Minelab F3, Service Manual

Page 1: ...FIELD SERVICE MANUAL Issue 1 4 4th February 2005 Part No 4904 0003 F3 Metal Mine Detector LEVEL 1 MAINTENANCE ...

Page 2: ...ED 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 5031 ...

Page 3: ... 3 Disassembly And Reassembly Procedures 12 3 1 Speaker Pod 12 3 2 Handle 15 3 3 Armrest 18 3 4 Electronics Pack 21 3 5 Coil 29 3 6 Shafts 34 3 7 Battery Pack 44 4 Faultfinding Procedures 51 4 1 Switch On Test Faultfinding 51 4 2 Noise Cancel Faultfinding 51 4 3 Audio Reset Faultfinding 51 4 4 Ground Balance Faultfinding 51 4 5 Test Piece Faultfinding 51 4 6 Alarm Tone Faultfinding 52 4 7 Earset F...

Page 4: ...ector and does not require any specialized facilities but does require the F3 Service Tool Kit Level 2 Level 2 maintenance encompasses Level 1 maintenance plus repairs to the earset earphone and coil socket replacement This level of maintenance requires electronic workshop facilities and the F3 Service Tool Kit Level 3 Level 3 maintenance encompasses Level 1 and Level 2 maintenance plus electronic...

Page 5: ...F3 Field Service Manual Level 1 Maintenance Page 5 LEVEL 1 MAINTENANCE ...

Page 6: ...mbly Ensure that the Sensitivity Endcap is correctly positioned and in good condition Replace Endcap in accordance with Section 2 5 of the F3 Operations Manual Ensure that the Battery Pack lid O ring is present clean and in good condition Ensure that the tether attaching the BP lid to the BP is present and in good condition Ensure that the coil can be tilted smoothly and holds its position without...

Page 7: ...lised ground hot rock or a fired tile that produces a response from the F3 2 2 1 Switch On Test Hold the coil at least 600mm 24ins from the ground and away from any metallic objects and switch on the F3 Ensure that four or five rising tones taking 12 to 15 seconds are heard A steady threshold tone should be heard a few seconds after the rising tones finish Figure 1 Switch On Procedure If the corre...

Page 8: ...etector will begin to Ground Balance Figure 3 Audio Reset Procedure Within two seconds the threshold tone will return to its correct level If the threshold tone does not return to the correct level go to Section 4 3 for faultfinding procedures 2 2 4 Ground Balance Test Note Ensure the operator s hands and arms are free of metallic objects watches rings etc and that no other metallic objects are ne...

Page 9: ...ion 2 2 4 a Press down and hold the green Ground Balance button and slowly lower the coil directly to the ground touching the ground then lift the coil up again 150mm 6ins Continue to lower and raise the coil until the Ground Balance OK tone is heard Ground Balance OK tone consists of a short high pitched double beep Note Movement of the coil during the entire Ground Balance procedure should be sl...

Page 10: ...orrect response is not heard go to Section 4 5 for faultfinding procedures Turn the detector off b Red Endcap Remove the black endcap and fit the red endcap Turn the detector on wait for the start up procedure to finish Hold the Test Piece above the middle of the coil with the rounded end containing the metallic target towards the coil Move the Test Piece towards the centre of the coil until it li...

Page 11: ... near plug is being tested ensure that the threshold tones cannot be heard from the detector loudspeaker If a volume control is fitted to the earset cable ensure that it operates correctly If any faults are found go to Section 4 6 for faultfinding procedures or replace the earset Turn the detector off 2 2 8 Battery Cable Test if supplied Remove the battery pack from the detector Connect the batter...

Page 12: ... Note Numbers in brackets on all figures refer to the item number from the applicable figure 3 1 Speaker Pod 3 1 1 Speaker Pod Disassembly Remove battery pack and sensitivity endcap from the detector Figure 7 Speaker Pod Exploded View 3004 0017 SPKR GB SW POD KIT SVC F3 1 SPEAKER POD TOP HALF 2 SPEAKER POD LOWER HALF 3 2701 0092 DECAL SPEAKER HANDLE F3 4 4003 0083 SCREW M3X10 SS not part of Kit 5 ...

Page 13: ...alf of the speaker pod to the handle The nut for this screw sits in a recess between the two handle halves P0713 A Figure 9 Lower Speaker Pod showing screw securing Lower Speaker Pod to Handle Remove the lower half of the speaker pod lift the rear of the pod upwards and remove the pod towards the front of the detector Note The speaker pods halves should always be kept attached to each other during...

Page 14: ...seal between the loudspeaker and ground balance audio reset button to the pod housing Damaging this seal may allow water into either the loudspeaker or switch If the plug and socket are dry smear a small amount of silicon grease around the shroud to ensure they will be waterproof Plug the speaker pod plug into the socket on the main wiring loom Roll the speaker pod plug shroud back over the socket...

Page 15: ... 0031 SWITCH ASSY SLIDER F3 7 9511 0023 WIRING LOOM F3 SHAFT HANDLE 8 4003 0082 BOLT M4X20 SKT SS 9 4003 0081 BOLT M4X10 SKT SS Figure 14 Handle Parts List Undo and remove the four bolts and nuts holding the handle halves together Carefully separate the left handle half from the upper shaft Remove the earset dustcap 5 Remove the nut 4 that secures the lower speaker pod screw to the handle The main...

Page 16: ...e bottom of the handle Excess cable should be carefully pulled through from the rear of the upper shaft Ensure that the on off switch slider is correctly positioned Figure 15 Right Handle Half showing loom in cable channel yellow blue on off switch slider red upper screw boss orange and cable under screw boss green Place the nut which secures the speaker pod assembly to the handle into the recess ...

Page 17: ...ely Fit one short 10mm bolt and nut to the top position in the handle this will ensure that the internal nut stays in place Fit one long 20mm bolt and nut to the rear of the handle under the on off switch slider Fit one long 20mm bolt and nut to the front of the handle below the noise cancel button Fit one short 10mm bolt and nut to the remaining hole near the centre of the handle Tighten the four...

Page 18: ...REST HALF part of ARMREST L R F3 5 3004 0015 RIGHT ARMREST HALF part of ARMREST L R F3 6 8008 0005 CAM LEVER F3 7 8008 0026 PRESSURE BLOCK ARMREST F3 8 8008 0030 WEAR PLATE F3 9 8005 0018 STRAP ARMREST F3 Figure 19 Armrest Parts List Unlace the armstrap if required Undo and remove the three bolts and nuts holding the armrest halves together Carefully separate the armrest halves The cam lever cam l...

Page 19: ...ate can now be replaced if required Glue the new wear plate into the pressure block with a small drop of super glue allow the super glue to dry before reassembly P0720 A Figure 20 Glue the Wear Plate with a small drop of super glue Wear Plate Armrest Pressure Block ...

Page 20: ...nded portion away from the detector and up see blue circle feed the strap from the outside into the slot in the right arm rest half 1 o Feed the strap back over the top of the right arm rest half and back through the lower slot in the buckle same slot as the start of the strap 2 o Feed the strap back through the slot in the right arm rest half 3 o Tighten the strap so that the buckle sits near the...

Page 21: ...OSI SS 8 4309 0039 O RING BULKHEAD 50MM 9 0703 0095 COVER BULKHEAD F3 10 4003 0084 SCREW NO 3X16 POSI SS 11 4003 0084 SCREW NO 3X16 POSI SS 12 4309 0044 GROMMET BULKHEAD F3 13 0703 0097 COVER RIBBON CABLE F3 Figure 23 Detector Parts List This step only required if access to the split grommet is required Undo and remove the two screws 11 holding the ribbon cable cover 13 to the bulkhead cover Caref...

Page 22: ... and remove the upper two screws 7 securing the electronics pack to the upper shaft Slide the electronics pack back along the upper shaft approximately 10cms 4ins Note The coil plug retainer 4 is designed to aid in coil plug removal refit In addition it stops the coil cable sliding down the shafts and stops the curled coil cable from unravelling Disconnect the coil plug 5 use the coil plug retaine...

Page 23: ...RING ENDCAP BP EP F3 6 0701 0029 COVER BLACK EP F3 7 SHIM if fitted Figure 26 Electronics Pack Parts List Using the 7 8 tubular socket spanner remove the plug retaining nut at the front of the electronics pack The washer bayonet lever bayonet and shim if fitted can now be removed if required Remove 4 screws holding the cap front to the electronics pack housing Remove the cap front Remove 4 screws ...

Page 24: ...using over the PCB against the O ring on the electronics pack rear panel F3 logo towards front of the detector Refit the four screws securing the housing to the electronics pack rear panel Ensure that these screws are done up evenly otherwise the O ring in the electronics pack rear panel may be damaged Ensure that an O ring is fitted in the cap front and on the plug base Refit the cap front and fo...

Page 25: ... see picture below and reconnect the coil plug 5 to the electronics pack Use the coil plug retainer 4 to tighten the coil plug Remove excess sealant Figure 28 Apply a small amount of silicon sealant to the coil plug thread Note The coil plug must be tightened to ensure that water does not enter the rear of the electronics pack Slide the electronics pack all the way along the upper shaft Ensure tha...

Page 26: ...Loom in cut out orange and Ribbon Cover blue Split grommet red and Bulkhead Cover green on Main Wiring Loom Ensure that the ribbon cable cover split grommet and bulkhead cover are threaded on the main wiring loom in that order Note Extreme care must be taken when plugging in the main wiring loom plug ...

Page 27: ...ectronics Pack yellow arrow shows O ring under bulkhead cover Fold excess main wiring loom cable into the electronics pack above the plug Figure 31 Fold excess cable into the Electronics Pack Note If the O ring or the split grommet is dry smear a small amount of silicon grease around them Ensure that an O ring 8 is positioned correctly in the groove under the bulkhead cover in the electronics pack...

Page 28: ...ion into the bulkhead cover Figure 32 Split grommet red arrow over thickened area of main wiring loom yellow If required fit the ribbon cable cover 13 over the grommet and secure with two screws Route the Main Wiring Loom around the cable router on the side of the bulkhead cover as per the following figure Figure 33 Main Wiring Loom around cable router Refit sensitivity endcap and battery pack ...

Page 29: ...edure Figure 34 Coil Exploded View 3004 0003 COIL KIT SVC F3 1 2004 0037 RETAINER COIL BLACK F3 2 2021 0054 COIL F3 3 4005 0039 BLOCK FRICTION COIL F3 4 8009 0007 RETAINER PLUG F3 Figure 35 Coil Parts List Remove coil plug retainer from around the coil plug Ensure that excessive force is not applied to the coil plug The coil plug will now slide down into the shafts Figure 36 Removing the Coil Plug...

Page 30: ...le out from inside the shafts Carefully lever the skid plate off the coil using the 6 5mm screwdriver Note If there is any damage to the coil or coil cable the coil must be replaced There are no repairable parts of the coil 3 5 2 Coil Refit Refit the skid plate by pushing it onto the coil Ensure that the lower camlock assembly is completely reassembled Connect the coil cable puller to the coil plu...

Page 31: ... is resting above the coil Figure 41 Coil with puller through the shafts Note It is important that the curly cable or pull through is not twisted as this will change the number of turns in the curly cable If the correct number of turns is not present the curly cable may stop the shafts from retracting correctly Refit the lower camlock assembly to the coil top The flats on the friction blocks shoul...

Page 32: ...he cut outs in the rear of the coil top Pivot the front of the coil retainer cover down towards the coil top Use the palm of the hand to snap the coil retainer cover into the coil top Figure 43 Positioning Coil Retainer Cover Figure 44 Snap the Coil Retainer Cover into the Coil top Figure 45 Coil Retainer Cover in place ...

Page 33: ...the coil plug clear of the shaft fit the coil plug retainer and disconnect the coil cable pull through Figure 46 Fitting the Coil Plug Retainer Refit the electronics pack Section 3 4 4 Electronics Pack Refit the coil plug is reconnected during this procedure ...

Page 34: ...Pack Removal and Section 3 5 1 Coil Removal a Lower camlock and lower shaft Figure 48 Lower Camlock Assembly Exploded View 3004 0011 CAMLOCK KIT LOWER SHAFT F3 1 8007 0022 CAMLOCK BODY LOWER F3 2 8008 0031 PRESSURE BLOCK LOWER F3 3 8008 0030 WEAR PLATE F3 4 8008 0029 CAM LEVER LOWER CAMLOCK F3 5 4308 0008 PIN LOWER CAMLOCK F3 Figure 49 Lower Camlock Assembly Parts List Lower Shaft Upper Shaft Midd...

Page 35: ...t and the other holds the lower cam lever in place Remove the lower camlock body from the lower shaft Remove the lower pressure block from the lower camlock body if required The wear plate can now be replaced if required Glue the new wear plate into the pressure block with a small drop of super glue allow the super glue to dry before reassembly Figure 51 Glue the Wear Plate with a small drop of su...

Page 36: ...cam lever pivot pin from the middle camlock body Remove the cam lever Remove the pressure block by pushing it out from inside the shaft The wear plate can now be replaced if required Glue the new wear plate into the pressure block with a small drop of super glue allow the super glue to dry before reassembly Figure 54 Glue the Wear Plate with a small drop of super glue Remove the middle camlock bod...

Page 37: ... Kit Figure 56 Upper Camlock Kit Parts List Use the 3mm T handle hex driver to push out the cam lever pivot pin from the upper camlock Remove the cam lever Remove the upper pressure block by pushing the block out from inside the shaft The wear plate can now be replaced if required Glue the new wear plate into the pressure block with a small drop of super glue allow the super glue to dry before rea...

Page 38: ...per Shaft square holes aligned Place the tail of the upper pressure block into the recess in the rear of the upper camlock body and push the block down into the square hole Refit the cam lever and cam lever pivot pin Ensure that the pressure block does not protrude too far into the shaft push it back into the camlock body if required or difficulty may be encountered when fitting the middle shaft F...

Page 39: ...F3 1 3004 0012 CAMLOCK KIT MIDDLE SHAFT F3 not shown see next figure 2 8007 0024 MIDDLE SHAFT BLACK F3 3 8003 0019 COLLAR SHAFT MIDDLE F3 Figure 61 Middle Shaft Parts List Attach the two collar shafts to the rear of the middle shaft They should fit snugly on the shaft and sit closely together Figure 62 Attaching Collar Shafts to Middle Shaft Upper Shaft ...

Page 40: ...KIT MIDDLE SHAFT F3 1 8008 0023 CAMLOCK BODY MIDDLE F3 2 8008 0005 CAM LEVER F3 3 8008 0030 WEAR PLATE F3 4 8008 0024 PRESSURE BLOCK MIDDLE CAMLOCK F3 5 4308 0003 CAM LEVER PIVOT PIN Figure 64 Middle Camlock Assembly Parts List Refit the middle camlock body to the middle shaft ensuring that that the square hole in the camlock is aligned with the cut out in the middle shaft Middle Shaft Upper Shaft...

Page 41: ...it back into the camlock body if required or difficulty may be encountered when fitting the lower shaft Figure 65 Reassembling the Middle Camlock Assembly Slide the middle shaft all the way into the upper shaft and close the upper cam lever Open the middle cam lever c Lower camlock and shaft Refit the cam lever with a lower camlock pin into the camlock body Open the lower cam lever Place the lower...

Page 42: ...r pressure block falling out slide the lower camlock assembly fully onto the lower shaft with a twisting motion Figure 68 Slide the lower Shaft into the Lower Camlock Body with a twisting motion Turn the detector back over and ensure that the lower camlock assembly is positioned on the lower shaft with the cam lever uppermost Refit the other lower camlock pin Figure 69 Lower Camlock Body and Lower...

Page 43: ...ual Level 1 Maintenance Page 43 Refit the friction blocks to the lower camlock body Figure 70 Refit the Friction Blocks Refit the Coil and Electronics pack Section 3 5 2 Coil refit and Section 3 4 4 Electronics Pack Refit ...

Page 44: ...703 0079 CAP FRONT BP F3 7 3004 0005 RIVET part of TETHER WITH RIVET KIT SVC BP F3 8 0705 0015 PANEL ASSY LID BP F3 BATTERY PACK LID 9 0703 0098 FACEPLATE CAP FRONT BP F3 10 4003 0079 SCREW M3X25 POSI SS Figure 72 Battery Pack Parts List a Faceplate Front Cap Battery Pack Lid and Tether Undo the battery pack lid Remove the 4 screws 10 from the faceplate 9 Remove the faceplate The front cap and bat...

Page 45: ...oded View 0705 0015 PANEL ASSY LID BP F3 BATTERY PACK LID 1 4003 0073 SCREW NO 4X16 POSI SS 2 4005 0061 WASHER 3 5904 0085 PCB LID BP F3 4 3004 0005 TETHER part of TETHER WITH RIVET KIT SVC BP F3 5 4309 0047 O RING 50MM BP LID F3 6 0304 0018 LID BP F3 7 4309 0038 O RING 11MM BP LID F3 8 4313 0002 LOCK LID BP F3 9 3004 0005 RIVET part of TETHER WITH RIVET KIT SVC BP F3 Figure 75 Battery Pack Lid an...

Page 46: ...AP REAR BP F3 2 4002 0026 COLLAR BAYONET CAP BP F3 3 4003 0067 SCREW NO 4X3 8 POSI SS 4 5904 0052 PCB CAP BP F3 5 2302 0029 SKT 6 PIN BP F3 Figure 77 Battery Pack Lid Parts List The housing and battery tube can now be removed and replaced if required Using the 7 8 tubular socket spanner remove the socket retaining nut Remove the two screws from the PCB The PCB and collar bayonet can now be removed...

Page 47: ...R part of TETHER WITH RIVET KIT SVC BP F3 5 4309 0047 O RING 50MM BP LID F3 6 0304 0018 LID BP F3 7 4309 0038 O RING 11MM BP LID F3 8 4313 0002 LOCK LID BP F3 9 3004 0005 RIVET part of TETHER WITH RIVET KIT SVC BP F3 Figure 79 Battery Pack Lid and Tether Parts List Assemble all parts to the battery pack lid assembly ensure that the O ring is present in the lock lid the lock lid pin is in the reces...

Page 48: ...nt of the front cap Fit the rivet into the hole at the end of the tether and push the pin fully into the rivet Figure 82 Tether through the Front Cap Front Cap O ring yellow Figure 83 Fitting the Rivet Ensure that the O ring is present in the rear of the front cap Position the front cap onto the housing ensure that the tether is between the battery tube and housing ...

Page 49: ... of the front cap may be damaged b Rear Cap Ensure that an O ring is present in the rear cap and on the plug base Figure 85 Rear Cap O ring and Plug O ring Align and position PCB to the rear cap and refit the two screws to the PCB Position the collar bayonet to the rear cap Note The recess in the collar bayonet must be positioned over the protruding lug in the rear cap Figure 86 Position the reces...

Page 50: ...rear cap onto the housing ensure that the over current sensor is between the battery tube and housing Figure 88 Ensure that the over current sensor is between the battery tube and housing yellow arrow Refit the four screws Ensure that these screws are done up evenly otherwise the O ring in the rear of the cap may be damaged ...

Page 51: ...noise cancel button or the electronics pack Replace these one at a time until the faulty component is identified 4 3 Audio Reset Faultfinding If the detector does not audio reset correctly the problem may be either the audio reset ground balance button part of speaker pod assembly main wiring loom or electronics pack Replace these one at a time until the faulty component is identified Note The aud...

Page 52: ...d or removed whilst the detector is switched on the problem may be either the red endcap or the electronics pack The red endcap should have a small cylindrical magnet in the bottom right hand corner looking into the endcap if this is present the red endcap is OK and the electronics pack is faulty 4 7 Earset Faultfinding For any faults replace the earset ...