FIELD SERVICE MANUAL F1A4 Metal Mine Detector NSN 6665-66-142-9741 LEVEL 1 MAINTENANCE LEVEL 2 MAINTENANCE Date: 1st June, 2005
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F1A4 Field Service Manual – Level 1 and Level 2 Maintenance WARNING THIS DOCUMENT CONTAINS MINELAB ELECTRONICS LIMITED RIGHTS TECHNICAL DATA OR RESTRICTED RIGHTS DATA OR BOTH. Minelab Electronics This work is copyright. Apart from any use as permitted under the Copyright Act 1968, no part may be reproduced by any process without written permission from Minelab Electronics 118 Hayward Avenue, Torrensville South Australia.
CONTENTS SECTION PAGE 1. Introduction ...................................................................................................................5 1.1 Levels of Maintenance ............................................................................................5 1.2 How to use this Manual ...........................................................................................5 Level 1 Maintenance ...............................................................................................
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 1. INTRODUCTION This manual is intended to instruct service technicians in functional testing and Levels 1 and 2 maintenance of the F1A4 mine detector. All sub-assemblies of the F1A4 can be replaced without the need for adjustment or calibration. This service manual includes all Level 1 and Level 2 maintenance procedures, including functional testing and troubleshooting. 1.
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F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 2. MECHANICAL AND FUNCTIONAL TESTING OF THE F1A4 This section details mechanical and functional testing of the F1A4. Section 2.1 lists all mechanical testing and directs the user to applicable Level 1 repair procedures if any defects are found. Section 2.2 lists functional testing of the F1A4 and will refer the user to the applicable fault finding procedure if a fault is found.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 2.2 FUNCTIONAL TESTING This section details functional testing of the F1A4. It should be used to confirm serviceability of an F1A4 before it is returned to the field for use and whenever doubt exists about the serviceability of an F1A4. The F1A4 must pass all these tests to be considered serviceable. Remedial action is included for repair if required.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 2.2.3 Ground Balance Testing Note: The F1A4 Control Box will memorise its last Ground Balance settings when switched off and then on again. If a Control Box/Coil combination has been previously balanced to the GB Test Piece, on re-testing, a response to that hot rock will not be heard again. The same Control Box/Coil combination must be rebalanced with a GB Test Piece with different characteristics before re-testing.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 2.2.4 Coil Connector Test Loop the coil cable and hold against side of the control box, approximately 250mm from the coil connector. Grasp the coil cable 75mm from the coil connector and gently turn 30 degrees side to side, listening for a change of threshold. If there is a noticeable threshold change (ie similar in volume to test piece threshold change), the Coil should be replaced (Section 3.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 3. MAINTENANCE PROCEDURES This section details mechanical maintenance procedures and covers the following: 1. Camlock repair procedures (Section 3.1) 2. Handle replacement procedures (Section 3.2) 3. Hand grip replacement procedure (Section 3.3) 4. Coil replacement procedure (Section 3.4) 3.1 CAMLOCK REPAIR PROCEDURES This procedure details the dismantling and re-assembly of the Camlocks fitted to the Upper Shaft of the F1A4.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 3.1.1 Servicing the Upper and Lower Camlocks 1. Knock out Camlock Pivot Pin with the 3 to 3.5mm punch. 2. Remove Cam Lever from the Camlock Body. 3. Remove Pressure Block from the Camlock Body. 4. Slide the Camlock Body from the shaft. 5. Assembly is the reverse of the dismantling procedure, with attention to the following: 1. use only new components from the appropriate Camlock Service Kit, 2.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 3.1.2 Servicing the Handle Camlock 1. Knock out Camlock Pivot Pin with the 3 to 3.5mm punch and Remove the Cam Lever. 2. Remove the Stainless Steel Wear Plate, 3. Assembly is the reverse of the dismantling procedure, with attention to the following: 1. Use only new components from the Handle Camlock Service Kit. 2. Ensure that the Stainless Steel Wear Plate is correctly seated in the Handle Moulding until the Cam Lever is installed.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 3.2 REPLACING THE HANDLE ASSEMBLY 1. Remove the Control Box, Lower Shaft and Armrest (if fitted) from the Upper Shaft. Remove the Upper Camlock as described in Section 3.1. 2. 3. Release the Camlock Handle and slide the old Handle off the shaft. 4. Slide the New Handle onto the shaft ensuring correct orientation. 5. Refit the new Upper Camlock as described in Section 3.1.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 3.3 REPLACING THE HANDGRIP 1. 4. Remove the hand strap from the handle (refer to the ‘F1A4 Operations Manual if required). Cut the foam hand-grip down its length and remove it. Using water, wet the handle and the foam and slide the foam hand-grip onto the handle. Refit the hand strap. 3.4 REPLACING THE COIL 2. 3. 3.4.1 To Remove a Coil: 1. 2. 3. 4. 5. 6. 7. 8. Carefully remove the dust cap from the Coil Plug.
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F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 4. TESTING THE F1A4 CONTROL BOX This procedure details testing of the F1A4 Control Box and Earset, and should be carried out if there is any doubt about the serviceability of the F1A4, or after any repairs have been completed to the F1A4 Control Box. A Ground Balance (GB) Test Piece is required to properly test the F1A4. This is needed to simulate mineralised or ‘noisy’ ground and ensure correct F1A4 Ground Balance operation.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 4.3 GROUND BALANCE TEST Note: The F1A4 Control Box will memorise its last Ground Balance settings when switched off then on again. If a Control Box/Coil combination has been previously balanced to the GB Test Piece, on re-testing, a response to that hot rock will not be heard again. The same Control Box/Coil combination must be re-balanced with a GB Test Piece with different characteristics before re-testing.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 4.5 NOISE CANCEL TEST Momentarily press the NOISE CANCEL button. The F1A4 should immediately “beep” After 70 seconds the F1A4 should “beep” four times: BEEP BEEP BEEP BEEP If the correct tones are not heard, go to Section 5.1.4 4.6 AUDIO RESET TEST Momentarily press the AUDIO RESET button. The F1A4 should immediately BEEP.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 5. TROUBLESHOOTING AND REPAIR OF THE F1A4 CONTROL BOX This section covers troubleshooting and repair of the F1A4 Control Box, required after Section 4 testing. After any repair has been completed, return to Section 4 for a complete test of the F1A4 Control Box. 5.1 TROUBLESHOOTING THE F1A4 CONTROL BOX 5.1.1 Initial Power On Troubleshooting 5.1.1.1 Power On Test Procedure Connect the F1A4 to a good Coil and charged battery pack.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 5.1.2 Sensitivity Troubleshooting 5.1.2.1 Sensitivity Test Procedure Hold the Test Piece Mine Detector in one hand, with the end containing the target away from the Coil. Move the Test Piece Mine Detector towards the centre of the coil until it lightly touches the centre of the coil and then move it sideways off the coil (the Test Piece Mine Detector should be moved slowly and smoothly during this procedure).
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance Release the switch so that it returns to the SEARCH position. Continue to move the GB Test Piece up and down, approximately 25 to 100mm from the Coil. The F1A4 should not respond to the test piece. If a response is heard check that there is no metal on the technician or the GB Test Piece and repeat the test. 5.1.3.2 Troubleshooting If a response is still heard repeat the test. If a response is still heard, replace the coil and repeat the test.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 5.1.5 Audio Reset Troubleshooting 5.1.5.1 Audio Reset Test Momentarily press the AUDIO RESET button. The F1A4 should immediately BEEP. After 3 seconds the F1A4 should give five “high / low” beeps: BEEP BEEP BEEP BEEP BEEP The threshold tone level should now be set at the correct operating level (ie just audible). 5.1.5.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 5.2 F1A4 CONTROL BOX REPAIR PROCEDURES This section covers individual F1A4 Control Box repair procedures required after Section 5.1 Troubleshooting. After any repair has been carried out, return to Section 4 for a complete functional test of the F1A4 Control Box. 5.2.1 Loudspeaker Replacement 1. 2. 3. 4. 5. 6. 7. 8.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 4. Remove the Ground Lead retaining screw (if fitted). 5. Rotate the Rear Panel so that it can follow the PCB through the Main Box.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 6. Pull the Front Panel, PCB and Rear Panel out of the Main Box from the Front. 7. 8. Unplug the blue ribbon connector from the Front Panel. Desolder all the wires, at the PCB, from the coil plug, loudspeaker, switch and earset connector (note wiring/PCB connections). Remove the Front Panel from the PCB. Desolder all the wires, at the PCB, from the power connector (note wiring/PCB connections). Remove the Rear Panel from the PCB.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 12. 13. factory repair facility. Assembly is the reverse of the dismantling process, with attention to the following: 1. Ensure that the PCB is correctly orientated before fitting into case. The coil connector and power connector will be nearest the black mounting block and the power connector at the end with the clips. 2.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 5.2.5 Front Panel Replacement 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Place F1A4 Control Box on an Anti-static mat, ensuring that the wrist strap is being worn and is firmly connected to the Anti-static mat. Remove the 6 screws from the Front Panel and pull the Front Panel away from the case. Remove PCB from the case (refer to 5.2.4 if required). Unplug the blue ribbon cable.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 5.2.6 Earset Repair Procedures 5.2.6.1 Four Pin plug repair Refer to the illustration at end of this section. Parts required: Minelab PN 1. 2301-0013 2. 9501-0024 3. NA Qty one (if req’d) 1.5m (If req’d) 10mm 4. NA 98mm 5. 6. NA NA As Req’d As Req’d Description Four pin plug Earset cable Green heatshrink, 3.2mm, non-adhesive (Earset Speaker Off only) Black heatshrink, 4.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 8. 9. 10. water, contact cleaner or other water based lubricant, ensuring that no moisture gets on the soldered pins. Slide down the back shell over the toothed inner sleeve onto the plug and screw down all the way.
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F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 5.3 Battery Carrier Repair Procedures Repairs to the Battery Carrier are limited to battery terminal and wire link replacement. 5.3.1 Battery Terminals 1. Check the Battery terminals, ensure they are not broken or loose. Replace as required. Refer to the illustration below. Note: When desoldering, or resoldering these terminals, do not use excessive heat as the plastic Battery Carrier housing may be damaged. 5.3.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 6. RETERMINATING THE COIL CONNECTOR The F1A4 has specialised cables that require exacting soldering methods. To solder the coil cable to the plug a good quality liquid flux, soldering iron (temperature controlled at 420°C to 460°C of around 60 watts) and good quality multi-core solder are required Procedure: 1. Prepare the cable in accordance with the connection details in “Coax Connection” in Section 7. 2.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 7. F1A4 CONTROL BOX INTERNAL CONNECTION DETAILS 7.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 7.
F1A4 Field Service Manual – Level 1 and Level 2 Maintenance 7.4 PCB WIRING - ILLUSTRATION Earset plug, Loudspeaker, Ribbon Cable and Switch to PCB connections BLACK BLACK BLUE RIBBON CABLE RED RED RED (ON/SEARCH) BLUE (BALANCE) YELLOW EARSET PLUG LOUD SPEAKER ON/OFF/GROUND BALANCE SWITCH Coil plug to PCB connections RED BLACK BLUE YELLOW Power plug to PCB connections ORANGE BLACK RED YELLOW (COMMON) WHITE RED BLUE – Connected via screw to case.
