SERVICE INSTRUCTIONS AUTOLOAD® FILMOSOUND® 16mm PROJECTOR ne (AUTOMATIC THREADING) MODELS 1585C/CH 1590¢/cs 1585CH/CHS. 1s92c/cs 1585ML/MLS. 1592CH/CHS 1978 Bell & Howell Company 11 Rights reserved BELL & HOWELL GENERAL SERVICE DEPT. 7100 McCORMICK ROAD CHICAGO, ILLINOIS 60645 SoraAIN? PART NO. 74404 PRINTED IN U.S.A, May 1978FACTORY SERVICE RECEIVING ADDRESS Faxing onan eo re {| Bet & Howell Company | eather | Sesto, | oe oI 3 673~ 3300 [acess eeeipeteteeeeeay see eceere)| TABLE OF CONTENTS Page INTRODUCTION ..... 1-3 DISASSEMBLY PROCEDURE eee deetee 4-9 REASSEMBLY PROCEDURE 10 - 20 ADJUSTMENTS . 2.20... ao General instructions Optical Alignment Adjusting the Intermittent Mechanism. Lens Currier Adjustment . Adjusting the Animation Clutch (1592 Modela Only) | Adjusting the Fire Shutter (1592 Models Only). -- Adjusting the Reel Arms and Rewind Clutch» << Adjusting the Soundhead Projector speed Checks ‘Auto-Load System Adjustmé ‘Adjusting the Loading Guides : Checking and Adjusting Loop Restorer ‘Timing the Sprockets Checking the Exciter Lamp Cover Clearance | Gear Shift Tension Adjustment Idler Gear Backlash Adjustment |. 2.” > a 2B 25 3 2 2 2 23 30 30 32 pace Ey 4 3 ‘TROUBLE SHOOTING 35-43“ Model 1592¢ Autoload Filmosound Projector FEATURE DESCRIPTION LIST sees 120VAC, 6OHE [120VAC, 50/60H: cs +++ Pally automatic Operating Voltage (Domestic) Operating Voltage (Export)... Film Threading .----- Projector Control: ‘Models 1585 and 1590... Model 1592s --- - . Forward and reverse projection only 1 Forward, Teverse and still projection with “Directamotion" control ss Belnch (/1.4 Projection Lens (Standard)... . Projection Lamp: ‘Models 1565 and 1892 Model 1590 : Exciter Lamp -- 25 hour, 250 watt P/N 47431 25 how, 250 watt P/N 44223 c++ devolt Type BAK P/N 34884 ‘Solid state with integrated clreult; output, 10 watts RMS fete eee eee ees $80 watts Aroplifier « - ‘Total Power Consumption 6... eee ee ee eeee Enni/3eF | MosOUNS? PROJECTORS MODELS 1585, 1590, 1592 Introduction GENERAL. This Service Manual has been prepared to assist in the repair and” adjustment of Bell & Howell Company Automatic ‘Threading 16mm Sound Pro- jectore, Models 1585, 1590 and 1882. Design speci- fications are Iirted in the Feature Description List fon the preceding page. An illustrated Parte Catalog fe ineladed 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, projectors covered in these instructions are Yersions of the basic projector models (I585C, 1890C and 1892C). The additional suffix letters are used to Identify Variations of the basic models, as follows. ‘The sulfix letter "5" signifies & basic “C* or ML model equipped with a front cover and speaker asvembly (Parts Catalog Figure 15) rather than the standard front cover (Parts Catalog Figure 1, item 3). ‘The sulfix totter H signifies a basic "C* model wired for §0/60Hz operation rather than 60Hz only. ‘The Models 1585ML and MLS are militarized versions of the 1S85CH and CHS and also are de- ‘signed for 50/601z operation. Except for the above variations, the O5, CH, CHS, ML and MLS versions are identical with the asic “C" models and almost all components are interchangeable. The most notable physical ditfer- ‘once in the 1565 models are the M1. and MLS pro- jectors, the top covers of which are provided with two five amp Slo-blo fuses. Part number differ are indicated by the use of isable on Code" column of the parts lists, The coding system is explained fon page 2 of the Parts Catalog. All models are ‘equipped with a 15-watt amplifier. Only the 1597 models are equipped with the "sti" picture control and animation feature. ‘The atep-by- ‘Step motion {8 accomplished by placing te" Run-Stil control knob in the “Still” position and the "Motor~ Lamp" switch in either the "Forward-Lamp" oF ‘“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. Uf the lever is held down, the frames will continue to advance inequence Wor the animation effect) until the lever is released. ‘Thete 16mm sound projectors are completely gear driven, with shifting from forward to rewind Socomplished by means of a rocker plate/idler gear arrangement. The autoload system consists of aneries of guides, loopformers and rollers which, when the system 1s in the “load position (closed), will guide the film through the threading path to thefilm tako-up eel. When the system is in the "open" position, the guldes and rollers clear the film path. ‘The upper and lower guides are connected by a mechanical linkage with a locking lever at the lower fend to uctuate (close) the system. A film escape me- cchanism is included at the upper end of the linkage 10 reveat damage to the film due to jamming. When a {Bim Jam occurs, the film will fol¢ and flow out through the Kickplate of the escape mechanism until the op- erator has had an opportunity to stop the projector. SPECIAL MAINTENANCE PRECAUTIONS. ‘Tre removal and installation of most projec tor parts can be accomplished with tools normally ‘available in photo equipment repalr shops. A pencil type soldering gun should be available for elec tHleal repairs, and the Bristol wrenches listed in the following chart will aloo be required. Special tools and gages necessary for projector alignments and adjustments are illustrated and listed In Fig- ure A and its accompanying chart. BRISTOL SETSCREW WRENCHES REQUIRED FOR MAINTENANCE BAH Part No. No. of Setscrewsize} Flutes | Handle | Wrench No. 4-40 6 Jorn | Giazi-x2 No. 6-82 6 |sreasse-b| stKases-a No. 8-32 6 |arss-ri_ | c1es-x2 NOTE: Wrench G165-F3 Is needed to tighten setscrew in tool handles. CLEANING. All film path areas must be kept free from emulsion build-up, or film jamming will take place ‘uring the automatic threading operation. Use Toluo} and/or an orange stick to remove emulsion fromSERVICE INSTRUCTIONS ‘ue film path areas, being careful not to scratch the surfaces. Pay particular attention to the film peth parts of the soundhoud cover and soundnead. Do not use trichloroethylene solvents to clean plastic parte, Use a naphtha base cleaning fluid and be sure that grease 1s NOT wiped off critical areas. fof Jubrication: Do not use solvents on these critical areas, especially in the auto-threading linkage, since lubrication ie applied during assembly and it would be difficult to replace without disassembling the link age. Use & soft lint free cloth when necessary to Feniove any accumulation of dust or film chips. During periodic maintenance of the projector, the "transport mechaniem should be removed and thoroughly cleaned. Brush or blow out all large parucles of dirt. Wash all moving parts except ‘Olite™ bearings with ary good petroleum solvent Wash “Olite” Bearings and the pull-down cams with naphtha. Wesh the cam ollers in naphtha, and re- place if not thoroughly cleaned by washing. Discard ‘and replace the cam wiper and cam wiper wick. At soon at parts have been washed and dried, coat with @ ight film of the specified lubricant. LUBRICATION. ‘The following Lubrication Chart lists those items “which are to be lubricated during reassembly. Lub- Fieants apecitied can be ordered from Bell & Howell by part mumber. Be careful not to over-lubricate. A drop or two of oil and a light film of grease (spplied ible) will be adequate. Wipe away ‘lint-free clot. Felt pads and wicks should be placed in a shatiow pan of the specified grease or oi! andallowed to stand ‘Until suturated. 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, the following proce- dure is recommended. Refer to Parts Catalog Pig ure2 a. 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. b. Remove the te strips from around the wiring sat both ends af the motor. €- Loosen the screws In both motor bracket straps (28, Figure 3) and lift off the atrape and stabilizer bracket (28) aa» group. . Ralge the motor just enough to permit the belt to be passed beneath the motor toward the ‘ransformer. Be very careful not to lift the motor 80 high an to damage the blower fan at the end of the motor shaft f¢. Disconnect the push-on connectors which con rect the motor leads t0 the slarting capacitor (iter ZC. Figure 2) and remove the erimp-type soldetlee connector which Joins the grey-yellow motor lead to the three white leads. The belt can now be re= moved from the projector. 4. 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 (lett end of motor) bears on the motor mounting bracket @8, Figure 8). LUBRICATION CHART Parts to be Lubricated Lubricant Machined aurfaces (non= ‘bearing) of all castings ‘ont (P/W 070003) Sprocket shafts (27 and 29, ‘Fagure 10) 81 (P/¥ 08963) Framer shaft @6, Figure 12) and bearing face of worm gear (24, Figure 13) (on (P/N 04978) Felt oil pads in cams, and sliding parts (friction Surfaces) aot otherwise specified Se $$$ ‘ofl (P/W 070052) The worm gear teeth and sprocket gear teeth iare to be lubricated with special grease P/N “The following items are to be lubri- coated with general purpose grease P/N 070034 ‘All other gear and pinion testh; all bearings find ‘pivot ‘poste; reel arm lock buttons: al ‘hatte; oam wiper and wick. Specific instruc- ions are noted in the reassembly section. ‘TEST FILM CHART ‘TFL-S5-NXL Centering and framing loop TPL-S1-NxKL Buzz track loop ‘TFL-26-Nx3 ‘TKH2 azimuth loop. TFL-23-NKI 400H: power output loop ‘TFR-DS5O-NXS ——_Antlo-Center-Framing roll ‘TFS-DSS0-NXI Loop restorer atrip (ad holes) ‘TPS-DS50-NXS Loop restorer strip (Glongated holes)SPRING, P/N 6124 FILMOSOUND PROJECTORS MODELS 1585, 1590, 1592 re REMOVE 1/16! FROM UPPER GUIDE BAR SEE INSET oO ABOVE 0 oO Mt 1" a INDEX NO. TOOL NO. TOOL NAME USE 1 $-1552-1-N1 Lamp Plug 2 8-550-2-N1 Lene Plug 8 8-550-2-N2 Alignment Rod Alignment of optical system (Figure E) 4 8-560-2-NB_—_ Aperture Plug 8 Make in Shop Torque Wrench Adjust rewind torque (check torque with Chatillon #LP-72 (0 to 72 oz.) push-pull scale, Master Gauge Co., Chicago 60622) 6 8-550-5-N2 Stoke Gago Measure shuttle stroke (Figure F) 7 8-09701-35N2 Shuttle Height Gage ‘Check shuttle protrusion (Figure G) 8 8-552-2-N1 Restorer Positioning Tool Adjusting the loop restorer (Figure R) ® 8-552-4-Ni Shuttle Tension Gage ‘Adjusting shuttle tension (Figure H) 10 8-552-4-N2 Weight for Shuttle Tension Gage Adjusting shuttle tension (Figure H) n S-552-1-Ni Timing and Alignment Plato ‘Timing the sprockets (Figure R) 12 ———$-582-5-N1_—_Soundhead Locating Gage Positioning the soundhead (Figure Mj 2B 8-550-8-NI Alignment Tool Aligning sound drum and photocell (Figure L) 8-550-5-N1 Shuttle Stroke Target Measuring sbuttle stroke (Figure J) 4 ‘Shop made Rewind torque reel (use Torque adjustments, P/N 014870) ~ Purchase Push-Pull Scale (Chatillon #LP-72 (Master Gage C0, Chicago 60622 Torque adjustments Figure A. Special Service ToolsSERVICE INSTRUCT IONS Disassembly Procedure 1. GENERAL PRECAUTIONS. a. Be sure to use the proper size tools for dis~ ‘assembly and reassembly procedures. After remo¥- ing attaching parts (screws, nuts, etc.), loosely re~ install these ‘parts to the ‘removed part or tapped holes to prevent lost b. Cemented or adhesive backed parts aresonoted in the parts lists and can be removed by prying up fone edge with « knife blade. Be careful not to scratch Surrounding areas, and remove traces of old adbe- sive with solvent. cc. When unsoldering is required to remove elec- trical parte, if is advisable to tag leadwires or make a ‘sketch of leadwire connections to facilitate fastallation of the parts. Unsolder leads with a pen- ‘oil type soldering gun, using a heat sink if available, or etipping the lead with a pliers to provide addl- ‘ional heat dissipation. d. When removing riveted parts for replacement, the old rivet must be drilled out witha drill equal to, or ‘lightly emaller 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, a8 necessary, in their indexed order of disas- Bembly, noting the’ following special precautions. NOTE: The CS, CHS and MLS models are equipped with « front cover and speaker assembly (Parts Catalog Figure 15) rather than the standard front cover (item 1, Parts Catalog Figure 1). Unlatch and remove the front cover assembly ). If latohes are 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, 80 that it can fully engage the screw heads. ©. 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 brackots (9C) from the cover. NOTE; ‘The 1585ML and MLS are equipped with two additional fuses (9D) which are mounted in the top cover assembly. d. Remove three screws (11) and (12) and disas- smble the lamphouse assembly (13) from the main- “The lower screw also attaches the air deflector (44), The SULl/Run knob (13F) is used only on the $502 models. The lower end of the still-run lever en- gages the pin on the crank lever (item 121A, 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 ‘tlt 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: ‘Tit the projector so that the four screws (3) and ‘one spacer (SA) which secure the end caps (6) and @) to the base can be removed. Then set the pro- jector upright and remove the remaining four screws (4) which are ingerted through the front side of the mainplate. Be careful not to lose the speed nuts (5) assembled to the mounting bosses af the end caps- cc. The 1592 models use a single knob (11) for upyd-Rev-Lamp" control plus a crank lever (11A) to provide for the "Sill/Run" control operation, 4. To remove the projection lamp (12), press down the lamp retaining spring and pull the lamp straight out 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 (5) fare secured to the mainplate with two screws (13)- 4. REMOVAL OF ELECTRICAL PARTS (Figure 3) Before removing electrical components, note the man- ner in which the leadwires are routed and tied. The pictorial wiring diagrams at the rear of the Parts Cutaog, will aseiat'in the proper reconnection of 1585 and 1592 If only the power transformer (4) is to be replaced, remove the two hex nuts (1), screws (2) and lockwashers (3) at the upper ends of the brackets (7) and (8). Export models also require spacers (3A) which are located between the bracket (8), brace (SA) and transformer. If the lamp transformer (10E) is to be replaced, the entire transformer group (items 1 through 10) must be removed {rom the base, In order to gain access to the two screws (9A), the amplifier cover (item 16, Figure 6) must also be removed., 1590 Mateln only, Tene projectors ste equipped wilh only » power transformer (14) whic [itcured to the base with four screws (13). The routing. Drackete (Jac) and (14D) can be Fepiaced By driting out the rivets (144). However, if the Starsformer ‘teelt te faulty, replace the complete transformer and bracket assembly (14). e. The drive motor and blower components must be removed #8 a unit to permit belt replacement or motor and blower repairs. This is accomplished by Femoving the four motor mounting screws (15) and tne four blower housing screws (16). it the drive belt (@3) Is in need of replacement, it can be cut with a Sharp alfe. if the belt 1s in good condition, slip 1t eigewise 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) {rom the housing cover @2). Loosen the setscrew (20) and disassemble the fan and. hub assembly (21) and cover (22) from the motor shaft 4. Loosen the screws in the top ears of the motor clamps (26) and dieussemble the clamps and mounting brackets (30) {rom the motor end bells. Note the difference in motor clamp brackets (28) as used in earlier models and in the more current designs, fas well as the addition of the coil-like thermal fuse (9A). -e- 1592 Models Only. Remove the twoserews (33) and. disassemble’ the timation switch and bracket assembly (94) and rotary switch and bracket assem- bly (35) from the projector mainplate, Disassemble as necessary, for repair or parts replacement. {. 1395 and 1590 Models Only. Remove the nut (86), lockwashor (87) and rosary switch (38) from the ‘mainplate. Remove the screw (40) and the fuse~ holder (42). 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 replacement, disassemble the retaining ring (1), washer @), spur gear (4) and a second re- {taining ting (1) from the end of the reel arm shaft. Note the manner in which the reel arm dise (27) is ‘positioned before disassembling the screws (25) and isc (7) from the mainplate; then carefully with- ‘raw the reel arm assembly, catching the lock button (20) and spring (31) a3 they pop free. b. To remove the front reel arm assembly (28) for repair or replacement, disassemble the gear ‘and cluten parts (15) through (18) from the end of the reel arm shalt. Note the manner in which the reel arm dise (27) is positioned before disassembling. the screws (26) and disc (27) from the mainplate. Carefully withdraw the Teel arm assembly, catching the lock button (80) and spring (81) as they pop free. Fi LMosousd’ PROJECTORS MuvELS 1585, 1590, 1592 c. To remove the soundhead assembly (40) for repair or replacement, it first 1s 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 uppropnate wiring dia~ gram). Assuming thal the transformer assembly has ‘rendy been removed (paragraph 4), referto Figured and disassemble the retaining ring (32), flywheel (95) find washers (93) and (24) from the end of the sound rum shaft. Then remove three screws (36) and ‘washers. (37) and carefully sft the soundhead as- Aembly from the mainplate. @. No special instructions are required for re moval of ‘the drive gearing in Figure 4 except to note in whieh direction the gear hubs are facing. Inspect all gears for chipped or broken teeth and renlace if necessary, Clean and re-lupricate all Feusable gears 6. REMOVAL OF RUN-STILL LINKAGE AND ME- CHANISM ASSEMBLY (Figure 3). Remove parts, fs necessary. in their indexed order of disassembly, fhoting the following special precautions. NOTE: The disassembly procedures in. steps through d, following apply ‘only to the 1592 model projectors. Steps € 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 Tink assembly (18) and dis Assemble the ‘rod, collars and spring (3) from the ‘stop pawl 1B. Loosen the setscrew (6) anc remove the collar (6) and spring (7) trom the lower end of the fre shut- ter Tod. Disengage the upper end of the rod from the fire hatter and remove the rod (8). ©. Disassemble the still-run lever (9) from the ‘mainplate. 4. Remove the two shoulder screws (12) and lift tne aliding link assembly (13) and. the two spacers (14) from the malnplate: Remove the pivot screw (1S) and disassemble the pivoting link assembly (8), spacer (19), torsion spring (20) and flat washer (21) from the mainplate. @. Remove two retaining rings (22) and lift out the torsion spring (28). Remove the shoulder studs (2h, belt shifter bracket (25) and the spacers (26). [. Hold the mechaniem assembly (29) securely while removing the four screws (27) and. the idler tear adjustment bracket (28). Carefully withdraw the Thechanism assembly from the mainplate. 7. REMOVAL OF BASE COMPONENTS (Pigure 6) Remove parts, as necessary, in their indexed order of disastembiy, 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 INSTRUCT LONS then secured with sorew (4). Do not disturb these Hems unless obvious damage indicates a need for replacement. b. Remove the adapter shaft (7) and lift out the {nim 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 let out both assemblies. When ‘separating the edge connector from the amplilier pall them straight apart without wriggling or tist= ing them and thus distorting the pins. Note the spacers (21) located beneuth 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 contro! Assembly into the base. fe: Remove the screw (26) and lockwasher (27) and disassemble the ult bar (28) from me lover fend of the tilt gear rack (39). Remove two screws (37) and disassemble the adapter (38) and gear rack (89) from the base. Remove the retaining ring (40) land Tift out the tlt gearshaft (41) and spring tension washer (42). Drive ‘out te spring pin (43) and lift ‘ut the tilt worm gear (4) 6. DISASSEMBLING THE FRONT REEL ARM (Fig- ure 7). Disassemble the front reel arm in the fol~ Towing manner, noting any special precautions. 4. Remove the two screws (1) and lift the reel arm cover (2) from the froat 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. W spindle parts are damaged, loosen the setscrews, (A) and remove the gear (SB) and washer (5C) {rom the spindle (SD). ce. Remove the retaining ring. (7) trom the spring post in the reel arm to froe the end of the torsion Spring (10). Loosen the setscrews (8) and (BA) and Tift the gear (9) and torsion spring (10) from the reel arm shalt (14)- i damaged, disassemble the plastic sleeve (9A) From the gear ub. d. Remove the two retaining rings (11) and dis~ accemble the reel arm shaft (14) and washers (12) ‘and (13) from the reel arm. €. Remove the retaining ring (15) and withdraw the upper spur gear (16) from the gearshalt (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 bearing posts of the reel arm. Inspect the nylon bearings (21) and, if damaged, press, them from the bearing Pot ‘ 9. DISASSEMBLING THE REAR REEL ARM (Figure 8). Disassemble the Tear reel arm in the following, manger, noting any special precautions a. Remove the two screws (i) and lift the reel arm cover (2) {rom the rear arm (82). Note the shim Washers (3) located between the cover and the reel ‘brim mounting bosses. bb. Press the take-up arm agsinst 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 (6) as it drops free. Remove the screw (6) and disassemble the take-up spindle and pulley assembly (1) 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). ¢. Remove the retaining ring (10) and large Nat washer (13) from the end of the gearshalt (16). Re- move the rubber sleeve (12) fram the hub of the gear (14). Loosen the gear setscrew (13) and disassemble the gear (14), the shim washer (J5) and the goarshaft (16) trom the reel arm. 4. Remove the retaining ring (27) 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). fe. Remove the retaining ring (18) and slide the upper spur gear (20) toward the upper face gear (27) until the upper gear retaining chip (21) ean be removed. Move the gearshaft (24) down until the up= er 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 Dearing poste “of the reel atm. Inspect the aylon bearings (25) and, if damaged, press them from the bearing posts. f Loccen the setscrew (26) and lift the upper face gear @7) from the reel arm shaft (G1). Re- move the retaining ring (26) and disassemble the Feel arm shaft (31) and washer (29) from the reel 10. DISASSEMBLING THE EXCITER LAMP COVER AND SOUNDHEAD (Figure 9). Disassemble the ex- ‘elter lamp cover and soundhead assembly in the fol- Towing manner, noting any special precautions. 8. Inspect exeiter lamp cover parts (1 through 7) and disassembie only a8 necessary for replacement. b. Make a careful note of leadwire connections be = fore disconnecting or unsoldering leads during disas- ‘sembly of the sounchead. Remove the exciter lamp (8), wipe off fingerprints, and wrap the lamp in tissue paper. © Do not loosen the clamping screw (10) oF dis~ turb the Interal position of the optical elit assembly (11) unless i hae been determined that the optical slit is in need of replacement or adjustment.4d. Unhook and remove the stabilizer arm spring (12). Remove the retaining ring (13) and disassemble the roller adjusting serew (14) and complete stabil- Mer arm assembly (15) from the soundhead casting Remove the two screws (J5A) and washers (15B) and disassemble the rollers (1SC) and (15D) from the stabilizer arm roller shafts. The removal of screws GSE) will free the torsion spring (15G) and stabilizer arms (15), (SH) and (153). fe. Remove two screws (16) and disassemble the lamp contact assembly (17) and lamp release ring (18) trom the soundhead casting. f. Loosen the setacrew (19) which bears against the Light pipe and photocell retainer (22). Then Fe: 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 Ussve paper to protect them from damago. Do not remove the edge guide screw (24). To remove the stabilizer tension adjuster, remove the retaining ring (25) from the adjuster G1), and unscrew the adjusier from the tapped hole inthe spring retainer (28)- Be careful not to lose the friction washer (26) located at the lower tend 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 (3), pry cout 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) 1 used with the upper pin and the flat washer (4) with the lower pin. ‘To disassemble the lens carrier, remove the two screws (5A) and remove the pressure plate (8B), flat washers (SD), springs (GE) and pressure plate lever (GF). The adjustment plate (5H) need not be removed. Pry up the nameplate (53) with a knife blade. Remove two screws (SK) and disse: semble the spring (SL) and the knob and pinion as. Sembly (SM) from the lens carrier (SK). D. Remove the retaining ring (6) and withdraw ‘the ‘actuating lever (7) from the animation switch actuating rad. Remove the two screws (8) and the hhood (10). fc. Loosen two setscrows (11) in each eprocket gear (12) and (13) and. remove the gears, tension washers (14) and flat washers (14) fromthe aprocket shafts. Remove two screws (15)andthe upper sprooket Guard assembly (16), and withdraw the upper sprocket ‘Assembly (17) and its thrust washer (18)fromthe me~ chaniom housing. Disassemble the lower sprocket ‘assembly (19), flange (20) and thrust’ washer (21) ‘from the mechaniem housing. d. Remove the retaining ring (22) from the lower fend ‘of the rewind button shaft, and lift the rewind Dutton (23) and its epring (24) from the top of the mechaniam housing. FiLMosqUND? PROVE CTORS MODELS 1585, 1590, 1592 When removing sprocket guards (27) and (28), note the manner in which the torsion springs (30) fare assembled so that they may be properly re= ‘notalled. {. 2892 Models Only. Loosen the setscrew (24) and disassemble the thimation switch lever assern~ Diy (35) and ewiteh lever erank (37) from Uke mech- ‘anism housing- Note: In Models 1585 and 1590, the crank opening in the housing 16 sealed with a plug. (8). 12. DISASSEMBLING THE MECHANISM (Figure 11) Remove parts, a8 necessary, in their indexed order of isassembiy, noting the following special pre- ‘cautions. a. Remove the three serews (1) andflanged rollers. ). Note the manner in which the torsion spring (8) ‘installed. Remove the retaining ring (3) and with- raw the threading arm (4) and torsion spring (5) ‘rom ‘the mounting, posts| of the guard mounting plates. b. Note the manner in which the legs of the torsion spring (14) are engaged. Remove the screw (6), idler roller (7), roller stud (8), locking lever ‘eccentric (9), torsion spring (10) ‘and autothread ever assembly (1)- - Note the manner in which the legs af the tor- sion spring (14) are engaged. Remove the retaining Fing (12) and Iift off the lower loopformer (13) and torsion spring (14). . Remove the screw (25) and back-up bracket (66). 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 28) end lower film guide (24) from the mounting plate: €. Loosen the locking screw (27) and disassem- ble the threading lever assembly (28) from the Fear shaft end of the looplormer (G1). Remove the retaining ring (30) and withdraw the upper loop- former assembly (G1). Remove the connecting link and stud assembly (35). 1. The ex head screw (36) is used to adjust the lens carrier and should not be disturbed. Do not move the lens carrier catch (88) unless damaged and ‘in need of replacement. &- Remove (wo 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 shalt and link assembly (43), torsion spring (44), ‘washer (45) and the loopformer and lock paw! as sembly (46) from the mechanism housing. Do not disassemble the loopformer and lock pawl assembly unless parts are damaged and obviously im need of replacement.SERVICE INSTRUCT IONS he Remove the screw (48) and flat washer (60) and’ disengage and remove the tension spring (91). Remove the screw (82) and flat washer (63) and Tit out the cam follower and support assembly (64). Do not disassemble unless parte are dam- Seed and in need of replacement. Loosen the hex ead locking ‘screw (85) and disassemble the arm Resembly (66), flat washer (57) and the lever and Shaft assembly (68) from the mechanism housing. |. Remove tne two screws (60), lock washers (61) and fat washers. (62) which secure the self~ Centering assembly (63) to the mechanism hous~ ing. The seif-centering device is furnished only as-an assembly. i. Remove screws (64) and the aperture plate assembly (65). Refer to paragraph 15 for aper~ 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- ‘eautions. a. Loosen the two getserews (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 sesembly (3), used on 1592 model pro~ Jectors. Disassemble the fire shutier only if parts fare damaged and neod of replacement. B. Remove two screws (5) and the heat baffle (6) Remove the shutter nur (7). counterbalance weight (8), shutter (9) and fiber washer (10) ¢. Unless obviously in need of replacement, do not disassemble the ball and stud assemblies (12) oF the Shuttle link bearing (A7A) from the shutle arms (17). Inspect the pull-down cam follower (178) 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. Unhook the extension Spring (13) from the end of each shuttle arm and remove the felt wiper (14) and shuttle arms. The cam wiper wick (5) is inserted within the coils Of the “spring 3). If the wiper and wick appear especially dirty, diseard them. 4d. 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 mechanism housing. Inspect the cam follower (21A) and spring (21B) and replace if damaged. Remove two screws (22) and the shuttle farm Plate assembly (23). Inspect the bearing support (24) and replace If damaged. ¢. Pull out the stop pln (25) and unscrew the tramier lob and. shaft (26) from the mechanism housing. Remove the screw (27), the in-out spring (Gl) and the shuttle retractor pin @3). f- 1592 Models Only. Remove the two retaining rings (90) and disassemble the stop paw! shaft (31) ind stop pawl (22), Remove the screws (38) and (35) and disassemble the bearing bracket (94) and stop pawt shaft. bracket (36) from the mechanism hous- Tne. inspect the grommets G7) and, if damaged, press them from the Bracket (96) AM. DISASSEMBLING THE MECHANISM (Figure 13)- Remove parts, as necessary, in thelr indexed order of disassembly, noting the following special pre~ ‘cautions. 1892 Moses Oty Remove, toe round ma) and washer (2) and disassemble the shuttle adjust meat bracket {@) from the animated clutch bracket SSsembly. Remove the screws (4) and (5) and lock ‘washers. (6) and Iift the animated clutch bracket Sssembly ‘(r) from the mechanism housing. If the Bracket assembly parts are in need of replace ment, procee! as follows. Remove the three re~ Taining rings (7B) and slide the shaft (7C) trom the clutch mounting bracket (iL), removing the Slide bumper (7D, washer (7E}, ‘spring (7F) and Clutch slide bar assembly (7G) from the shaft as {tis withdrawn. Remove the screw (7H) and washer (25) to free the strike (7K) from the clutch slide ar . 1585 and 1590 Models Only. Remove the two retaistag: Fngs-@) and CEE], The two screws (9) and the bearing loading spring (10). Loosen the set- Serews (U1) and (244) in the loop restorer cam Gat) and worm gear (24) and press the camshaft (G0) to the left until the Bearing (12) is forced from fis 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 camshait is withdrawn from the housing. c. 1592 Models Only. Remove the lange retaining ring. Gye The tae Screus (@) and the bearing 1oad= Ing) spring (00). Loosen the Setscrew (1) in the loop "restorer cam (27) and press the camshaft G0) to the left until the beuring (12) ts forced from the mechanism housing. Pull the bearing from the Camshaft. Remove retaining rings (6) and (28) from the camshaft ant press the camshaft to the ight to force the large bearing (29) from its seat Remove the elutch, gear and cam parts (13) through (2) a5 the camshaft is withdrawn. Make « note Of the manner ia which the torsion spring (14) is fssembled. Inspect worm gear parts (4A through 24D) and, if damaged, disassemble for replacement. 15. DISASSEMBLING THE APERTURE PLATE (Fig- lure 14), Disassemble the aperture plate by remov— ing patis, a8 necessary, in their indexed order of Gisasgembly. Be very careful 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 oecessary for repair- ing the cover and speaker assembly. Refer to the Accompanying schematic (Pigure 16) for proper lead- wire connections. 17, TESTING AND REPAIRING THE AMPLIFIER ASSEMBLY (Figure 19). Amplifier circuit board repairs are not recommended except as anemengency measure and then only If qualified electronics per- Sonne) and test equipment are available. f a faulty Condition 1 traced to the amplifier, replace the complete assembly. Using standard electronic. shop teat equipment and teehmiques, check the amplifier assembly and its components for continuity and for Shorts and open cireuits. Refer to the appropriate wiring dlagram for voltages and ratings of com- ponents and for test points. Defective solder-secured parts can be replaced by cutting the leads as close [8s possible to the body of the part or by unsolder- Fs Mosound® progect ons MODELS 1585, 1590, 1592 ing the leads from thetr terminal points. When n= Soldering, it 13 advisable to use a heat sink to avoid the direct application of heat to adjacent components When replacing parts, note the following special precautions. 8. Each of the three transistors are fuenished with’ a special lock washer and a_mica washer. ‘The lock washer 1s to be installed beneath the bead of tho screw with ite teeth against the flat washer ‘Apoly thermal compound (Bell & Howell Spec. 28-7— O01) to both sides of the mica washer and install this) washer between the trangiator and the mot heat sink bracket. The metal collector plate of the Yeanaistor must be toward the heat sink, b. The integrated circuit must be installed with ite polarity mark or notch toward the edge. of the board indieated by the dashed arrow drawn on the top of the circuit ia Figure 19. This arrow is not Imprinted on the Inagrated clroult.SERVICE INSTRUCTIONS Rearsembly Procedurg 18. GENERAL REASSEMBLY INSTRUCTIONS. a. Before reassembling parts, be sure to clean them thoroughly. Metal parts can be immersed 1n 2 pan of non-flammable solvent oF wiped vith a cloth dampened with solvent; then blown dry with 43 low pressure Jet of compressed air or dried with {lint-free cloth. Do not clean plastic or electrical Components with solvent. Simply wipe plastic and ‘lectrical components with a clean, dry cloth. Clean ‘Optical pars with 4 good quallty lens cleaner and Tens tissue or a lint-free cloth. b. Wnen reassembly procedures include staking or riveting operations, it is wise to perform these ‘operahions. belore assembling other parts. Be sure fo support the major casting oF plate solidly during Staking operations to aveld distorting the casting or plate, ‘¢. When installing electrical components, refer to the appropriate wiring diagram at the rear of the Parts Catalog for the proper connection of Ieacwires. Wien resaldering components to the amp Mifier assembly (Figure 18), use a heat sink to avoid the direct application. of heat t0 adjacent ‘components on the board. Refer to paragraph 17 {for special instructions regarding circult board com= ponent replacement. d. Most of the nameplates and the instruction plates are provided with an adhesive backing. Make Sertain. that the area to which such parte are to 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 Tulodol to one part of tri~ Chiorosthylene. When the adhesive is tacky, press the nameplate carefully but firmly in place. Wipe away any excess adhesive with a cloth dampened with solvent. ©. Labrication instructions are provided in the Introduction section of this service manual. Do not over-tubricate. Apply grease and oll sparingly aS indicated, and. wipe away any excess lubricant Mina lint-free cloth. Gears should be lubricated by specking te gear teeth and then running the projector for a few moments to distribute the grease. Where ofl Is indicated, a drop of two will usually auitice. 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 spriag (7) and the film tension rail (@). to the aperture plate. The fends of the spring should engage the notches in the film tension rail and the center of the spring Should bear aguinat the staked pip in the aper= fre plate. Assemble the spacer bushings (5) and Spring retaining cover (4) 10 the aperure plate land inatall the two screws (8) fe. 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 MECHANDM (Figure 13) Reassemble Figure 13 parts as outlined in the following paragraphs NOTE: When reassembling 1582 madel projectors Use only steps 4 through following. When reas~ Sembling 1845 and 1590 model projectors, refer to steps b and j only a. Assemble the strike (7K) to the clutch slide bar assembly (7G) with the screw (7H) and washer Gi). Insert the shalt (7C) part way through the Fight-hand arm of the mounting bracket assem- bly GL) and install the dumper (7D) on the end Of the ‘shaft. Hold the slide bar assembly (7) in position between the arms of the bracket a6~ ‘Sembly and continue to Insert the shaft, assem~ Bling the flat washer (7E) and the spring (TF) oa the ‘shaft before It 1s inserted through the left- and arms. Install the three retaining mings (7B), with the center ring to the right af the spring and washer. The Setscrew (7A) must be adjusted at final assembly to limit slide bar travel. AS~ semble the complete clutch bracket assembly (7) to the mechanism housing with the two screws (4) and (6) and lock washers (6), and press down firmly on the bracket while tightening the screws. AS Semble the adjustment bracket () to the end ofthe longer screw (5) and install the washer (2) and the round nut (1), tightening the nut finger tia. . Lightly grease both bearing openings in the cast arms of the mechanism housing. Press. the ‘hall bearing (12) into its bearing opening unt! fully seated. Assemble the large Dearing (29) to the Camshaft (30) until the bearing is seated agninat the shoulder of the shaft. Install ine retaining ring. (28) to the camshaft with the bowed surface of the Fing facing away from the ball bearing, cc. Assemble the three rubber bushings (25) into the corresponding openings in the face of the worm gear assembly (24). Accemble the bearing exsembly (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 beuring 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 (29) to the ‘sleeve bearing (l8) and press the bearing through the bearing assembly (23) and {nto the worm gear d. insert the end of the camshaft (90). with ball bearing (29) assombled, trough the Dearing hole im the right-hand cast arm of the mechanism bous- ing. ‘To the shaft, assemble the 1oop restorer cam Gi), shim washer (26) and the essembled worm gear group. Assemble the torsion epring (14) over the Rob of the driven clutch (15), spreading the legs of the spring 60 that they straddle the bent ear at te 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 ‘clutehes on. the camshaft. When Installed, the Dent ear of the driven clutch (18) must be par= allel with the camshaft flat for the loop restorer eam (27) fe. Slide the camshaft all the way in place, in sorting the end of the camshalt into bearing’ (12) ‘while seating the large bearing (29) In the bearing: hole. of the cast arm. Assemble the two retaining Fings (16) to the camshalt, one between wasber (26) and loop restorer cam (27); the other between washer (7) and cluteh (15). Clutch and loop restorer adjust mente will be made after reassembly has been completed. {. Fasten the bearing loading spring (10) to the ‘cast arm of the mechaniom housing with two screws @). Assemble the large retaining ring (8) into the Hing groove of the housing arm, with the bowed face of the ring against the bearing (22). G: Insert 2 0.190-tnch feeler gage between the loop restorer cam and the cast arm of the mechan Fiumosound? Prose croRs MODELS 1585, 1590, 1592 tam housing. Hold the cam firmly against the feeler gage while tightening the setecrew (11) aguinat the flat of the camshaft. Remove the leeler gage: NOTE: Steps h through ), following apply only to the 1585 and 1590 mose! projectors. 1h. Lightly grease both bearing openings in the cast arms of the mechanism housing. Press the Dall bearing (12) into its bearing opening until fully seated. Assemble the large bearing (29) fo the cam~ ‘shaft (80) until the bearing 1s 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. Insert the long end of tne camshaft through the bearing hole in the long cast arm of the mech anism housing. A® the shaft end protrudes through the cast arm, assemble the loop restorer cam (27), shim washer (26) and worm gear (24) (0 the shaft Continue stiging 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 (J0) to. the left-hand cast -arm wath the two screws (@). Assemble the large retaining ring. (8) into the inner ring groove in. the right- hand Dearing opening. The bowed surface of the Ting ‘must face the lange bearing (28). J. Incert 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 Teeler gage while tightening its setscrew (11) against the flat of the camshaft. Remove the feeler Rage: Tighten the worm Rear setscrew (24a) enough to ‘bold until final adjustment can be made 21, REASSEMBLING THE MECHANISM (Figure 12) Reassemble Figure 12 parts as outlined in the fol- Towing paragraphs. 4. 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 af the camshaft. Secure the loop end of the spring 10 the coasting with the screw (27). D. Screw the framer knob and shaft (26) down into the mechanism housing. Orient the stop pin (25) 50 that the flat side of the pin is parallel with and facing the framer shalt, and press the pla in place Screw the bearing support (24) all the way up into the staked nut of the chute arm plate assembly 3). 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 feast arm of the mechaniam housing with the to screws @22). cc: Loosely assemble the in-out cam (20) to the cam bracket assembly (21) s0 that the nylon face of the cam follower (21A) rides against the polished ‘surface of the eam (indicated by the dash arrow In uSERVICE INSTRUCT IONS Figure 22). Install this assembled group over the fend of the camahaft and secure the cam bracket as~ fembly to the cast arm of the mechanism housing ‘Min the two screws (39) d. At this point, refer to Figure 12 and install the assembled aperture plate (65) with screws (64) ‘Then return to Figure 12 and continue with reas- sembly as follows ©. Make certain that the shuttle Link bearings (ITA) are firmly pressed into the notches at the frontend of each shuttle arm (7) and that the ‘cam followers (17B) are assembled into the center ‘nolehed section of each arm (see Figure B). Insert the lubricated cam wiper wick (15) into the coils ‘of the extension spring (13). Assemble the Tubri- feated felt wiper (14) and the extension spring (13) fo the shuttle arms as chown in Figure B. Assem- ble "the ball and stud assemblies (02) to the ends of the ‘arms with the hex nuts (11), tightening the nats only” fingertight. Carefully insert the front fends of the shutile arms between the guides of the in-out bracket assembly (21). Assemble the Shuttle (16) 10 the front ends of the shuttle arm 0 that the shutlle 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 wnpolished face of the cam rests down. 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’ ie fully In place. The hnotch in the inner face of the pull-down cam must eccentare FRAMING ARM SHUTTLE AR PLATE ASSY cam FOLLOWER saute swurtee Batt AND Stub Assy \ Feur wiPeR Figure B. Shuttle and Shuttle Arms Assembled ‘engage a mating protrusion on the face of the In ‘out cam. Back ov! the bearing mupport (24) until fs gocket-like nylon pad engages the ball of the upper stud assembly (12). The ball of the lower fod assembly ahould rest In the socket of the nylon ‘pad mounted on the shuttle arm plate assembly (23) Temay be necessary to loosen the hex nute (11) and ‘abift the ball snd stud assemblies (12) until proper ‘Alignment is obtained. {. Install. the fiber washer (10) on the camshaft and up aguinst the pull-down cam (18) 80 that the lot 18 the washer Is signod with the slot In the cum. ‘Assemble the shutter (9) 10 the camshaft and Install the counterbalance weight (8) 60 that 11s pin ‘engages the alots In the shutter and the pull-down Cams Install the shutter nut (2) with its shoulder in the center hole of the counterweight. Grip the flats lat the end of the camshaft with an open-end wrench tnd tighten the nut (7) securely. g- 1592 Models Only. Assemble the grommets (67) into the bracket (6). Assemble a. retaining Ting (30) into the groove nearest the end of the pawl shaft (31) and insert the opposite end of the shalt Uhrough the shaft hole in the bearing: bracket (34) and both eare of the stop pawl (92)- Loosely attach the bearing bracket to the cast arm of the mechanism housing with two screws (83). Assemble bracket (36) 10 the opposite end of the Shaft and fasten the bracket to the mechanism hous ing with screws (35). Tighten screws (33) and (25) securely. Assemble the second retaining ring (30) into the groove of the shaft so that the right-hand car of the slop pawl ie held against the bearing: ‘bracket (94). NOTE: Only the 1592 model projectors are equipped Sith the fire shutter assembly (6). On 1585 and 1580 model projectors, a support bracket is installed fn place of the fire shutter. fh. Insert the rounded end of the beat baffle (6) up under the shutter and secure the baffle with the two serews (5). Fasten the bracket or fire abutter assembly (4) to the mechanism housing with four terews {9} and washers (BA). Install the pulley (2) fon the end of the camsbalt, and tighten the pulley ‘otscrews (1) down on the flats of the shaft 22, REASSEMBLING THE MECRANISM (Figure 11)- Reassemble Figure 11 parts as outlined in thefotlow- ‘ng paragraphs. ‘ Attach the pelf centering assembly (63) to the mechtnism housing with the two sorews (60), lock wusbere (61) and {lat washers (62). Assemble the Jever and shaft assembly (58) to the mechanism touaing and install the washer (57) and arm assembly (Ge) on the end of the abaft. The fork-like finger of the arm assembly must engage the pin of the self fostering assembly betwoen the two large washers. Insort a. 0.0015-Inch fecler gage betwoen the washer G1) abd the machined boss of the bousiag. Grip the ‘then G8) and arm (56) to hold the foeler gage whiletightening the hex head screw (55): then remove the feclcr gage. Assemble the retaining ring (59) to the ‘mnaft assembly (58)- NOTE; The shaft assembly (58), when installed, Trost 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 (S4A) through (644) as shown in Figure 11. Attach this assembled group to the arm asoembly (66) with the screw (52) ia washer (53). Tighten the screw Just enough to hold the follower group. Hook one end of the spring (51) Ground the end of the lever shaft (68) and secure the ‘otner end to the mechanism housing with the screw 19) and washer (50). ce: Assemble the film escape mechanism compon~ ‘ents (464) through (46G) in the follovang manner. AS~ Semble. the bub assembly (46F) to the locking paw! GE) wih the screw (46D). Insert the shaft (465) fhrough ‘one ear of the upper loopformer assembly (46G) and install the spring (46C) and the assembled ub and pawl on the shaft. Then engage the end of the Shaft with the second ear of the looplormer. Asser ‘le 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 Debind the upper finger of the hub assembly (46F) Tae spring should tend to rotate the hub and lock- ing pawl in'a clockwise direction. 4. Install the torsion spring (44), short leg first, fon the shaft of the shaft and link assembly (43) and insert the shaft through the bearing in the mechan gm Rousing. Hook the long leg of the spring beneath the tapped’ mounting boss in the upper left-hand comer of the ‘mechanism housing. Hook the short, bent cod of the spring behind the left edge of the Mink. Assemble the washer (45) and the film escape mechanism parts (step ¢, above) to the protruding fend of the shaft (43) and temporarily tighten the setecrews (42). ‘8. Attach the upper sprocket guard mounting plate (61) to the mechaniom housing with two screws (40), he’ upper screw being inserted through the half- ‘moon slot in the upper loopformer (46G)- f. Attach the lene carrier catch (38) to the me- ‘chuniom housing with the screw (37). Tura tbe hex head lens stop screw (36) into the tapped hole in the bousing until only one thread is visible. B may be neceosary to adjuat the catch and stop scrow at final aevembly to insure proper operation of the lona carrier. Assemble the shuttle retractor (94) to the Wink and stud assembly (35) with the screw (32), Tock washer, (93) and flat washer (3A). Assemble the upper loopformer assembly (31) to the upper fond of the connecting link (35) and install the re taining ring (90). Slip the pin end of the threading F iumosound” PROJECTORS modes 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 fub of the threading lever (28). Tighten the hex head locking screw (27) securely. Attach the leaf "spring (26) t0 the upper Toopform with ‘two serews (25) bh. 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~ Sorting the shaft of the toggle lever assembly (23) Ghrough 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~ raining forked end of the toggle lever with the pin I the lower end of the connecting tink (35) and 5e~ Cure the Tower 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 Tir Tange pivot hole slides over the sprocket shaft bearing in the housing. 1. Assemble one lange washer (18) and the lower film guide (19) over the lower sprocket 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 we second large Washer (18) and secure these parts with the retain~ sng Fiag (17). Fasten the back-up bracket (16) to the mount- ang plate (21) with the screw (15). Assemble the loop~ form (13) and the torsi0n spring (14) onto the lower Din of the connecting’ link (35) end install the retain~ Tag ring (12). The lege of the spring must bear against the underside of the loopform in such a manner that {hey will force the loopform to pivot clockwise around ‘the connecting Link pin k. Assemble the film guide (IE) 10 the auto~ uaread lever (11F) with the screw (11D), tightening the screw finger-tignt Assemble the roller (11C) land film guide (L1B) 0 the shaft of the autothread ever and secure with the screw (114) 1. 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~ terclockdee and held in at 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 ne looplorm (13). Assemble the torsion spring (10), hort leg first, to the eccentric (9). Hook the short Jeg of the epring Into the hole inthe mechanism housing above and to the left of the eccentric (9)- Hook the long leg of the spring in the V-like notch Along the left edge of the lever (11) im. Assemble the torsion spring (5) and threading arm {{) to the stud in the lower right-hand comer of the mounting plate (21). Engage the legs of the spring aSERVICE INSTRUCT IONS 440 that they tend to pivot the threading arm clock= ise. install the retalning ring (2) 40 secure the arm to the stud. 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 a3 out- lined in the following paragraphs. A. Lightly grease the gear teeth of the pinion as~ sembly (3M), the pinion slots of the carrier (SN), And the notches of the pinion spring (SL). b. Assemble the spring (SL) into the two grooves of the pinion assembly (5M) and assemble the pinion into ‘the grooves of the carrier (SN). Fasten the spring securely with the two screws (5K). Check to mate certain that the knob rotates smoothly. cc. Place the pressure plate (SB) on the work sur~ face, polished surface down and the forked end of the plate to the left. Assemble tne pressure plate lever GF) to the pressure plate with the small. extrusion Of the lever fitted into the corresponding hole 1n the Pressure plate. Assemble the flat washers (SD) Into the springs (GE) and assemble these parts and ‘the adjustment plate (SH) to the pressure plate, with the shorter bushing located at the lever (SF). Install lana tighten the two screws (5A) 4. Slip the adjustment plate, with pressure plate assembled, into place within the lens carrier and Toosely install the two screws (SG). 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 (SG) se curely and withdraw the lens plug. fe. Clean the nameplate area of the lens carrier swith a cloth dampened with solvent. Remove the back= Ing from the nameplate (GJ) and activate the adhesive fas 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 (Pigure 10). Reansemble Figure 10 parts as outlined in the fotlow- Ing paragraphs: ‘, Rotate and hold the lower loopform (19, Figure 11) folly counterclockwise and assemble the filter exit guide (92, Figure 10) to the mechanism bousing wath the screw (91). bb. Assemble the sprocket guards (27) and (28), rollers (29) and torsion springs (30) to the tapped Mounting posts of the guard mounting plates. The Follers must be assembled ax shown In the inset (of Figure. 10. The inner bent end of each spring te inserted into small spring holes in the mounting plates adjacent to the tapped posts. The outer bent fond of exch epring hooks over the outer edge of each sprocket guard (27) and (28). The springs should ‘end to rotate the free (unmounted) end of the sprocket “ guard toward the sprocket bearings In the mec [nism housing. Secure the sprocket guards to thelr mounting post with the screws (25) and the ehim washers (26). ©. Assomble 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 (21) Into the groove at the lower end of the shaft & Assemble the sprocket flange (@0) and thrust washer (21) onto the shaft of the lower sprocket as~ Sembly (8). Spread the two lower sprocket guards and insert the sprocket shaft through the lower bear~ {nge in the mechanism housing until the eprockot is fully seated. Release the sprocket guards. Assemble a flat washer (144), 2 spring tension washer (14) Gnd 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 setacrews, securely. The sprocket and gear mut turn freely Dut with only a minimum of end play. fe. 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 shalt throogh the upper bearings in the mechanism housing until the sprocket is fully seated. Release the sprocket guard. 4, Assemble the sprocket guard parts (16A) through (16D)- Slip the assembled sprocket gusrd (16) Up into position Denesth the upper sprocket and se~ cure the guard with two screws inserted trom the rear of the mechanism housing. Assemble a flat Washer (144), tension washer (I) and the upper sprocket gear (12) to the sprocket shaft. Align Cither setscrew (12) with the flat on the sprocket Shaft and carefully mesh the sprocket gear with the worm gear. Tighten both setacrews (11) se~ Curely. The sprocket and gear must turn freely, but with a minimum of end play. &- 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 Retuating lever (7, Figure 10) to the lever shaft. Iatall the retaining ring (6)- th. Hold the assembled lens carrier (5) between the hinge bosses of te mechanism housing. Insert the flat washer (4) on top of the lower hinge boss. find the apring tension washer (3) Deneath the upper Ringe boos. Frees the hinge ping (1) and (2) into place to bold the lens carrier. Adjust the Tens Carrier catch (38, Figure 11) 20 that It bolde the Teas ‘carrier firmly against tne stop screw (36, Figure 11) In the closed position; yet permite the carrier to bo opened easily. 1. All eritical adjustments axe to be made during the final assembly of the projector and are covered In the Adjustments section of EMS service manual.28. REASSEMBLING THE SOUNDHEAD AND EX CITER LAMP COVER (Figure 9). Reassemble the soundnesd and amp cover parts as outlined in the following paragraphs. If exciter lamp mounting pin parts (31) through (BIC) were replaced, assemble the spring (91C) and bushing (1B) 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. cc. Apply ahesive (BAH Spec. 1761-04) to the end four threads of the roller adjusting screw (14) and assemble the screw to the soundhead, leaving ap- proximately two threads exposed 4d. Assemble the light pipe and photocell assembly (23) and light pipe retainer (22) 10 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 place. Install the two screws (20), ‘turning them down in the tapped holes in the sound ‘drum housing. . Lightly oil the roller shafts of stabilizer arms (15H) and (53). Assemble the lower stabilizer arm (SH) over the short shaft end of the upper stabilizer ‘arm (J8d). Assemble the torsion spring (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 {wo screws (I5E)- Hook the bent end of the spring (SG) through the small hole near the end of stabilizer arm (15F). Wind the straight leg of the spring one full ‘tum clockwise and hook it behind the small post the lower arm (15H). Assemble the rollers (1SC) and (SD) 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 (ISA) and washers (ISB). Insert the shaft of ‘the upper stabilizer arm carefully through the sound head casting and the adjusting screw (14) and install the retaining ring (13). Position the retaining ring for 0.0008 to 0.005 inch ead play of the stabilizer arm shaft) See Figure C for stabilizer and installation. 4. Lightly grease both surfaces of the lamp re- Tease ring (18) and assemble the release ring and ‘the lamp contact assembly (17) to the soundhead casting with the two screws (16) & Insert the optical alit assembly (11) toto its ‘opening In the soundhead casting and tighlen screw (10) just enough t0 hold the slit in place. F 1LMOSOUND™ PROJECTORS MODELS 1585, 1590, 1592 TENSION ADJUSTER SPRING RETAINER Figure C Stabilizer Arms Installed on Seundhend hh, Insert the small end of the stabilizer tension adjuster (27) through the hole in the top of the sound hhead 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 af the casting, assemble the friction washer (26), bowed face up, to the end of the adjuster. Assemble the retaining ing (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 (24). Install the exctter lamp (8)- Refer to paragraph 40 for soundhead adjustments. i. Reassemble the exciter lamp cover as follows. Remove the cloth backing {rom the light shield (6) and assemble the ight 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 oF 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 hate plug (5) into the hhole’ 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 Inatall the screws (@)- Insert a 0.020-inch spacer between the guide flange and the cover, press the flange against the spacer, and tighten the screws (@) securely. Remove the spacer. 26. REASSEMBLING THE REAR REEL ARM AS~ SEMBLY (Figure 3). Reassemble the rear reel farm ax outlined in-the following paragraphs. 1. Apply ofe drop of oil to the unflanged end of the beating in the rear reel arm (2). Assemble one re- taining rjng (28) to the rear reel arm shaft (91) 10 the igroove" nearest the two narrow flats on the shalt. AS— emble the thrust washer (29) over the longend of the asSERVICE INSTRUCT IONS ‘shah and down againat the rotaining fing. Incr the shaft chrough tho reel arm bearing. Assemble Ue face gear @7) to the reol arm shah (1), gear ‘town facing wp, a0t tighten sctecrew (28) agulnet fiat of shat. ‘Asemble the aylon twarings (25) Into the cast tearing arma of the rear reel arm, engaging the key raring wih ibe oronaatts of Oe Rea ng bales. Assemble the lower gear (22) to that ead of dee gear shaft (24) whore the flats are nearest the ced. "The gear face with the square recess mast face Seay from the cant bearing boss. Install the gear re- {ining clip (21). tnaert the gear shaft through both nylon bearings (25). Assemble the washer (23) and gear retaining clip (21) to the end of the gear shaft. fratall the upper gear (20), equare recess facing 1n- ‘to enguge chip (21), and assemble the grip ring {18} to the end of the sbaft. Insert 0.010 inch feeler gage between the upper gear (20) and washer (23) and Press ihe grip ring (19) In against the gear. Remown fevler gage: cc. Assemble the rubber sleeve (12) to the hub of ‘tne face gear (14). The sleeve must Peat down against ‘he shoulder of the gear. Insert the small diameter fend of gear shaft (16) up through the hole in the lower ‘end of the feel atm. Wold the shaft in place and a8— Semmle the washer (5), the tace gear (14) and the large washer (11) to the gear shaft. Secere these aris with the retaining ring (10)- dd, Install the setscrew (13) into the tapped bole ‘the reel afm casting near the lower end of gear fhaft (16) Do not tighien the setscrew. Move the gear bait (i6) 40 engage the terth of the face gear (ra) with the lower spur eat (22) and tghten the Seucrew U3). Rotate the face gear in both direc~ {lone to check backlash. There should be approxi - mately 0.005 to 0.018 Inch backlash around the total Frar circumference. f necessary, loosan the set- sctew (13) and Temesh year teeth until proper back Tan io ctiained, then "Ughten setecrew securely. ce. Apply a Iignt film of grease to all gear twetn land to the hub of the woper {ace gear (27). Assemble the torsion spFing G8) to the bub of face gear (21) ‘with the loup of the spring over the casting Doss oear Upper spur neat (20). Secure the spring loop to the ‘ont with the fetaining ring (17). Rotate the upper face gear in both directions to make corain thet ‘the retaining Ping dots not restrict movement of fre apring loop on te bons. Reposition retaining ng if neresuary f Apply one drop of oll to the mouth of the bear~ ing. in tne tike-up arm assembly. Assemble te washer (8) 10 the shalt of the take-up spindle (7) tnd ineert the shaft through the take-up arm bearing. Inatall hand ‘tighien the screw (6). Assemble the fuke-up arm ‘w% the mounting pin In the reel arm. ‘Aneemble te take-up belt (4) around the ‘pulley and the futher sleeve of the lower tace grat. See Figure D. insert the tension epring (3) Into the ‘receas in the take-up arm and compress the spring, ‘vaxcur Figure D. Take-Up Arm Assembled with & plece of shim stock when assembling the reel Arm cover. (2) 10 the reel ame Be nure to place & fhm wasber (2) on each of th reel arm mounhing Dosses before lowering the cover in place. Inetall and ‘tipnten the two screws (1)- 21. REASSEMBLING THE FRONT REEL ARM AS- SEMBLY (Figure 7). Reassemble tho front Fret ‘eutlined in the following paragraphs. 4, Assemble the wusber (5C) and then the face (BB) down against the shoulder of the feed GD). Install bu do not tighen the two suscrews (6A). B. Place the real arm @22) on the bench with the tower (spindle) end of the arm at your leit. Assemble Ge nylon bearings (21) into the cast besring, ‘of the roel arm, exgaring the key tabs of the bear ings with the crose slots in the bearing bosnes. in ‘The gear shaft (20) through the nylon bearings ‘right to left, make sure that the enc with the furthest {rom the tip of the abait 18 at the Piet yr eed of the Teel arm). Assemble the lower ‘gear, (10) 20 the left end of the shaft. The sear Shas the aquare recess must face away from toe bow otaining clip (7) E ‘3, 3 orageT e & 8 8g fy e. Assemble the rotaial jareat whe two fiae circumference of each gear. By the trial and error method, loosen the gear aetecrows (5A) or (8) and ‘thea ‘of face gears with spur {S00ze until proper backlash ie obtained. Then tighten arm mounting Dosses and carefully sssamble the cover G) to the reel arm. install and tighten the two serews (1)- 20, REASSEMBLING THE BASE COMPONENTS (Fig- ‘ure 6). Raassenble Figure 6 parts ax outlined in ‘te following paragraphs. 1. Lightly grease the teeth of the worm gear (44), ui gearahatt (41) and gear rack (39). Assemble spring washer (42) to the lt gearshaft (41), bowed ‘surface toward. the worm gear. Insert the shaft Uhrough the hole in the base and secure it with Totaining ring (40). Fasten the tilt adapter (28) Yoosely to the base with the screw (31). Assemble ‘Sear rack G9) and worm gear (C4) into the balding the worm gear beiween the twoformed ‘with all gear teeth (worm ges . Secure the worm bo. Assemble the rubber feet (31) and flat washer (92) to the base with the four screws (00). Asvem= ‘Me the “lt har (20) to the lower end ofthe gear rack 29) with the screw (26) and Yock washer (27). The short leg the iit bar muBt be toward the front (operating side) of the base. New rubber feet (23) sare cemented tothe tlt bar. F itmosound> ro se¢1 woos 1585, 1580, E #8 t 3 i f | ¥ NOTE: At this point, refer to Figure § and care- fully assemble the complete mechanism sazembly 8) 10 the mainplate with the four screws (27), the upper two screws also serving to attach the idler guide assembly (10) no that the ‘are between the cast ture $}. Reasvemble Figure 5 parte as outlleed in ‘the following paragraphs. Lightly gresse the elongated slot aod sling Sent safle stn bet het brecke! assembly (25) and assemble the spacers (26) and bracket sasembly (25) to the tapped bosses of the ‘nol plate wth ee two shoulder tte Gor Assemble one toop end af the Jerson spring @3} to the right-hand shoulder stud (24) and the Geeiap ent to the beat ear of the bracket n= Seebly foal above. the shoulder std, iatall the Fetaining rings (22) to ‘rain the spring, loops: "SERVICE INSTRUCT 1ONS b. All Modols. Assemble the lever stop and pint stieaBiy Gi to the bese with the screw (4, Before tightening the screw, insert «0.060 Inch {(a2mm) shim Between the atop pin and snubber [over of the mechanism assembly. Rotate the stop luntil. the ‘stop pin Just touches the shim and hold ‘the stop securely while tightening the wcrew 4) ‘securely. Remove the shim. NOTE: Seps ¢ through g, following, apply only to 1892 model projector: + Agaemble one loop of the torsion spring (20) over the shoulder stud of the pivoting link assembly (is). Assemble the large washer (21) down against the shoulder. Position the link sesembly against the projector mainplate, with the end of the stud engaged In the rectangular opening just below the projection lamp socket area, adi the other end onthe tapped boas (of the mainplate. Insert the spacer (19) between the Tink assembly and the tapped boss and install the pivot screw (18). Secure the shaft of the link (18) ‘with the washer (17) und retaining ring (16). d. Engage the remaining loop of the torsion spring (20) with the pin at the lower end of the sliding Vink Assembly (13) while assembling the spacers (14) and Siding link to the projector mainplate. Install and ‘tighten the two shoulder screws (12) + Assemble a retaining ring (®) 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 ube (11), engaging the key lugs of the arm in the ‘lot of the tube and the alot In the end of the arm With the staked pin at the upper end of the sliding Wok assembly (3). lastall the second retaining. Fing (8) Into the ring groove at the end of the ‘tube (11). Insert the long straight end of the fire shutter Fed (8) down behind the pivoting link asnembly (16) {and through the hole in the emt ear of the link. kage the upper end of the rod wath the hole in the five ahutter filter arm. Assemble the spring (7) and Collar (6), amall diameter up to tne lower end of the Fed, and tighten the collar setecrew (5)- B+ Assemble 1 collar @), small diameter up, to ‘the ‘atiflerun rod (4). Insert the atraight end of the ftilt-run rod up through the hole in the tip of the ‘lop paw! of the mechanism assembly. Hook the bent nd of the rod through the bole in the long arm of the ing link axsembly (18). Asscrabe the spring (3) Bnd the second collar (2), small diameter down, 10 upper end of the rod. Slide the lower collat up inst the underside of the stop pawl and compress ‘the spring slightly with the upper collar. Tighien ‘both collar setscrews (1) securely. 30, INSTALLING THE SOUNDHEAD, REEL ARMS AND GEATS (Figure 4). install Figure 4 parts a ‘outlined in the following paragraphs. i a8 Carefully assemble the soundhesd assembly (60) to the projector matnplate. Be sure that all Jeadwires are pulled through behind the, mainplate 420 As tet to be pinched between the mainplate and ‘the soundhead. Hold the soundhead while installing and tightening the three screws (36) and thelr washers (81). Refer to the appropriate wiring diagram at the rear of the Parts Catalog for proper wiring connec -Hlons between soundhead and ather projector parts. D. Assemble the bowed washer (34) und the fly- ‘wheel @5) to the sound drum sha, with the bowed face of the washer agaiast the flywheel, Install the fiat washer (G3) and retaining ring (22) on the end ‘of the sound drum abait. Spin the flywheel to make ‘certain that the shaft rotates smoothly. ¢. Insert a spring (31) and a reel arin tock bution (0) Jato the opening to the right of the rear reel arm mounting hole in mainplate. Hold the button in with plece of shim stock while assembling the rear rool firm (29) to the mainplate. Assemble the reel arm dine G27) over the shoulder of the reel arm, with the bent fingers of the diac pointing away from the main- Plate. Align the screw holes in the disc with those Jn ‘Be reel arm and install and tighten the screws (26). Install the front reel arm assembly (28) In the same manner. ‘Assemble the spur gears (25C), hubs inward, ‘to the gear studs of the rewind lever assembly (25D). Place & washer (25B) on the gear stud nearest the tend 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 @e rewind lever to the Rear stud of the maine Plate (located near the upper left-hand comer of the (Cut-out for the mechanism assembly). Wind the short leg of the spring one full turn counterclockwive and hook the ent end behind the edge of the cut-out. ‘Assemble the idler gear @23), hub inward, and the aster (22) to the protruding gear ated,” meshing gear (23) with gears (25C). Install the retaining Fing @1)- fe. Assemble the gear retaining key (19) to the stat’ of the front rect afm shaft. Assemble the re: ‘wind gear (18) to the shaft ao that the equare recess: fn the inner ‘ace of the gear engages the retain ing Rey. Lightly grease the outer hub of the rewind fear. Assemble the cluich gear (17) to the shaft With ‘the longer end of the ‘clutch gear mating up ith the formed cullive of the rewind goar. Ase Semble the gest and bearing assembly (16) to the halt and up against the clutch gear 00 that the Dearing epring Is. positioned between the two bosses fon the face of the clvich gear. Inatall the retain Ing fing (15) 10(0 the groove of the shaft to lock the entire clutch ausembly in f. Assemble the gear (118), long bub out, 10 the gear atud of the arm assembly (11C) and install the Fetaining ing (114). Assemble the rewind clutch ae Sembly {14) and flat washer (13) to the upper sprocket that and sapemble the gear retaining Rey (12) 10ia Salas Soneath ‘slop. pawl) and tighten ie sotscr 1, 4895 and 1590 Models Qnlz, Aitach the fose- holder’ (41) with the perew (40). Assemble the switch {(B0) to the projector maleplate with the lookit (G8) and lockwasher 67). c. 1892 Models Only. Aasemble the rotary awitch 956) “aoe bessket foverply (50) win the look tng Aut Q5A) and Jockwasher (SB). Lift the as eembled ‘switch and bracket @5) up into position Against the mainplate while guiding the owitch shaft through the tude (item 1, Figure §) already an- embled to the mainplate.” Engage the free end of the animation switch lever crank (tem 31, Figure 420) tmio the hole at the top of the animation switch bracket (item 34, Figure 3) and secure both switch rackets (4) and (35) to the malaplate with two F1pmosound’ PROJECTORS MODELS 1585, 1590, 1592 screws (33), Insert & 0.010 inch feeler gage be- ‘gle ‘animation switch lever (Item 33, Fig ) and the mechanlem housing and hold the ‘Oe shim while preasing the orunk yn agulnat the mcch~ eet ial ae tHe iste il HE i ¥ | ately ‘motor and temporarily tighten the setacrews ‘strain falle! (24) to the jacket “sssemble the atrain relief fn. the atubillzer bracket (28). ‘sround the motor pulley ‘the motor shaft through the ‘cover (22). Assemble the blower of the motor shaft, with the fan facing toward the mo- he shalt wo that the end ‘approximately 1/16-Inch below the ter fan bub and tighten the two set- G0). Assemble the fan housing (19) to the jer with the Chree ecrews (17). Manually rotate “motor pulley to make certaln that the fan In not the cover or housing. . al [ft the aasembled motor and tote Ea EE position on the projector sane, Gresding the Grive belt through the loop of the belt shitter bracket assembly (item 25, Figure S)- Guide the belt edgewise upward and around the large mechanlam pulley. Align the motor and blower poles with those Im the base, and install tad Ugnten the eight mounting screws (18) and Gs). Refer 10 the appropriste wiring diagram at Ghe end of De Parts Catalog section and make age gre aa He For 3 E i aig Ry SE Furr ie i | pus aE I Assemble the power trans assembly (14) 0 the projector base with tour ecrews (13)- Refer to the appropriate wir~ diagram at Uie end of the Paria Catalog section ‘Asnemble the "Toc} and (10D), mounling flanges facing ‘5 Be lamp tranatormer (LOE) with the dcreve (10B) and hex pus (10A). Make wiring con- Mio the transformer according to the appro~ Sriate wiring diagram. Position the transformer #0 Biot the moveting Boles in the bracket arc aligned ‘with thoee tn the base, Install the two front screws Gi; then tip he projector ao that the two rear screws JA) oan be Inserted up through the base. Tighten Assemble the brackets (7) and &) 10 fe top of tre lamp transformer with the screws ) amet hex outs G). Make wiring connections {0SCAVICE INSTRUCT 1ONS the power transformer (4) acconting to the appro- priate wiring dlagram. Secure the power trans former to the upper fingers of the brackets (7) and 48) with two screws (2) with lockwashers @) and hhex mula (1). Note that two sleeve spacers (JA) are inserted between the bracket (8) and transformer ‘on 1892H and 1392BH model projectors. ‘92. REASSEMBLING END CAPS ANO LAMP COM- PONENTS (Figure 2). Reassemble Figure 2 parte ‘as outlined In the following paragraphs. ‘a, Pull the lamp leads through the access hote tn the mainplate and connect them to the terminals, of the lampholder (15). Secure the lampholder and the lamp shield (4) to the matnplate with the two screws (13), and pull excess lamp Icads back be~ hind the mainplate. Assemble the projection lamp (12) into the lamp socket and swing the lamp re~ ‘taining spring up Into place. 1b, Loosely assemble the stilt-run lever (114) to the “ewitch shaft with Ks setscrew. Assemble the ‘control Knob (11) to the shaft, presaing In until {fully seated. cs Ansemble the axuiliary speaker jack (9) and its Insulating washer (20) to the rear end cup (7) with the hex locking nut (8). Reassemble the Fear fend. cap components. (TA) through (7H), noting that only ‘the 1892 model projectors are equipped with ‘the Directamation remote contral receptacle (7 ‘An adheaive-backed cover (7G) tv installed over the Teceptacle opening In 1585 and 1590 model pro- Jectors. The starting capacitor (7C) la mounted wih Its terminals up and the top end of the capa Clo appraximately 1/8-inch above the top sige of the capacitor clamp (7B). Secure the clamp to ‘the rear end cap with two screws (TA). 4. Asnemble the speaker (6B) over thefour molded pins of the front end cap (6C) and install the four Reip-type retalning rings GA}. Speaker should be Inatalled with the terminals at the top. fe. Make certain that all twelve apeed nuts (5) ‘are in place on the formed maunting ears of the two end caps. Position the front end cap assembly (6) (08 the base with mounting bolos aligned and, trom Beneath the bese, install the two hase-tomchd cap mounting screws (3) finger tight: then install two Screws (4) through the Mainplate and nto the speed ‘nuts on the front mounting ears of the end ci ‘Tehten all four screws securely. Install the rear end cap assembly (1) In the same manner. f. Assemble the tI knob (2) to the protruding. end of the lt uhaft and tughlen the wetsctew (1) fecurely. Rotate the tilt knob 10 check the tilting mechanism. i Refor ta the appropriate wiring diagram at the. end of the Parts Catalog section for proper wiring connections. 39. REASSEMBLING LAMPHOUSE AND COVERS (Figure 1). No. special Instructions ere necessary for the reassembly of the lamphouse oF cover com- ponents, ‘These items need not be installed untit titer all adjustments have been made (see the fol- lowing section).F 1LMosouNt™ PROJECTORS MODELS 1585, 1590, 1592 Adjustments SOCKET MOUNTING system of the projector. The fn the Introduetion section, ‘Many of the procedures Itsted tn this aso- Hon require operation with the rear projec~ tor cover removed. To avoid shock hes tarde, dleconnect the power and discharge the’ motor starting capacitor, when not required. LENS PLUG (1) Pyneiae ALIG! ROD (2) Figure E. Aligning the Optical SystemSERVICE INSTRUCTIONS 38. OPTICAL ALIGNMENT. It te important that these alignments be por- formed. in the following listed sequence (etepe & through d). AI spectal tools and. fixtures required for optical alignment are shown In Figure A; These shown installed in the projector in Fig- ure E. Be sure to turn the mechanism manually luntil the shutter blade in clear of the aperture Opening, before inserting alignment tools. ‘a. Aligning the Aperture Plate. {1) Remove the projection lens from the leas carrier. Open the lamphouse and remove ‘the projection lamp and the condensingvens assembly. Swing the lone. carrier fully open and de- tes ‘assemble the pressure plate from the curr () Loosen the two aperture plate mounting screws just enough to permit movement of ‘the aperture plate, and insert the aperture plug (item 5, Figure A) into the aperture ‘Opening. Clove the lens carrier. (4) Insert the alignment rod (Figure £) through the lens plug unt the rod end enough to install abe spring (P/N 6124). Insert. the tena plug into the lene barrel luntil the tip of the alignment rod engages ‘the aperture plug previously installed. Tip ‘the projector carefully onto tte beck (ena Opening facing up). The alignment rod snust slide freely through the aperture plug with ‘out binding. Hf necessary, ehift the aperture plate slightly util free rod movement 18 ‘obtained: then tighten aperture plate screws. 1. Aligning the Lamp Socket. (0) Tip the projector back Into Its normal, ‘upright. position and reassemble the pres to to the lens carrier. Close the Tens carrier. (2) Loosen the two lampholder mounting screws: just enough to permit movement of the Iampholder. insert lamp plug (1, Figure A) {nto lamp socket und secure the lamp spring. Slide alignment red completely ino place until ip of rod engages the hole in Lamp plug. Shift socket as neceasary antil rod slides {reely in the lamp plug hole. Then tighien the screws securely ‘and remove all tools. 96. ADVUSTING THE INTERMITTENT MECHANISM. ‘4. Checking Shuttle Tooth Side Clearance. Ad- vance’ [om manually ‘shutue is mt the center of Its stroke us shown in Pigure F. ‘Tho clearaace from the edge of the shuttle slot to the inner end of the shuttle tooth (neareat the aper~ w @) Shuttle stroke tneorrect. See paragraph 26, step 4, Shuttle Stroke Adjustment. @) Link bearing missing from end of sbetile ‘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 assemhly (Figure _ By and Ughten stud nut securely. 02s 20,0008 |e, FaaWEL Br eewran Toot Figure F. Aperture Plate and Shuttle Tooth ClearanceShuttle Tooth Height, Swing open the ‘manually un- tthe center of Its atroke as shown igure F. Hold the sbuttle tooth height guge (Fig~ ‘A) by ta tourled handle and place i againat the eure nthe rals. The center ears, ther i # NOTE: the mechanism assembly in installed on ‘the mainframe, iM will be necessary to remove the lamphouse,” the projection lamp and the lamp~ holder before proceeding. (2) Turo te mechanism drive pulley by hand ‘until the access holes in the shutter and the fire shutter bracket are aligned as shown in Figure G. @) Insert a No. 4 Bristol Wrench Into these ‘access openings and engage it in the socket of the in-out cum follower screw. 8) UC the shuttle teeth were too low (No-Go fear passes over shuttle teeth), turn the cam follower screw counterclockwise 10 ‘increase shuttle tooth height. Ifthe abuttle teeth were too high (Go. ear catches ‘against shuttle teeth), tan we cam fol lower screw clockwise. Tl may be neces sary to recheck shuttle tooth height with the gage several times before the proper Deight bas been obtained. i-OUT shuTTER Ass“¥ amacKer (3-81a0e SHOWN) in-But can FOLLOWER, FARE SHUTTER On SUPPORT BRACKET NOTES INSERT WRENCH THROUGH ALINED MOLES AT "x" Figure G. Adjusting Shuttle Tooth Height Fitmosounderose Tors MODELS 1585, 1590, 1592 (4) Uf one of the teeth cannot be brought Into tolerance by the above method, ft’ may be necessary to loosen the screws which at- uch the in-out bracket (Figure G) and ehift the bracket slightly. Tighten the mounting ‘screws securely and check and adjust shut~ lle tooth height as outlined above. i NOTE: lf projector has Just been lubricated, run for two or three minutes before proceeding with thi G) Open film gate and turn projector mechan tam by hand until ahuttle teeth are retrac- ted and have moved downward 0 approxi- mately the center ofthe atroke (center tooth ‘approximately on borizontal center line of aperture). Slip the guide bars of tool 5-852- 4-N1 over casting {© which shuttle mounting plate Is atlached (Figure H). When tool (A) ts positioned ao that stud (B) can bear on ‘huitle arm (C), tighten thumbscrew (D)Just ‘enough to bold tool in position. Engage hook of tool §-852-4-N2 In the slot of stud (B) ‘shown, and allow weight (E) to swing down: ward. Tilt projector, if required, 20 thatthe Weight does not rub on any stationary parts 2) Loosen upper bearing support assembly (F) approximately one turn. Rotate projector tramer knob so that pointer (G} moves above witness mark (H). Then turn framer knob in the opposite direction untit pointer (G) moves back down in tine with mark (H)- S-552-h=n2 DRIVE HOTOR MUST BE REMOVED $0 WEIGHT CAN SWING FREE Figure H. Adjusting Fit of shuttle Arms to Pull-Down Cam