© EASTMAN KODAK COMPANY, 2005 HEALTH GROUP

{PreventiveMaint}{Production}{Health Group}{None} Publication No. PM4825-1

10DEC05
Supersedes PM4825-1
09JAN04

PREVENTIVE MAINTENANCE
for the
Kodak DirectView CR 825/850 SYSTEMS
Service Codes: 5634, 4825
Important
Qualified service personnel must do these procedures.

H177_0500AC
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 PLEASE NOTE The information contained herein is based on the experience and knowledge relating to the
Page subject matter gained by Eastman Kodak Company prior to publication.
2 of 30
No patent license is granted by this information.
Eastman Kodak Company reserves the right to change this information without notice, and
makes no warranty, express or implied, with respect to this information. Kodak shall not be
liable for any loss or damage, including consequential or special damages, resulting from any
use of this information, even if loss or damage is caused by Kodak’s negligence or other fault.

This equipment includes parts and assemblies sensitive to damage from electrostatic
discharge. Use caution to prevent damage during all service procedures.

Table of Contents
Description Page

Necessary Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Checking the Error Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Checking the Scan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cleaning the FILTER - 2.4 GHz PC only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cleaning the PMT/DAS BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning the PMTs and COLLECTOR AY . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cleaning and Applying Lubricant to the CASSETTE HANDLING AY . . . . 9
Cleaning the BAR CODE READER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cleaning the EXTRACTION BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cleaning and Applying Lubricant to the SLOW SCAN SLIDES . . . . . . . . 13
Cleaning the ERASE LAMP AY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cleaning the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installing the New LIGHT SEALS on the TOP COVER . . . . . . . . . . . . . . . 16
Installing the New CLAMP BAR PLUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installing the New RIGHT and LEFT LIGHT BAFFLES . . . . . . . . . . . . . . . . 19
Installing the New REAR CLIP AY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installing the New LIGHT SEAL PLUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installing the New LEAF SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installing the New FIXED LIGHT SEAL PADDLE. . . . . . . . . . . . . . . . . . . . . 24
Installing the New LIGHT SEAL PADDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installing the New CASSETTE DRIVE ROLLERS . . . . . . . . . . . . . . . . . . . . 26
Checking the CAM and MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Checking the Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Checking the Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1
Page
3 of 30
Necessary Materials

Part No. Description Quantity Notes

--- soap - solution --- Purchase locally
3E0899 soft LINT-FREE CLOTH --- Package of 300
1C8026 LUBRICANT ---
TL-4071 VACUUM CLEANER ---
1C8000 LENS CLEANER ---
952807 LENS PAPER --- Package of 50
5E6777 SPINDLE OIL --- 4-oz BOTTLE
1C8067 CANNED AIR --- Package of 2
7E7978 PM KIT 1
6E5266 LIGHT SEAL - left 1 Included in PM KIT.
6E5267 LIGHT SEAL - right 1
1F2215 PLUSH - clamp bar 2
1F5142 LIGHT BAFFLE - right 1
1F6140 LIGHT BAFFLE - left 1
1F7859 LIGHT SEAL AY - front 1
1F2941 CLIP AY 1
1F5817 PLUSH - light seal 2
1F6723 SPRING - leaf 3
9F6823 PADDLE - light seal, fixed 1
1F5967 PADDLE - light seal, plush 3
1F5661 ROLLER - cassette drive 2
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Maintenance Plan
Page
4 of 30
Procedure Do:
Checking the Error Logs Every service call
Checking the Scan Operation Every service call
Cleaning the FILTER - 2.4 GHz PC only Every 6 months
Cleaning the PMT/DAS BOARD Every 6 months
Cleaning the PMTs and COLLECTOR AY Every 6 months
Cleaning and Applying Lubricant to the CASSETTE HANDLING AY Every 6 months
Cleaning the BAR CODE READER Every 6 months
Cleaning the EXTRACTION BAR Every 6 months
Cleaning and Applying Lubricant to the SLOW SCAN SLIDES Every 6 months
Cleaning the ERASE LAMP AY Every 6 months
Cleaning the System Every 6 months
Installing the New LIGHT SEALS on the TOP COVER Every 6 months
Installing the New CLAMP BAR PLUSH Every 6 months
Installing the New RIGHT and LEFT LIGHT BAFFLES Every 6 months
Installing the New REAR CLIP AY Every 6 months
Installing the New LIGHT SEAL PLUSH Every 6 months
Installing the New LEAF SPRINGS Every 6 months
Installing the New FIXED LIGHT SEAL PADDLE Every 6 months
Installing the New LIGHT SEAL PADDLE Every 6 months
Installing the New CASSETTE DRIVE ROLLERS Every 6 months
Checking the CAM and MOTOR Every 6 months
Checking the Adjustments Every 6 months
Checking the Operation Every service call
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Checking the Error Logs
Page
5 of 30 1 Check the Error Logs. See Checking the Error Logs.

Important
If you see more than one error code of the same component or assembly, you might have to
install new parts or do adjustments during this procedure.

2 Do an evaluation of the error logs.

3 Continue with Checking the Scan Operation.

Checking the Scan Operation

Important
You must check the scan operation before de-energizing the system.

1 Observe the scan operation or all CASSETTE sizes and make repairs before doing
preventive maintenance procedures.
2 Is this service call a 6 - month call?
Yes No
Continue with Cleaning the FILTER Advance to Checking the Operation.
- 2.4 GHz PC only.
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Cleaning the FILTER - 2.4 GHz PC only
Page
6 of 30

Caution
2.4 GHz
Dangerous Voltage
computer
1 De-energize the system. See
Energizing the System.
2 Remove the REAR PANEL.
3 Use the VACUUM CLEANER to remove
dust from the FILTER in the computer.
4 Install the REAR PANEL.
5 Continue with Cleaning the PMT/DAS
BOARD.
FILTER

H194_0029GCA
H194_0029GC
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Cleaning the PMT/DAS BOARD
Page
7 of 30 1 Remove the PMT/DAS BOARD.

Caution
PMT/DAS BOARD • Use the VACUUM CLEANER to remove
dust before using the CANNED AIR.
• Use the CANNED AIR to move debris
away from the OPTICAL CAVITY.

2 Use the VACUUM CLEANER to remove

dust from the PMT/DAS BOARD.
3 If necessary, use the CANNED AIR
1C8067 to remove dust from the PMT/
DAS BOARD.
4 Continue with Cleaning the PMTs and
COLLECTOR AY.

H194_1076GCA
H194_1076GC
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1
Page Cleaning the PMTs and COLLECTOR AY
8 of 30
1 If necessary remove the PMT/DAS BOARD.
2 Remove the PMTs and COLLECTOR AY.

2 PMTs
Caution
• Use the VACUUM CLEANER to remove
COLLECTOR AY dust before using the CANNED AIR.
• Use the CANNED AIR to move debris
away from the OPTICAL CAVITY.

3 Use the VACUUM CLEANER to remove

dust from:
• 2 PMTs
• COLLECTOR AY
• OPTICAL CAVITY
4 If necessary, use the CANNED AIR to
remove dust from:
• 2 PMTs
• COLLECTOR AY
• OPTICAL CAVITY
OPTICAL
H194_1077GCA
H194_1077GC CAVITY 5 Install:
• PMTs and COLLECTOR AY
• PMT/DAS BOARD
6 Continue with Cleaning and Applying
Lubricant to the CASSETTE
HANDLING AY.
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Cleaning and Applying Lubricant to the CASSETTE HANDLING AY
Page
9 of 30 1 Remove the CASSETTE HANDLING
AY.

Caution
Use the VACUUM CLEANER to remove
dust before using the CANNED AIR.

2 Use the VACUUM CLEANER to remove

dust from the CASSETTE HANDLING
AY.
3 If necessary, use the CANNED AIR to
remove dust from the CASSETTE
CASSETTE
HANDLING AY
HANDLING AY.
H194_1078ACA
H194_1078AC
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1
Page
10 of 30
DRIVE
ROLLER AY

CAM BLOCK

STOP PIN

RIGHT LIGHT
SEAL AY
LEFT LIGHT CAM BLOCK
SEAL AY
STOP PIN FRONT LIGHT SEAL H194_1079HCA
H194_1079HC

4 Apply lubricant to:

• STOP PIN for the RIGHT LIGHT SEAL AY
• STOP PIN for the LEFT LIGHT SEAL AY
• CAM BLOCK for the FRONT LIGHT SEAL
• CAM BLOCK for the DRIVE ROLLER AY
5 Continue with Cleaning the BAR CODE READER.
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Cleaning the BAR CODE READER
Page
11 of 30 1 If necessary, remove the CASSETTE
HANDLING AY.

Caution
Use the VACUUM CLEANER to remove
dust before using the CANNED AIR.

2 Use the VACUUM CLEANER to remove

dust from the BAR CODE READER.
3 If necessary, use the CANNED AIR to
remove the dust from the BAR CODE
READER.
BAR CODE
READER H194_1080ACA
H194_1080AC

4 If the CANNED AIR does not remove the contamination from the BAR CODE READER,
clean the BAR CODE READER with:
• LENS CLEANER SOLUTION 1C8000
• LENS PAPER 952807
5 Continue with Cleaning the EXTRACTION BAR.
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Cleaning the EXTRACTION BAR
Page
12 of 30 1 If necessary, remove the CASSETTE
HANDLING AY.

Caution
Use the VACUUM CLEANER to remove
dust before using the CANNED AIR.

2 Clean the EXTRACTION BAR with a

LINT-FREE CLOTH.
3 Install the CASSETTE HANDLING AY.
EXTRACTION BAR 4 Continue with Cleaning and Applying
Lubricant to the SLOW SCAN
H194_1081ACA
SLIDES.
H194_1081AC
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Cleaning and Applying Lubricant to the SLOW SCAN SLIDES
Page
13 of 30
CARRIAGE

holes
EXTRACTION BAR

SLOW SCAN
SLIDES
LEAD
SCREW

SLOW SCAN AY

H194_1082BCA
H194_1082BC

1 Use a LINT-FREE CLOTH to clean:

• SLOW SCAN SLIDES
• top of the EXTRACTION BAR

Caution
Do not apply SPINDLE OIL on the LEAD SCREW.

2 Apply 2 drops of SPINDLE OIL on each of the 2 SLOW SCAN SLIDES.

3 Rotate the LEAD SCREW up and down to apply the lubricant.
4 Apply 2 drops of SPINDLE OIL in the holes on the CARRIAGE.
5 Continue with Cleaning the ERASE LAMP AY.
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Cleaning the ERASE LAMP AY
Page
14 of 30 1 Disengage the LATCH.
2 Pull the ERASE LAMP AY.
LATCH
3 Use a LINT-FREE CLOTH to clean
ERASE LAMPS.
4 Use the VACUUM CLEANER to remove
dust from the ERASE LAMP AY.
5 If necessary, use the CANNED AIR to
remove the dust from the ERASE LAMP
AY.

4
5
1
ERASE

2
3
LAMPS 6 Continue with Cleaning the System.

4
5

ERASE
LAMP AY
H177_2104GCB
H177_2104GC
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Cleaning the System
Page
15 of 30
Caution
Dangerous Voltage

1 De-energize the system. See Energizing the System.

2 Use the VACUUM CLEANER to remove dust from the inside of the system.
3 Continue with Installing the New LIGHT SEALS on the TOP COVER.
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Installing the New LIGHT SEALS on the TOP COVER
Page
16 of 30 TOP COVER narrow ends of
LIGHT SEALS Top View back edge of SLOT

LEFT
LIGHT
SEAL

RIGHT
LIGHT
SEAL H194_1083BCA
front edge of SLOT H194_1083BC

1 Open the TOP COVER.

Important
• The narrow end of the LIGHT SEAL must be toward the front edge of the SLOT.
• The LIGHT SEAL must make a seal against the back edge of the SLOT.

2 Remove:
• LEFT LIGHT SEAL - discard
• RIGHT LIGHT SEAL - discard
3 Install the new:
• LEFT LIGHT SEAL
• RIGHT LIGHT SEAL
4 Continue with Installing the New CLAMP BAR PLUSH.
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Installing the New CLAMP BAR PLUSH
Page
17 of 30 1 Remove:
LEFT CASSETTE GUIDE
• 2 COVERS
RIGHT CASSETTE GUIDE
• 4 SCREWS
• LEFT CASSETTE GUIDE
• RIGHT CASSETTE GUIDE
2 COVERS
4 SCREWS • 2 SCREWS
• CASSETTE LOAD CRADLE

2 SCREWS

H194_1062GCA
CASSETTE
H194_1062GC LOAD CRADLE
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 2 Remove:
Page
18 of 30 CLAMP BAR PLUSH • 2 SCREWS
• CLAMP BAR PLUSH
CLAMP BAR
3 Install:
• new CLAMP BAR PLUSH
2 SCREWS
• 2 SCREWS
4 Reverse Step 1.
5 Continue with Installing the New
RIGHT and LEFT LIGHT BAFFLES.

H194_1084GCA
H194_1084GC
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Installing the New RIGHT and LEFT LIGHT BAFFLES
Page
19 of 30 1 Remove:
• 2 SCREWS
CASSETTE • CASSETTE LOAD CRADLE
LOAD CRADLE

H194_1074ACA
2 SCREWS H194_1074AC

2 Remove:
2 SCREWS
LEFT LIGHT 2 SCREWS
• 2 SCREWS
BAFFLE • LEFT LIGHT BAFFLE - discard
• 2 SCREWS
• RIGHT LIGHT BAFFLE - discard
3 Install:
• new LEFT LIGHT BAFFLE
RIGHT LIGHT • 2 SCREWS
BAFFLE
• new RIGHT LIGHT BAFFLE
• 2 SCREWS
H194_1085ACA CASSETTE
H194_1085AC LOAD CRADLE 4 Reverse Step 1.
5 Continue with Installing the New
REAR CLIP AY.
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1
Page Installing the New REAR CLIP AY
20 of 30
1 Open the TOP COVER.
2 Remove:
REAR BRACKET AY • 4 SCREWS
• REAR BRACKET AY

4 SCREWS

H194_1086GCA
H194_1086GC

3 Remove:
• 2 SCREWS
REAR CLIP AY • REAR CLIP AY - discard
4 Install:
• new REAR CLIP AY
• 2 SCREWS
5 Reverse Step 2.
6 Continue with Installing the New
2 SCREWS H194_1087ACA
H194_1087AC
LIGHT SEAL PLUSH.
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1
Page Installing the New LIGHT SEAL PLUSH
21 of 30
1 Remove:
LEFT CASSETTE GUIDE
• 2 COVERS
RIGHT CASSETTE GUIDE
• 4 SCREWS
• LEFT CASSETTE GUIDE
• RIGHT CASSETTE GUIDE
2 COVERS
4 SCREWS • 2 SCREWS
• CASSETTE LOAD CRADLE

2 SCREWS

H194_1062GCA
CASSETTE
H194_1062GC LOAD CRADLE
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 2 Remove:
Page
22 of 30 • 2 SCREWS
• RIGHT PLUSH PADDLE AY
• 2 SCREWS
• LIGHT SEAL PLUSH
3 Install:
• new LIGHT SEAL PLUSH
• 2 SCREWS
• RIGHT PLUSH PADDLE AY
• 2 SCREWS
2 SCREWS LIGHT SEAL
PLUSH
RIGHT PLUSH 4 Reverse Step 1.
PADDLE AY 5 Continue with Installing the New LEAF
SPRINGS.

H194_1088GCA
H194_1088GC 2 SCREWS
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Installing the New LEAF SPRINGS
Page
23 of 30 1 Remove:
• 3 SCREWS
• 3 LEAF SPRINGS - discard
2 Install:
• 3 new LEAF SPRINGS
• 3 SCREWS
3 Continue with Installing the New
FIXED LIGHT SEAL PADDLE.

3 SCREWS

3 LEAF
SPRINGS

H194_1090GCA
H194_1090GC
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Installing the New FIXED LIGHT SEAL PADDLE
Page
24 of 30 1 Remove:
• 2 SCREWS
• FIXED LIGHT SEAL PADDLE -
discard
2 Install:
• new FIXED LIGHT SEAL PADDLE
• 2 SCREWS
3 Continue with Installing the New
LIGHT SEAL PADDLE.

2 SCREWS

FIXED LIGHT
SEAL PADDLE
H194_1091GCA
H194_1091GC
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Installing the New LIGHT SEAL PADDLE
Page
25 of 30 1 Remove:
• 3 SCREWS
• 3 LIGHT SEAL PADDLES - discard
2 Install:
• 3 new LIGHT SEAL PADDLES
PLUSH
• 3 SCREWS
• RIGHT PLUSH PADDLE AY
• 2 SCREWS
3 Continue with Installing the New
RIGHT PLUSH
CASSETTE DRIVE ROLLERS.
3 SCREWS PADDLE AY

3 LIGHT SEAL
PADDLES

H194_1092GCA
H194_1092GC 2 SCREWS
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Installing the New CASSETTE DRIVE ROLLERS
Page
26 of 30 1 Remove the CASSETTE DRIVE AY.
BELT 2 Remove and discard the 2 CASSETTE
E-RING
PULLEY DRIVE ROLLERS.
3 Install:
WASHER
• 2 new CASSETTE DRIVE
PULLEY 2 SETSCREWS
ROLLERS
BUSHING • CASSETTE DRIVE AY
4 Continue with Checking the CAM and
SHAFT CASSETTE
DRIVE AY MOTOR.

PIN

MOTOR

BUSHING

2 PINS 2 E-RINGS

2 CASSETTE
DRIVE ROLLERS
H194_1007GCA
H194_1007GCB
H194_1007GC
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Checking the CAM and MOTOR
Page
27 of 30 1 Remove the CAM MOTOR AY.
MOTOR CAM
2 Pull the CAM toward the MOTOR.Check
that the CAM does not move on the
SHAFT of the MOTOR by pulling to
CAM toward the MOTOR.
3 Does the CAM move on the SHAFT?
Yes No
Install new CAM Continue with Step
MOTOR AY. 4.
4 Install the CAM MOTOR AY.
5 Continue with Checking the
SHAFT Adjustments.
H177_3031ACA
H177_3031AC
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Checking the Adjustments
Page
28 of 30 1 Do:
• GALVO BOARD
• GALVO ROTATION
• FOLD MIRROR
• COLLECTOR AY
• INTERMEDIATE PLATE
• CAM SENSOR BOARD A8
• CAM MOTOR AY
• SLED CAM FOLLOWER
• CLAMP BAR
• CASSETTE END STOP
• REAR CASSETTE SENSOR
• EXTRACTION BAR HOME POSITION
• PLATE POSITIONING AY
• RIGHT and LEFT PLUSH AY - Alignment
• LEFT PLUSH AY - Vertical Position
• INTERNAL BAR CODE READER
• CASSETTE LOAD CRADLE
2 Continue with Checking the Operation.
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Checking the Operation
Page
29 of 30 1 Do:
• Setting the Laser Calibration Voltage
• Calibration for the CR 825/850 SYSTEM
• Checking the Operation
 PREVENTIVE MAINTENANCE
10DEC05
PM4825-1 Publication History
Page
30 of 30
Publication Publication Changed
ECO No. File Name Notes
Date No. Pages
09JAN04 pm4825-1 ---- --- pm4825_1.fm New Publication
10DEC05 pm4825-1 ---- 3,6 pm4825_1.fm Revised

Kodak and DirectView are trademarks of Eastman Kodak Company.

Printed in U.S.A. • pm4825_1.fm

EASTMAN KODAK COMPANY

Rochester, NY 14650 HEALTH GROUP