Fujinon XL 4400 Service Manual

The Fujinon XL 4400 is a professional broadcast lens designed for high-performance television production. This service manual covers technical specifications, disassembly procedures, optical alignment, maintenance schedules, troubleshooting, and repair guidelines for qualified service technicians. Below are key sections for technical overview, maintenance procedures, optical calibration, component replacement, and service troubleshooting.

1. Technical Specifications 2. Safety Precautions 3. Disassembly Procedures 4. Optical System Overview 5. Mechanical Components 6. Electrical System 7. Calibration Procedures 8. Maintenance Schedule 9. Component Replacement 10. Troubleshooting Guide 11. Parts List & Ordering

Technical Specifications

Key technical parameters and performance characteristics of the Fujinon XL 4400 broadcast lens.

Specification	Description
Focal Length Range	8.5-180mm (21x zoom)
Maximum Aperture	f/1.7 at wide end
Image Format	2/3-inch broadcast
Minimum Object Distance	0.8m from image plane
Zoom Ratio	21:1
Filter Size	112mm
Weight	Approximately 4.2kg
Length	Approximately 315mm
Operating Temperature	-10°C to +45°C
Storage Temperature	-20°C to +60°C

Safety Precautions

Essential safety guidelines for service personnel working with the Fujinon XL 4400 lens.

Always discharge static electricity before handling internal components.
Use certified Fujinon tools for disassembly and reassembly.
Handle optical elements with clean, lint-free gloves only.
Work in clean, dust-free environment to prevent contamination.
Follow electrostatic discharge (ESD) protection procedures.

WARNING! High voltage components present. Disconnect power before servicing. Use only Fujinon-approved replacement parts.

Disassembly Procedures

Step-by-step instructions for proper lens disassembly.

Remove front filter ring and protective housing.
Detach zoom and focus control mechanisms.
Carefully separate optical groups using specified tools.
Document component orientation for reassembly.
Store removed components in anti-static containers.

CAUTION! Improper disassembly may cause permanent optical misalignment. Follow torque specifications precisely.

Optical System Overview

Lens Configuration: 22 elements in 16 groups
Special Elements: 3 ED glass elements, 2 aspherical elements
Coating: Super EBC multi-layer coating
Zoom Mechanism: Precision cam-driven system
Iris System: 9-blade electromagnetic iris
Focus System: Internal focusing with floating elements
Image Stabilization: Optical stabilization system (if equipped)

Mechanical Components

Detailed description of mechanical systems and their maintenance requirements.

Zoom System: Precision ground cam tracks, roller followers, servo drive mechanism. Focus System: Helical focus mechanism, position sensors, motor drive assembly. Iris Mechanism: Electromagnetic actuator, blade assembly, position feedback.

Lubrication: Use only specified Fujinon lubricants. Apply sparingly to designated points only. Over-lubrication can contaminate optical elements.

Electrical System

Electronic components and control systems overview.

Disconnect all power sources before electrical service.
Verify servo motor specifications before replacement.
Check connector pinouts against service manual diagrams.
Test encoder feedback systems for proper operation.

Tip: Use multimeter to verify continuity and resistance values before power application.

Calibration Procedures

Optical and mechanical alignment procedures for professional performance.

Back focus adjustment using collimator and test chart.
Zoom tracking calibration at multiple focal lengths.
Focus scale alignment for accurate distance marking.
Iris calibration for precise f-stop values.
Image stabilization calibration (if equipped).
Servo response time adjustment.
Encoder position calibration.

WARNING! Calibration requires specialized test equipment. Do not attempt without proper training and tools.

Maintenance Schedule

Recommended maintenance intervals and procedures.

Daily: Clean exterior surfaces, check for physical damage. Monthly: Inspect mechanical movement, check mounting security. Quarterly: Clean optical surfaces, verify back focus. Annually: Complete mechanical inspection, lubrication, calibration check.

CAUTION! Use only Fujinon-approved cleaning materials. Improper cleaning can damage lens coatings.

Component Replacement

Authorized replacement procedures for common components.

Component	Replacement Procedure	Special Tools Required
Servo Motors	Disconnect power, remove mounting screws, replace motor, recalibrate	Torque screwdriver set
Optical Elements	Clean room environment, anti-static precautions, optical alignment	Lens spanner wrench set
Iris Assembly	Remove front element group, replace iris mechanism, reassemble	Precision tweezers
Encoder Strips	Careful removal of old strip, precise alignment of new strip	Alignment jig
Connector Cables	Document wiring, replace cable, verify continuity	Multimeter, crimp tool

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Image softness	Back focus misalignment	Recalibrate back focus using test chart
Zoom sticking	Contaminated cam tracks	Clean and relubricate zoom mechanism
Iris not responding	Motor failure or cable issue	Check continuity, replace servo motor if needed
Focus drift	Mechanical wear or calibration	Recalibrate focus mechanism and encoders
Vignetting	Element misalignment	Complete optical realignment procedure

Reset: Perform factory reset through service menu if available.

Service Support: Contact Fujinon authorized service center for complex issues.