This is a maintenance and quick set-up list. It is recommended this
list be checked every 6 months or as needed.
Mechanical:
1. Clean all rollers and capstan with alcohol, including rollers in
optical block gate. This is important to prevent the build up of wax
from positive prints. When cleaning check for frozen or binding
bearings. Clean particle roller with water and let dry, replace
often.
2. When the capstan roller becomes hard and slick it should be
replaced for best picture stability and precise frame counting. P/N
for wide/narrow grooved roller is F2-131900-195. P/N for wide/wide
grooved roller is F2-131900-038. To replace: remove Audio housing.
Swing audio pick-up arm up, turn allen screw on capstan shaft,
replace capstan.. Tighten arm and replace audio housing.
3. Tension arms should not have any play at end stops. If loose,
loosen metric Allen screw on end of arm and Allen screw at pivot
point. Tighten screw at end (2.5mm), then at pivot (4mm).
4. Check for worn or broken clips on core platters and reel platters
on FDLs with separate core and reel platters. Clip P/N is
F2-131900-151
5. Clean optics in front and rear. It is best to blow dust off
often, than to wait and have to wipe the glass surface and possibly
scratch the surface. When dust is baked on from lamp heat and can
not be blown off. Clean with a liquid lens cleaner and/or distilled water and soft lint free cloth, like Texwipe. Blow off dust on rear lens when cool to
prevent lens from cracking. Check ND wheel and IR filter for cracks,
replace if needed. If ND wheel needs replacing, be sure to wind
split spring gear on ND motor four gear teeth before installing. If
this is not done, the ND wheel will oscillate and chatter. If using
a FDL with 115V lamp, clean mirror in lamp box in front also. Remove
the condenser lens before removing front cover. Mirror
in lamp box is front surface and can be scratch easily.
6. Check lamp sockets for pitting or burn marks, replace if severely
pitted or burned. P/N for 24V lamp socket is F3-116900-014. P/N for
115V lamp socket is F3-116900-012. With the 24V Lamp: When removing
use caution not to lose the two spacing washers on each hold down
screw. For wiring: cut the two wires and solder on new socket. Cover
splice with shrink tubing. P/N for two Lamp Socket with the molex
connector is F0-000991-016. With this part no splicing
is needed. Molex pin P/Ns F3-130390-024 and P/N F3-130390-025
7. Clean filters located under the power and frame store rack.
These are remove from the front after removing 2 screws holding the
cover strip. Filters can be cleaned with soap and water. Replace if
needed. Failure to clean will cause FDL to over heat. Bottom Air filers P/N F1-011450-002.
8. Check all cooling fans: one on the audio rack, two on the
Digital/Store rack, one on top of the FDL, one on the Lamp House and
the grain reducer's ventilation fans. Bad bearings can
cause picture instability Electronic Rack fan P/N F3-128200-016, Top power
exhaust P/N F3-128200-012, Lamp house fan P/N F3-128200-018, TVU175 Fan
P/N 59-011214-001
9. With the lens capped or standby off check DC voltage at
the FD221 Correction Amp TP Video Input. The DC voltage must be
+.2v to +.3v. If not set with Preamp DC position pot.
Electronics:
1. Power Supplies voltages should be checked. All Voltages should be
+/- .3 volts using a DVM.
Voltages of interchangeable Switching Supplies X5-24NG:
+15.5v,+15.5,+8.5,+8.5,+8.5,+8.5,-15.5v,-15.5v and the
+18.5v PS. Note the +18.5V PS may be labeled 24v.
The +5 volts on the FD234 Film Timer should be +5v -.0/+.1 volts.
Set with pot "+5V" on card.
2. Correction Amps. Gains - Blacks/CCD bias
a) With open gate, put unit in standby, press play 24FPS forward for
30 seconds to warm lamp.
b) Remove from Standby and do FPN (Fix Pattern Noise) correction.
c) Observe Preamps on WFM while FPNing, all channels must be
between 60 and 100 IRE. If not make needed adjustments/changes.
Several items can cause gain levels to be out of range: Old
discolored lamps; Autowhite pot on BLK/WHITE card set too high,
set for 98 in green during FPNing; Red and Blue Preamp gains set
too high or low, set to 90; also if the lamp house alignment is
off, set for maximum flat light in all three channels.
d) Put in standby, play at 24FPS forward in positive mode.
e) Observe Preamp position on WFM. Set Gain Knob for approximately
97 IRE units in Green's peak white. Red and Blue should be
approximately 10 IRE units lower in level (80-90).
f) Observe Correction amp on WFM, green should now be approximately
100 IRE. If not adjust with gain pot on the front of the Green
Correction Amp.
g) FPN and check level again.
h) Set Red and Blue correction Amp gains to the same level as Green.
i) FPN and check levels again.
j) If the white level is not flat and shading errors are more than
2 IRE units. Gain 3 pot on the appropriate Correction Amp can
be adjusted to minimize the shading errors. Looking at each
channel at the Correction Amp with the WFM in the IRE response
mode and the gain expanded. FPN and check level again.
CCD Bias:
1) Turn on TEST staircase signal on Video control panel.
2) Observe Main amp on WFM. Expand gain to see blacks. Set
black level knob so the bottom step is at same level as blanking.
3) Turn TEST signal off to the NORMAL operation mode.
4) Cap lens or turn standby off.
5) Adjust CCD Bias pot on the Correction Amp front panels so the
black levels are equal and at the same level as the blanking
black level.
5) If the black level is not flat. The ADJZERO pot on the Correction
Amps can be adjusted to minimize any shading errors.
FPN and check black level again.
3. Sprocket Wheel pulses.
Checking Pulses:
a) Place Sprocket Pulse Shaper card ( second card from right in
digital rack) on extender.
b) Use a dual trace scope to observe V-pulse and Ripple Pulse on
pins a26 and a25 of extender.
c) Thread up a good 16mm film, play at 24 FPS forward.
d) Check that the ripple pulse is near a 50% duty cycle.
e) Then trigger on V-pulse, use delayed sweep to observe edges of
the V-pulse. Leading and trailing edges must not coincide
with the ripple pulse edges. Use +/- trigger switch to observe
both edges.
Aligning pulses, for FD178 Sprocket pulses, without Super8 pulses.
If pulses are not correct or the capstan servo is not locking then:
a) Unplug lamp supply power cord.
b) Remove the cover from the Tacho wheel assembly.
c) Observe on scope pins 5 and 6 of Sprocket Pulse Wheel pickup card
(lugs with two white wires), V-pulse and Ripple Pulse.
d) Run 16mm film at 24 FPS Forward.
e) Adjust pot R23 OFFSET for 50% duty of Ripple Pulse with unit warm.
f) Adjust R20 (50K pot) for 50% duty cycle of V-pulse. Trigger on
V-pulse, use delayed sweep to observe edges of the V-pulse.
Leading and trailing edges must move when changing the
+/- trigger switch. Some scopes may need to be set to DC couple
on the trigger source select to observe this. R20 may be a fixed
36k resistor, if so change to 50k pot.
g) If leading or trailing edge coincides with the ripple pulse
edges. Stop the film and carefully loose the two screws that hold
the optic pick-up and slightly reposition it. Retighten and check
pulses. Repeat till correct. Use care not to scratch glass disc.
If replacing the optic pick-up check with PHILIPS service for any
updates that may apply.
Other useful part numbers:
Push button lamps 3-116300-108 14v 40ma
Interior dome Lamp P/N F3-116300-116 24V 18w Osram 6480
Capstan tacho lamp P/N F3-116300-021, a 6v 5w
Audio Meter lamp 185V 30 mA P/N F3-116300-000
Audio Exciter Lamp 6V 20W P/N F3-116400-054, ESB, Osram 64-2500
Spooling motor belts P/N F3-149900-390
Lamp 24V 250W P/N F1-000162-686, EHJ, Osram 64-655 HLX
Q201 IC P/N F3-114801-201 - Q207 IC P/N F3-114801-207
Bottom Air filers P/N F1-011450-002