaft 30 until the bearing is seated against the shoulder of the shaft Install the retaining ring 28 to the camshaft with the bowed surface of the ring facing away from the ball bearing c Assemble the three rubber bushings 25 into the corresponding openings in the face of the worm gear assembly 24 Assemble the bearing assembly 23 to the worm gear so that the formed ears of the bearing are aligned with corresponding notches in the worm gear Insert the bent ears of the clutch yoke 21 through the slots in the bearing assembly while assembling the spring 22 over the protrud ing finger of the clutch yoke and into the hole in the bearing assembly Hold these parts together while assembling the two shoulder pins 20 to the bear ing assembly pressing them in until they engage the bent ears of the clutch yoke Assemble the trigger 19 to the sleeve bearing 18 and
60. e following proce dure is recommended Refer to Parts Catalog Fig ure 2 Remove the rear cover item 7 Figure 1 to expose the drive belt and associated components Manually run the drive belt off of the large me chanism pulley and pull the free end of the belt from the belt shifter loop T b Remove the tie strips from around the wiring at both ends of the motor c Loosen the screws in both motor bracket straps 28 Figure 3 and lift off the straps and Stabilizer bracket 29 as a group d Raise the motor just enough to permit belt to be passed beneath the motor toward the transformer Be very careful not to lift the motor so high as to damage the blower fan at the end of the motor shaft e Disconnect the push on connectors which con nect the motor leads to the starting capacitor item TC Figure 2 and remove the crimp type solderiess connector which joins the grey yellow motor lead to the three white leads The belt can now be re moved from the projector f Install the new belt by reversing the above order of removal Replace the crimp type solder less connector with a screw on type connector and when securing the motor with the motor bracket Straps make sure that the motor grounding strap left end of motor bears on the motor mounting bracket 28 Figure 3 LUBRICATION CHART Parts to be Lubricated Lubricant Oil P N 070003 Machined surfaces non bearing of all castings Sprock
61. e mechanism assembly 29 securely while removing the four screws 27 and the idler gear adjustment bracket 28 Carefully withdraw the mechanism assembly from the mainplate 7 REMOVAL OF BASE COMPONENTS Figure 6 Remove parts as necessary in their indexed order of disassembly noting the following special pre cautions a The lever stop and pin 5 has been carefully adjusted to insure the proper advance of film and a SERVICE INSTRUCT I ONS then secured with screw 4 Do not disturb these items unless obvious damage indicates need for repiacement b Remove the adapter shaft 7 and lift out the film guide roller 8 Remove the screw 9 and lift the sliding film guide assembly 10 from the flanges on the base Disassemble if necessary for replace ment of damaged parts c To expose the amplifier assembly 20 and edge connector assembly 18 remove the five screws 15 and the cover 16 Remove the four screws 17 and 19 and lift out both assemblies When separating the edge connector from the amplifier pull them straight apart without wriggling or twist ing them and thus distorting the pins Note the spacers 21 located beneath the amplifier d Remove the four screws 22 and the cover 23 to expose the volume and tone control as sembly 25 Four screws 24 secure the control assembly into the base e Remove the screw 26 and lockwasher 27 and disassemble the tilt bar 28 from the lower
62. e the washer 8 to the shaft of the take up spindle 7 and insert the shaft through the take up arm bearing Install and tighten the screw 6 Assemble the take up arm to the mounting pin in the reel arm Assemble the take up belt 4 around the spindle pulley and the rubber sleeve of the lower face gear See Figure D Insert the tension spring 5 into the recess in the take up arm and compress the spring 16 TAKEUP ARM TENS TON SPRING TAKEUP BELT PULLEY AND GEAR ASS Y Figure D Take Up Arm Assembled with a piece of shim stock while assembling the reel arm cover 2 to the reel arm Be sure to place a shim washer 3 on each of the reel arm mounting bosses before lowering the cover in piace Install and tighten the two screws 1 27 REASSEMBLING THE FRONT REEL ARM AS SEMBLY Figure 7 Reassemble the front reel arm as outlined in the following paragraphs a Assemble the washer 5C and then the face gear 5B down against the shoulder of the feed spindle 5D Install but do not tighten the two setscrews 5A b Place the reel arm 22 on the bench with the lower spindle end of the arm at your left Assemble the nylon bearings 21 into the cast bearing bosses of the reel arm engaging the key tabs of the bear ings with the cross slots in the bearing bosses In sert the gear shaft 20 through the nvlon bearings from right to left make sure that the end with the flats furthest from the tip of t
63. ector with audio framing test film TFR D550 NX5 and connect 16 ohm 15 watt load resistor and output meter to the speaker jack NOTE A pair of hairpin tongs approximately 6 in ches long and formed with the ends turned inward and tapered to engage holes in end of slit barrel are very useful in adjusting the optical slit They can be made from 20 to 26 gage music wire or 1 16 inch diameter drill rod 4 Set the volume control at approximately 12 o clock position and start projector Move slit toward or away from film as required to obtain an output reading Rotate the slit to obtain peak reading and simultaneously move in or out until maximum outputis ob tained If film was threaded with emulsion toward the optical slit move slit toward film until output drops 1 1 2 to 2 DB If emul sion is toward sound drum move slit away from film to obtain 1 1 2 to 2 DB drop in output Tighten slit clamping screw 10 se curely to lock the adjustment f Buzz Track Adjustment Figure 9 The lateral position of the film in the soundhead is controlled by the flanged roller 15C and edge guide screw 24 Unless the adjustment has been disturbed it is not probable that the edge guide screw 24 will require resetting Thread the projector with buzz track test loop TFL 37 NX1 and adjust volume control to a suitable listening level Turn adjusting screw 14 to move flanged roller laterally NOTE Originally two types of buzz track were
64. eeth against the flat washer Apply thermal compound Bell amp Howell Spec 28 7 001 to both sides of the mica washer and install this washer between the transistor and the metal heat sink bracket The metal collector plate of the transistor must be toward the heat sink b The integrated circuit must be installed with its polarity mark or notch toward the edge of the board indicated by the dashed arrow drawn on the top of the circuit in Figure 19 This arrow is not imprinted on the integrated circuit SERVICE NSTRUCT IONS Reassembly Procedure 18 GENERAL REASSEMBLY INSTRUCTIONS a Before reassembling parts be sure to clean them thoroughly Metal parts can be immersed in a pan of non flammable solvent or wiped with a cloth dampened with solvent then blown dry with a low pressure jet of compressed air or dried with a lint free cloth Do not clean plastic or electrical components with solvent Simply wipe plastic and electrical components with a clean dry cloth Clean optical parts with a good quality lens cleaner and lens tissue or a lint free cloth b When reassembly procedures include staking or riveting operations it is wise to perform these operations before assembling other parts Be sure to support the major casting or plate solidly during staking operations to avoid distorting the casting or plate c When installing electrical components refer to the appropriate wiring diagram at the rear of the Parts Catalog fo
65. eight gages Slowly slide the gage downward The ear should pass over the shuttle tooth without catch ing Rotate the gage so that the No Go over the shuttle slot and once more slide the gage downward The No Go ear must not pass over the shuttle teeth H the shuttle teeth are too high or two low adjust height as follows NOTE If the mechanism assembly is installed the mainframe it will be necessary to remove the lamphouse the projection lamp and the lamp holder before proceeding 1 Turn the mechanism drive pulley by hand until the access holes in the shutter and the fire shutter bracket are aligned as Shown in Figure G 2 Insert a No 4 Bristol Wrench into these access openings and engage it in the socket of the in out cam follower screw 3 If the shuttie teeth were too low No Go ear passes over shuttle teeth turn the cam follower screw counterclockwise to increase shuttle tooth height If the shuttle teeth were too high Go ear catches against shuttle teeth turn the cam fol lower screw clockwise It may be neces sary to recheck shuttle tooth height with the gage several times before the proper height has been obtained IN OUT SHUTTER ASS Y BRACKET 3 BLADE SHOWN FOLLOWER FIRE SHUTTER OR SUPPORT BRACKET NOTE INSERT WRENCH THROUGH ALINED HOLES AT X Figure G Adjusting Shuttle Tooth Height F ILM0S0U ROJECTORS MODELS 1595 1590 1592 4
66. et shafts 17 and 19 Oil P N 08963 Figure 10 Framer sha t 26 Figure 12 and bearing face of worm gear 24 Figure 13 Oil P N 04978 Felt oil pads in cams and Cil P N 070032 sliding parts friction surfaces not otherwise specified The worm gear teeth and sprocket gear teeth are to be lubricated with special grease P N The following items are to be lubri cated with general purpose grease P N 070034 other gear and pinion teeth all bearings x and pivot posts reel arm lock buttons al shafts cam wiper and wick Specific instruc tions are noted in the reassembly section TEST FILM CHART TF L 55 NX1 TFL 37 NXI TFL 26 NX3 TF L 23 NX1 TFR D550 NX5 TFS D550 NX1 Centering and framing loop Buzz track loop 7KHz azimuth loop 400Hz power output loop Audio Center Framing roll Loop restorer strip bad holes Loop restorer strip elongated holes TFS D550 NX5 FILMOSOUND PROJECTORS MODELS 1585 1590 1592 7 REMOVE 1 16 FROM UPPER GUIDE BAR F l SEE INSET Z ABOVE 10 k 13 INDEX NO TOOL NO TOOL NAME USE 1 1552 1 N1 Lamp Plug 2 S 550 2 N1 Lens Plug 3 S 550 2 N2 Alignment Rod Alignment of optical system Figure E 4 S 550 2 N3 Aperture Plug 5 Make in Shop Torque Wrench Adjust rewind torque check torque with Chatillon LP 72 0 to 72 oz push pull scale Master Gauge Co Chicago 60622 6 550 5 N2 Sttoke Gage Me
67. former assembly 14 to the projector base with the four screws 13 Refer to the appropriate wir ing diagram at the end of the Parts Catalog section for proper wiring connections g 1585 and 1592 Models Onlv Assemble the brackets 10C and 10D mounting flanges facing inward to the lamp transformer 10E with the screws 10B and hex nuts 10A Make wiring con nections to the transformer according to the appro priate wiring diagram Position the transformer so that the mounting holes in the bracket are aligned with those in the base Install the two front screws 9 then tip the projector so that the two rear screws 9A can be inserted up through the base Tighten all screws Assemble the brackets 7 and 8 to the top of the lamp transformer with the screws 6 and hex nuts 5 Make wiring connections to I9 SERVICE INSTRUCTIONS the power transformer 4 according to the appro priate wiring diagram Secure the power trans former to the upper fingers of the brackets 7 and 8 with two screws 2 with lockwashers 3 and hex nuts 1 Note that two sleeve spacers 3A are inserted between the bracket 8 and transformer on 1592H and 1592BH model projectors 32 REASSEMBLING END CAPS AND LAMP COM PONENTS Figure 2 Reassemble Figure 2 parts as outlined in the following paragraphs a Pull the lamp leads through the access hole in the mainplate and connect them to the terminals of the lampholder 15 Secure the lamp
68. ful not to scratch or nick the rails or aperture plate with the screwdriver when removing screws 16 COVER AND SPEAKER ASSEMBLY Figure 15 No special instructions are necessary repair ing the cover and speaker assembly Refer to the accompanying schematic Figure 16 for proper lead wire connections 17 TESTING AND REPAIRING THE AMPLIFIER ASSEMBLY Figure 19 Amplifier circuit board repairs are not recommended except as emergency measure and then only if qualified electronics per sonnel and test equipment are available If a faulty condition is traced to the amplifier replace the complete assembly Using standard electronic shop test equipment and techniques check the amplifier assembly and its components for continuity and for shorts and open circuits Refer to the appropriate wiring diagram for voltages and ratings of com ponents and for test points Defective solder secured parts can be replaced by cutting the leads as close as possible to the body of the part or by unsolder FILMOSOUND PROJECTORS MODELS 1585 1590 1592 ing the leads from their terminal points When un soldering it is advisable to use a heat sink to avoid the direct application of heat to adjacent components When replacing parts note the following special precautions a Each of the three transistors are furnished with a special lock washer and a mica washer The lock washer is to be installed beneath the head of the screw with its t
69. g screws just enough to permit movement of the aperture plate and insert the aperture plug item 5 Figure A into the aperture opening Close the lens carrier 4 Insert the alignment rod Figure E through the lens plug until the rod end protrudes enough to install the spring P N 6124 Insert the lens plug into the lens barrel until the tip of the alignment rod engages the aperture plug previously installed Tip the projector carefully onto its back lens opening facing up The alignment rod must slide freely through the aperture plug with out binding If necessary shift the aperture plate slightly until free rod movement is obtained then tighten aperture plate screws b Aligning the Lamp Socket 1 Tip the projector back into its normal upright position and reassemble the pres sure plate to the lens carrier Close the lens carrier 2 Loosen the two lampholder mounting screws just enough to permit movement of the lampholder Insert lamp plug 1 Figure A into lamp socket and secure the lamp spring Slide alignment rod completely into place until tip of rod engages the hole inlamp plug Shift socket as necessary until rod slides freely in the lamp plug hole Then tighten the Screws securely and remove all tools 22 36 ADJUSTING THE INTERMITTENT MECHANISM a Checking Shuttle Tooth Side Clearance Ad vance the mechanism manually until the shuttle is at the center of its stroke as shown in Figure F The clear
70. h anism housing Note in Models 1585 and 1590 the crank opening in the housing is sealed with a plug 38 12 DISASSEMBLING THE MECHANISM Figure 11 Remove parts as necessary in their indexed order of disassembly noting the following special pre cautions a Remove the three screws 1 andflanged rollers 2 Note the manner in which the torsion spring 5 is installed Remove the retaining ring 3 and with draw the threading arm 4 and torsion spring 5 from the mounting posts of the guard mounting plates b Note the manner in which the legs ofthe torsion spring 14 are engaged Remove the screw 6 idler roler 7 roller stud 8 locking lever eccentric 9 torsion spring 10 and autothread lever assembly 11 c Note the manner in which the legs of the tor sion spring 14 are engaged Remove the retaining ring 12 and lift off the lower loopformer 13 and torsion spring 14 d Remove the screw 15 and back up bracket 16 Remove the large retaining ring 17 and lift off the lower film guide 19 and two washers 18 Remove two screws 20 and the lower guard mount ing plate 21 Remove the retaining ring 22 and disassemble the toggle lever and pivot assembly 23 and lower film guide 24 from the mounting plate e Loosen the locking screw 27 and disassem ble the threading lever assembly 28 from the rear shaft end of the loopformer 31 Remove the retaining ring 30 and withdraw
71. he clutch gear 17 to the shaft with the longer end of the clutch gear mating up with the formed outline of the rewind gear As semble the gear and bearing assembly 16 to the shaft and up against the clutch gear so that the bearing spring is positioned between the two bosses on the face of the clutch gear install the retain ing ring 15 into the groove of the shaft to lock the entire clutch assembly in place f Assemble the gear 11B long hub out to the gear stud of the arm assembly 110 and install the retaining ring 11A Assemble the rewind clutch as sembly 14 and flat washer 13 to the upper sprocket shaft and assemble the gear retaining key 12 to the ftlats of the shaft Assemble the large hole in the idler arm over the inner shoulder of the spur gear 9 and install these parts and washer 10 on the upper sprocket shaft Slide the gear 9 inward until the square recess in its face engages the key 12 The staked pin of the idler arm must be in serted into the triangular cut out in the rewind lever 25D Install the spring tension washer 7 bowed face out and the grip ring 6 g Install the washers 5 and spur gears 4 hubs in on their respective gear studs and secure them with the retaining rings 1 Assemble the washer 3 and the spur gear 2 to the shaft and install the retaining ring 1 h Speck all gear teeth sparingly with grease After the projector is completely assembled grease can be d
72. he loop end of the spring over the spring boss of the reel arm Secure the loop with the retaining ring 7 and tighten the gear setscrew 8 securely The retaining ring 7 must not be so tight as to restrict movement of the spring loop when the face gear is rotated d Apply one drop of oil at the flanged end of the reel arm lower bearing Assemble the feed spindle assembly 5 down through the reel arm bearing Install and tighten the screw 4 securely e Rotate face gears 5B and 9 in both direc tions to check backlash There should be approxi mately 0 005 0 018 inch backlash around the total circumference each gear the trial and error method loosen the gear setscrews 5A or 8 and reposition the engagement of face gears with spur gears until proper backlash is obtained Then tighten setscrews securely f Place a shim washer 3 on each of the reel arm mounting bosses and carefully assemble the cover 2 to the reel arm Install and tighten the two screws 1 28 REASSEMBLING THE BASE COMPONENTS Fig ure 6 Reassemble Figure 6 parts as outlined in the following paragraphs a Lightly grease the teeth of the worm gear 44 tilt gearshaft 41 and gear rack 39 Assemble spring washer 42 to the tilt gearshaft 41 bowed surface toward the worm gear Insert the shaft through the hole in the base and secure it with the retaining ring 40 Fasten the tilt adapter 38 loosely to the base with the screw
73. he same as those in the basic service manual In place of the stacked transformer arrangement items 3 1 through 3 10 the X models are equipped with the power transformer item 3 14 similar tothe Model 1590 Since the X models are provided with a separate line cord and plug in socket Figure any reference to the strain relief items 3 24 and line cord wiring connections are to be disregarded SCREW P N 535198 4 VOLTAGE SELECTOR NUT P N 436950 P N 077606 LINE CORD RECEP SCREW P N 536959 TACLE P N 709737 6 BRACKET P N 710252 7 WIRE TIES P N 072348 Figure A Cord Wrap and Socket Assembly Since the X models are not provided with the animation feature the animation switch item 3 34 is not included All X models use rotary switch assembly item 3 39 therefore references to other rotary switch designs items 3 34 and 3 35 can be disregarded The solenoid and its related components items 3 44 through 3 47 are not used on X models Parts which are peculiar only to the Models 1585CX 1592CX and 1592CSX are the amplifier fuses and fuse board mounted near the drive motor These parts are shown in Figure B of this Supplement REPAIR OF FIGURE 4 ITEMS The disassembly reassembly procedures for Mod els 1585CX 1592CX and 1592CSX are the same as those in the basic service manual REPAIR OF FIGURE 5 ITEMS The disassembly reassembly procedures for Mod els 1585CX 1592CX and 1592CSX are the s
74. he shaft is at the right upper end of the reel arm Assemble the lower spur gear 19 to the left end of the shaft The gear face with the sauare recess must face away from the cast bearing boss Install the gear retaining clip 17 to the flats of the gear shaft Assemble the washer 18 and the second gear retaining clip to upper end of the gear shaft 20 Assemble the upper spur gear 16 to the shaft with the square recess of the gear engaging the retaining clip Install the grip ring 15 on the end of the shaft Insert a 0 010 inch feeler gage between the upper spur gear 16 and washer 18 and press the grip ring in against the gear Re move the feeler gage c Assemble the retaining ring 11 into the ring groove nearest the two flats of reel arm shaft 14 Assemble the washer 12 onto the shaft and down against the retaining ring Place drop of oil at the unflanged end of the reel arm upper bearing Insert the long end of the shaft 14 through the upper bear ing and install the spacer washer 13 and the second retaining ring 11 Make certain that the setscrews 8 and 8A are not protruding into the shaft hole of the face gear 9 and that the sleeve 9A is in place on the hub of the gear Apply a light coat of grease to the gear teeth Assemble the torsion spring 10 to the hub of the gear with the loop end of the spring furthest from the gear teeth Assemble the face gear to the reel arm shaft while engaging t
75. hile loosening or tight ening the nut on the clutch hub Rewind torque also 2 5 to 4 5 in lbs is adjusted by means of the rewind clutch assembly item 14 Figure 4 This clutch is installed with the adjusting nut facing in ward toward the mainplate and a special wrench item 5 Figure A must be used for the adjustment 41 ADJUSTING THE SOUNDHEAD Removal 1 Remove the projection lens from the lens carrier and wrap it in tissue or a soft cloth 2 Loosen the cover thumbscrew and remove the exciter lamp cover from the sound head 3 Remove the rear cover Figure 1 from the projector Remove the assembled power transformer and lamp transformer Fig ure 3 from the projector base being ful not to place undue strain on the trans former leads Remove the flywheel 35 Figure 4 from the sound drum shaft 4 Refer to the wiring diagram at the rear of the Parts Catalog section and discon nect or unsolder soundhead leadwires as necessary 5 With sharp pencil scribing tool scribe a line on the projector main plate along the front edge of the soundhead casting This will provide a reference mark for locating the soundhead during installation 6 Remove the three screws 36 Figure 4 and flat washers 37 and carefully with draw the soundhead assemby from the pro jector main plate disengaging the Volume control shaft from its opening in the sound head housing SERVICE INSTRUCTION
76. holder and the lamp shield 14 to the mainplate with the two screws 13 and pull excess lamp leads back be hind the mainplate Assemble the projection lamp 12 into the lamp socket and swing the lamp re taining spring up into place b Loosely assemble the still run lever 11A to the switch shaft with its setscrew Assemble the control knob 11 to the shaft pressing in until fully seated c Assemble the axuiliarv speaker jack 9 and its insulating washer 10 to the rear end cap 7 with the hex locking nut 8 Reassemble the rear end cap components 7A through 7H noting that only the 1592 model projectors are equipped with the Directamotion remote control receptacle 7F An adhesive backed cover 7G is installed over the receptacle opening in 1585 and 1590 model pro jectors The starting capacitor 7C is mounted 20 with its terminals up and the top end of the capa citor approximately 1 8 inch above the top edge of the capacitor clamp 7B Secure the clamp to the rear end cap with two screws 7A d Assemble the speaker 6B over the four molded pins of the front end cap 6C and install the four grip type retaining rings 64 Speaker should be installed with the terminals at the top e Make certain that all twelve speed nuts 5 are in place on the formed mounting ears of the two end caps Position the front end cap assembly 6 on the base with mounting holes aligned and from beneath the base install the
77. ides are connected by mechanical link age The system is actuated by a cocking lever at the lower end of the linkage and the movement is stopped 30 at the top end of the linkage The specitied clearances must be checked with the system in the load position If the need for adjustments is detected itis important that the repairman proceed in the sequence listed in this section The sprocket timing and the locating of the soundhead may be done without disturbing the film guide adjustments 44 ADJUSTING THE LOADING GUIDES a Swing open the lens carrier upper take up sprocket guard 1 Figure N and remove the re taining screw 2 b Place the timing plate S 552 1 N1 over the sprocket hubs 3 and 4 Figure N The timing plate locating pin should enter the counterbore from which screw 2 was removed If the locating pin does not enter counterbore loosen three sprocket guard plate FILMOS UND P ROJECTORS MODELS 1585 1590 1592 1 Guard plate attaching 5 Heel of lower loopform 10 Kickplate setscrews screw 6 Entrance guide roller li Eccentric pivot screw 2 Sprocket guard plate 7 Upper guard plate screws 12 Eccentric pivot 3 Aperture plate screw 8 Film escape kickplate 13 Leaf spring screw 4 Lower loopform assembly 9 Hood 14 Leaf spring Figure P Autoload System Adjustments View II attaching screws 1 Figure and rotate the lower guard plate 2 until pin enters hole Then tighten the three screw
78. ifficult to replace without disassembling the link age Use a soft lint free cloth when necessary to remove any accumulation of dust or film chips During periodic maintenance of the projector thd transport mechanism should be removed and thoroughly cleaned Brush or blow out all large particles of dirt Wash all moving parts except bearings with any good petroleum solvent Wash Olite bearings and the pull down cams with naphtha Wash the cam oilers in naphtha and re place if not thoroughly cleaned by washing Discard and replace the cam wiper and cam wiper wick AS soon as parts have been washed and dried coat with a light film of the specified lubricant LUBRICATION The following Lubrication Chart lists those items which are to be lubricated during reassembly Lub ricants specified can be ordered from Bell amp Howell by part number Be careful not to over lubricate A drop or two of oil and a light film of grease applied with a brush if possible will be adequate Wipe away excess lubricant with a lint free cloth Felt pads and wicks should be placed in a shallow pan of the specified grease or oil and allowed to stand until saturated Permit the excess lubricant to drain away before installing these felt parts DRIVE BELT REPLACEMENT Because of the compactness of design of these projectors the drive belt is not easily accessible for replacement To avoid extensive disassembly at the rear of the projector th
79. istributed by running the projector briefly 31 INSTALLING ELECTRICAL COMPONENTS Fig ure 3 Install Figure 3 parts as outlined in the following paragraphs Refer to the appropriate wir ing diagram at the rear of the Parts Catalog for proper connection of leadwires between components a 1592 Models Only Place the solenoid assem bly 47 on the work surface with the rod pointing toward you and the tapped holes in the solenoid bracket facing up leadwires at the right Place the mounting plate 47B over the tapped holes with the leg containing the single mounting hole toward you and at the left Install and tighten the two screws 47A Assemble the three rubber bush ings 46 small diameter first into the mounting holes of the mounting plate 47B Install a collar 43 large diameter first on the solenoid rod pressing it up against the yoke while tightening its setscrew 42 Assemble this solenoid group to the support plate mounted on the long cast arm of the mechanism assembly while guiding the sole noid rod down through the hole in the tongue of the Stop pawl Fasten the mounting plate 47B to the mechanism support plate with the three screws 44 inserting the spacer washers 45 between the rubber bushings 46 and the mechanism sup port plate Temporarily assemble the reamining collar 43 on the lower end of the solenoid rod beneath the stop pawl and tighten its setscrew b 1585 and 1590 Models Attach
80. it is withdrawn Remove the screw 7H and washer 7J to free the strike 7K from the clutch slide bar b 1585 and 1590 Models Only Remove the two retaining rings 8 and 28 the two screws 9 and the bearing loading spring 10 Loosen the set screws 11 and 24A in the loop restorer cam 27 and worm gear 24 and press the camshaft 30 to the left until the bearing 12 is forced from its seat in the housing Then press the camshaft to the right to force the large bearing 29 from its seat Remove the worm gear and loop restorer cam as the camshaft is withdrawn from the housing c 1592 Models Only Remove the large retaining ring 8 the two screws 9 and the bearing load ing spring 10 Loosen the setscrew 11 in the loop restorer cam 27 and press the camshaft 30 to the left until the bearing 12 is forced from the mechanism housing Pull the bearing from the camshaft Remove retaining rings 16 and 28 from the camshaft and press the camshaft to the right to force the large bearing 29 from its seat Remove the clutch gear and cam parts 13 through 27 as the camshaft is withdrawn Make a note of the manner in which the torsion spring 14 is assembled Inspect worm gear parts 24 through 24D and if damaged disassemble for replacement 15 DISASSEMBLING THE APERTURE PLATE Fig ure 14 Disassemble the aperture plate by remov ing parts as necessary in their indexed order of disassembly Be very care
81. just paragraph 36 step d Double image 1 Incorrect shuttle stroke 1 Adjust 36 step 2 Excessive shuttle protrusion 2 Adjust paragraph 36 step b Weave due to faulty 1 Sticking edge guide 1 Clean guide aperture plate 3 2 Replace tension spring lost 2 Replace spring 3 Fixed edge guide out of position 3 Reposition guide Poor illumination 1 Optics out of line 1 Realign paragraph 35 2 Fire shutter sticking 2 Check mechanical linkage binding Poor focus 1 Dirty lens and or aperture 1 Clean lens and or aperture 2 Warped film 2 Recondition or replace film 3 Projector lens mount out of line 3 Realign paragraph 37 4 Pressure plate spring lost 4 Replace spring 5 Bent pressure plate 5 Replace pressure plate 6 Pressure plate out of line 6 Realign pressure plate Frame line creeps 1 Framer eccentric loose 1 Align and tighten para graph 36 step e Insufficient framing 1 Framer eccentric out of adjustment 1 Adjust paragraph 36 step Trailer ghost 1 Shutter out of line 1 Reassemble properly 35 52 FILM TRANSPORT TROUBLES AND REMEDIES FILMOSOUND PROJECTORS MODELS 1585 1590 1592 TROUBLE PROBABLE CAUSE REMEDY Loss of loops 1 Damaged film 1 Repair or replace film 2 Inadequate shuttle protrusion 2 Adjust paragraph 36 step b 3 Inadequate or excessive shuttle 3 Adjust paragraph 36 step d stroke 4
82. lamp cover parts as outlined in the following paragraphs a If exciter lamp mounting pin parts 31 through 31C were replaced assem ble the spring 31C and bushing 31B into the opening in the casting and insert the mounting pin 31A forcing the end of the pin carefully through the bushing b Fasten the terminal 30 to the soundhead cast ing with the screw 29 The free end of the terminal Should be approximately at the 5 o clock position Loosely assemble the optical slit locking screw 10 the setscrew 19 and the edge guide screw 24 to the soundhead casting Leave approximately three threads of the guide screw exposed c Apply ahesive B amp H Spec 1761 34 to the end four threads of the roller adjusting screw 14 and assemble the screw to the soundhead leaving ap proximatelv two threads exposed d Assemble the light pipe and photocell assembly 23 and light pipe retainer 22 to the sound drum and shaft assembly 21 and insert the sound drum shaft carefully through the opening in the soundhead casting Hold the sound drum while tightening the setscrew 19 against the retainer 22 just enough to hold all parts in piace Install the two screws 20 turning them down in the tapped holes in the sound drum housing e Lightly oil the roller shafts of stabilizer arms 15H and 157 Assemble the lower stabilizer arm 15H over the short shaft end of the upper stabilizer arm 15J Assemble the torsion s
83. late Hold the button in with a piece of shim stock while assembling the rear reel arm 29 to the mainplate Assemble the reel arm disc 27 over the shoulder of the reel arm with the bent fingers of the disc pointing away from the main plate Align the screw holes in the disc with those in the reel arm and install and tighten the screws 26 Install the front reel arm assemblv 28 in the same manner d Assemble the spur gears 25C hubs inward to the gear studs of the rewind lever assembly 25D Place a washer 25B on the gear stud nearest the end of the lever and secure the gears with the re taining rings 25A Hook the bent end of the long leg of the spring 24 through the hole in the upper lip of the rewind lever 25D and assemble the spring loop and the rewind lever to the gear stud of the main plate located near the upper left hand corner of the cut out for the mechanism assembly Wind the short leg of the spring one full turn counterclockwise and hook the bent end behind the edge of the cut out Assemble the idler gear 23 hub inward and the washer 22 to the protruding gear stud meshing gear 23 with gears 25C install the retaining ring 21 e Assemble the gear retaining key 19 to the slot of the front reel arm shaft Assemble the re wind gear 18 to the shaft so that the square recess in the inner face of the gear engages the retain ing key Lightly grease the outer hub of the rewind gear Assemble t
84. led sprocket guard 16 up into position beneath the upper sprocket and se cure the guard with two screws inserted from the rear of the mechanism housing Assemble a flat washer 14A tension washer 14 and the upper sprocket gear 12 to the sprocket shaft Align either setscrew 11 with the flat on the sprocket Shaft and carefully mesh the sprocket gear with the worm gear Tighten both setscrews 11 se curely The sprocket and gear must turn freely but with a minimum of end play g Fasten the hood 10 to the mechanism housing with the two screws 9 Press down and hold the up per loopformer 31 Figure 11 while assembling the actuating lever 7 Figure 10 to the lever shaft Install the retaining ring 6 h Hold the assembled lens carrier 5 between the hinge bosses of the mechanism housing Insert the flat washer 4 on top of the lower hinge boss and the spring tension washer 3 beneath the upper hinge boss Press the hinge pins 1 and 2 into place to hold the lens carrier Adjust the lens carrier catch 38 Figure 11 so that it holds the lens carrier firmly against the stop screw 36 Figure 11 in the closed position yet permits the carrier to be opened easily i All critical adjustments are to be made during the final assembly of the projector and are covered in the Adjustments section of this service manual 25 REASSEMBLING THE SOUNDHEAD AND EX CITER LAMP COVER Figure 9 Reassemble the soundhead and
85. ller 2 Sound drum 3 Upper sprocket 4 Film suide 5 Film guide 6 Upper sprocket shoe UPPER SPROCKET CAM SETSCREW CAM BELOW CAMSHAFT LOWER SPROCKET TIMING PLATE LOCATING x p O7 Figure R Autoload System Adjustments View 33 SERVICE INSTRUCTIONS screws securely Be sure that the ear of the loop restorer arm is positioned between the two spring loaded keeper plates of the self centering assembiy b Rotate the mechanism pulley until the setscrew in the loop restorer cam is at the bottom diretly be low the camshaft see inset B Figure R The clear ance between the upper tip of the cam follower blade and the face of the cam should be 0 015 inch To ad just this clearance loosen the cam follower support mounting screw inset B and rotate the support ac cordingly then retighten the screw securely Now check the clearance between the upper end of the cam follower and the small diameter of the loop restorer cam inset C This clearance should be 0 040 inch 0 005 inch Be sure that the cam setscrew is still positioned at the bottom of the cam below the cam shaft To adjustthis clearance loosen the two follower screws inset B and raise or lower the cam follower blade as necessary then retighten the two screws securely c Recheckthe clearance between the loop restorer roller and upper sprocket shoe guide roller as outlined in step a above Remove the restore
86. lowly toward the shut tle to the right until the shuttle teeth are retracted below the level of the aperture plate rails Retighten the Allen nut 3 Refer to View D Figure K Adjust the set screw in or out to obtain a clearance of 0 094 inch between the left hand ear of the clutch slide bar andthe end of the setscrew 4 The shuttle interlock retainer is secured to the right end of the worm gear Note in View C that the curved lip of this retainer must overlap the downward bent finger of the clutch slide bar If necessary bend this finger to obtain positive overlap as shown 25 SERVICE INSTRUCT IONS OF NTERLOCK LEVER FINGER OF CLUTCH SLIDE BAR CLUTCH WORM ALLEN SOLENOID MS SOLENOID 32 TO 1 8 N SHUTTLE ADJUST VIEW C MENT BRACKET LOWER COLLAR 0 094 IN TSCREW i CLUTCH SLIDE BAR TRIGGER 0 010 TO 0 015 1 VIEW A 0 015 IN STRIKE CLEARANCE VIEW D CLUTCH YOKE FINGER CLUTCH CLUTCH STRIKE SOLENOID BRACKET LOCK SCREW 2 TONGUE OF 2 CLUTCH CH CLUTCH en SOLENOID evel YOKE BEARING PLUNGER TRIGGER lt gt TZ d ZN IAL UPPER fh COLLAR Wl COLLAR 1 STOP PAWL STOP LOWER STOP PAWL SS NOTCH IN PAWL COLLAR BENT EAR DRIVEN CLUTCH a Q Figure K Animation Clutch Adjustments Adjusting Clutch Solenoid Li e Refer to to 0 015 in
87. ment disassemble the retaining ring 1 washer 3 spur gear 4 and a second re taining ring 1 from the end of the reel arm shaft Note the manner in which the reel arm disc 27 is positioned before disassembling the screws 26 and disc 27 from the mainplate then carefully with draw the reel arm assembly catching the lock button 30 and spring 31 as they pop free b To remove the front reel arm assembly 28 for repair or replacement disassemble the gear and clutch parts 15 through 19 from the end of the reel arm shaft Note the manner in which the reel arm disc 27 is positioned before disassembling the screws 28 and disc 27 from the mainplate Carefully withdraw the reel arm assembly catching the lock button 30 and spring 31 as they pop free R F LMOS OUND PROJECTORS MODELS 1585 1590 1592 To remove the soundhead assembly 40 for repair or replacement it first is necessary to re move the amplifier cover item 16 Figure 6 so that the soundhead leads can be unsoldered from the edge connector terminals refer to appropriate wiring dia gram Assuming that the transformer assembly has already been removed paragraph 4 referto Figure4 and disassemble the retaining ring 32 flywheel 35 and washers 33 and 34 from the end of the sound drum shaft Then remove three screws 35 and washers 37 and carefully lift the soundhead as sembly from the mainplate d No special instructions are
88. mp Projector 30811 Screw Hex washer head 12 49532 Shaft Rear reelarm 31011 Bearing spe woy WS 6 49696 Cover lt x sx 31135 DDEIHS Ax 12 49945 Switch Rotary 31237 Washer Nylon 12 308638 31239 Gear SUT us Z wu 12 707073 Knob Control e 9s 31241 Clip Retaining 12 707110 uw 31245 Ring Retaining 12 707112 Gear 31557 Shuttlea 334 vada 5 707211 Spring 31561 Foot Rubber 93s 5 707281 Capacitor d UIS US 33385 Gears SOULS 4 ec 43 6 707747 Speaker wo 34766 Bar 44e 3d 1 708246 Screw Hex washer head 34878 Washer BD ep at Se BE 2 12 765777 Ring 34884 Lamp EE a 4 vex 12 99828 Ring 34889 Screw Binding head 12 09712 Bearing Assembly Support 35814 Guard Sprocket 5 09807 KODO Tilta 35 eX N 35830 DOPING AX 4 eae as ee Ae 12 09828 Contact Assembly Exciter lamp 35846 Guide Upper 3 011214 Shaft and Link Assembly 35850 Guide Lower arm 3 011221 Lever and Pivot Assembly 36013 Wiper Felt Sa w 12 011235 Bearing and Arm Assembly 36014 Wick Catt 12 011236 In Out Bracket Assembly 36015 Sod as Bow dee de CY 12 012132 Pla
89. n rod up through the hole in the tip of the stop pawl of the mechanism assembly Hook the bent end of the rod through the hole in the long arm of the pivoting link assembly 18 Assemble the spring 3 and the second 2 small diameter down to the upper end of the rod Slide the lower collar up against the underside of the stop pawl and compress the spring slightly with the upper collar Tighten both collar setscrews 1 securely 30 INSTALLING THE SOUNDHEAD REEL ARMS AND GEARS Figure 4 install Figure 4 parts as outlined in the following paragraphs 18 a Carefully assemble the soundhead assembly 40 to the projector mainplate Be sure that all leadwires are pulled through behind the mainplate so as not to be pinched between the mainplate and the soundhead Hold the soundhead while installing and tightening the three screws 36 andtheir washers 37 Refer to the appropriate wiring diagram at the rear of the Parts Catalog for proper wiring connec tions between soundhead and other projector parts b Assemble the bowed washer 34 and the fly wheel 35 to the sound drum shaft with the bowed face of the washer against the flywheel install the flat washer 33 and retaining ring 32 on the end of the sound drum shaft Spin the flywheel to make certain that the shaft rotates smoothly c Insert a spring 31 and a reel arm lock button 30 into the opening to the right of the rear reel arm mounting hole in mainp
90. n until the up per spur gear 20 and washer 23 can be removed Remove the lower gear retaining clip 21 and lower spur gear 22 and slide the gearshaft 24 from the bearing posts of the reel arm Inspect the nylon bearings 25 and if damaged press them from the bearing posts f Loosen the setscrew 26 and lift the upper face gear 27 from the reel arm sha t 31 Re move tbe retaining ring 28 and disassemble the reel arm shaft 31 and washer 29 from the reel arm 10 DISASSEMBLING THE EXCITER LAMP COVER AND SOUNDHEAD Figure 9 Disassemble the ex citer lamp cover and soundhead assembly in the foi lowing manner noting any special precautions a Inspect exciter lamp cover parts 1 through 7 and disassemble only as necessary for replacement b Make a careful note of leadwire connections be fore disconnecting or unsoldering leads during disas sembly of the soundhead Remove the exciter lamp 8 wipe off fingerprints and wrap the lamp in tissue paper c Do not loosen the clamping screw 10 or dis turb the lateral position of the optical slit assemblv 11 unless it has been determined that the optical slit is in need of replacement or adjustment LINE WHT ______ 4A 250V SLO BLO VOLTAGE SELECTOR SW 53 40V eco v t20 V Pos pos 5 FULL PHOTO DIODE BLK MICROPHONE Mic JACK CIRCUIT MODEL 158560 ON
91. nd arm assembly 56 on the end of the shaft The fork like finger of the arm assembly must engage the pin of the self centering assembly between the two large washers Insert a 0 0015 inch feeler gage between the washer 57 and the machined boss of the housing Grip the shaft 58 and arm 56 to hold the feeler gage while tightening the hex head screw 55 then remove the feeler gage Assemble the retaining ring 59 to the shaft assembly 58 NOTE The shaft assembly 58 when installed must be positioned approximately as shown in Fig ure 11 with the notched area in its upper edge po sitioned beneath the lower sprocket shaft bearing of the mechanism housing b Assemble the cam follower parts 54 through 54F as shown in Figure 11 Attach this assembled group to the arm assembly 56 with the screw 52 and washer 53 Tighten the screw just enough to hold the follower group Hook one end of the spring 51 around the end of the lever shaft 58 and secure the other end to the mechanism housing with the screw 49 and washer 50 C Assemble the film escape mechanism compon ents 46A through 46G in the following manner As semble the hub assembly 46F to the locking pawl 46E with the screw 46D Insert the shaft 468 through one ear of the upper loopformer assembly 46G and install the spring 46C and the assembled hub and pawl on the shaft Then engage the end of the shaft with the second ear of the loopforme
92. nd of the shuttle retractor must not strike the casting g Close film gate while observing to see that the film pressure plate does not contact the aperture plate If pressure plate remains in contact with aperture plate either the pressure plate lift off ear 8 Figure ear 9 the threading guide linkage is bent Reform ear or ears as necessary h Loosen the screw 10 Figure N and align the film guide 11 so that film will feed squarely to the sprocket then retighten screw 10 i Loosen screw 11 Figure P lock the system and check to make certain that loop form heel 5 is bearing on shoulder of roller stud 6 If necessary rotate the eccentric pivot 12 with a wire pick or pin punch until heel bears against stud shoulder When loop form is pressed downward there must be no clearance between heel and stud shoulder Recheck clearance between rear of loop form and aperture rails step c preceding Also make certain that end of upper loop form 8 is tangent to or slightly ahead of the plane of the aperture plate film support rails readjustment is necessary refer to steps c through e preceding Lock the system and try to insert film into the feed sprocket If film slips in too freely loosen the two screws 13 Figure P and move leaf spring 14 downward to increase pressure on the film H film buckles as it is inserted move leaf spring upward to reduce pressure then tighten screws
93. nd wiring 3 Clean sound drum 1 Correct grounded condition 2 Trouble in printed circuit board 2 Check out the circuit board 94 TROUBLE SHOOTING AUTOLOAD SYSTEM a General Any obstruction in the film path such as caked emulsion film chips or splicing tape can be expected to interfere with proper threading Time will be saved by cleaning the threading path and at the same time making a visual inspection of all shoes and guides before attempting to localize the trouble Do not use metal tools to remove ma terial adhering to guides or rollers Use an orange stick plastic rod or toothpick whenever scraping is necessary Pipe cleaners dampened with toluol napth tha or 150 are very convenient for cleaning in restricted areas Do not use trichloro ethylene or carbon tetrachloride as cleaning solvents as they might damage or stain plastic parts Do not use excessive amounts of solvents or lubricants will be removed from linkage pivots slides etc and will have to be replenished b Test Film The autoload system has been designed to function properly with all films which can be described as being in projectable condition see Operators Instructions for limits of shrinkage curl etc Generally any film which functions pro perly in other Bell amp Howell projectors such as De signs 399 542 and 552 can be used for testing the autoload system Any film which does not thread properly
94. o paragraph 15 for ture plate disassembly instructions 13 DISASSEMBLING THE MECHANISM Figure 12 Remove parts as necessary in their indexed order of disassembly noting the following special pre cautions a Loosen the two setscrews 1 and withdraw the mechanism pulley 2 from the end of the camshaft Remove four screws 3 and lift off the support bracket 4 used on 1585 and 1590 models or the fire shutter assembly 4 used on 1592 model pro jectors Disassemble tne fire shutter only if parts are damaged and need of replacement b Remove two screws 5 and the heat baffle 6 Remove the shutter nut 7 counterbalance weight 8 shutter 9 and fiber washer 10 c Unless obviously in need of replacement do not disassemble the ball and stud assemblies 12 or the shuttle link bearing 17A from the shuttle arms 17 Inspect the pull down cam follower 17B for wear The cam follower is staked in place in the recess of the shuttle arm and can be reversed or turned end for end if badly worn Unkook the extension spring 13 from the end of each shuttle arm and remove the felt wiper 14 and shuttle arms The cam wiper wick 15 is inserted within the coils of the spring 13 If the wiper and wick appear especially dirty discard them d Withdraw the pull down cam 18 from the cam shaft Remove the two screws 19 and disassemble the in out cam 20 and cam bracket assembly 21 together from the mechani
95. obstruction of top sprocket 2 Damaged sprocket guard 2 Replace sprocket shoe 3 Sprocket guard and sprocket 3 Realign misaligned laterally Film strikes top of 1 Upper loop former 8 Figure P bent 1 Straighten or replace if bent aperture plate and or out of adjustment readjust per paragraph 44 begins to pile up step e 2 Lower loop former 4 Figure P set 2 Readjust per paragraph 44 too close to aperture plate step e Film butts into or goes 1 Upper loop former 8 Figure P bent 1 Straighten or replace if bent under top end of aperture causing sidewise deflection of film readjust per paragraph 44 plate side tension rail or step e strikes fixed rail 2 Lower loopformer 4 Figure P bent 2 Straighten or replace if bent or out of adjustment readjust per paragraph 44 step c Film butts against top of 1 Lower loop former 4 Figure P out 1 Readjust per paragraph 44 film pressure plate or of adjustment step c passes over outside of pressure plate 2 Pressure plate not lifting off of aper 2 Bent parts need straightening ture plate when film gate is closed paragraph 44 step g or re placing Film ejects between 1 Lower loopformer 13 Figure 11 1 Straighten remove bind or bottom of gate and top bent or sticking replace as necessary of take up sprocket or piles up in this area 2 Lower loop former spring 14 2 Replace spring Figure 11 broken 3 Loop restorer out of adjustment or 3 Readjust
96. or mainplate while inserting the Volume control shaft through the sound head casting Install and tighten the Volume control mounting nut 2 Install the three screws 36 Figure 4 with their washers 37 from the rear of the mainplate and tighten the screws finger tight Shift the soundhead until the forward edge of the soundhead housing is aligned with the scribe or pencil mark on the main plate and maintain this position while tight ening the three screws securely 3 Refer to the appropriate wiring diagram at the rear of the Parts Catalog section and reconnect or resolder all soundhead leadwires 4 Assemble the bowed washer 34 Figure 4 flywheel 35 and flat washer 33 to the sound drum shaft and secure these parts with the retaining ring 32 28 LOCKING CLAMP SETS CREW SILICON PHOTOCELL SOUND DRUM Figure L Positioning the Sound Drum and Silicon Cell 5 Reinstall the assembled power transformer and lamp transformer Figure 3 to the projector base e Optical Slit Adjustment Figure 9 1 Insert the optical slit 11 into its opening in the soundhead The adjusting hole in the barrel of the slit must be at top center 2 Insert a 0 050 inch feeler gage between the tip of the optical slit and the sound drum and press the optical slit in against the feeler gage Hold in this position while tightening the locking screw 10 just enough to hold the slit in place 3 Thread the proj
97. or make a rough sketch of leadwire connections to facilitate installation of the parts Unsolder leads with a pen cil type soldering gun using a heat sink if available or gripping the lead with a pliers to provide addi tional heat dissipation d When removing riveted parts for replacement the old rivet must be drilled out witha drill equal to or slightly smaller thean the diameter of rivet to be in stalled Refer to parts lists for the rivet diameter 2 REMOVAL OF COVERS Figure 1 Remove the parts as necessary in their indexed order of disas sembly noting the following special precautions NOTE The CS CHS and MLS models are equipped with a front cover and speaker assembly Parts Catalog Figure 15 rather than the standard front Cover item 1 Parts Catalog Figure 1 a Unlatch and remove the front cover assembly 1 H latches to be replaced the rivets 1B must be carefully drilled out b The rear cover 7 is secured by seven screws 6 and 6A three along the bottom edge and two at each side Use a thin wall socket wrench to re move these screws grinding it down if necessary so that it can fully engage the screw heads c Remove two screws 8 near the top of the mainplate to free top cover assembly 9 Remove the four screws 9A and disassemble the carrying handle 9B and brackets from the cover NOTE The 1585ML and MLS are equipped with two additional fuses 9D which are mounted in th
98. own in the notch in the shoulder of the camshaft Assemble the pull down cam 18 to the camshaft spreading the shuttle arms lightly until the cam is fully in place The notch in the inner face of the pull down cam must ECCENTRIC FRAMING ARM SHUTTLE ARM CAM FOLLOWER SHUTTLE ARMS SHUTTLE BALL AND STUD ASSY FELT WIPER Figure B Shuttle and Shuttle Arms Assembled 12 engage a mating protrusion on the face of the in out cam Back out the bearing support 24 until its socket like nylon pad engages the ball of the upper stud assembly 12 The ball of the lower stud assembly should rest in the socket of the nylon pad mounted on the shuttle arm plate assembly 23 It may be necessary to loosen the hex nuts 11 and shift the ball and stud assemblies 12 until proper alignment is obtained f Install the fiber washer 10 on the camshaft and up against the puli down cam 18 so that the slot in the washer is aligned with the slot in the cam Assemble the shutter 9 to the camshaft and install the counterbalance weight 8 so that its pin engages the slots in the shutter and the pull down cam Install the shutter nut 7 with its shoulder in the center hole of the counterweight Grip the flats at the end of the camshaft with an Spenesnd wrench and tighten the nut 7 securely g 1592 Models Only Assemble the grommets 37 into the bracket 36 Assemble a retaining ring 30 into the groove neare
99. pring 15G straight leg first over the tapped hub of the lower stabilizer arm 15H Assemble the stabilizer arm 15F to the tapped hubs of the upper and lower arms and install the two screws 15E Hook the bent end of the spring 15G through the small hole near the end of stabilizer arm 15F Wind the straight leg of the spring one full turn clockwise and hook it behind the small post in the lower arm 15H Assemble the rollers 15C and 15D to their respective roller studs Roller 15D must be installed with its narrow flange nearest the shoulder of the stud Secure both rollers with the screws 15A and washers 15B Insert the shaft of the upper stabilizer arm carefully through the sound head casting and the adjusting screw 14 and instail the retaining ring 13 Position the retaining ring for 0 0005 to 0 005 inch end play of the stabilizer arm shaft See Figure C for stabilizer and installation f Lightly grease both surfaces of the lamp re lease ring 18 and assemble the release ring and the lamp contact assembly 17 to the soundhead casting with the two screws 16 g Insert the optical slit assembly 11 into its opening in the soundhead casting and tighten screw 10 just enough to hold the slit in place F ILMOSOUND P ROJECTORS MODELS 1585 1590 1592 TENSION ADJUSTER lm SPRING RETAINER Figure C Stabilizer Arms Installed on Suundhead h Insert the small end of the stabilizer tension
100. procket bearing at the same time inserting the pin at the lower end of the connecting link 35 through the hole in the arm of the film guide 19 Install the second large washer 18 and secure these parts with the retain ing ring 17 Fasten the back up bracket 16 to the mount ing plate 21 with the screw 15 Assemble the loop form 13 and the torsion spring 14 onto the lower pin of the connecting link 35 and install the retain ing ring 12 The legs of the spring must bear against the underside of the loopform in such a manner that they will force the loopform to pivot clockwise around the connecting link pin k Assemble the film guide 11E to the auto thread lever 11F with the screw 11D tightening the screw finger tight Assemble the roller 110 and film guide 11B to the shaft of the autothread lever and secure with the screw 114 l Assemble the autothread lever 11 and eccen tric 9 to the mounting plate 21 with the threaded stud 8 The loopform 13 must be pivoted coun terclockwise and held in that position while install ing these parts Again hold the loopform 13 in the counterclockwise rotation while securing the idler roller 7 to the stud 8 with the screw 6 Release the loopform 13 Assemble the torsion spring 10 short leg first to the eccentric 9 Hook the short leg of the spring into the hole in the mechanism housing above and to the left of the eccentric 9 Hook the
101. r Assem ble the retaining rings 46A to the shaft with the center ring between the spring 46C and hub as sembly 46F Hook one end of the spring over the outer ear of the loopformer and hook the other end behind the upper finger of the hub assembly 46F The spring should tend to rotate the hub and lock ing pawl in a clockwise direction d Install the torsion spring 44 short leg first on the shaft of the shaft and link assembly 43 and insert the shaft through the bearing in the mechan ism housing Hook the long leg of the spring beneath the tapped mounting boss in the upper left hand corner of the mechanism housing Hook the short bent end of the spring behind the left edge of the link Assemble the washer 45 and the film escape mechanism parts step c above to the protruding end of the shaft 43 and temporarily tighten the setscrews 42 e Attach the upper sprocket guard mounting plate 41 to the mechanism housing with two screws 40 the upper screw being inserted through the half moon slot in the upper loopformer 46G f Attach the lens carrier catch 38 to the me chanism housing with the screw 37 Turn the hex head lens stop screw 36 into the tapped hole in the housing until only one thread is visible It may be necessary to adjust the catch and stop screw at final assembly to insure proper operation of the lens carrier i g Assemble the shuttle retractor 34 to the link and stud assembly 35
102. r positioning tool and once more check loop restorer operation with the test films 46 TIMING THE SPROCKETS a Open the film gate and turn down the framer shaft as far as it will go Then turn the mechan ism manually until the shuttle is at the bottom of the stroke teeth protruding and the edge of the shutter blade bisects the aperture opening b Push upward on the underside of the worm gear and check to make certain that the tongue on the driver clutch bears against edge of notch in driven clutch see Figure K View B c Open the film shoes and place the timing plate item 11 Figure A over the sprocket hubs View D Figure K Dip the end of a straightened paper clip in red lacquer and insert it down through the peep holes to mark the face of each sprocket Remove timing plate and place a light pencil mark on the face of each sprocket in line with the teeth nearest the red dot If this pencil mark does not align with the red dot the sprockets are out of time Note the direction in which each sprocket must be rotated to bring the teeth back in line with the peep holes then proceed as follows d To retime the sprockets the rear cover of the projector must be removed to expose the large sprocket gears at the rear of the mechanism assembly Hold the sprocket gear stationary while loosening its set screws then still holding the gear stationary care fully rotate the sprocket and shaft assembly in the proper direction
103. r the proper connection of leadwires When resoldering components to the amp lifier assembly Figure 19 use a heat sink to avoid the direct application of heat to adjacent components on the board Refer to paragraph 17 for special instructions regarding circuit board com ponent replacement d Most of the nameplates and the instruction plates are provided with an adhesive backing Make certain that the area to which such parts areto be secured is thoroughly clean by wiping with a cloth dampened with solvent Remove the protec tive paper backing and brush the adhesive with a mixture of three parts Tulouol to one part of tri chloroethviene When the adhesive is tacky press the nameplate carefully but firmly in place Wipe away any excess adhesive with a cloth dampened with solvent e Lubrication instructions are provided in the Introduction section of this service manual Do not over lubricate Apply grease and oil sparingly as indicated and wipe away any excess lubricant with a lint free cloth Gears should be lubricated by specking the gear teeth and then running the projector for a few moments to distribute the grease Where oil is indicated a drop or two will usually suffice 10 19 REASSEMBLING THE APERTURE PLATE Fig ure 14 a Assemble the film guide 9 to the aperture plate 10 with the screw 8 The right end of the film guide should be square with the edge of the aperture plate b Assemble the side tension
104. r toward or away from the target until a sharply focused image of the step at end of stroke gage just reaches from line A to line B Figure J g Slide the stroke gage up out of field of view and turn mechanism pulley until center tooth of shuttle is at top of stroke indicated by image of tooth near line A Adjust framer if required until projec ted image of edge of tooth just touches line A h Turn mechanism pulley until center tooth of shuttle reappears at top of target Rock mechanism pulley to find top of shuttle stroke Edge of tooth used as reference in step g must fall between lines C and D Figure J If image falls be tween C and A stroke is too short If image falls beyond D stroke is too long 2 Procedure for Adjusting Shuttle Stroke Loosen the two shuttle plate mounting screws just enough to permit movement of the shuttle arm plate a To lengthen the stroke shift the shuttle arm plate toward the pull down cam b To shorten the stroke shift the shuttle arm plate assembly away from the pull down cam After adjusting stroke recheck shuttle tooth side clearance as instructed in paragraph 36 step a and readjust if necessary CAUTION Do not attempt to eliminate film slap by setting stroke outside established tolerance This will produce double image and or jump with films having different shrink or stretch e Framing Adjustment Thread projector with framing test film loop
105. rear reel arm as outlined in the following paragraphs a Apply one drop of oil to the untlanged end of the bearing in the rear reel arm 32 Assemble one re taining ring 28 to the rear reel arm shaft 31 in the groove nearest the two narrow flats on the shaft As semble the thrust washer 29 over the long end of the 15 SERVICE INSTRUCT IONS shaft and dowm against the retaining ring Insert the shaft through the reel arm bearing Assemble the face gear 27 to the reel arm shaft 31 gear teeth facing up and tighten setscrew 26 against flat of shaft b Assemble the nylon bearings 25 into the cast bearing arms of the rear reel arm engaging the key tabs of the bearings with the cross slots of the bear ing holes Assemble the lower gear 22 to that end of the gear shaft 24 where the flats are nearest the end The gear face with the square recess must face away from the cast bearing boss Install the gear re taining clip 21 Insert the gear shaft through both nylon bearings 25 Assemble the washer 23 and gear retaining clip 21 to the end of the gear shaft Install the upper gear 20 square recess facing in ward to engage clip 21 and assemble the grip ring 19 to the end of the shaft Insert a 0 010 inch feeler gage between the upper gear 20 and washer 23 and press the grip ring 19 in against the gear Remove feeler gage c Assemble the rubber sleeve 12 to the hub of the face gear 14 The slee
106. required for re moval of the drive gearing in Figure 4 except to note in which direction the gear hubs are facing Inspect all gears for chipped or broken teeth and replace if necessary Clean and re lubricate all reusable gears 6 REMOVAL OF RUN STILL LINKAGE AND Mz CHANISM ASSEMBLY Figure 5 Remove parts as necessary in their indexed order of disassembly noting the following special precautions NOTE The disassembly procedures in steps a through d following apply only to the 1592 model projectors Steps e and f apply to all models a Loosen the setscrews 1 in the collars 2 then disengage the lower end of the still run rod 4 from the pivoting link assembly 18 and dis assemble the rod collars and spring 3 from the stop pawl b Loosen the setscrew 5 and remove the collar 6 and spring 7 from the lower end of the fire shut ter rod Disengage the upper end of the rod from the fire shutter and remove the rod 8 c Disassemble the still run lever 9 from the mainplate d Remove the two shoulder screws 12 and lift the sliding link assembly 13 and the two spacers 14 from the mainplate Remove the pivot screw 15 and disassemble the pivoting link assembly 18 spacer 19 torsion spring 20 and flat washer 21 from the mainplate e Remove two retaining rings 22 and lift out the torsion spring 23 Remove the shoulder studs 24 belt shifter bracket 25 and the spacers 26 f Hold th
107. ring 8 into the ring groove of the housing arm with the bowed face of the ring against the bearing 29 g Insert a 0 190 inch feeler gage between the loop restorer cam and the cast arm of the mechan FILMOSOUND PROJECTORS MODELS 1585 1590 1592 ism housing Hold the cam firmly against the feeler gage while tightening the setscrew 11 against the flat of the camshaft Remove the feeler gage NOTE Steps h through j following apply only to the 1585 and 1590 model projectors h Lightly grease both bearing openings in the cast arms of the mechanism housing Press the ball bearing 12 into its bearing opening until fully seated Assemble the large bearing 29 to the cam shaft 30 until the bearing is seated against the shoulder of the shaft Install the retaining ring 28 to the camshaft with the bowed surface of the ring facing away from the ball bearing i Insert the long end of the camshaft through the bearing hole in the long cast arm of the mech anism housing As the shaft end protrudes through the cast arm assemble the loop restorer cam 27 shim washer 26 and worm gear 24 to the shaft Continue sliding the shaft to the left inserting the end of the shaft into the left hand bearing 12 while seating the large bearing 29 in the bearing opening of the right hand cast arm Make certain that both bearings are fully seated then install the bearing loading spring 10 to the left hand cast arm with the two screw
108. s 9 Assemble the large retaining ring 8 into the inner ring groove in the right hand bearing opening The bowed surface of the ring must face the large bearing 29 Insert a 0 190 inch feeler gage between the loop restorer cam and the cast arm of the me chanism housing Hold the cam firmly against the feeler gage while tightening its setscrew 11 against the flat of the camshaft Remove the feeler gage Tighten the worm gear setscrew 24A enough to hold until final adjustment can be made 21 REASSEMBLING THE MECHANISM Figure 12 Reassemble Figure 12 parts as outlined in the fol lowing paragraphs Assemble the shuttle retractor pin 29 and in out spring 28 and insert the rounded end of the pin into the hole in the long cast arm just to the right of the camshaft Secure the loop end of the spring to the casting with the screw 27 b Screw the framer knob and shaft 26 down into the mechanism housing Orient the stop pin 25 so that the flat side of the pin is parallel with and facing the framer shaft and press the pin in place Screw the bearing support 24 all the way up into the staked nut of the shuttle arm plate assembly 23 Engage the fork like end of the shuttle arm plate framing arm with the cut out at the lower end of the framer shaft and fasten the plate to the cast arm of the mechanism housing with the two screws 22 c Loosely assemble the in out cam 20 to the cam bracket assembly 21
109. s critical Lens stop screw should be turned only a few degrees between tests for sharpness 38 ADJUSTING THE ANIMATION CLUTCH 1592 Models Only a Checking Stop Pawl to Trigger Clearance Ro tate the mechanism by hand until the finger ofthe trig ger is adjacent to the inner bent ear of the stop pawl as shown in View A Figure K If the trigger fails to clear the stop pawl ear adjust as follows Loosen the bearing bracket screws item 33 Figure 12 and shift the bearing bracket item 34 Figure 12 up or down as necessary to obtain approximately 0 010 to 0 015 inch clearance between the stop pawl ear and the end of the trigger then tighten the two screws securely b Checking Shuttle Retraction Turnthe mechan ism pulley by hand while pressing down on the clutch pawl at a point where the clutch rod passes through it The ear of the clutch pawl should latch behind the trigger as shown in View B Figure K Note also the clearance required between the finger on the clutch yoke and the curved arm of the strike Adjust as follows 1 Loosen the clutch strike screw View B Figure K to permit the strike to be shifted Insert a 0 015 inch feeler gage between the clutch yoke finger and the strike arm and press and hold the strike against the feeler gage while retightening the strike screw Remove the feeler gage 2 Refer to View C Figure Loosen the round Allennutslightly and shift the shuttle adjustment bracket s
110. s on a centerline between the take up sprocket and sound drum Shift the soundhead toward the take up sprocket until the sound drum bears lightly against the end of the gage and tighten the soundhead attaching screws se curely 42 PROJECTOR SPEED CHECKS Speed of the pro jector is not adjustable Therefore speed checks are primarily for the purpose of determining that the equipment is operating properly and as a means of detecting excessive mechanism loads damaged drive belt or similar conditions a Methods of Measurement Various devices and procedures can be used to check projector speed The most common ones are as follows 1 Photocell and Frequency Meter Used to measure the number of pulsations of the projection beam persecond Pulsations per second is then converted to projector speed This methodis quite practical in large vol ume shops 2 Strobatac or Similar Strobe Light Usually synchronized with interrupter shutter of shuttle Shutter makes one revolution per frame Shuttle rnakes one stroke perframe 3 Tachometer Preferably Having a Speed Range with a Maximum Speed of 150 200 RPM Used to measure RPM of the sprocket 4 Strobe Disc Attached to sprocket by means of suction cup or rubber foot For viewing with light fram 60 Hz source disc should have 70 dots for sound speed 93 dots for silent speed Count number of apparent rev olutions of patternfor one minute If pattern drifts in direction of
111. s securely c Remove retaining ring that secures the actuat ing assembly 5 Figure N and lock the auto ioad sys tem Place a 0 015 inch feeler gage between the film support rails of the aperture plate and the rear sur face of the lower loop form assembly 4 Figure P This surface should touch the feeler gage just as the heel of the loop form 5 Figure P strikes the shoulder on the mounting stud for the entrance guide roller 6 Figure P To adjust loosen two screws 7 Figure P which attach the upper sprocket guard plate Press 31 SERVICE INSTRUCTIONS downward on front end of loop form assembly and ro tate upper sprocket guard plate until heel of loop form strikes shoulder of stud ana rear surface clears ap erture rails by 0 015 inch Then tighten screws 7 Figure P securely NOTE Depress and hold the lower loop form assem bly 4 Figure P and check at rear of mechanism to see that the pin in the threading lever clears the bot tam of the elongated slotin the loop form shaft link by approximately 1 64inch See Figure Q If necessary loosen the hex head screw that secures the threading lever and rotate the lever to obtain the proper clear ance then retighten the hex head screw d Cneck operation of the film escape mechanism by leaving the auto thread system open Manually ad yance the film and jam it in the upper channel The film should fold and flow out through the kickplate in the loop former 14 Figure
112. s sticking 1 Clean sprocket shoe pivots perforations 2 Shuttle not retracting 2 Adjust per paragraph 44 step 3 Sprockets out of time 3 Retime per paragraph 46 4 Inadequate pressure on leaf spring 4 Adjust per paragraph 44 26 Figure 11 step 5 End of film leader not cut clean and 5 Check your film cutter square replace if dull or broken FILMOSOUND PROJECTORS MODELS 1585 1590 1592 TROUBLE PROBABLE CAUSE REMEDY EE Film escape mechanism i Film exit latching is out of adjustment 1 Readjust per paragraph 44 does not open to permit step d exit of film ns Film escape locking pawl 1 Torsion spring 46C Figure 11 is 1 Connect torsion spring does not seat properly disconnected film exits constantly 2 Locking pawl 46E Figure 11 out of 2 Readjust locking pawl per adjustment x paragraph 44 step d 43 SUPPLEMENT NO AUTOLOAD FILMOSOUND 16mm PROJECTOR MODELS 1585CX 1592CX 1585CXU 1592CSX 1979 Bell amp Howell Company All Rights Reserved NOTE THIS SUPPLEMENT CONTAINS THE SERVICE PARTS REPLACEMENT DATA PECULIAR TO IMM SOUND MOTION PICTURE PROJECTORS EXPORT MODELS 1585CX I592CX 1592CSX AND 1585CXU AND 15 TO BE USED WITH BASIC SERVICE MANUAL NO 74404 A HOWELL INTERNATIONAL SERVICE DEPT SUPPLEMENT PART NO 74404 MARCH 1979 SUPPLEMENTAL DATA FOR SERVICE MANUAL NO 74404 MODEL 1585CX 1585CXU 1592CX AND 15
113. sition the pulley so that its inner face is ap proximately 1 4 inch from the rubber mounting ring of the motor and temporarily tighten the setscrews 26 Assemble the strain relief 24 to the jacket of the line cord 25 and assemble the strain relief into the center hole in the stabilizer bracket 29 Loop the drive belt 23 around the motor pulley and insert the end of the motor shaft through the blower fan housing cover 22 Assemble the blower fan 21 to the end of the motor shaft with the fan hub containing the setscrews facing toward the mo tor Position the fan on the shaft so that the end of the shaft is approximately 1 16 inch below the face of the outer fan hub and tighten the two set screws 20 Assemble the fan housing 19 to the cover with the three screws 17 Manuallv rotate the motor pulley to make certain that the fan is not striking the cover or housing e Models Lift the assembled motor and blower group into position on the projector base threading the drive belt througn the loop of the belt shifter bracket assembly item 25 Figure 5 Guide the belt edgewise upward and around the large mechanism pulley Align the motor and blower mounting holes with those in the base and install and tighten the eight mounting screws 15 and 16 Refer to the appropriate wiring diagram at the end of the Parts Catalog section and make the necessary wiring connections f 1590 Models Assemble the power trans
114. sm housing Inspect the cam follower 21A and spring 21B and replace if damaged Remove two screws 22 and the shuttle arm plate assembly 23 Inspect the bearing support 24 and replace if damaged e Pull out the stop pin 25 and unscrew the framer knob and shaft 26 from the mechanism housing Remove the screw 27 the in out spring 28 and the shuttle retractor pin 29 f 1592 Models Only Remove the two retaining rings 30 and disassemble the stop pawl shaft 31 and stop pawl 32 Remove the screws 33 and 35 and disassemble the bearing bracket 34 and stop pawl shaft bracket 36 from the mechanism hous ing Inspect the grommets 37 and if damaged press them from the bracket 36 14 DISASSEMBLING THE MECHANISM Figure 13 Remove parts as necessary in their indexed order of disassembly noting the following special pre cautions 1592 Models Only Remove the round nut 1 and washer 2 and disassemble the shuttle adjust ment bracket 3 from the animated clutch bracket assembly Remove the screws 4 and 5 and lock washers 6 and lift the animated clutch bracket assembly 7 from the mechanism housing I the bracket assembly parts are in need of replace ment proceed as follows Remove the three re taining rings 7B and slide the shaft 7C from the clutch mounting bracket 7L removing the slide bumper 7D washer spring and clutch slide bar assembly 7G from the shaft as
115. st the end of the stop pawl shaft 31 and insert the opposite end of the shaft through the shaft hole in the bearing bracket 34 and both ears of the stop pawl 32 Loosely attach the bearing bracket to the cast arm of the mechanism housing with two screws 33 Assemble bracket 36 to the opposite end of the shaft and fasten the bracket to the mechanism hous ing with screws 35 Tighten screws 33 and 35 securely Assemble the second retaining ring 30 into the groove of the shaft so that the right hand ear of the stop pawl is held against the bearing bracket 34 NOTE Only the 1592 model projectors are equipped with the fire shutter assembly 4 On 1585 and 1590 model projectors a support bracket is installed in place of the fire shutter h Insert the rounded end of the heat baffle 6 up under the shutter and secure the baffle with the two screws 5 Fasten the bracket or fire shutter assembly 4 to the mechanism housing with four screws 3 and washers 3A Install the pulley 2 on the end of the camshaft and tighten the pulley setscrews 1 down on the flats of the shaft 22 REASSEMBLING THE MECHANISM Figure 11 Reassemble Figure 11 parts as outlined in the follow ing paragraphs a Attach the self centering assembly 63 to the mechanism housing with the two screws 60 lock washers 61 and flat washers 62 Assemble the lever and shaft assembly 58 to the mechanism housing and install the washer 57 a
116. te Assembly Aperture 36018 Spring Leal 12 012133 Plate Assembly Kick 36038 SO TING 42e 12 012134 Hub and Bracket Assembly 36047 Follower Cam x39 s 12 013946 Sprocket Assembly 36064 Hall Film guide 3 014536 Sprocket Assembly Upper 36065 Snaft CAM ux S woe 2 014558 Solenoid Assembly 36083 Ring Retaining NN x 12 014573 Switch Assembly Animated 36769 Setscrew 24 014575 Lampholder Assembly 36771 24 014947 Gear and Bearing Assembly 36999 Guard 5 3 014949 Clutch Assembly Take up 37293 Rail Film tension 3 015569 Photocell and Lite Pipe 37302 Pawl Locking 3 Assembly 37302 Shaft Locking pawl 2 015573 Motor Assembly 41307 Cam Pull down 3 015919 Clutch Assembly Rewind 44312 Key Gear retaining 12 016394 Clutcb and Bearing Assembly 44370 KEE ENEE 22 es 3 016495 ac ua ee 44371 SOUR y saek 3 016530 Amplifier Assembly C C2 Co C NEN C2 k b2 2 2 P2 P2 P2 P co De C2 k FILMOSOUND PROJECTORS MODELS 1585 1590 1592 Vatroductton GENERAL This Service Manual has been prepared to assist in the repair and adjustment of Bell amp Howell Company Automatic Threading 16mm Sound Pro jectors Models
117. te the free unmounted end of the sprocket 14 guard toward the sprocket bearings in the mech anism housing Secure the sprocket guards to their mounting post with the screws 25 and the shim washers 26 c Assemble the spring 24 to the shaft of the rewind button 23 and insert the shaft down into the opening in the top of the mechanism housing Depress the button and assemble the retaining ring 22 into the groove at the lower end of the shaft d Assemble the sprocket flange 20 and thrust washer 21 onto the shaft of the lower sprocket as sembly 19 Spread the two lower sprocket guards and insert the sprocket shaft through the lower bear ings in the mechanism housing until the sprocket is fully seated Release the sprocket guards Assemble a flat washer 14A a spring tension washer 14 and the lower sprocket gear 13 to the sprocket shaft meshing the sprocket gear teeth with the worm gear Align either setscrew 11 with the flat on the sprocket shaft and tighten both setscrews securely The sprocket and gear must turn freely but with only a minimum of end play e Assemble the thrust washer 18 to the shaft of the upper sprocket assembly 17 Lift the free end of the upper sprocket guard 27 and insert the sprocket shaft through the upper bearings in the mechanism housing until the sprocket is fully seated Release the sprocket guard f Assemble the sprocket guard parts 16 through 16D Slip the assemb
118. tep paragraph 29 following 29 INSTALLING THE RUN STILL LINKAGE Fig ure 5 Reassemble Figure 5 parts as outlined in the following paragraphs a All Models Lightly grease the elongated slot and sliding contact surface of the belt shifter bracket assembly 25 and assemble the spacers 26 and bracket assembly 25 to the tapped bosses of the projector main plate with the two shoulder studs 24 Assemble one loop end of the torsion spring 23 to the right hand shoulder stud 24 and the other loop end to the bent ear of the bracket as sembly just above the shoulder stud Install the retaining rings 22 to retain the spring loops 17 SERVICE INSTRUCTIONS b All Models Assemble the lever stop and pin assembly 5 to the base with the screw 4 Before tightening the screw insert a 0 060 inch 1 52mm shim between the stop pin and snubber lever of the mechanism assembly Rotate the stop until the stop pin just touches the shim and hold the stop securely while tightening the screw 4 securely Remove the shim NOTE Steps c through g following apply only to 1592 model projectors C Assemble one loop of the torsion spring 20 over the shoulder stud of the pivoting link assembly 18 Assemble the large washer 21 down against the shoulder Position the link assembly against the projector mainplate with the end of the stud engaged in the rectangular opening just below the projection lamp socket area add the otheren
119. the fuse holder 41 with the screw 40 Assemble the switch 38 to the projector mainplate with the locking nut 36 and lockwasher 37 2 1592 Models Only Assemble the rotary switch 35C to the bracket assembly 35D with the lock ing nut 35A and lockwasher 358 Lift the as Sembled switch and bracket 35 up into position against the mainplate while guiding the switch shaft through the tube item 11 Figure 5 already as sembled to the mainplate Engage the free end of the animation switch lever crank item 37 Figure 10 into the hole at the top of the animation switch bracket item 34 Figure 3 and secure both switch brackets 34 and 35 to the mainplate with two 7 F ILMOS UND P ROJECTORS MODELS 1585 1590 1592 screws 33 Insert a 0 010 inch feeler gage be tween the animation switch lever item 35 Fig ure 10 and the mechanism housing and hold the lever against the shim while pressing the crank grip ring item 35 Figure 10 in against the mech anism housing Remove the shim d Models Assemble the motor mounting brackets 30 and motor bracket straps 28 with stahilizer bracket 29 to the motor end caps When mounted to the projector base the motor should be positioned so that the nameplate can be easily read Install the motor pulley 27 on the motor shaft small pulley diameter toward the motor If the pulley was replaced be sure to use the same color of pulley as the one which was removed Po
120. the gear shaft 20 from the bearing posts of the reel arm Inspect the nylon bearings 21 and if damaged press them from the bearing posts 9 DISASSEMBLING THE REAR REEL ARM Figure 8 Disassemble the rear reel arm in the following manner noting any special precautions a Remove the two screws 1 and lift the reel arm cover 2 from the rear arm 32 Note the shim washers 3 located between the cover and the reel arm mounting bosses b Press the take up arm against the reel arm casting and slip the take up belt 4 from the pulleys Release the take up arm slowly and catch the tension spring 5 as it drops free Remove the screw 6 and disassemble the take up spindle and pulley assembly 7 and shim washer 8 from the take up arm The take up arm and rear reel arm are replace able only as an assembly 32 c Remove the retaining ring 10 and large flat washer 11 from the end of the gearshaft 16 Re move the rubber sleeve 12 from the hub of the gear 14 Loosen the gear setscrew 13 and disassemble the gear 14 the shim washer 15 and the gearshaft 16 from the reel arm d Remove the retaining ring 17 from the spring post in the reel arm to free the end of the torsion spring 18 and lift the torsion spring from the hub of the upper face gear 27 e Remove the retaining ring 19 and slide the upper spur gear 20 toward the upper face gear 27 until the upper gear retaining clip 21 can be remo
121. top pawl is engaged with the trigger mechanically and is disen gaged electrically by the solenoid I the preload tension of the spring paragraph step 2 preceding is set too low the stop pawl may not engage the trigger properly and a chattering will result set too high the solenoid may not be able to overcome spring tension to disengage the stop pawl from the trigger Readjust spring tension until proper operation is obtained 39 ADJUSTING THE FIRE SHUTTER 1592 Models Only When the projector has been completely assembled install the projection lamp and lens and run the projector forward with the lamp on Turn the Still Run knob to the Still position and focus the image of the aperture on the screen Check for full pattern of the fire shutter disc on the screen image must show perforations of disc throughout Note that a bent ear onthe fire shutter bracket lim its the travel of the fire shutter filter arm If unfiltered light appears at the top or bottom of the aperture image it will be necessary to bend this stop ear so that the amount of filter arm travel is increased or decreased accordingly 40 ADJUSTING THE REEL ARMS AND REWIND CLUTCH a Front Reel Arm Adjustment See Figure 7 Adjust end play of the shaft 14 1070 008 inch 0 003 inch by positioning retaining ring 11 against 0 008 inch shim The backlash for both face gears should be between 0 005 inch minimum and 0 016 maximum
122. tor mounting screws 15 and the four blower housing screws 16 If the drive belt 23 is in need of replacement it can be cut witha sharp knife If the belt is in good condition slip it edgewise down between the mechanism pulley and the casting Lift the assembled motor and blower from the base Remove three screws 17 and dis assemble the fan housing 19 from the housing cover 22 Loosen the setscrew 20 and disassemble the fan and hub assemblv 21 and cover 22 from the motor shaft d Loosen the screws in the top ears of the motor clamps 28 and disassemble the clamps and mounting brackets 30 from the motor end bells Note the difference in motor clamp brackets 29 as used in earlier models and in the more current designs as well as the addition of the coil like thermal fuse 29 e 1592 Models Onlv Remove the two screws 33 and disassemble the animation switch and bracket assembly 34 and rotary switch and bracket assem bly 35 from the projector mainplate Disassemble as necessary for repair or parts replacement f 1585 and 1590 Models Only Remove the nut 36 lockwasher 37 and rotary switch 38 from the mainplate Remove the screw 40 and the fuse holder 41 5 REMOVAL OF GEARS REEL ARMS AND SOUND HEAD Figure 4 Remove parts as necessary in their indexed order of disassembly noting the fol lowing special precautions a To remove the rear reel arm assembly 29 for repair or repiace
123. ve must rest down against the shoulder of the gear Insert the small diameter end of gear shaft 16 up through the hole in the lower end of the reel arm Hold the shaft in place and as semble the washer 15 the face gear 14 and the large washer 11 to the gear shaft Secure these parts with the retaining ring 10 d Install the setscrew 13 into the tapped hole in the reel arm casting near the lower end of gear shaft 16 Do not tighten the setscrew Move the gear shaft 16 to engage the teeth of the face gear 14 with the lower spur gear 22 and tighten the setscrew 13 Rotate the face gear in both direc tions to check backlash There should be approxi mately 0 005 to 0 018 inch backlash around the total gear circumference If necessary loosen the set screw 13 and remesh gear teeth until proper back lash is obtained then tighten setscrew securely e Apply a light film of grease to all gear teeth and to the hub of the upper face gear 27 Assemble the torsion spring 18 to the hub of face gear 27 with the loop of the spring over the casting boss near upper spur gear 20 Secure the spring loop to the boss with the retaining ring 17 Rotate the upper face gear in both directions to make certain that the retaining ring does not restrict movement of the spring loop on the boss Reposition retaining ring if necessary f Apply one drop of oil to the mouth of the bear ing in the take up arm assembly Assembl
124. ved Move the gearshaft 24 down until the up per spur gear 20 and washer 23 can be removed Remove the lower gear retaining clip 21 and lower Spur gear 22 and slide the gearshaft 24 from the bearing posts of the reel arm Inspect the nylon bearings 25 and if damaged press them from the bearing posts Loosen the setscrew 26 and lift the upper face gear 27 from the reel arm shaft 31 Re move the retaining ring 28 and disassemble the reel arm shaft 31 and washer 29 from the reel arm 10 DISASSEMBLING THE EXCITER LAMP COVER AND SOUNDHEAD Figure 9 Disassemble the citer lamp cover and soundhead assembly in the fol lowing manner noting any special precautions a Inspect exciter lamp cover parts 1 through 7 and disassemble only as necessary for replacement b Make a careful note of leadwire connections be fore disconnecting or unsoldering leads during disas sembly of the soundhead Remove the exciter lamp 8 wipe off fingerprints and wrap the lamp in tissue paper c Do not loosen the clamping screw 10 or dis turb the lateral position of the optical slit assembly 11 unless it has been determined that the optical slit is in need of replacement or adjustment d Unhook and remove the stabilizer arm spring 12 Remove the retaining ring 13 and disassemble the roller adjusting screw 14 and complete stabil izer arm assembly 15 from the soundhead casting Remove the two screws
125. ver 16 until all wiring connections and ad justments have been made e Turn the base right side up and if the main plate 35 had been removed for any reason as semble the mainplate to the uprights of the base with the four screws 34 NOTE At this point refer to Figure 3 and care fully assemble the complete mechanism assembly 29 to the mainplate with the four screws 27 the upper two screws also serving to attach the idler gear adjustment bracket 28 Then refer to Figure 6 for balance of reassembly as follows f Assemble a roller 10C and the adapter 10B to the shaft at the squared end of the film guide bracket 10D Assemble the second roller 100 fo the shaft at the rounded end of the film guide bracket and install both retaining rings 10A En gage the free end of the adapter 10B with the guide rails of the film guide which is assembled to the lower rear corner of the mechanism as sembly see Figure 11 item 11B Lower the rear end of the film guide assembly 10 so that the ears of the adapter 10B are between the cast ears of the base Hold the guide roller 8 large diameter facing out between the ears while in stalling the adapter shaft 7 through the cast ears and roller Install the screw 9 to secure the as sembly g Assemble the lever stop 5 loosely to the base with the screw 4 The lever stop must be adjusted after the mechanism assembly has been installed Refer to s
126. xplained on page 2 of the Parts Catalog All models are equipped with a 15 watt amplifier Only the 1592 models are equipped with the still picture control and animation feature The step by step motion is accomplished by placing the Run still control knob in the Still position and the Motor Lamp switch in either the Forward Lamp or Reverse Lamp position then depressing the ani mation lever at the top of the mechanism housing The film will advance frame by frame each time the lever is depressed and released If the lever is held down the frames will continue to advance insequence for the animation effect until the lever is released These l6mm sound projectors are completely gear driven with shifting from forward to rewind accomplished by means of a rocker plate idler gear arrangement The autoload system consists of a series of guides loopformers and rollers which when the system is in the load position closed will guide the film through the threading path to thefilm take up reel When the system is in the open position the guides and rollers clear the film path The upper and lower guides are connected by a mechanical linkage with a locking lever at the lower end to actuate close the system X film escape me chanism is included at the upper end of the linkage to prevent damage to the film due to jamming When a film jam occurs the film willfold andflow out through the kickplate of the escape me

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