Joshua Repair Manual

Transcript

Repair Manual Joshua (Vision/JoyCam/Captiva) April 1993 Americas Business Center Technical Services 201 Burlington Road Bedford MA 01730 TEL: 1.781.386.5309 FAX: 1.781.386.5988 Polaroid Joshua Camera Service Manual Table of Contents 1. Description ............................................................................................................... 1-1 Introduction ............................................................................................................... 1-3 Unique Joshua Differences ........................................................................................ 1-2 In-Camera Picture Storage .................................................................................. 1-4 Compact Camera Size ......................................................................................... 1-5 Unique Microprocessor Controlled Exposure System .......................................... 1-7 Key Joshua Features ................................................................................................. 1-8 Using the Camera ...................................................................................................... 1-10 Loading Film ....................................................................................................... 1-10 Erecting Camera .................................................................................................. 1-10 Taking Picture ..................................................................................................... 1-11 Brightness Adjustment and Self-Timer ................................................................ 1-12 Major Functional Sub-Systems of the JoshuaCamera ................................................ 1-13 Erecting, Viewfinder and Camera Optical System ............................................... 1-13 Drive and Switching System ................................................................................ 1-16 Shutter System .................................................................................................... 1-18 Film Frame Transport and Spreading .................................................................. 1-21 Specification Summary ............................................................................................. 1-23 Camera Components, Covers and Panels ................................................................... 1-24 2. Theory of Operation ................................................................................................ 2-1 Sequence of Operation .............................................................................................. 2-3 Stages of Operation ................................................................................................... 2-3 Loading Filmpack into Erected or Folded Camera ............................................... 2-3 Powering Folded Camera for Dark-Slide when Filmpack is Inserted ................... 2-6 Powering Camera when Film Door is Closed, Latched and then Erected ............. 2-8 Maintaining Power for Processing after Camera is Folded ................................... 2-9 Darkslide Transport and Counter Wheel Indexing ............................................... 2-11 TC - 2 Exposing the Picture ............................................................................................ 2-12 Blocking the Viewfinder ..................................................................................... 2-13 Releasing the Taking Mirror ................................................................................ 2-14 Processing the Exposed Frame ............................................................................ 2-16 Reseating the Taking Mirror and Opening the Viewfinder Blind ......................... 2-19 Special Cases ............................................................................................................. 2-23 Darkslide when Film Door is Opened and Closed ............................................... 2-23 Folding the Camera during a Processing Cycle .................................................... 2-24 Safety Clutch on Feed Roll .................................................................................. 2-24 System Schematic ...................................................................................................... 2-24 3. Testing and Adjustments ........................................................................................ 3-1 General ...................................................................................................................... 3-3 Required Equipment ............................................................................................ 3-3 Description of Equipment .................................................................................... 3-3 Testing ...................................................................................................................... 3-5 Ambient Exposure Test ....................................................................................... 3-5 Strobe Exposure Test ........................................................................................... 3-8 Adjustments .............................................................................................................. 3-10 Ambient Exposure Calibration ............................................................................ 3-10 Strobe Exposure Calibration ................................................................................ 3-12 4. Disassembly and Reassembly .................................................................................. 4-1 Introduction ............................................................................................................... 4-4 Special Tools and Equipment Needed ....................................................................... 4-4 Disassembly and Assembly Procedures ..................................................................... 4-5 Rear Panel ................................................................................................................. 4-5 Removal .............................................................................................................. 4-5 Disassembly ........................................................................................................ 4-5 Reassembly ......................................................................................................... 4-7 TC - 3 Front Panel ................................................................................................................ 4-8 Removal .............................................................................................................. 4-8 Reassembly ......................................................................................................... 4-8 Left Hand Grip and Bottom Chute Cover .................................................................. 4-9 Removal .............................................................................................................. 4-9 Reassembly ......................................................................................................... 4-9 Bottom Chute Cover .................................................................................................. 4-10 Disassembly ........................................................................................................ 4-10 Reassembly ......................................................................................................... 4-10 Right Hand Grip ........................................................................................................ 4-11 Disassembly ........................................................................................................ 4-11 Reassembly ......................................................................................................... 4-11 Bottom Door Assembly ............................................................................................. 4-12 Removal .............................................................................................................. 4-12 Disassembly ........................................................................................................ 4-12 Reassembly ......................................................................................................... 4-15 Top Cover ................................................................................................................. 4-16 Removal .............................................................................................................. 4-16 Reassembly ......................................................................................................... 4-17 Shutter Assembly ...................................................................................................... 4-18 Removal .............................................................................................................. 4-18 Disassembly ........................................................................................................ 4-22 Reassembly ......................................................................................................... 4-27 Erect System (VMC/Bellows and Taking Mirror Carrier Assemblies) ....................... 4-28 Disassembly ........................................................................................................ 4-28 Reassembly ......................................................................................................... 4-30 Main Frame (Non-Gear Side) .................................................................................... 4-31 Disassembly ........................................................................................................ 4-31 Reassembly ......................................................................................................... 4-32 TC - 4 Main Frame (Gear Side - Outer) ............................................................................... 4-33 Disassembly ........................................................................................................ 4-33 Reassembly ......................................................................................................... 4-34 Main Frame (Gear Side - Inner) ................................................................................ 4-35 Disassembly ........................................................................................................ 4-35 Reassembly ......................................................................................................... 4-35 5. Troubleshooting ..................................................................................................... 5-3 Introduction .............................................................................................................. 5-3 Functional Test of a Joshua Camera .......................................................................... 5-5 Tools and Parts Needed for Troubleshooting ............................................................ 5-7 Common Camera Failure Modes and Corrective Procedures .................................... 5-8 Isolating the Problem (Camera Mainframe or Shutter Assembly?) ............................ 5-12 Appendix ................................................................................................................. A-1 Glossary of Terms to Describe the Joshua Cameras ................................................. A-2 TC - 5 [This page intentionally blank] 1. Description 1-1 1. Description Table of Contents Introduction ........................................................................................................................... 1-3 Unique Joshua Differences .................................................................................................... 1-4 In- Camera Picture Storage .............................................................................................. 1-4 Compact Camera Size ..................................................................................................... 1-5 Unique Microprocessor Controlled Exposure System ...................................................... 1-7 Key Joshua Features ............................................................................................................. 1-8 Using the Camera .................................................................................................................. 1-10 Loading Film ................................................................................................................... 1-10 Erecting Camera .............................................................................................................. 1-10 Taking Picture ................................................................................................................. 1-11 Brightness Adjustment and Self-Timer ............................................................................ 1-12 Major Functional Sub-Systems of the Joshua Camera ........................................................... 1-13 Erecting, Viewfinder and Camera Optical System ........................................................... 1-13 Drive and Switching System ............................................................................................ 1-16 Shutter System ................................................................................................................ 1-18 Film Frame Transport and Spreading .............................................................................. 1-21 Specification Summary ......................................................................................................... 1-23 Camera Components, Covers and Panels ............................................................................... 1-24 1-2 1. Description Introduction The Polaroid Joshua is a compact, folding, single-lens reflex camera which stores its own finished pictures and the darkslide. Camera operation is fully automatic and produces 10 full-color, instant Polaroid pictures from one Joshua film pack. Picture format can be either vertical or horizontal. The Joshua camera has an integral, fully automatic electronic flash; through-the-lens reflex viewing; and a unique microprocessor- controlled exposure process. Joshua Instant Color Film has an image area of 7.29 x 5.46 cm (2.87 x 2.15 inches). Each 10-exposure film pack contains an integral, mercury-free battery for powering the Camera electronics and motor drive systems. Figure 1-1. Joshua Single-Lens Reflex Instant Camera 1-3 Unique Joshua Differences Three major, unique design goals have been successfully achieved in the Joshua Camera: • • • Storage of finished pictures within the Camera Compact size with extremely rugged construction Improved exposure control and picture sharpness under virtually all lighting conditions Each of these Joshua differences will now be briefly described. In-Camera Picture Storage Each film frame after exposure is picked and driven by feed rollers into a semi-circular chute chamber . . . makes a U-turn . . . is fed into the processing rollers (spread system) . . . and picked a second time into a storage chamber (Figure 1-2). The process is repeated for all subsequent exposures, placing all frames (including the initial darkslide) in the camera storage chamber. The picture counter decrements one count each time another frame is processed. The last picture taken is visible through the storage chamber window. Finished pictures may be removed/ replaced from the chamber at any time. Figure 1-2. Film frame moved through chute by feed rollers, into spread system and finally into storage chamber on underside of Camera 1-4 Compact Camera Size When folded, the Joshua Camera measures about 57 x 96 x 180 mm (2.25 x 3.79 x 7.1") and weighs 760 gm (27 oz) with a full film pack. The Camera is erected by holding the camera as shown and depressing the Release Button Latch on the Strobe Tower with your right thumb (Figure 1-3). Erecting the Camera automatically charges the Strobe, when a film pack is in place. Figure 1-3. Erecting and Collapsing the Camera 1-5 Film Loading and Picture Removal Doors provide access to the film pack compartment and the picture chamber, respectively (Figure 1-4). Loading a film pack into the Camera and closing the Film Door brings the pack to the image plane and automatically transports the darkslide into the storage chamber, unless this chamber is full. If it is, a warning LED will light and an audio signal will sound, and darkslide will occur after the picture storage chamber has been emptied. Up to ten finished (processed) pictures may be removed and also re-inserted, if desired, in the picture chamber, by opening the Picture Removal Door. Figure 1-4. Access to the Film Pack and Picture Storage Areas 1-6 Unique Microprocessor-Controlled Exposure System (Figure 1-5) Significant improvement in exposure accuracy and picture sharpness, under virtually every conceivable picture-taking condition, has been achieved in the Joshua. The Camera uses entirely new methods of measuring and controlling the ambient and strobe contributions to exposure, and optimizing the shutter aperture at which the exposure is made. Advances in integrated circuit technology permit measuring and combining, in microseconds, the IR and visible ambient photometer readings. Ambient brightness is also measured prior to exposure. To predict the optimum aperture at which to fire the strobe, and secondarily to determine whether the subject is near or far from the Camera, Joshua employs a strobe wink system. This involves firing approximately one-tenth of the strobe energy prior to exposure and measuring its reflected IR value. Using these ambient (visible) and IR measurements, a micro- processor then selects the optimum strobe fire aperture and total exposure value from a lookup table. This table contains stored values for the best aperture, percent strobe and percent ambient to use, for thousands of photo situations. In addition, a highly-developed encoder system provides precise shutter blade position information, allowing the strobe to be fired at the correct aperture. This system is not dependent on blade speed, as in the past; consequently, the Camera needs no proJoshua for adjusting shutter blade speed. Figure 1-5. Microprocessor Control of Exposure 1-7 Key Joshua System Features (Figure 1-6) • Automatic focus, automatic exposure, automatic flash with rapid recharge (less than 5.3 seconds between shots), automatic film advance. • High-quality multi-element optics: Three-element, 107mm lens (front element is coated glass). Aperture range f/12 to f/72. Use of accessory close-up lens adds another lens element. • Picture storage compartment with viewing window. • SLR viewfinder presents bright image identical to image which will appear on photo (you get exactly what you see). • Use of small apertures and two focus zones provides close-distance sharpness. • Flash Range 0.6 - 3m (2 - 10 ft.). SPAR (Strobe Preferred Automatic Recharge) strobe charging, energy-saving hybrid quench system. • Picture counter counts down (shows exposures remaining). • Brightness Override switch adjusts exposure +3/4 stop; automatically resets when camera is folded. • Built-in Self-Timer: blinking LED and beep with increasing rapidity during 12-sec. countdown interval. • Steady red LED signals flash charging or filmpack battery is low. • Flashing red LED signals empty filmpack, storage compartment full or picture stopped. • Audible signals for empty film pack, picture storage compartment full, picture stopped, self-timer. • Integral snap-on mount with accessory close-up lens. • Lens protected by top cover when camera is closed. • Camera automatically adjusts for manufacturing variations in film pack speed. • Attached neck strap with measurement link. • Tripod mount. • Weighs 760 grams (27 oz.) with full filmpack. • Film speed ISO 600/29. • Film frame size: 11.1 x 6.4 cm (4.4 x 2.5 inches). Picture area: 7.3 x 5.5 cm (2.9 x 2.15 inches). 1-8 Figure 1-6. Joshua System Features 1-9 Using the Camera Note: See the Operator’s Instruction booklet for more information. Loading Film Use only Polaroid Joshua instant film. Film may be loaded (Figure 1-7) with Camera erected or collapsed: Camera is easier to handle when collapsed. Open film door by sliding the door latch; lift the door up and slide film pack in. When door is closed and latched, you will hear the film cover (darkslide) transported into the picture storage compartment and see it in the window; counter will advance to 10. Figure 1-7. Loading the Film Erecting Camera Hold Camera with left hand grasping rubber grip (Figure 1-8). Press button on top of Strobe tower with right thumb and raise the flash until the Camera clicks into its open position. (The erect linkage on left side of bellows will be firmly locked in position and Viewfinder image will not be blocked). Red LED on rear of strobe will light indicating strobe is charging, followed by green strobe-ready LED. (Strobe shuts off automatically after 30 seconds to save energy, but will turn on as soon as your finger lightly touches the shutter button.) Figure 1-8. Erecting the Camera 1 - 10 Taking Picture Hold Camera horizontally or vertically (keep flash on top), frame your picture and press shutter button (Figure 1-9). (If Viewfinder is black, Camera is not fully erected — push flash tower forward until it clicks.) If green LED is not lighted, touch shutter button lightly to charge flash. The picture advances automatically into the storage compartment, over the previous pictures. Figure 1-9. Framing and Formatting the Picture Pictures can be removed immediately, by opening the picture removal door, or left in the storage compartment (Figure 1-10). When the compartment contains 10 pictures plus the dark slide, the camera beeps and operation is inhibited until the pictures are removed. Figure 1-10. Viewing and Removing Pictures 1 - 11 Brightness Adjustment and Self-Timer To reshoot a picture that is too dark, move the Brightness Override Switch toward the white-dot arrow (Figure 1-11). To take a darker picture, move the Switch to the left, toward the black-dot arrow. (Camera must be erected; Switch will reset to normal when Camera is collapsed.) To operate Self-Timer, set Camera on tripod, frame picture and slide switch toward clock symbol (it will spring back). Camera will beep and red LED will flash at increasing rate during the next 12 seconds, then strobe will fire. May be cancelled by pushing switch to right again, or collapsing Camera, or lightly touching the shutter button. Figure 1-11. Brightness (Lighten/Darken) and Self-Timer Controls 1 - 12 Major Functional Subsystems of the Joshua Camera Note: The following descriptions and illustrations are intended to familiarize you with what the Camera subsystems are. How these subsystems work is covered in the Theory of Operation section. Erecting, Viewfinder and Camera Optical System Figure 1-12 shows in simplified form the linkage which erects the Camera and accurately positions the optical elements for viewing the scene and exposing the picture. When the release button latch on the top of the strobe tower is depressed, a latch at the base of the strobe unlatches the top cover. Further rotation of the strobe tower swings the shutter assembly up to a vertical position, where the erecting linkage latches all pivoted assemblies in place and in proper optical alignment. Figure 1-12. Erecting Sequence of the Joshua Camera 1 - 13 The image path through the single-lens reflex viewfinder, from the scene to the camera user’s eye, is shown in Figure 1-13. From the taking lens, the image is directed onto a fixed viewing mirror at 45 degrees . . . then to a textured fresnel focusing screen . . . back to the viewing mirror . . . and then to a concave mirror, which directs the image of the object through an eyelens to the user’s eye. The visual framing field equals the photographic field at all distances. Figure 1-13. Image Path through Single-Lens Reflex Viewfinder 1 - 14 As shown in Figure 1-14, a second mirror — the taking mirror — is mounted on the underside of the fresnel screen. When the shutter button is fully depressed, the pivoted fresnel screen/taking mirror assembly is unlatched and driven upward into the optical path to the 45-degree angle position shown. A fraction of a second earlier, a blind was moved into place within the viewfinder window to prevent stray light from reaching the film. If the subject is 2.7 m (9 ft.) or more from the Camera (determined automatically from strobe wink reflectance data), an internal far focus lens is automatically rotated into the optical path, for proper focusing. Film exposure occurs as the shutter blades are opened and closed. Then the taking mirror is driven back down to its original position and the viewfinder blind is opened. Figure 1-14. Movement of Taking Mirror into Optical Path during Exposure 1 - 15 Drive and Switching Systems You will note similarities between some of the components of the Joshua drive system shown in Figures 115 and 1-16, and comparable parts of Spectra/Image, 640, Impulse and SX-70 drives — for example, motor-driven reduction gear train, single-revolution timing gear with cammed surfaces, counter wheel, pick assembly and wireform switches. However, many Joshua drive system parts are new and unique. These include: • Recock Link, one-way wrap-spring Clutch Gear and Recock Latch system for positioning and returning the Taking Mirror. • Viewfinder Blind system which prevents stray light from striking the film during exposure. • Motor operation in both forward and reverse directions. • Film frame transport via two pick systems and two sets of rollers. One pick pulls the frame into the feed rolls which drive it through the “chute”, and a second pick moves the frame into the storage chamber as it exits the spread system rollers. • Separate wireform switchblocks for logic functions and powering the camera: - A 5-wire “Logic” switch (Figure 1-15) on the gear train side of the drive assembly controls Electronic Trim, Chamber Full, Self-Timer, End of Pack, Darkslide/ End of Cycle, Shutter Release and Film Speed functions. - A separate 3-wire “Erect” (Power) switch (Figure 1-20) located on the opposite side of the mainframe controls B+, VER and GND lines, and operates in conjunction with the Door Latch Sensor, Erect Sensor, Power Actuator and Film Shade. Logic Switch (See Switch Block Assembly in Figure 1-16) Power On at Start of Processing (Camera Erect) Figure 1-15. Logic Switch and Power On switch 1 - 16 Figure 1-16. Principal Parts of the Joshua Drive System 1 - 17 Shutter System (Figures 1-17, 1-18 and 1-19) Key components of the Joshua shutter system, shown in Figure 1-17, include the Front Lens, Far Focus Lens and its Solenoid 2, Walking Beam, Inertia System, the two Blades and their Solenoid 1 and Ambient/ IR Lens. The Blade Position Encoder system (Figure 1-18) includes the band of vertical slots near the bottom of the Blades, a photodiode and photo-transistor (Figure 1-18) on the PC board, and circuits in the Exposure IC. Because the Joshua is a single-lens reflex (SLR) camera in which the image is viewed through the taking lens, the shutter must normally be open for subject viewing. The Blade Opening Spring attached to the Walking Beam holds the Blades in this normally-open position, until they are closed prior to exposure by rotation of the Walking Beam, when Solenoid 1 is energized. Figure 1-17. Key Components of the Joshua Shutter System 1 - 18 Figure 1-18. Joshua Blade Position Encoder System Ambient Visible and IR levels are measured by a dual- photocell Photometer on the PC board, through green and black lenses on the lens mounting plate and corresponding apertures in the shutter blades. Each of these exposure components — ambient and IR — is individually integrated (electronically summed) by its own integrator. The Two-Zone Focus System uses, under microprocessor control, the main three-element Taking Lens only, for near zone (0.6 to 2.7 m or 2 to 9 ft.) exposures — or the main Lens plus the automaticallypositioned Far Focus Lens for exposures between 2.7 m (9 ft.) and infinity (Figure 1-19). 1 - 19 The microprocessor determines which zone to use, based on IR reflectance data resulting from the strobe wink. (Although the electronics uses the wink mode to determine whether the subject is near or far from the camera, the primary purpose of the wink mode is to predict the strobe fire aperture.) When the Far Focus Lens is needed, it is pivoted into the optical path by Solenoid 2 and latched by the Lens Latch and Latch Actuator (Figure 1-19). Figure 1-19. Two-Zone Focus System Components As exposure begins, the two blades are opened relatively slowly (about 40 ms from closed to fully open), to maximize the amount of ambient light used in the exposure, and the time the blades are at smaller apertures, to enhance depth of field. The rack and pinion (inertia link and inertia gear, respectively) of the inertia system act as an effective multiplier of inertial forces, to allow the blades to begin opening slowly. (The blades are coupled to the Inertia Link and Gear through the Walking Beam and Inertia Spring.) Blade position is very accurately monitored and controlled by the Blade Encoder system. The photodiode encoder pair (on the PC board) and horizontal rows of nine slits in the blades together act as a pulse generator, as the slits successively overlap during blade opening. Because of the accuracy of the Encoder in supplying blade position/aperture information, no proJoshua for blade speed adjustment is needed in the Joshua shutter. The strobe is fired at an aperture selected by the microprocessor from a lookup table, and quenched 2.5 ms later or when the IR integrator reaches the strobe contribution value selected by the microprocessor. 1 - 20 Exposure ends and the blades are closed when the sum of the visible and IR integrator values equals the selected total. (If this selected total has not been reached when the strobe is quenched, the blades stay open and the ambient integrator is turned back on (enabled) until additional ambient completes the exposure or a 40 ms Timeout is reached. To end the exposure and close the blades as rapidly as possible, Solenoid 1 is energized and the Inertia is left behind. A weak Inertia Coupling Spring then resets the inertia to its original position, after the shutter has closed. Note: For a simplified pictorial presentation of these steps, see the Exposure section of the Polaroid Joshua Sequence of Operations chart at the beginning of the Theory of Operation section. (See Page 2-4) Film Frame Transport and Spreading (Figures 1-20 and 1-21) When exposure of a film frame has been completed, the drive motor starts in the forward direction, turning the Timing Gear. This causes: the Darkslide/End of Cycle switch (DKEC) to close; the picture Counter Wheel to index one count; and the exposed frame to be pulled into a set of two Feed Rolls by a Pick Assembly. These rolls have rubber tires (O rings) which contact the frame along its edges, drive it through the chute and into the Spread System Rolls (Figure 1-20). Just before the frame enters the Spread Rolls, it passes over opposing, slightly projecting molded surfaces on the bottom of the Film Box and part of the Spread Roll Assembly (Figure 1-21). These molded features help position the reagent more evenly in the picture area before actual spreading occurs. At the same time the frame enters the Feed Rolls, a mechanical Film Shade (similar in function to the frog’s tongue in other Polaroid cameras) is automatically positioned over the first 1.9 cm (.75") of the picture Viewing Window. The Film Shade prevents light-piping fogging of undeveloped film through its transparent mylar coating. The frame now enters the Spread Rolls which break open the reagent pod and spread the reagent. A second chamber Pick (See Figure 2-27 on Page 2-21) in the Door catches the end of the processed frame from the mating point (nip) of the Spread Rolls. This is to ensure that the processed frame is pulled clear of the Spread Rolls and is positively carried into the picture Storage Chamber, where it will not interfere with the next frame to be spread. The film Chute, Chamber and associated transport mechanisms are designed to permit trouble-free insertion of additional film frames, either from the Chute or through the storage chamber Door, until 10 frames and a darkslide are in the storage chamber. At that point, a Full-Chamber Switch is closed, inhibiting further picture taking. 1 - 21 Figure 1-20. Film Frame Transport, Spreading and Storage Figure 1-21. Features for Even Reagent Distribution in Pod 1 - 22 Specification Summary — Joshua Camera Camera Type Folding, single-lens reflex with integral strobe and picture storage/viewing in camera. Film Type Polaroid Joshua instant color print film; 10 exposures per pack with integral mercury-free battery. Frame Size 11.1 x 6.4 cm (4-3/8" x 2-1/2"). Image Size 7.3 x 5.5 cm (2-7/8" x 2-1/8"). Focusing System Automatic, two-zone: • • 0.6 m - 2.7 m (2 - 9 ft.). 2.7 m - infinity (9 ft. -infinity). Accessory close-up lens permits fixed focus at 0.3 m (1.0 ft). Strobe Range 0.6 m - 3.0 m (2 ft. - 10 ft.). Strobe Operation SPAR system, hybrid quench, typical recharge time less than 5.3 sec. Exposure System Strobe-always, fill flash, Wink Aperture Priority (flash fire aperture based on IR reflectance and value selected from lookup table by microprocessor). Overall Dimensions • • Folded: 57 x 96 x 180 mm (2.25 x 3.79 x 7.1"). Erected: 114high x 109 deep x 180 wide (mm) (4.48high x 4.29 deep x 7.1" wide). Weights • • 634 g (22 oz) empty. 758 g (27 oz) with film pack. Indicators • Empty Film Pack - • • • Strobe Charging or Battery Low Strobe Ready Chamber Full or Picture Jam - • Self-Timer On - Controls Red LED flashes eight times, four beeps sound. Steady red LED. Steady green LED. Red LED flashes eight times, two-tone beep sounds four times. Front red LED flashes Shutter button, camera erect, brightness adjustment, self-timer. 1 - 23 Components, Covers and Panels Figure 1-22 on the following foldout page is an exploded view showing principally the removable parts, panels and covers of the Joshua Camera. Please note that this illustration is for general information only and NOT intended as a disassembly guide or representation of major sub-assemblies of the camera. (That information is presented in other sections of this Service Manual.) 1 - 24 Figure 1-22. Joshua Components, Covers,and Panels 1 - 25 [This page intentionally blank] 2. Theory of Operation 2-1 2. Theory of Operation Table of Contents Sequence of Operation .......................................................................................................... 2-3 Stages of Operation ............................................................................................................... 2-3 Loading Filmpack into Erected or Folded Camera ........................................................... 2-3 Powering Folded Camera for Dark-Slide when Filmpack is Inserted ............................... 2-6 Powering Camera when Film Door is Closed, Latched and then Erected ......................... 2-8 Maintaining Power for Processing after Camera is Folded ............................................... 2-9 Darkslide Transport and Counter Wheel Indexing ........................................................... 2-11 Exposing the Picture ........................................................................................................ 2-12 Blocking the Viewfinder ................................................................................................. 2-13 Releasing the Taking Mirror ............................................................................................ 2-14 Processing the Exposed Frame ........................................................................................ 2-16 Reseating the Taking Mirror and Opening the Viewfinder Blind ..................................... 2-19 Special Cases ......................................................................................................................... 2-23 Darkslide when Film Door is Opened and Closed ........................................................... 2-23 Folding the Camera during a Processing Cycle ................................................................ 2-24 Safety Clutch on Feed Roll .............................................................................................. 2-24 System Schematic .................................................................................................................. 2-24 2-2 2. Theory of Operation Sequence of Operation Figure 2-1 shows an overall, pictorial summary of the entire sequence of operations from power up through processing, followed by detailed descriptions of what happens during each of the major stages. Note: A Circuit Diagram of the Joshua Camera is included at the end of this section. Refer to the Glossary in the Appendix of this Service Manual for a definition of the Joshua terms used in this section. Stages of Operation Note: To prevent confusion, the terms erected and folded (or collapsed) will be used to describe the camera position. Open and closed will be used in reference to camera doors. Loading Film Pack into Erected or FoldedCamera Inserting a new film pack into the camera, and closing and latching the film door (assuming there are no pictures in the storage chamber) results in: • Film pack to be positioned in the film plane. • Camera to be powered up. • Darkslide to be transported from the film pack to the picture chamber. • Picture counter wheel to be indexed from a blank position to the number 10. • Strobe to be charged, when the camera is erected. Note: If the picture chamber is full, a red warning LED will flash and a two-tone beep will sound if the camera is erected. When the chamber is emptied, normal darkslide will occur immediately and the camera will be ready for use. 2-3 2-4 Figure 2-1. Pictorial Chart Showing Joshua Camera Sequence of Operation The film pack frame and platen assembly mounted on the film loading door permit easy insertion and removal of a film pack. As shown in Figure 2-2, these parts accurately position the topmost frame in the correct optical plane for exposure, when the door is closed. Figure 2-2. Film Pack Positioning when Door is Closed The second result of inserting a film pack and latching the door closed — powering the camera — is accomplished by the Erect (Power) Switch shown in Figure 2-3, one of two wireform switches in the Joshua. (The other switch controls logic functions and is located next to the drive mechanism, timing gear and pick carrier assemblies.) The Erect Switch is located on the opposite side of the mainframe from the drive assembly, near the lower erect link, door latch and film shade, on which it depends for operation. Figure 2-3. Erect (Power) Switch (See Figure 2-5) 2-5 As you would expect, this switch powers the camera circuits after the VER to Gnd contact is opened and the VER to B+ contact is closed. The VER and B+ wires are variously actuated by the door latch, lower erect link or the film shade lug, depending on whether the camera is folded or erected. For clarity, therefore, only the parts which are operative in a given situation will be shown in each of the following explanations. Powering a Folded Camera when a Filmpack is Inserted Since film may be loaded when the camera is folded, and because darkslide should occur immediately, darkslide power is needed in a normally unpowered camera. In the Joshua, this requirement is met by the action of a Film Shade lug on the Dark Slide Link, a pivoted finger on the Power Actuator. When the film door is opened, the spring-loaded Dark Slide Link rotates to a downward-pointing position, becoming a rigid extension of the Power Actuator (Figure 2-4). Figure 2-4. Film Door Open When the film pack is inserted and the door closed, a lug on the Film Shade forces the Dark Slide Link/ Power Actuator assembly upward, raising VER and breaking the VER - GND contact (Figure 2-5). Figure 2-5. Film Door Closed 2-6 As the door is latched, the Door Latch cam rotates the Door Latch Sensor CCW, allowing the B+ wire to drop and contact VER (Figure 2-6). Power is now made and darkslide occurs. The Film Shade moves to the left into its blocking position, then returns. Figure 2-6. Door Closed and Latched On its return, its lug pushes the Dark Slide Link to the right (Figure 2-7), out of the way, allowing the Power Actuator assembly to pivot CCW back down again. This allows VER to break contact with B+, turning off power, and to contact GND again. Note: With an erected camera, the Dark Slide Link/Power Actuator are not needed for darkslide power. Instead, the Erect Link and Erect Sensor, described later, open VER to GND, and close VER to B+.) Figure 2-7. Film Shade Retracted, Power Actuator Pivoted CCW 2-7 Powering Camera when Film Door is Closed, latched and then Erected As shown in Figure 2-8, a cam surface on the Door Latch engages the end of the Door Latch Sensor. Closing and latching the Door pivots the Sensor CCW, allowing the B+ wire to drop, but not far enough to contact VER when the camera is in the folded position. (The important effect on the power circuit of latching the Door, as contrasted to simply closing the Door, is discussed below.) Figure 2-8. Effect of Door Latch on B+ Wire of Power Switch With the Door closed and latched (the B+ wire down), erecting the camera now causes the Erect Link to pivot the Erect Sensor clockwise, lifting VER. This movement of VER first breaks the VER to GND contact, then makes the VER to B+ contact (Figure 2-9). Figure 2-9. Effect of Erect Link on VER Wire of Power Switch 2-8 If the camera is now folded, the reverse happens: VER opens from B+ and is then shorted to GND. This discharges a capacitor in the Power Supply, so that when the Camera is later erected, the microprocessor knows the strobe should be topped off. As mentioned above, it is the Door Latch, not the Door, that affects the B+ wire of the Power Switch. The reason is to prevent application of power and motor start when the Door is almost but not fully closed. The camera could attempt to darkslide and to rotate the drive gears in the Mainframe before they were smoothly and fully meshed with the gears in the Door. Thus closing the Door has no effect on the power circuit, but latching the Door does. Conversely, using the Door Latch in the power circuit rather than the Door also means that power is cut off before the Door is opened and the gear mesh is broken. When the Door is unlatched, the Door Latch cam allows the Door Latch Sensor to pivot upward (CW), driving the B+ wire upward and out of contact with VER. Maintaining Power for Processing after Camera is Folded Folding the camera from an erect position would normally cause the Erect Link and Erect Sensor to shut off the power, as just described. But folding the camera while a processing cycle is taking place (after the mirror is down) must not be allowed to interrupt the power. If it did, the motor would stop in mid-cycle, ruining the picture. How does the camera maintain power long enough to complete the processing cycle, after it has been folded? Figures 2-10 and 2-11 show how the novel Power Actuator Assembly, in conjunction with the movement of the Film Shade, performs this critical power-maintaining function. In Figure 2-10, at the start of the film processing cycle, the camera is erect and power is on because the Erect Sensor is holding VER in contact with B+. If the camera is now folded, wireform VER would normally drop down, opening B+ to VER and killing power. Figure 2-10. Power On at Start of Processing (Camera Erect) 2-9 But, as shown in Figure 2-11, the Film Shade has moved to the left, into its blocking position. A lug on one edge of the Film Shade has slid under the finger on the Power Actuator, pivoting the Actuator upward. The molded tab or shoulder on the Actuator is now snug up against VER, in contact with B+. Even if the camera were now folded, pivoting the Erect Sensor down away from VER, VER is held up in contact with B+ by the tab on the Power Actuator. Thus power is maintained until the processing cycle is completed. When the Film Shade retracts and its lug moves to the right (position shown in Figure 2-10), it allows the spring-loaded Power Actuator to pivot downward again. VER drops away from B+ and closes to GND. Figure 2-11. Camera Folded; Film Shade Lug Pivots Power Actuator Upward Keeping VER and B+ Closed 2 - 10 Darkslide Transport and Counter Wheel Indexing The third and fourth results of loading a film pack into the camera are the darkslide cycle and picture counter decrementing (counting down) or indexing. When power is made as VER closes to B+, the microprocessor checks the status of the Full Chamber, EOP (End of Pack) and DKEC (Dark Slide End Of Cycle) Switches. If the picture chamber is not full and the counter wheel has not reached the tenth exposure, their corresponding switches will be open. The microprocessor will then signal the strobe to recharge (the fifth result of loading the film pack), and through the power IC, run the motor because the DKEC switch is closed. The motor runs, rotating the Timing Gear (see Figure 2-12), which cams the Door Stop Link down to its DKEC-closed position. (Actually, the DKEC Switch is already closed.) Figure 2-12. Timing Gear Cam Actuates DKEC Switch through Outer Door Stop Link Another cam on the Timing Gear advances the Pick Carrier (Figure 2-13), causing the Pick to pull the darkslide into the Feed Rolls. From there the darkslide hits the Spread Rolls, after which the Chamber Pick moves the darkslide the final fraction of an inch into the picture storage chamber. Figure 2-13. Cam Advances and Holds Pick Assembly Forward for Entire Camera Cycle 2 - 11 During the forward stroke of the Pick Carrier, the Counter Wheel (Figure 2-14) is indexed by a spring arm on the Pick Carrier. The Counter detent acts as a ratchet. After one full revolution, the Timing Gear cam allows the Outer Door Stop Link to rotate CCW, opening the DKEC switch which signals the microprocessor to shut off the motor. Figure 2-14. Counter Wheel Indexed Exposing the Picture Note: Described below are the electromechanical actions of the main drive train which take place during exposure — how the viewfinder blind and the taking mirror are moved. For an overall list of the steps in the exposure and processing sequence of operations, see the Sequence of Operations chart at the beginning of the Theory of Operation. When the shutter release (S1A-S1B) button is depressed, Solenoid 1 is energized and begins closing the shutter blades. The main drive train now has the following tasks: to block the Viewfinder with the Viewfinder Blind before the Taking Mirror begins to move, to prevent the film from being light- struck; and second, to release and drive the Taking Mirror into position for exposing the film. Here is how these actions are accomplished. 2 - 12 Blocking the Viewfinder The motor is momentarily run in reverse, rotating the Recock Latch a short distance counterclockwise (Figure 2-15). (The Latch, on the same shaft as the Clutch Gear, is turned by the leg of a one-way-slip wrap spring on the hub of the Clutch Gear. When the motor reverses the Clutch Gear, the spring tightens on its hub and turns with it, also turning the Recock Latch. When the motor runs forward for the processing cycle, the spring slips and has no effect.) Figure 2-15. Recock Latch Rotation by Clutch Gear Spring Leg Motion of the Recock Latch is transmitted to the Viewfinder Blind through the Viewfinder Blind Link and the Viewfinder Overtravel Spring (Figure 2-16). When the Latch turns counterclockwise, the Viewfinder Blind Link is driven to the right, rotating one leg of the Blind Overtravel Spring. The Spring, in turn, pivots the Viewfinder Blind upward, covering the Viewfinder window completely before the Recock Link (and the Taking Mirror) begins to move. The Viewfinder Blind comes to rest against the upper edge of the Viewfinder Window, however, before the Recock Latch has finished its rotation. To accommodate this, the Blind Overtravel Spring opens up further. 2 - 13 Figure 2-16. Recock Latch Pivots Viewfinder Blind Upward Through Viewfinder Blind Link and Blind Overtravel Spring Releasing the Taking Mirror As previously described, the brief motor reversal rotated the Recock Latch a few degrees counterclockwise. This action frees the Recock Link to pivot upward from the force of the stretched Recock Link Spring (see Figure 2-17). As the Recock Link swings upward, a shoulder surface on its left end pushes against one edge of the Taking Mirror Carrier, forcing it into its 45-degree exposure position (Figure 2-18). Figure 2-17. Recock Link Spring pulls up unlatched Recock Link 2 - 14 Figure 2-18. Recock Link Drives Taking Mirror Carrier into Position for Exposure As described in the Exposure section of the Sequence of Operations, ambient and wink measurements are now made, strobe fire aperture selected from the lookup table, Solenoid 1 released, blade position carefully monitored and the strobe is fired — all under microprocessor control. To end the exposure, Solenoid 1 is again energized to close the shutter blades. If the Far Lens was used for the exposure, it is now unlatched and spring-returned to its normal position, out of the optical path. The exposed frame is now ready for processing. 2 - 15 Processing the Exposed Frame The motor now runs forward, rotating the Timing Gear which cams the Outer Door Stop Link to close DKEC (Figure 2-19). Another cam, on the underside of the Timing Gear, drives the Pick Carrier forward (to the left) to its full stroke and holds it there (Figure 2-20). A spring arm on the Pick Carrier indexes the Counter Wheel (Figure 2-21). Figure 2-19. Timing Gear Cam Lifts Outer Door Stop Link to Close DKEC Figure 2-20. Timing Gear Pick Advance cam (On Underside) Advances and Holds Pick Assembly Forward 2 - 16 Figure 2-21. Spring Arm on Pick Carrier Indexes Counter Wheel The Pick Carrier also drives the Override Slider in the Door. The Slider actuates the Film Shade through a reversing linkage, moving the Film Shade into position to cover approximately the first 1.9 cm (.75") of unexposed film (Figure 2-22). Figure 2-22. Override Slider in Storage Pick Assembly Pivots Film Shade Actuator Link 2 - 17 The exposed frame is now pulled into the Feed Rolls by the notched Pick Strap — a pivoted, spring-loaded arm attached to the end of the Pick Carrier (see Figure 2-23). The Feed Rolls drive the frame around the chute. Figure 2-23. Pick Strap on Pick Carrier Pulls Frame into Feed Rolls The Pick Strap in the Joshua System, which pushes the film frame into engagement with the Feed Rolls, is specifically designed to provide a more positive grip on the film frame. Spring force in a downward direction keeps the Strap in constant contact with the film frame surface, and a sharp, inclined notch assures positive engagement with the edge of the frame. 2 - 18 Reseating the Taking Mirror and Opening the Viewfinder Blind To return the Taking Mirror to its down position, the Recock Link is pivoted downward by yet another cam on the underside of the Timing Gear (Figure 2-24). Figure 2-24. Taking Mirror Carrier Driven Down by Recock Link As the Recock Link swings down, it pulls the Taking Mirror Carrier down, through the Midlink and Mirror Hold-Down Spring. This spring coupling is a safety proJoshua which allows the Recock Link to continue to move, even if something impedes the motion of the Taking Mirror Carrier (e.g., finger in the bellows). The Viewfinder Blind is opened, uncovering the Viewfinder Window, after the Taking Mirror Carrier is seated. This action happens during Recock Link overtravel, when the Recock Latch rotates to the latched position (Figure 2-25). Figure 2-25. Viewfinder Blind Opened by Recock Latch Rotation 2 - 19 The Latch is rotated by a combination of the Recock Latch Spring and the drag of the spring clutch in the overrunning direction. As the Recock Latch rotates clockwise, it pulls the Blind down through the Viewfinder Blind Link, uncovering the Viewfinder Window. The Timing Gear has now rotated to a position where its DKEC cam releases the Outer Door Stop Link, opening the DKEC switch. This signals the micro to open the shutter blades. The Outer Door Stop Link is cammed up again, closing the DKEC switch. The sequence of DKEC switch actuations by the Timing Gear cam can be seen in Figure 2-26. At the beginning of a cycle, the Timing Gear cams the Door Stop Link to close the switch. Half-way through the cycle, the Door Stop Link momentarily opens and then recloses the switch (as described above), signalling that the mirror is down. This mirror down signal lets the electronics know that the Viewfinder Blind can be opened, so that with the shutter blades reopened, the Viewfinder does not remain dark. At the end of the cycle, the DKEC switch opens again, shutting off the motor. Figure 2-26. DKEC Switch Actuations by Timing Gear During Normal Cycle 2 - 20 The final stages of processing involve the frame being fed into the Spread Rolls and spread, and the Timing Gear rotating to a position where the Pick Carrier Advance/Hold Forward cam on its underside allows the Pick Carrier to retract under its own spring tension. The Override Slider (part of the Storage Chamber Pick Assembly), under its own spring load, follows the Pick Carrier. This causes the Chamber Pick first to advance and then retract (inset, Figure 2-27), pulling the frame a short distance clear of the Spread Rolls and into the storage Chamber (Figure 2-27). This prevents possible interference as the next frame moves through the Spread Rolls. The Film Shade now retracts, and the Outer Door Stop Link opens the DKEC Switch a second time, shutting off the motor. Figure 2-27. Chamber Pick Pulls Processed Frame Clear of Spread Rolls and intoCchamber 2 - 21 The process is repeated until all 10 film frames have been processed and transported to the Storage Chamber. The 10 film frames and the dark slide will now cause the Full ChamberLink to close the Full Chamber contacts of the Logic Switch (Figure 2-28), preventing further operation until the chamber is emptied. The Full Chamber Switch is also used to detect film jams. During each normal cycle, the Full Chamber Switch is closed and remains closed until the end of the cycle, when it opens. Should a jam occur, the Chamber Pick will be unable to retract, in turn preventing the Full Chamber switch from reopening. The camera logic then interprets this as a jam, triggering audible and LED alarms. Figure 2-28. Full Chamber Switch Contacts in Logic Switch 2 - 22 The End of Pack Switch (Figure 2-29) is operated by a cam on the Counter Wheel, when the Wheel reaches the 0 position. Figure 2-29. End of Pack (EOP) Switch and Counter Wheel Cam Special Cases Darkslide when Film Loading Door is Opened and Closed When the Door is opened to remove/replace film or clean the Spread Rolls, the Pack Frame drives down the Door Stop (See Figure 2-30). Figure 2-30. Effect of Door Stop on Inner and Outer Door Stop Links and DKEC Switch 2 - 23 This rotates the Inner Door Stop Link far enough to be caught by the Pick Carrier, which acts as a detent. Rotation of the Inner Door Stop Link also rotates the Outer Door Stop Link, closing the DKEC switch. Closing the Film Door rotates the Door Stop back up, but the Door Stop Links remain in their detented position. When the micro senses the DKEC closed at the beginning of a cycle (power up), it interprets this as a do a darkslide command and causes the camera to automatically go through a normal processing cycle (no motor reverse or mirror release). This is an important action for mid-cycle clearing. The Inner Door Stop Link is released when the Pick Carrier is driven forward, but the DKEC Switch remains closed. (The Timing Gear has rotated far enough to prevent the Outer Door Stop Link from dropping.) The camera then acts as it would in a normal cycle. Folding the Camera during a Processing Cycle The cycle will end on the return of the Pick (so-called maintaining power). When the Camera is erected the next time, the DKEC Switch will still be closed and the motor will run forward very briefly. It will stop very soon, when the Outer Door Stop Link drops off its Timing Gear cam and opens the DKEC Switch, bringing the system to its normal stopping point. This brief motor run is referred to as a hiccup. System Schematic Figure 2-31 shows the Circuit Diagram for the Joshua Camera. 2 - 24 2 - 25 Figure 2-31. Circuit Diagram [This page intentionally blank] 3. Testing and Adjustments 3- 1 3. Testing and Adjustments Table of Contents General .................................................................................................................................. 3-3 Required Equipment ........................................................................................................ 3-3 Description of Equipment ................................................................................................. 3-3 Testing ................................................................................................................................... 3-5 Ambient Exposure Test .................................................................................................... 3-5 Strobe Exposure Test ....................................................................................................... 3-8 Adjustments ........................................................................................................................... 3-10 Ambient Exposure Calibration .......................................................................................... 3-10 Strobe Exposure Calibration ............................................................................................. 3-12 3- 2 3. Testing and Adjustments General The following paragraphs list and describes the required equipment necessary to test and make adjustments to the Joshua camera. Required Equipment • • • • • Joshua Test Cover (Part Number 13552) Joshua Horn Assembly (Part Number 13532) Alignment Gauge (Part Number 13551) Base Riser (Part Number 13559) Star Tester (Part Number 12650-2) Description of Equipment Joshua Test Cover The Joshua Test Cover (Figure 3-1) contains a test switch that is used to switch from the Strobe (STB) to the Ambient (AMB) test mode. It also inhibits the strobe and the IR input to the Joshua camera exposure system while taking Ambient measurements. Important: The Joshua Test Cover must be used for the Ambient and Strobe exposure test. Figure 3-1. Joshua Test Cover Joshua Horn Assembly The Joshua Horn Assembly (Figure 3-2), as with previous horn assemblies, allows exposure tests to be performed with the Star Tester. However, this horn assembly has many differences in terms of its 3- 3 mechanical and electronic components. Because electronic noise is developed during each cycle of the Joshua camera, gating circuitry has been added to the horn assembly to eliminate any developed noise during an Ambient or Strobe Exposure Test. This horn assembly has five (5) external components: Two switches (SW 1 and SW 2), two LED's (Green and Red) and one photo transistor. Switch 1 (SW 1) is used to toggle from its Strobe to Ambient mode of operation. The two LED's indicate the state of the Strobe mode. The green LED lights to indicate when the Strobe mode is in its ready state. The red LED lights to indicate when the Strobe mode is in its not ready state. Pushbutton switch 2 (SW 2) can be used to place the Strobe mode in its ready state. During the Strobe mode of operation, the photo transistor detects both the wink and strobe pulse. The Green and Red LED's turn on/off during this period (this is part of the gating function of the horn assembly). For Ambient measurements, Switch 1 (SW 1) must be set to its Ambient (AMB) position. The internal electronics of the horn assembly controls the gating function for the Ambient mode of operation. HORN SWITCH 1 RED LED GREEN LED SWITCH 2 Figure 3-2. Joshua Horn Assembly Alignment Gauge The alignment Gauge (Figure 3-4) is used in place of the 640 Nest Assembly on the Star Tester for the Joshua camera. It references the Joshua camera photocell and taking lens of the camera to the light source of the Star tester. Base Riser The Base Riser (Figure 3-4) is used to vertically align the Joshua camera to the Star Tester. If the Star Tester has leg risers, the Base Riser must be used. If it does not have leg risers, the Base Riser should not be used. 3- 4 Testing Ambient Exposure Test Purpose The Ambient Exposure Test is used to measure the energy of the film plane during an ambient (visible) light exposure. The Star Tester light integrating sphere provides a constant scene brightness level of 100 candles/ft2. Setup (Figure 3-3) 1. Open the camera door. 2. Using a solder aid tool, manually trip the camera door switch into its down position. 3. Using a solder aid tool, remove the front cover from the camera. 4. Install the Joshua Test Cover in place of the removed front cover. 5. Set the Joshua Test Cover Strobe/Ambient(STB/AMB) switch to its Ambient (AMB) position. 6. Place the camera with the Joshua Test Cover onto the Joshua Horn Assembly. 7. Remove the 640 Nest Assembly from the Star Tester. CAMERA JOSHUA TEST COVER CAMERA DOOR SWITCH AMBIENT/STROBE TRIM WHEELS JOSHUA HORN ASSEMBLY Figure 3-3. Ambient Exposure Test Setup 3- 5 8. Install the Alignment Gauge in place of the removed 640 Nest Assembly. 9. Position the Joshua Horn Assembly up against the Star Tester (Figure 3-4). The tab guide on the Alignment Gauge properly centers the camera in front of the light source window of the Star Tester. Note: The VIS/IR photocell and the taking lens should be centered on the light source window. 10. Set switch 1 (SW 1) of the Joshua Horn Assembly to its Ambient (AMB) position. 11. Slide the camera trim switch to its center (normal) position. 12. Set the Star Tester selector switch to its AMBIENT position. AM BI E NT STOPS E RRORS CAMERA ALIGNMENT GAUGE TAB GUIDE BASE RISER Figure 3-4. Positioning Camera on Horn Assembly against Star Tester 3- 6 Test Procedure 1. Press the camera shutter button. 2. Record readings shown on the STOP ERROR display of the Star Tester. 3. Repeat steps 1 and 2 two more times, recording all reading shown on the STOP ERROR display of the Star Tester. (Because of the SLR system there is only one reading for every two cycles of the camera.) -.10 + 0.25 STOP Note: Ambient Specification Limits 4. If the STOP ERROR display readings are within specification, proceed to the Strobe Exposure (Graywall) Test. 5. If the STOP ERROR display readings are not within specifications, perform the Ambient Exposure Calibration procedure. 3- 7 Strobe Exposure Test Purpose The Strobe Exposure Test is used to measure the resultant energy of the film plane during a 4.5 ft. (137 cm) Strobe (Graywall) light exposure. Setup (Figure 3-3) 1. Open the camera door . 2. Using a solder aid tool, manually trip the camera door switch into its down position. 3. Using a solder aid tool, remove the front cover from the camera. 4. Install the Joshua Test Cover in place of the removed front cover. 5. Set the Joshua Test Cover Strobe/Ambient (STB/AMB) switch to its Strobe (STB) position. 6. Place the camera with the Joshua Test Cover onto the Joshua Horn Assembly. 7. Place the Joshua Horn Assembly on top of the Star Tester (Figure 3-5) at a marked position 137 CM (4.5 Feet) from the Graywall Target. 4.5' (137CM) 4' (1.2 M STAR TESTER 4' (1.2 M) GRAYWALL TARGET Figure 3-5. Locating Joshua Horn Assembly and Camera in Relation to Graywall Target 3- 8 8. Center the Joshua Horn Assembly on the Star Tester with respect to the Graywall. The camera lens must be 4.5 feet (137 cm) from the Graywall. Note: The front of the camera must be parallel to the Graywall and the area visible in its viewfinder must be free of all objects. 9. Set switch 1 (SW 1) of the Joshua Horn Assembly to its Strobe (STB) position. 10. Slide the camera trim switch to its center (normal) position. 11. Set the Star Tester selector switch to its FLASH EXP position. Test Procedure 1. Press the camera shutter button. 2. Record readings shown on the STOP ERROR display of the Star Tester. 3. Repeat steps 1 and 2 two more times, recording all reading shown on the STOP ERROR display of the Star Tester. (Because of the SLR system their is only one reading for every two cycles of the camera.) Note: Strobe Specification Limits -.10 + 0.25 STOP 4. If the STOP ERROR display readings are not within specifications, perform the Strobe Exposure Calibration procedure. 3- 9 Adjustments Ambient Exposure Calibration Setup (Figure 3-3) 1. Open the camera door. 2. Using a solder aid tool, manually trip the camera door switch into its down position. 3. Using a solder aid tool, remove the front cover from the camera. 4. Install the Joshua Test Cover in place of the removed front cover. 5. Set the Joshua Test Cover Strobe/Ambient (STB/AMB) switch to its Ambient (AMB) position. 6. Place the camera with the Joshua Test Cover onto the Joshua Horn Assembly. 7. Remove the 640 Nest Assembly from the Star Tester. 8. Install the Alignment Gauge in place of the removed Nest Assembly. 9. Position the Joshua Horn Assembly up against the Star Tester (Figure 3-4). The tab guide on the Alignment Gauge properly centers the camera in front of the light source window of the Star Tester. Note: The VIS/IR photocell and the taking lens should be centered on the light source window. 10. Set switch 1 (SW 1) of the Joshua Horn Assembly to its Ambient (AMB) position. 11. Slide the camera trim switch to its center (normal) position. 12. Set the Star Tester selector switch to its Ambient position. Adjustment Procedure 1. Press the camera shutter button. 2. Record readings shown on the STOP ERROR display of the Star Tester. 3. Repeat steps 1 and 2 two more times, recording all reading shown on the STOP ERROR display of the Star Tester. (Because of the SLR system there is only one reading for every two cycles of the camera.) -.10 + 0.25 STOP Note: Ambient Specification Limits 3 - 10 4. If the STOP ERROR display readings are not within specifications, adjust the Ambient Calibration wheel (Figure 3-6) with a dental pick. Rotate wheel clockwise (CW) to decrease exposure or counter clockwise (CCW) to increase expoxure. 5. Retest the camera. If necessary, repeat this calibration procedure until Ambient exposure is correct. AMBIENT TRIM WHEEL JOSHUA TEST COVER CAMERA STROBE TRIM WHEEL JOSHUA HORN ASSEMBLY Figure 3-6. Ambient/Strobe Exposure Adjustments 3 - 11 Strobe Exposure Calibration Setup (Figure 3-3) 1. Open the camera door . 2. Using a solder aid tool, manually trip the camera door switch into its down position. 3. Using a solder aid tool, remove the front cover from the camera. 4. Install the Joshua Test Cover in place of the removed front cover. 5. Set the Joshua Test Cover Strobe/Ambient (STB/AMB) switch to its Strobe (STB) position. 6. Place the camera with the Joshua Test Cover onto the Joshua Horn Assembly. 7. Place the Joshua Horn Assembly on top of the Star Tester (Figure 3-5). 8. Center the Joshua Horn Assembly on the Star Tester with respect to the Graywall. The camera lens must be 4.5 feet (137 cm) from the Graywall. Note: The front of the camera must be parallel to the Graywall and the area visible in its viewfinder must be free of all objects. 9. Set switch 1 (SW 1) of the Joshua Horn Assembly to its Strobe (STB) position. 10. Slide the camera trim switch to its center (normal) position. 11. Set the Star Tester selector switch to its Flash position. AdjustmentProcedure 1. Press the camera shutter button. 2. Record readings shown on the STOP ERROR display of the Star Tester. 3. Repeat steps 1 and 2 two more times, recording all reading shown on the STOP ERROR display of the Star Tester. (Because of the SLR system there is only one reading for every two cycles of the camera.) Note: Strobe Specification Limits -.10 + 0.25 STOP 3 - 12 4. If the STOP ERROR display readings are not within specifications,adjust the Strobe Exposure Calibration Wheel (Figure 3-6) with a dental pick. Rotate wheel clockwise (CW) to decrease exposure or counter clockwise (CCW) to increase exposure. 5. Retest the camera. If necessary, repeat this calibration procedure until the Strobe exposure is correct. 3 - 13 [This page intentionally blank] 4. Disassembly and Reassembly 4-1 4. Disassembly and Reassembly Table of Contents Introduction ........................................................................................................................... 4-4 Special Tools and Equipment Needed ................................................................................... 4-4 Disassembly and Assembly Procedures ................................................................................. 4-5 Rear Panel ....................................................................................................................... 4-5 Removal .................................................................................................................... 4-5 Disassembly .............................................................................................................. 4-5 Reassembly ............................................................................................................... 4-7 Front Panel ...................................................................................................................... 4-8 Removal .................................................................................................................... 4-8 Reassembly ............................................................................................................... 4-8 Left Hand Grip and Bottom Chute Cover ........................................................................ 4-9 Removal .................................................................................................................... 4-9 Reassembly ............................................................................................................... 4-9 Bottom Chute Cover ........................................................................................................ 4-10 Disassembly .............................................................................................................. 4-10 Reassembly ............................................................................................................... 4-10 Right Hand Grip .............................................................................................................. 4-11 Disassembly .............................................................................................................. 4-11 Reassembly ............................................................................................................... 4-11 Bottom Door Assembly ................................................................................................... 4-12 Removal .................................................................................................................... 4-12 Disassembly .............................................................................................................. 4-12 Reassembly ............................................................................................................... 4-15 Top Cover ....................................................................................................................... 4-16 Removal .................................................................................................................... 4-16 Reassembly ............................................................................................................... 4-17 4-2 Shutter Assembly ............................................................................................................ 4-18 Removal .................................................................................................................... 4-18 Disassembly .............................................................................................................. 4-22 Reassembly ............................................................................................................... 4-27 Erect System (VMC/Bellows and Taking Mirror Carrier Assemblies) ............................. 4-28 Disassembly .............................................................................................................. 4-28 Reassembly ............................................................................................................... 4-30 Main Frame (Non-Gear Side) .......................................................................................... 4-31 Disassembly .............................................................................................................. 4-31 Reassembly ............................................................................................................... 4-32 Main Frame (Gear Side - Outer) ...................................................................................... 4-33 Disassembly .............................................................................................................. 4-33 Reassembly ............................................................................................................... 4-34 Main Frame (Gear Side - Inner) ...................................................................................... 4-35 Disassembly .............................................................................................................. 4-35 Reassembly ............................................................................................................... 4-35 4-3 Introduction The following procedures and illustrations cover complete disassembly of the Vision Camera and all Vision sub-assemblies. However, for many repairs, it is not necessary to completely disassemble the entire Vision Camera. Only certain panels, subassemblies or adjacent parts need to be removed to gain access to the part to be repaired or replaced. Reassembly procedures are provided for the more complex sub-assemblies (for example, the shutter and the gear trains). To reassemble Vision Camera assemblies, follow the disassembly procedures in reverse order. Special Tools and Equipment Needed Tools and equipment needed for the disassembly and reassembly of the Vision Camera subassemblies are: • Battery Contacts GO/NO-GO Gauge (# 13558) • Needlenose Pliers • Tweezers • Dental Pick • Square Drive Handle (# CPS 416) • Square Drive Bit (# 13553) • Jeweler's Screwdrivers • Solder Aid Tool (# 941168) • Narrow Blade (Notched) Flat Screwdriver (#13560) • Mid-Link Installation Tool (# 13557) • Dump Probe (# 13119) • Shutter Support Fixture (# 13556) 4-4 Disassembly and Reassembly Procedures Rear Panel 1. Removal (Figure 4-1) a. Using a square drive, remove the three (3) screws that secures the Rear Panel to the Main Body of the camera. b. Using a solder aid tool, gently pry up the Rear Panel to release it from the Main Body of the camera. c. Lift off the Rear Panel. CAMERA REAR PANEL Figure 4-1. Removal of Rear Panel 2. Disassembly (Figure 4-2) a. Using tweezers, remove the Self Timer Return Spring (Also used as Power Actuator Spring) from the Self Timer Button. b. Using a solder aid tool, gently pry up the Self Timer Button to release it from the Rear Panel. Lift off the Self Timer Button. 4-5 c. Using a solder aid tool, gently pry up the light/dark Trim Button to release it from the Rear Panel. Lift off the Trim Button. d. Using a solder aid tool, gently pry the plastic locking tab of the Control Panel Decorative Plate to release it from the Rear Panel. Lift off the Control Panel Decorative Plate being careful not to loose the counter Window (Lens). Note: The Counter Window (Lens) will fall out as the Control Panel Decorative Plate is removed. SELF TIMER RETURN SPRING SELF TIMER BUTTON PLASTIC LOCKING TAB LIGHT/DARK TRIM BUTTON REAR PANEL COUNTER WINDOW (LENS) FLAT SURFACE OF COUNTER WINDOW (LENS) FACES BOTTOM OF DECORATIVE PLATE CONTROL PANEL DECORATIVE PLATE Figure 4-2. Disassembly of Rear Panel 4-6 3. Reassembly To reassemble and reinstall the Rear Panel, follow the disassembly steps in reverse order. Note: When installing the Rear Panel onto the Main Body of the camera make sure: • • Flat part of the Counter Window (Lens) is facing the bottom of the Control Panel Decorative Plate. Self-Timer and Light/Dark Trim tabs (Figure 4-3) are positioned so that each one properly inserts into the Main Body of the camera. BRIGHTNESS OVERRIDE (LIGHT/DARK) SWITCH CAMERA LIGHT/DARK TAB SELF-TIMER TAB REAR PANEL SELF-TIMER SWITCH Figure 4-3. Location of Light/Dark Trim Tabs 4-7 Front Panel 1. Removal (Figure 4-4) a. Using a square drive, remove the three (3) screws that secures the Front Panel to the Main Body of the camera. b. Using a solder aid tool, gently pry up the Front Panel to release it from the Main Body of the camera. c. Lift off the Front Panel being careful not to break its plastic locking tab. CAMERA PLASTIC LOCKING TAB FRONT PANEL Figure 4-4. Removal of Front Panel 2. Reassembly To reinstall the Front Panel, follow the removal steps in reverse order. Note: When re-installing the Front Panel make sure the plastic locating tab is properly positioned before inserting the Front Panel into the Main Body of the camera. 4-8 Left Hand Grip and Bottom Chute Cover 1. Removal (Figure 4-5) a. Open the camera door. b. Using a square drive, remove the two (2) long neck strap screws that clamps the Left Hand Grip andBottom Chute Cover to the Main Frame of the camera. c. Gently lift off the Left Hand Grip and the Bottom Chute Cover. If necessary, use a solder aid tool to separate the two parts from the Main Frame of the camera. LEFT HAND GRIP CAMERA CAMERA DOOR STRAP COVER LATCH BOTTOM CHUTE COVER SHORT SIDE OF STRAP FACES IN LONG NECK SCREWS Figure 4-5. Removal of Left Hand Grip and Bottom Chute Cover 2. Reassembly To reinstall the Left Hand Grip and Bottom Chute Cover, follow the removal steps in reverse order. Note: When re-installing the Left Hand Grip and the Bottom Chute Cover make sure: • • • • Cover latch is released (to release push up metal tab). Neck Strap is properly positioned around the screw posts (Short side of the strap faces in on both sides). Neck Strap MUST be re-installed or light leaks may occur. Both long neck screws MUST be tight or light leaks may occur. 4-9 Bottom Chute Cover 1. Disassembly (Figure 4-6) a. Remove Neck Strap from the screw posts. b. Using tweezers, remove the Door Latch Return Spring from the Door Latch and the Bottom Chute Cover. c. Using a narrow blade flat screwdriver, gently pry up the Door Latch locking tab to release it from theBottom Chute Cover. Lift off the Door Latch. DOOR LATCH LOCKING TAB DOOR LATCH BOTTOM CHUTE COVER DOOR LATCH RETURN SPRING Figure 4-6. Disassembly of Bottom Chute Cover 2. Reassembly To reassemble the Bottom Chute Cover, follow the disassembly steps in reverse order. 4 - 10 Right Hand Grip 1. Disassembly (Figure 4-7) a. Open the Picture Removal Door to expose the Right Hand Grip holding screw. b. Using a square drive, remove the screw that secures the Right Hand Grip to the Main Body of the camera. Lift out the Right Hand Grip. c. Pull out the S1 Button. ACTUATOR TAB S1 BUTTON POST RIGHT HAND GRIP PICTURE REMOVAL DOOR S1 BUTTON ACTUATOR TAB Figure 4-7. Disassembly of Right Hand Grip 2. Reassembly To reassemble the Right Hand Grip and S1 Button, follow the disassembly steps in reverse order. Note: When re-installing the Right Hand Grip and S1 Button make sure the S1 Button: (See insert in Figure 4-7) • • Actuator tab is properly inserted into its locating slot on the Main Body of the camera. S1 Button is properly placed on its support post on the Main Body of the camera. 4 - 11 Bottom Door Assembly 1. Removal a. Using a narrow blade flat screwdriver or tweezers, lift out the pins (Figure 4-8) that hinge the Bottom Door Assembly to the Main Body of the Camera. b. Gently Squeeze the Pack Frame together to disconnect it from the Door Stops on the Main Body of the camera. Lift out the Bottom Door Assembly. BOTTOM DOOR DOOR STOP HINGE PIN HINGE PIN MAIN BODY Figure 4-8. Removal of Bottom Door Assembly 2. Disassembly a. Gently squeeze and push inward the Picture Removal Door (Figure 4-9) to release it from the plastic hinge posts of the Bottom Door Assembly. Lift out the Picture Removal Door. PICTURE REMOVAL DOOR PLASTIC HINGE POST PLASTIC HINGE Figure 4-9. Removal of Picture Removal Door from Bottom Door 4 - 12 b. Gently push down and out to release the Pack Frame Hook Tabs (Figure 4-10) from the Platen of the Bottom Door Assembly. c. Squeeze the Pack Frame Hinges to release it from the plastic hinge posts on the Bottom Door Assembly. Lift out the Pack Frame. PACK FRAME PLASTIC HINGE POST SLOT IN PLATEN BOTTOM DOOR ASSEMBLY Figure 4-10. Removal of Pack Frame from Bottom Door d. Using tweezers, remove the Storage Pick Spring (Figure 4-11) from the Storage Pick Assembly. Lift out the Storage Pick Spring. e. Using a narrow blade flat screwdriver, gently pry out each latch to release the Platen from the Bottom Door Assembly. Lift out the Platen. METAL SPRING LATCH STORAGE PICK SPRING METAL SPRING LATCH PLATEN Figure 4-11. Removal of Platen from Bottom Door 4 - 13 f. Using a narrow blade flat screwdriver, lift up the red Spreader Bar to access its plastic locking tabs (Figure 4-12). g. Using a narrow blade flat screwdriver, gently pry up the plastic locking tabs above each of the Bottom Door plastic locating pins to release the Spread Roll Assembly from the Bottom Door. Gently lift out the Spread Roll Assembly. PLASTIC LOCKING TAB SPREAD ROLL ASSEMBLY BOTTOM DOOR ASSEMBLY PLASTIC LOCATING PINS SPREADER BAR Figure 4-12. Removal of Spread Roll Assembly from Bottom Door h. Lift up and out the Film Shade from the plastic locating pin on the Actuator Link (Figure 4-13). i. Lift out Storage Pick Assembly. (NOTE: In reassembly, be certain the Full Chamber Link lies on top of the Storage Pick Assemnbly. See the inset in Figure 4-13.) j. Lift out Actuator Link. FILM SHADE FULL CHAMBER LINK BOTTOM DOOR ACTUATOR LINK STORAGE PICK ASSEMBLY STORAGE PICK ASSEMBLY Figure 4-13. Removal of Film Shade, Storage Pick, and Actuator Link from Bottom Door 4 - 14 3. Reassembly To reassemble and reinstall the Bottom Door Assembly, follow the disassembly and removal steps in reverse order. Note: When re-installing the Spread Roll Assembly (Figure 4-14) make sure the Storage Pick Assembly is properly positioned to allow the Spread Roll Assembly to slide into postion without damaging the pick. If the Storage Pick Assembly is properly positioned then: • • Pick should be in its retract position. Film Shade should be over the Actuator Link. Once the Storage Pick Assembly and the Film Shade are properly positioned, gently insert the Spread Roll Assembly into its slots on the Bottom Door Assembly making sure that the pick is properly positioned inside the provided slot (opening) in the Spread Roll Assembly. Manually actuate the Pick to make sure it operates properly. (Pick slides freely between opening in Spread Rollers.) SPREAD ROLL ASSEMBLY STORAGE PICK ASSEMBLY ACTUATOR LINK LOCATING PIN PICK FILM SHADE ACTUATOR LINK Figure 4-14. Installation of Spread Roll Assembly 4 - 15 PICK Top Cover 1. Removal a. Using needlenose pliers or tweezers, pull out the pins (Figure 4-15) that hinge the Top Cover to the Main Body of the Camera. (The Top Cover springs will retract.) TOP COVER SHORT HINGE PIN LONG HINGE PIN Figure 4-15. Removal of Top Cover Hinge Pins b. Gently pry up the Top Cover (Figure 4-16) to release it from the Shutter Assembly and the Main Body of the camera. Lift off the Top cover. LIFT TOP COVER TAB Figure 4-16. Removal of Top Cover 4 - 16 2. Reassembly To reassemble the Top Cover, follow the removal steps in reverse order. Note: When reassembling the Top Cover (Figure 4-17) make sure: • • Top Cover Springs are inserted into the grooves on the Main Body of the camera. Hinge pins are properly installed. - Long pin into left side - Short pin into right side LONG PIN (LEFT SIDE) TOP COVER SPRING SHORT PIN (RIGHT SIDE) Figure 4-17. Installation of Top Cover 4 - 17 Shutter Assembly 1. Removal a. Using a narrow blade flat screwdriver, push aside the end of the rubber Flapper to access the Shutter Link pin (Figure 4-18) and then push the pin out. b. Using needlenose pliers, pull out the Shutter Link pin to release the top portion of the Shutter Link from the Shutter Assembly. RUBBER FLAPPER END OF FLAPPER LINK PIN Figure 4-18. Removal of Shutter Link Pin c. Using a solder aid stick, gently pry up the corner of the Shutter Decorative Plate (Figure 4-19) to release it from the Shutter Assembly. Lift off the Shutter Decorative Plate. SOLDER AID TOOL SNAP REMOVE SHUTTER DECORATIVE PLATE . Figure 4-19. Removal of Shutter Decorative Plate 4 - 18 d. Using a narrow blade flat screwdriver or a dental pick, pry the bellows retainer tabs (two places) (Figure 4-20) out and then release the VMC/Bellows Assembly from the Shutter Assembly . SHUTTER ASSEMBLY BELLOWS RETAINER TAB BELLOWS RETAINER TABS GRIP FLASH WITH HAND BELLOWS LOCKING TAB BELLOWS LOCKING TAB BELLOWS Figure 4-20. Disconnect VMC/Bellows Assembly from Shutter Assembly e. Manually retract VMC/Bellows Assembly (Rubber Bellows) to access back of Shutter Assembly. Note: If necessary, straighten the Bellows locking tabs with tweezers or needlenose pliers. f. Place the Shutter Assembly into the Shutter Support Fixture (Figure 4-21). g. Using a narrow blade flat screwdriver, gently push in the slot of the Flex Connector Cap to release its locking tab. A snap sound occurs indicating that it is unlocked. FLEX FLEX CONNECTOR CAP SHUTTER ASSEMBLY SHUTTER SUPPORT FIXTURE #13556 Figure 4-21. Release (Unsnap) Flex Connector from Shutter 4 - 19 h. Release the Flex from the Connector Cap (Figure 4-22). Caution: i. When prying out the unsnapped Flex Connector Cap be careful not to scratch, dirty or damage the lens. Using a solder aid tool, remove the plastic Cap (Connector) from the Flex (Figure 4-22). SOLDER AID TOOL FLEX CONNECTOR CAP CONNECTOR CAP FLEX TAB SHUTTER ASSEMBLY Figure 4-22. Removal of the Flex Connector j. Using a solder aid stick, gently pull out the Flex (Figure 4-23) to make it easier to remove the Shutter Assembly hinge pins. FLEX SOLDER AID TOOL SHUTTER ASSEMBLY Figure 4-23. Pulling Out Flex to Facilitate Removal of Shutter Hinge Pins 4 - 20 k. Using needlenose pliers, pull out each Shutter Assembly hinge pin (Figure 4-24) to release it from the Main Body of the camera. SHUTTER ASSEMBLY HINGE PIN HINGE PIN FLEX Figure 4-24. Removal of Shutter Assembly l. Lift out the Shutter Assembly. Caution: The plastic Mirror Catcher (Figure 4-25) will fall out as the Shutter Assembly is removed. Do not lose it. MIRROR CATCHER Figure 4-25. Location of Mirror Catcher 4 - 21 2. Disassembly of Shutter a. Using a narrow blade flat screwdriver, gently push the Flapper Hinge Retainer (Figure 4-26) up and to the left to release it from the locking tabs of the Shutter Assembly. Lift off the Flapper Hinge. (See Key # 30 in Plate 2 of the Parts Catalog.) b. Using a narrow blade flat screwdriver, gently pry open the locking tabs that secures the Rear Lens to the Base Block Assembly. Remove the Rear Lens. c. Using a narrow blade flat screwdriver, gently pry up the retainer to release the Concave Mirror from the Base Block Assembly. Remove the Concave Mirror. RUBBER FLAPPER LOCKING TABS FLAPPER HINGE RETAINER SHUTTER ASSEMBLY REAR LENS CONCAVE MIRROR CONCAVE MIRROR RETAINER Figure 4-26. Removal of the Flapper Hinge d. Using a square drive, remove the five (5) screws that secures the Front Shutter Housing (Figure 4-27) to the Base Block Assembly. Lift off the Front Shutter Housing. Note: If necessary, use a narrow blade flat screwdriver to gently pry up the Front Shutter Housing to release it from the Base Block Assembly. Caution: Discharge the Strobe Capacitor with a Dump Probe (Figure 4-28) before continuing with this disassembly. e. Using a finger, gently push the Ambient/IR Lens down and out to release it from its locking tab on the Lens Mounting Plate (Figure 4-29) . Lift off the Ambient/IR Lens. f. Using a narrow blade flat screwdriver, gently pry and twist up the Solenoid Contact Retainer to release it from the Lens Mounting Plate. Lift off Solenoid Contact Retainer and the two copper contacts. 4 - 22 BASE BLOCK ASSEMBLY FRONT SHUTTER HOUSING Figure 4-27. Removal of Front Shutter Housing DUMP PROBE STROBE CAPACITOR CONTACTS Figure 4-28. Discharging Strobe Capacitor e. Using a square drive, remove the screw that secures Solenoid # 2 to the Lens Mounting Plate. Gently lift off Solenoid # 2 being careful not to catch on the locating pin of the Far Focus Lens. f. Using a solder aid tool, gently pry open the locking tabs that secures the front Lens to the Lens Mounting Plate. Remove the Front Lens. h. Using a narrow blade flat screwdriver, gently release the locking tabs (Figure 4-30) that secures the PC Board and Lens Mounting Plate to the Base Block Assembly. i. Once the locking tabs are released, turn over the Assembly (approximately 1800) so that the Base Block Assembly faces down. Gently lift off the PC Board and Lens Mounting Assembly. 4 - 23 j. Using tweezers, remove the Release Button Spring (Figure 4-31) from the Release Button Latch. k. Lift out the Release Button Latch from the Base Block Assembly. SOLENOID #2 SOLENOID CONTACT RETAINER CONTACTS FRONT LENS AMBIENT/IR LENS LENS MOUNTING PLATE PC BOARD Figure 4-29. Removal of Ambient/IR Lens, Solenoid Retainer/Contacts, Front Lens and Solenoid #2 LOCKING TAB BASE BLOCK ASSEMBLY PC BOARD AND LENS MOUNTING PLATE Figure 4-30. Removal of PC Board and Lens Mounting Plate Assembly 4 - 24 RELEASE BUTTON SPRING RELEASE BUTTON LATCH BASE BLOCK ASSEMBLY Figure 4-31. Removal of Release Button Latch, Rear Lens and Concave Mirror m. Remove the Walking Beam, Inertia Link, and related components from the Lens Mounting Plate (Figure 4-32): • • • • • Inertia Gear Disengage Inertia Spring Inertia Link Assembly Opening Spring Walking Beam INERTIA GEAR INERTIA LINK ASSEMBLY INERTIA SPRING OPENING SPRING WALKING BEAM Figure 4-32. Removal of the Walking Beam, Inertia Link and Related Components 4 - 25 n. Remove the Far Focus Lens from the Lens Mounting Plate (Figure 4-33) by removing the following: • • • Lift out the Lens Latch Spring Lift out the Lens Latch Push Blades towards solenoid # 1 to access Far Focus Lens. Lift out Far Focus Lens. FAR FOCUS LENS LENS LATCH SPRING LENS LATCH FAR FOCUS LENS SOLENOID #1 PLUNGER SOLENOID #2 (See Re-Assembly Note on Page 4-27) Figure 4-33. Removal of Far Focus Lens o. Remove the PC Board from the Lens Mounting Plate. Pull PC board straight out (Figure 4-34) to release it from Lens Mounting Plate. p. Remove Blades from Lens Mounting Plate (Figure 4-35). If re-using the Blades, use gloves to prevent oil deposits from getting on the Blades. q. Remove Solenoid #1 from Lens Mounting Plate. Push up and then pull out to release it from the Lens Mounting Plate (Figure 4-35). 4 - 26 LENS MOUNTING PLATE PC BOARD Figure 4-34. Removal of PC Board BLADES SOLENOID #1 LENS MOUNTING PLATE Figure 4-35. Removal of Blades and Solenoid #1 3. Reassembly To reassemble and reinstall the Shutter Assembly, follow the disassembly and removal steps in reverse order. Note: When re-installing the Far Focus Lens make sure its pin is inserted into the locating tab at the end of the plunger of solenoid # 2. (See insert in Figure 4-33.) 4 - 27 Erect System (VMC/Bellows and Taking Mirror Carrier Assemblies) 1. Disassembly a. Using a narrow blade flat screwdriver, lift tabs (Figure 4-36) to release VMC/Bellows Assembly (Rubber Boot). VMC/BELLOWS ASSEMBLY TAB TAB Figure 4-36. Release Boot Tabs b. Rotate the Clutch Gear (Figure 4-37) counter clockwise (CCW) until the Pick retracts. c. Rotate the Clutch Gear clockwise (CW) until the Mirror flys. Note: Once the Mirror flys, remove the Baffle to facilitate the removal of the Mid-Link. BAFFLE CLUTCH GEAR . Figure 4-37. Retracting Pick 4 - 28 e. Rotate Clutch Gear until bottom and top of Mid-Link is visible (Figure 4-38). f. Using a dental pick or a slotted narrow blade flat screwdriver, remove the Mid-Link from the Re-cock Link. SLOTTED NARROW BLADE SCREWDRIVER MID-LINK RECOCK LINK MID-LINK MID-LINK Figure 4-38. Removal of Mid-Link g. Using tweezers, remove the Mirror Carrier hinge pins (Figure 4-39) to release the VMC/ Bellows Assembly and the Taking Mirror Carrier Assembly from the Main Body of the camera. h. Lift off VMC/Bellows Assembly and the Taking Mirror Carrier Assembly. Keep Assemblies together. HINGE PIN (LONG) HINGE PIN (SHORT) Figure 4-39. Removal of Mirror Carrier Hinge Pins 4 - 29 2. Reassembly To reassemble and reinstall the Erect System, follow the disassembly and removal steps in reverse order. Note: When re-installing the Erect System make sure it is installed as a single unit. Once it is in position: • • • • Align the hinges of the VMC/Bellows and the Taking Mirror Carrier Assemblies to the hinge posts on the Main Body of the camera. Install the hinge pins using needlenose pliers or tweezers. Rotate the Clutch Gear counter clockwise (CCW) until the Re-cock Link is visible. Install the Mid-Link to the Re-Cock Link (Figure 4-40) using the Mid-Link Installation Tool. RECOCK LINK MID-LINK TOOL MID-LINK Figure 4-40. Installation of Mid-Link 4 - 30 Main Frame (Non-Gear Side) 1. Disassembly (Figure 4-41) a. Using a square drive, remove the screw that secures the Switch Retainer to the Main Body of the camera. b. Using a narrow blade flat screwdriver, gently pry out both ends of the Switch Retainer to release it from the plastic locking tabs of the Erect Switch. Lift out the Switch Retainer. c. Using needlenose pliers or tweezes, remove the Power Actuator Spring. Lift out the Power Actuator Assembly. d. Remove the Erect Sensor Spring and Door Latch Sensor. e. Using a square drive, remove the screw that secures the Erect Switch to the Main Body of the camera. f. Using a narrow blade flat screwdriver, gently pry up the Erect Switch to release it from the Main body of the camera. Lift off the Erect Switch. g. Remove the Erect Sensor. h. Using a narrow blade flat screwdriver, gently pry out the Flex Plug Switch Block to release it from the Drive Cover on the Main Frame - Gear Side. Lift off the Flex Plug Switch Block. i. Using a narrow blade flat screwdriver, gently pry up and push out to release each Battery Contact from the Main Body of the Camera. Lift off each Battery Contact. j. Remove the Overcenter Spring from its tab connection on the Main body of the camera. k. Unwrap or peel off the Interconnecting Flex from the Flex Plug to its Motor Connections. l. Gently pull up and out to disconnect the Interconnecting Flex from its Motor Connections. m. Using a square drive, remove the screw that secures the Door Stop to the Main Body of the camera. Lift off the Door Stop. 4 - 31 2. Reassembly To reassemble the Non-Gear Side of the Main Frame of the camera, follow the disassembly steps in reverse order. Note: When re-installing the Erect Switch make sure its contacts are properly positioned with the applicable Sensor: (Refer to insert in Figure 4-41 for location of contacts.) • • • Erect Sensor Door Latch Sensor Power Actuator Use the Battery Contact GO/NO GO gauge when installing the Battery Contacts. (Refer to inset in Figure 4-41.) (h) FLEX PLUG SWITCH BLOCK (k, l) INTERCONNECTING FLEX (j) OVER CENTER SPRING UNACCEPTABLE: contact touches front of gauge (i) BATTERY CONTACTS (e, f) ERECT SWITCH (g) ERECT SENSOR ACCEPTABLE: contact touches or is close to underside of gauge BATTERY CONTACT GO/NO-GO GAUGE #13558 (m) DOOR STOP LOCKING TAB POWER ACTUATOR POWER ACTUATOR SPRING (d) ERECT (g) ERECT SENSOR (e, f) ERECT SWITCH (c) POWER ACTUATOR SPRING (a, b) SWITCH RETAINER (c) POWER ACTUATOR (d) DOOR LATCH SENSOR Figure 4-41. Disassembly of Main Frame (Non-Gear Side) 4 - 32 SENSOR SPRING Main Frame (Gear Side - Outer) 1. Disassembly (Figure 4-42) Note: If applicable, remove the Mirror Catcher. a. Using a square drive, remove the six (6) screws that secures the Drive Cover to the Main Body of the camera. Lift off the Drive Cover. b. Using a solder aid stick, gently pry out the plastic locking tabs of the Outer Viewfinder Lens to release it from the Drive Cover. Lift out the Outer Viewfinder Lens. c. Using the applicable tool (dental pick, needlenose pliers, narrow blade flat screwdriver), remove the following from the Main Frame: • • • • • • • • • • • • • • • • • • • • • • (1) Gear #4 (white plastic) (2) Clutch Gear (3) Idler Gear (4) 5-Wire Detail Switch Assembly (If necessary, gently pry up the 5-Wire Detail Switch Assembly to release it from its plastic locating pin.) (5) Counter Return Spring (6) Inner Door Stop Link (7) Counter Wheel (8) Outer Door Stop Link (9) Carrier Spring (The Carrier Spring connects the Pick with the Counter Detent.) (10) Counter Detent (11) Door Stop (12) Pick Assembly (13) Recock Latch Spring (14) Recock Latch (15) Viewfinder Blind Assembly (16) Viewfinder Blind Over Travel Spring (17) Trim Slider (18) Re-cock Link Spring (19) Re-cock Link (20) Trim Detent (21) Inner Viewfinder Lens Clip (22) Inner Viewfinder Lens 4 - 33 2. Reassembly To reassemble the Gear Side -Outer of the Main Frame of the camera, follow the disassembly steps in reverse order. Note: When reassembling Gear Side -Outer of the Main Frame of the camera make sure: • • • Contacts of 5-Wire Detail Switch are properly positioned. (See nsert in Figure 4-42 for location of contacts.) Zero (0) position of the Counter wheel must be aligned with the screw post on the Main Frame of the camera. Cam of the Timing Gear must initially sit behind the metal Pick tab. MIRROR CATCHER TIMING GEAR 21 18 22 19 14 16 15 9 13 3 2 COUNTER WHEEL 20 17 1 5 11 12 7 6 8 10 DRIVE COVER 4 OUTER VF LENS Figure 4-42. Disassembly of Main Frame (Gear Side - Outer) 4 - 34 Main Frame (Gear Side - Inner) 1. Disassembly (Figure 4-43) a. Using a square drive, remove the screw that secures the Gear Head Cover to the Main Body of the camera. Lift off the Gear Head Cover. b. Using the applicable tool (tweezers, needlenose pliers), remove the following from the Main Frame: • • • • • Gear #3 Gear #2 Gear #1 Top Feed Roll Bottom Feed Roll c. Using a small Phillips screwdriver, remove the two (2) screws that secures the D.C. Motor to the Main Frame. Push out the D.C. Motor. DC MOTOR GEAR #1 MOTOR SCREWS GEAR #2 TOP FEED ROLL GEAR #3 GEAR HEAD COVER BOTTOM FEED ROLL Figure 4-43. Disassembly of Main Frame (Gear Side - Inner) 2. Reassembly To reassemble the Gear Side-Inner of the Main Frame of the camera, follow the disassembly steps in reverse order. 4 - 35 [This page intentionally blank] 5. Troubleshooting 5-1 5.Troubleshooting Tableof Contents Introduction ........................................................................................................................... 5-3 Functional Test of a Joshua Camera ...................................................................................... 5-5 Tools and Parts Needed for Troubleshooting ........................................................................ 5-7 Common Camera Failure Modes and Corrective Procedures ................................................ 5-8 Isolating the Problem (Camera Mainframe or Shutter Assembly?) ........................................ 5-12 5-2 5. Troubleshooting Introduction The Joshua Camera employs electronics of a unique design, utilizing a single PC Board mounted within the Shutter Subassembly. A single Flex interconnects the PC Board, Battery, Motor, 3-wire Erect (Power) Switch and 5-wire Logic Switch (Figures 5-1, 5-2 and 5-3). Because analysis of PC Board performance, in most cases, would require an oscilloscope and other fairly sophisticated test equipment, it is not a practical field troubleshooting procedure at this time. Thus, if a camera failure is traceable to the PC Board, the present recommended procedure is to replace the entire Shutter/PC Board Assembly. Limited repair experience thus far from early returns also indicates that some problems are related to rework piece parts, notably in the Mainframe and Mirror Catcher. Hence most repairs at this time will necessitate replacing sub-assemblies (Mainframe, Door, Erect System or Shutter), rather than individual parts. Note: Certain Joshua piece parts are available, which may offer solutions to some service problems encountered. In such cases, the piece part should be replaced, rather than an entire sub-assembly. In the near future when defective cameras can be analyzed with less sophisticated equipment, and when reworked piece parts are not used, a set of troubleshooting charts will be available. In the meantime, use the procedures and guides which follow to troubleshoot Joshua Cameras, starting with the Joshua Camera Functional Check. To Logic Switch See Fig. 5-3 S1 A Trim SPD E OP S1B DKEC Battery + Ful l Ch amb e r Trim + GND VCC GND M o tor Motor + To Connector on Rear of Shutter Assembly To Erect (Power) Switch See Fig. 5-2 Battery - VE R Note: Flex Shown Completely Unfolded (Contact Side Up) GND B+ Figure 5-1. Joshua Camera Flex Interconnections 5-3 Motor + Motor - See Fig. 5-1 To PC Board in Shutter Assembly ERECT LINK ERECT SENSOR B+ DOOR LATCH SENSOR VE R TO BATTERY GND TO MOTOR DARK SLIDE LINK FLEX POWER ACTUATOR Figure 5-2. Flex Connections to Erect (Power) Wireform Switch GND TR IM TR IM SE L F-TI M E R S1 A FI L M SPEED E OP DKEC S1B FULL CHAMBE R LOGIC SWITCH FLEX Figure 5-3. Flex Connections to Logic Wireform Switch 5-4 Functional Test of Joshua Camera This procedure verifies whether a Joshua Camera is operating normally or not, during each stage of operation. If you do not obtain the performance results described here, the Camera is not operating properly and should be adjusted/repaired. Perform each test in this Check List to substantiate the customer’s complaint or to identify the actual failure mode occurring. Note: The Camera should be in the following state: • • • • • 1. 2. Camera should be collapsed Film Pack loading door open Film storage compartment empty Trim Switch in normal (middle) position Counter window should be blank Dark Slide Test Install Fresh Film Pack Dark slide cycle occurs. Flash does not fire. Counter indexes from 0 to 10. Dark slide moves to storage chamber. Erect camera Short motor jog occurs. Red LED lights (flash is charging), then goes out. Green LED lights and stays on (flash is ready). Exposure Test (Take a Picture) Press Shutter Button (S1A/S1B) Down Fully Flash fires. Camera cycles, blades open and close, motor runs. Counter indexes from 10 to 9. Film frame moves into storage chamber. Red LED lights (flash is charging), then goes out. Green LED lights and stays on (flash is ready). Review Picture Quality. Move L/D Switch to Dark Arrow and Take a Picture Is resulting picture darker? Counter indexes from 9 to 8. Move L/D Switch to White Arrow and Take a Picture Is resulting picture lighter? Counter indexes from 8 to 7. Press Shutter Button Three More Times Counter indexes to 6, 5 and 4. 5-5 3. 4. Focusing Test Aim Camera at Object Exactly 5 Feet (1.5m) from Lens. Press Shutter Button. Check resulting photo for sharp focus. Camera counter should now display 3. Aim Camera at Object Exactly 10 Feet (3.0m) from Lens. Press Shutter Button. Check resulting photo for sharp focus. Camera counter should now display 2. Self-Timer Test Slide Self-Timer Button toward Symbol of Clock 5. Red LED's on back of strobe tower and on front of Camera blink and beeper sounds, both at faster rate during a 12-second countdown period. Flash fires. Camera cycles, blades open and close, motor runs. Counter indexes from 2 to 1. Red LED lights (flash is charging), then goes out. Green LED lights and stays on (flash is ready). Film frame is moved into storage chamber. End of Pack Test Press Shutter Button Flash fires. Camera cycles, blades open/close. Counter indexes from 1 to 0. Film frame is moved into storage chamber. Red LED on strobe tower will flash twice. Audible signal will sound four times to signal empty film pack. Press Shutter Button Red LED will flash and two-tone beep will sound four times, signalling you to remove 10 pictures and the dark slide from the storage chamber. Note: The camera will not operate when storage chamber is full. This may occur with 9, 10 or 11 pictures in chamber (due to film thickness variations). If test 1 through 5 in the Check List are satisfactory, make a visual check of the Camera: • • • Check viewfinder and lens for cleanliness. Check that structural parts are not scratched. Check that moving parts don’t bind. 5-6 Tools and Parts Needed for Troubleshooting • Flex Extension Ribbon Cable (P/N 13562) (See Figure 5-4) • Square drive tool (Handle P/N CPS416, bit P/N 13553) • Known good Shutter/PC Board/Strobe Assembly (P/N 1A2631A) • Film packs for Joshua Camera (Polaroid 95 Instant Film) • Narrow flat blade screwdriver or dental pick (to release Flex Connector Cap from PC Board) • Needlenose pliers or tweezers • Soldering aid (greenstick) (P/N 94168) 5-7 Common Camera Failure Modes and Corrective Procedures 1. Audible or Visual Jam Signal (Film pack in camera, but no film jammed) (Two-tone beep four times; red LED on flash tower flashes eight times) • • • • • • • • 2. No Dark Slide (Camera not erected) • • • • • • • • • 3. Check camera for mid-cycle condition. Check Full Chamber Link and Switch contacts (See Figure 2-28). Check position of Storage Pick (See Figure 2-27). Check condition of DKEC Switch (See Figure 2-19). Check position of Film Shade in door (See Figure 2-22). Check position of Actuator Link in door (See Figure 2-27). Check Flex connection to Logic Switch (See Figure 5-3). Check for short from solder slivers in Flex connection to Shutter, and slivers on Flex itself. Check condition of Door Power Actuator (See Figures 2-3 to 2-7). Check condition of Door Power Actuator Dark Slide Link/Spring (See Figures 2-4 to 2-7). Check DKEC Switch (should be closed) (See Figure 2-19). Check Flex connection to Erect (Power) Switch (See Figure 5-2). Check condition of B+, VER and GND wireforms in Erect (Power) Switch (See Figure 2-11). Check Flex connection to back of Shutter Assembly. Check Flex connection to Motor (See Figure 5-1). Check condition of battery contacts. Check S1A/S1B Switch connections (must not be shorted) (See Figure 5-3). No Dark Slide (Camera erected) • • • • • • • • • • Check condition of Door Latch (See Figure 2-8). Check condition of Door Latch Sensor (See Figure 2-8). Check condition of Erect Sensor (See Figure 2-9). Check condition of B+, VER and GND wireforms in Erect (Power) Switch (See Figures 2-8 and 2-9). Check DKEC Switch (should be closed) (See Figure 2-19). Check Flex connection to Erect (Power) Switch (See Figure 5-2). Check Flex connection to Motor (See Figure 5-1). Check Flex connection to back of Shutter Assemby. Check condition of battery contacts. Check S1A/S1B Switch connections (must not be shorted) (See Figure 5-3). 5-8 4. No S1 • • • • • • Is S1 Button sticking? Check condition of Erect Sensor and Door Latch Sensor (See Figures 2-8 and 2-9). Check action of S1A/S1B wireform contacts on Logic Switch (See Figure 5-3). Check DKEC Switch (should be open) (See Figure 1-15). Check condition of S1 Button/Spring Check condition of Self-Timer Switch wireform contacts (should be open) (See Figure 5-3). Note: Camera will not run if Self-Timer Switch is shorted. 5. Frame Feed Failure • • • • • • • • • • • Check that primary Pick is not bent, dirty, etc. (See Figure 2-23). Check for presence of plastic burr in chute. Check Chamber Pick position: must be in returned/start position (See Figure 2-27). Check Motor condition. Check condition of rubber tires on Feed Rolls. Check that Spread System is seated properly. Check that Door is fully closed and latched. Check for missing teeth/broken gears in gear train/spread system. Check for foreign matter on Rolls. Check that film box plastic tang on Mainframe is present (See Figure 5-4). Check film pack for defective frames (can cause double feed frame failures). TANG ON MAINFRAME FITS INTO THIS SLOT TANG ON MAINFRAME Figure 5-4. Film Box Tang on Mainframe 5-9 6. Black Pictures • • • • 7. Check condition of Mirror Catcher (See Figure 4-25). Check condition of Mirror Catcher Actuator located on Shutter (See Figure 4-25). Check condition of Taking Baffle (distorted, etc.). Check Shutter Assembly for failure: substitute known good Shutter Assembly as described in preceding section. Replace Shutter Assembly if necessary. No Strobe Charge Note: At this time, the only repair is to replace the Shutter/PC Board/Strobe Assembly. 8. No Strobe Fire Note: At this time, the only repair is to replace the Shutter/PC Board/Strobe Assembly. 9. Film Jam/Film Jam Signal (Film frame actually jammed in Camera) Note: Also refer to Clearing Jams, page 49 of the Customer Service Information Manual dated August 1992, for a jam removal procedure. First, clear the film jam as follows: a. Pull Film Door open firmly but carefully (this may require more force than usual). b. Pull the stopped picture out of the Camera carefully. If pulling the film is unsuccessful, manually advance the Clutch Gear in the Mainframe to remove the film. (See page 4-28, Figure 4-37 of the Assembly/Disassembly Section of this Manual.) c. Remove film pack and clean the rollers. d. Reload the film pack: the next print will advance into the storage compartment. If print does not advance, press the Shutter Button (S1A/S1B) once, twice or three times, as necessary, until print advances. Note: Picture counter will reset to 1 and miscount the rest of the pack. Next, find what caused the film jam: • • • • • • • • Check Pack Frame for distortion (See Figure 4-10). Check Gear #3: is it stripped? (See Figure 4-43). Check condition of Platen (tabs not seated, etc.) (See Figure 4-11). Check for solder slivers where Flex plugs into Shutter (See Figures 4-21 and 4-22). Check for mid-cycle condition (See Failure Mode 10, following). Check condition of DKEC Switch (See Figure 1-15). Check position of primary Pick after cycling: it should be fully retracted (See Figure 2-23). Check Storage Pick for distortion (See Figure 4-13). 5 - 10 10. Mid-Cycle Failure (Camera stops before completing normal, full cycle) • • • • • • • • • 11. No Self-Timer • • • • 12. Check Flex connection to Logic Switch Block (See Figure 5-3). Check condition of DKEC Switch (See Figure 1-15). Check for solder slivers on Flex at Shutter connection (See Figures 4-21 and 4-22). Check condition of Outer/Inner Door Stop Links (See Figures 1-16 and 4-42). Check condition of Flex Plug: broken snap? (See h, Figure 4-32). Check condition of Battery Contacts: clean, not deformed, etc. (See i, Figure 4-32, and Page 4-33). Check condition of Door Latch (on Chute) (See Figure 4-6). Check condition of Full Chamber Link (See Figure 2-28). Check Full Chamber Switch wire: is it stuck on Gear Drive Cover? (See Figure 2-28). Check condition of Self-Timer Spring (See Figure 4-2). Check condition of Self-Timer Switch wires on Logic Switch (See Figure 5-3). Check condition of Flex connection to Logic Switch (See Figure 5-3). Check for solder slivers on Flex at Shutter connection (See Figures 4-21 and 4-22). Film Speed Switch Failure • • • Check condition of Film Speed switch wires in Logic Switch (See Figure 5-3). Check condition of Flex connection to Logic Switch (See Figure 5-3). Check for solder slivers on Flex at Shutter connection (See Figures 4-21 and 4-22). 5 - 11 Isolating the Problem: (Camera Mainframe or Shutter Assembly?) If you are uncertain whether a failure originates in the Camera Mainframe or in the Shutter/PC Board/Flash Assembly, connect a known, good Shutter/PC Board/ Flash Assembly in place of the one in the Camera, using the following parts and procedure: Parts and Tools Needed • Known, good Joshua Shutter/PC Board/Flash Assembly (P/N 1A2631A) • Flex Extension Ribbon Cable (P/N 13562) • Square drive tool (Handle P/N CPS416, bit P/N 13553) • Needlenose pliers or tweezers • Narrow flat-blade screwdriver or dental pick • Soldering aid (greenstick) (P/N 94168) Procedure Note: Refer to Section 4, Disassembly and Re-assembly, for illustrations and more detailed instructions, if needed. 1. Remove the Rear Panel from the Camera (Figure 4-1). 2. Remove the Top Cover by removing the hinge pins (Figures 4-15 and 4-16). 3. Remove Link Pin from Shutter Assembly (Figure 4-18). 4. Remove the Bellows Retainer Tabs (access from the front; Figure 4-20). 5. Disconnect the Bellows Assembly from the Shutter Assembly (Figure 4-20). 6. Fold the Erect Linkage down out of the way. 7. Disconnect the Flex from the Shutter Assembly by releasing the Flex Connector Cap with a narrow screwdriver or dental pick (Figure 4-21). 8. Connect the Flex Cap end of the Flex Extension Ribbon Cable to the Camera Flex tab just disconnected from the Shutter (Figure 5-5). 9. Connect the other end of the Flex Extension Ribbon Cable to the flex connector in a known, good Shutter/PC Board Assembly. 5 - 12 Note: The Flex Extension Ribbon Cable and corresponding connectors have 6 conductors on one side of the locating hole/pin and 7 conductors on the other side. Observe this pattern when making connections. 10. Using a square drive tool, remove the screws holding the Front Panel (Figure 4-4), then gently pry off the Front Panel using a greenstick. 11. Now insert a modified Q Tip between the top of the Erect Sensor and the Mainframe, as shown in the inset at the right in Figure 5-5, to hold the Sensor down and maintain power to the Camera. 12. If Camera operation with the new Shutter Assembly still exhibits the same problem, look for the cause of the problem in the Mainframe. If the problem no longer occurs with the new Shutter Assembly connected, replace the original Shutter Assembly. KNOWN GOOD SHUTTER ASSEMBLY EXTENSION CABLE P/N 13562 DISCONNECT FLEX FROM SHUTTER Q TIP CUT 2" LONG HEAD WRAPPED WITH SCOTCH TAPE FLEX CAP 6 CONNECTORS 7 CONNECTORS Figure 5-5. Connecting a known, good Shutter Assembly in place of Camera Shutter Assembly 5 - 13 5 - 14 5-14 5 - 15 Figure 5-7. Joshua Camera Timing Diagram [This page intentionally blank] Appendix A-1 Glossary of Terms to Describe the Joshua Camera Note: Includes Polaroid meanings of terms used to describe Camera operations, parts and assemblies. Camera part names are capitalized. Actuator, Power Part of Power (Erect) Switch which maintains power for darkslide or processing when camera is folded. Ambient Visible light illuminating subject. Asleep and Wake Up Modes Low (idle) power and full operating power levels of camera electronics. B+ Operating voltage (nominally tbd V) for camera electrical and electronic circuits. Blade Position Encoder Sophisticated electro-optical system using photo-interrupter in Shutter Blades to accurately determine Blade position. Brightness Override Electronic Lighten/Darken switch to adjust exposure by about +/- 3/4 f/stop. Moving a slider operates Logic Switch wireforms. Camera Cycle All steps occurring in exposure and processing, from darkslide to film frame transport into storage chamber. Chute Semi-circular cavity at end of Camera into which film frame is transported by Feed Rolls, which reverses the direction of frame travel to permit frame storage. Closed Refers to Camera doors, not the Camera itself. Clutch, Wrap-Spring One-way clutch in drive system Clutch Gear that unlatch Recock Latch in CCW direction, but slips in CW direction. Collapsed Refers to Camera in folded position (opposite of erect). Counter Detent Metal arm in Drive System which acts as a ratchet on Counter Wheel, after Wheel is indexed by forward stroke of spring arm on Pick Carrier. Counter Wheel Indicating disk numbered 1 - 10, which displays number of frames used. Darkslide The paper covering the top frame in a film pack, automatically removed and stored in the picture storage chamber when the filmpack is inserted; also, the process just described. A-2 Darkslide Cam A two-segment cam on the top of the Timing Gear, which actuates the DKEC Switch through the Door Stop Link. Darkslide Link Pivoted arm on Power Actuator, driven upward by Film Shade when Film Door is closed, to close VER to B+ and power Camera for darkslide. DKEC Switch One element of wireform Logic Switch which controls Darkslide, End of Cycle and Mirror Down conditions. Door Latch Sensor Piece part of Power (Erect) Switch actuated by Door Latch cam. Lifts B+ wire when Door Latch is opened, lowers B+ when Door Latch is closed. Prevents driving the gears until fully meshed. Door Stop Pivoted arm actuated by Film Door; closes DKEC through Door Stop Links when Film Door is opened. Door Stop Link DKEC-actuating arm, cammed by Timing Gear. Encoder, Blade Position See Blade Position Encoder. Encoder Pair Phototransistors used to detect shutter blade motion from passage of light through coincident blade openings, as blades slide over each other. EOC End Of Cycle, signalled by Timing Gear opening DKEC Switch. EOP End Of Pack, signalled by EOP Switch closed after 10th exposure by cam on Counter Wheel. Erected Refers to Camera ready for picture taking (opposite of collapsed). Erect Link Bottom link in Camera erecting linkage; its motion actuates Erect Sensor. Erect Sensor Part of Power (Erect) Switch rotated by Erect Link when Camera is erected, which opens GND - VER contact and closes VER - B+. Erect Switch One of two wireform switches in Joshua. Controls power from filmpack battery to camera circuits through movement of GND, VER and B+ wires. Exposure IC Integrated circuit in camera electronics which processes exposure measurement data. Far Focus Lens Supplementary lens moved into optical path for subjects in far focus zone (2.4 m to infinity). Feed Roll Clutch Allows upper Feed Roll to be rotated backwards if film frame must be manually removed, without backdriving the gears. A-3 FEM Finite Element Modeling, a computer-modeling technique for measuring stresses; used in Joshua design to significantly increase strength and reliability of camera structures. Film Carrier Frame on Film Chamber Door which positions Filmpack. Film Chamber Compartment in Joshua for holding finished pictures. Film Door Access door to Film Chamber. Film Shade Sliding metal cover actuated by Pick mechanism, to prevent light-striking unexposed film via light-piping through mylar layer. Film Speed Switch Compensates exposure for slow film pack; actuated if film pack has no notch (normal pack has notch); part of Logic wireform Switch. Fill Flash Use of strobe to add to ambient light, to produce satisfactory exposure. Flash Fire Aperture Shutter blade aperture at which the strobe should be fired to produce optimum exposure and sharp focus. Flex, Interconnect Flexible mylar printed wiring to connect camera power source and circuits. Focus Zone Near or far zone occupied by subject, which determines whether near (front) lens system only, or near and far focus lenses will be used. Folded Refers to Camera in collapsed position (opposite to erected). Framing Field Area seen in viewfinder; in Joshua, same as photographic field. Fresnel Focusing Screen A highly reflective screen employing concentric Fresnel rings, to provide uniform brightness over the entire image area. Full Chamber Link Actuated by the 10th film frame to enter Film Chamber (or by a film jam); closes Full Chamber Switch on Logic Switch to inhibit operation of Camera. Gear, Timing Key element of Drive System; has cams on front and back which control DKEC, Pick Carrier and Recock Link. GND Ground wireform of Power Switch. When shorted to VER, discharges capacitor in Power Supply, shuts off power from all circuits. Hiccup Very brief Motor run when Camera is erected, to complete previous camera cycle left unfinished when power was broken. Hybrid Quench Energy-saving strobe quench method incorporating approximately 0.4 stop excess aperture to compensate for system inaccuracies. A-4 Hybrid Exposure Combination of follow focus and quenching systems. Inertia System Rack and pinion system with zinc inertia gear, coupled to blade-opening Walking Beam; used to reduce blade opening speed. Infrared Invisible portion of electromagnetic spectrum. Used in Joshua exposure calculations since many fabric dye colors have similar IR reflectivity values. Inhibits Prevention of Camera operation when bad/no picture would result (storage chamber full, end of pack, strobe not charged). Integrator (Ambient, Hybrid) Electronic circuit for summing and storing measured light values. Interconnect Flex (See Flex, Interconnect). IR Abbreviation for infrared. IR Reflectivity Property of a material to reflect/emit infrared radiation. Used in Joshua exposure calculations since many fabric dyes of differing colors possess similar IR reflectivity values. Jam Film frame misfeed and incomplete transport into storage chamber. Jog, Reverse Motor Brief, initial CCW rotation of Motor to release Recock Latch, allowing VF Blind to block VF window and Recock Link to lift Taking Mirror. Joshua Code name for Joshua Camera during development. LED Abbreviation for Light Emitting Diode. Logic Switch Multi-element wireform switch in Joshua, controlling Exposure Trim, Self-Timer, End of Pack, DKEC, S1A-S1B, Film Speed and Full Chamber functions. Look-Up Table In the Joshua microprocessor, a stored collection of ambient and Wink reflectance values arranged as rows and columns, the intersections of which provide optimum exposure data for thousands of different photographic situations. Mainframe Primary molded frame on which all other camera subassemblies, frames and structures are mounted. MCU Circuit designation of microprocessor IC in Joshua Camera. Microprocessor (Micro) Integrated circuit chip containing CPU elements of control logic, decoding, arithmetic processing and memory. A-5 Mirror-Down Signal One of three signals generated by DKEC cam on Timing Gear; occurs halfway through cycle, when cam momentarily opens DKEC switch. Used to re-open Viewfinder after exposure. Mirror, Fixed Mirror at 45-degrees to image path which directs image to Fresnel screen, concave mirror and Viewfinder optics. Mirror, Taking Mirror driven upward to 45-degree angle, into image path, todirect image onto film. Mirror, Viewing Same as Fixed Mirror. Open Term used with Joshua to describe condition of doors, not the position of the Camera. Override Slider Part of the Storage Chamber Pick Assembly in the Film Door; actuates Chamber Pick to pull picture from nip of Spread Rolls into Storage Chamber; also coupled to Film Shade through Actuator Link. Overtravel Spring Part of VF Blind/VF Blind Link mechanism; allows VF Blind to close before Mirror is released; also compensates for Recock Latch rotation after VF Blind cannot move further. Pack, Film Ten Joshua instant color print film frames with darkslide and mercury-free battery in a film box. Pack Frame Guide frame for film pack in Film Door. Photodiode System Dual photodiodes behind green and black lenses, to measure visible (ambient) and IR (strobe) light values. Photographic Field Area captured on film (in Joshua, same as viewing field). Photometer See Photodiode System. Picking Transporting film frame by motion of a notched, reciprocating arm (Joshua has two picks: one moves frame into feed rolls, the other into Storage Chamber). Pick Carrier Reciprocating arm in Drive System driven forward by cam on Timing Gear, returned by spring load. Includes Pick Strap to pull film into Feed Rolls and arm to index Counter Wheel. Pick Carrier Advance Cam Cam on underside of Timing Gear that advances and holds forward the Pick Carrier. Pick Strap Part of Pick Carrier that pulls frame into Feed Rolls. A-6 Picture Chamber Area in Joshua in which darkslide and processed pictures are stored. Picture Door Access door to remove prints from Camera. Piezo Audible signal device (beeper) which sounds on Self-Timer count, End of Pack, etc. Platen Assembly Structure in Film Door to position film pack properly. Power Actuator See Actuator, Power. Power IC Integrated circuit chip in Camera electronics which controls power voltages to Exposure and Microprocessor ICs, motor, strobe, solenoids, piezo, etc. Power Switch Same as Erect Switch. Process Rolls (Spread Rolls) Driven rolls which crush pod in film frame and distribute reagent over emulsion. Quench To turn off strobe flashtube after it has delivered required amount of illumination to satisfy exposure requirements. Reagent Chemical film developing agent contained in internal pod in integral Polaroid film. Reflectance, IR Infrared energy reflected by subject and measured at Camera (see IR Reflectivity). Recock Latch Drive System element which, when latched, holds Mirror Recock Link and Taking Mirror down, prior to exposure. Reverse motor jog turns Latch CCW, unlatches Recock Link which lifts mirror to picture-taking position. Recock Link Drive System element actuated by Timing Gear cam; lifts Taking Mirror to picture-taking position, drives it down after exposure. S1A-S1B Circuit designation of Joshua Shutter Release button. Closing S1A charges strobe, closing S1B initiates exposure. Secondary Pick Chamber Pick; pulls frame into Storage Chamber. Self-Timer Programmed delay set by camera user, causing exposure 10 seconds after Slide control is set. Six Sigma Design Statistical designation of product reliability, in which no more than 30 failures to meet performance specifications are allowed in one million products manufactured. The Joshua Camera is such a design. A-7 SlimPulse Battery Mercury-free battery used in Joshua Filmpacks. SLR Abbreviation for Single Lens Reflex. Solenoid 1 Electromagnetic device which converts electrical signal into linear motion of plunger, to close Shutter Blades through Walking Beam. Solenoid 2 Similar device to Solenoid 1, for position Far Focus Lens in optical path. SPAR Abbreviation for Strobe Preferred, Automatic Recharge of strobe. Spreading Passing film frame through motor-driven rollers to crush pod and spread developing reagent over emulsion. Spread Rolls See Process Rolls. SQF Abbreviation for Subjective Quality Factor, a Polaroid measure of ???. Storage Chamber See Film Chamber. Storage Pick See Secondary Pick. Strobe-Always Operation Camera operation in which strobe is fired automatically on every exposure (Joshua). Strobe Tower Molded enclosure containing Strobe flashtube and release button; used for erecting camera from folded position. Switchblock Assembly Power and Logic Wireform Switch Assemblies. Taking Lens Front multi-element lens for picture exposure. Taking Mirror Movable mirror positioned in image path during exposure, then returned to original position out of optical path. Timing Gear Key component in Drive System: starts and stops camera cycle, advances Pick Carrier and operates DKEC Switch. TM Carrier Pivoted frame holding Taking Mirror and Fresnel Screen. Top Off Continuation of strobe charge to maximum capacity prior to next exposure. Tower, Strobe See Strobe Tower. A-8 Track & Hold System Exposure determination and control system developed for Joshua Camera, using high IC switching speeds and implemented in chip design. Ambient and strobe contributions are determined in advance, strobe is fired at smallest practical aperture, ambient integration continued until exposure is complete. Trap End Film frame end opposite to pod end. Two-Zone Focus System In Joshua, consists of 0.6 to 2.4 m and 2.4 m to infinity. Near zone uses Main Lens system only, far zone adds Far Focus Lens. VER, Ver Erect Voltage line; when closed to B+, camera is powered. VF Abbreviation for viewfinder. Viewfinder Blind Pivoted mask which covers Viewfinder window during exposure, preventing entrance of stray light. Viewfinder Mirror Concave mirror which redirects image from Fixed Mirror to Eyelens. Visible Integrator Electronic summing circuit for visible (ambient) light measurements by Photometer. Walking Beam Pivoted arm in Shutter System which couples Solenoid 1 to Blades, closing them when Solenoid is energized. (Blades are normally open, under spring load). Wake-Up Mode Camera cycle initiation at full operating voltage, triggered by . . . (reset signal? from microprocessor?). Wink Pre-exposure discharge of about 10% of strobe energy and measurement of reflected IR. Wink Aperture Priority System Prediction of smallest possible practical aperture for strobe fire (and thus maximum depth of field), based on Wink strobe fire and measurement. Primary purpose of Wink is aperture prediction; also determines if Far Focus Lens is needed. Wireform Switch Design used for Power and Logic Switches; flexible wires mounted in molded switchblock contact a common ground plane when deflected by manually or drive-pivoted arms. Wrap-Spring Clutch See Clutch, Wrap Spring. A-9 [This page intentionally blank]