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SECTION 4 DISASSEMBLY AND ADJUSTMENT

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DISASSEMBLY AND ADJUSTMENT Table of Contents

Table of Contents
4.1 Preface.......................................................................................... 5
4.1.1 Before Work ...................................................................................................... 5 4.1.2 Don'ts ................................................................................................................ 6 4.1.3 Check after Work............................................................................................... 6 4.1.4 Notations in Procedures.................................................................................... 7

4.2

Diassembling and Assembling ...................................................... 9

1. Cover...................................................................................................................... 9 REP1.1 OPERATION PANEL (PL1.1), COVER TOP ASSY (PL1.9), SWITCH I/L ASSY (PL1.15) .................................................................... 9 REP1.2 COVER REAR (PL1.6) ........................................................................... 11 REP1.3 COVER RIGHT (PL1.7) .......................................................................... 12 REP1.4 COVER FRONT (PL1.8) ......................................................................... 13 REP1.5 COVER LEFT (PL1.9)............................................................................. 14 2. 150/250/550 Paper Cassette / Option 250/550 Cassette .................................... 15 REP2.1 ROLL ASSY RETARD (PL2.4/3.4/3.4/21.4/23.4).................................... 15 REP2.2 GEAR SECTOR (PL2.23/3.23/3.25/21.23/23.25), RACK SIZE (PL2.24/3. 24/3.25/21. 24/23.25), GUIDE END150/250 (PL2.28/3.28/3.29/21.28/23.29) .......................... 16 REP2.3 PLATE ASSY BTM (PL2.35/3.36/3.45/21.36/23.45)............................... 18 REP2.4 GEAR LEVER LOCK (PL2.17/3.17/21.17/23.17), LEVER BTM LOCK (PL2.18/3.18/21.18/23.18) .................................... 20 3. 550 Paper Cassette / Option 550 Cassette ......................................................... 22 REP3.1 SUPPORT GUIDE IND(PL3.31/23.31), GUIDE INDICATOR1 (PL3.33/23.33), GUIDE INDICATOR2 (PL3.34/23.34) ...................................................... 22 REP3.2 GUIDE INDICATOR3 (PL3.35/23.35) ..................................................... 23 REP3.3 LOW INDICATOR (PL3.36/23.36), LOW IND FRONT (PL3.37/23.37) .. 24 4. 150 Paper Feeder ................................................................................................ 25 REP4.1 150 FEEDER ASSY (PL4.1) ................................................................... 25 REP4.2 GEAR NUDGER (PL4.10), ROLL ASSY NUDGER (PL4.11), CLUTCH ONEWAY NUDGER (PL4.44), CLUTCH ONEWAY FEED (PL4.45), ROLL ASSY FEED (PL4.46)......... 26 REP4.3 ROLL REGI RUBBER (PL4.13) .............................................................. 27 REP4.4 CLUTCH ASSY PH (PL4.22), CLUTCH REGI (PL4.24)......................... 28 REP4.5 SENSOR REGI (PL4.31) ........................................................................ 29 REP4.6 SENSOR NO PAPER (PL4.40), ACTUATOR NO PAPER (PL4.6)......... 30 REP4.7 SENSOR TONER (PL4.50) .................................................................... 31 5. 250/550 Paper Feeder ......................................................................................... 32 REP5.1 GUIDE TRAY R ASSY (PL5.1), GUIDE TRAY LOWER (PL5.9) ............ 32

4-1

DISASSEMBLY AND ADJUSTMENT Table of Contents
REP5.2 GUIDE TRAY L ASSY (PL5.6) ................................................................ 33 REP5.3 250/550 FEEDER ASSY (PL5.12) .......................................................... 34 REP5.4 GEAR NUDGER (PL5.20), ROLL ASSY NUDGER (PL5.21), CLUTCH ONEWAY NUDGER (PL5.31), CLUTCH ONEWAY FEED (PL5.32), ROLL ASSY FEED (PL5.33)......... 35 REP5.5 CLUTCH ASSY PH (PL5.24) .................................................................. 36 REP5.6 SENSOR NO PAPER (PL5.43), ACTUATOR NOPAPER (PL5.16)........ 37 REP5.7 SENSOR LOW PAPER (PL5.47)............................................................ 38 6. Xero...................................................................................................................... 39 REP6.1 ROS ASSY (PL6.1) ................................................................................. 39 REP6.2 WALL ROS (PL6.4), FAN SUB (PL6.5) .................................................. 41 REP6.3 GUIDE ASSY CRU L (PL6.8).................................................................. 43 REP6.4 INTERLOCK S/W 24V (PL6.13), INTERLOCK S/W 5V (PL6.14), LEVER LINK (PL8.14), LINK GEAR3 (PL8.16)..................................... 44 REP6.5 LEVER GUIDE (PL6.16) ......................................................................... 45 REP6.6 COVER GUIDE CRU (PL6.19), HARNESS ASSY FUSER (PL6.20)..... 46 REP6.7 FUSER ASSY (PL6.23), CHUTE EXIT FUSER (PL6.32)....................... 47 REP6.8 BTR ASSY (PL6.24)................................................................................ 48 REP6.9 CHUTE TRANSFER (PL6.25) ................................................................ 49 REP6.10 PWBA ASSY ANT (PL6.27) .................................................................. 50 REP6.11 GUIDE ASSY CRU R (PL6.29) ............................................................. 51 7. 250 Paper Exit (20PPM) .................................................................................... 52 REP7.1 250 EXIT ASSY (PL7.1) .......................................................................... 52 REP7.2 CHUTE EXIT ASSY (PL7.2) ................................................................... 53 REP7.3 CHUTE ASSY LOWER (PL7.3), MOTOR ASSY EXIT (PL7.11)............. 54 REP7.4 COVER REAR250 (PL7.12) ................................................................... 55 REP7.5 COVER DUP (PL7.13), COVER INLET DUP (PL1.8) ............................ 56 REP7.6 ROLL EXIT (PL7.23) ............................................................................... 57 8. Frame & Drive ...................................................................................................... 58 REP8.1 MOTOR COVER (PL8.1) ........................................................................ 58 REP8.2 MAIN MOTOR (PL8.2) ............................................................................ 59 REP8.3 GEAR ASSY HOUSING (PL8.3)............................................................. 60 REP8.4 GEAR 9 (PL8.8), GEAR ASSY PLATE (PL8.9) ...................................... 61 9. Electrical............................................................................................................... 62 REP9.1 SHIELD PLATE LVPS (PL9.3) ................................................................ 62 REP9.2 PWBA EXIT MOTOR (PL9.4) ................................................................. 63 REP9.3 LVPS (PL9.5) .......................................................................................... 64 REP9.4 POWER SWITCH (PL9.6), HARNESS ASSY AC100V (PL9.8) ............. 65 REP9.5 INTERLOCK S/W REAR (PL9.7)............................................................ 66 REP9.6 FAN MAIN (PL9.11)................................................................................. 67 REP9.7 PWBA ESS (PL9.14), SHIELD ASSY ESS (PL9.16).............................. 68 REP9.8 POST SCRIPT CARD (PL9.31), SHIELD ASSY WINDOW (PL9.17)..... 69 REP9.9 SHIELD PLATE HVPS (PL9.20), HVPS/MCU (PL9.21) ......................... 70 20. Option 250/550 Feeder ...................................................................................... 71 REP20.1 OPTION 250/550 FEEDER................................................................... 71 REP20.2 COVER RIGHT PLATE (PL20.1/22.1),

4-2

DISASSEMBLY AND ADJUSTMENT Table of Contents
COVER LEFT PLATE (PL20.5/22.5) ....................................................... 72 REP20.3 OPT ASSY SIZE (PL20.8/22.8) ............................................................ 73 REP20.4 DRIVE ASSY OPT (PL20.12/22.12), MOTOR FEEDER (PL20.21/22.21) ......................................................... 74 REP20.5 COVER RE250/550 (PL20.24/22.25), 250/550 FEEDER OPTION (PL20.40/22.40) ........................................ 75 REP20.6 SENSOR LOW PAPER (PL20.32/22.33).............................................. 76 REP20.7 PWBA FEEDER250/550 (PL20.35/22.36) ............................................ 77 REP20.8 GEAR NUDGER (PL20.49/22.49), ROLL ASSY NUDGER (PL20.50/22.50), CLUTCH ONEWAY NUDGER (PL20.72/22.72), CLUTCH ONEWAY FEED (PL20.73/22.73), ROLL ASSY FEED (PL20.74/22.74) ..................................................... 78 REP20.9 ROLL ASSY TURN (PL20.52/22.52) .................................................... 79 REP20.10 CLUTCH ASSY PH (PL20.57/22.57), CLUTCH PR-REGI (PL20.58/22.58) ..................................................... 80 REP20.11 SENSOR NO PAPER (PL20.70/22.70), ACTUATOR NO PAPER (PL20.45/22.45)............................................. 81 24.Option Duplex...................................................................................................... 82 REP24.1 DUPLEX................................................................................................ 82 REP24.2 HSG UPPER ASSY (PL24.1)................................................................ 83 REP24.3 HSG LOWER ASSY (PL24.5), HARNESS ASSY DUP (PL24.7) ......... 84 REP24.4 COVER TOP (PL24.13), PWBA DUPLEX (PL24.36), FAN DUPLEX (PL24.37), SENSOR DUP (PL24.38) ............................ 86 REP24.5 ROLLER DUP (PL24.20) ...................................................................... 87 REP24.6 COVER LEFT (PL24.28), COVER RIGHT (PL24.45) .......................... 88 REP24.7 MOTOR DUPLEX (PL24.31), SWITCH DUPLEX (PL24.32) ............... 89 26.Option MSI .......................................................................................................... 90 REP26.1 MSI ........................................................................................................ 90 REP26.2 COVER SIDE L (PL26.1), DIAL ASSY P/S (PL26.30).......................... 91 REP26.3 COVER SIDE R (PL26.4), MOTOR ASSY MSI (PL26.20), PWBA MSI (PL26.23) ............................................................................ 92 REP26.4 SENSOR NO PAPER (PL26.6), COVER UP ASSY MSI (PL26.43)..... 93 REP26.5 GEAR UNIT MSI (PL26.19) .................................................................. 94 REP26.6 SOLENOID MSI (PL26.21) ................................................................... 95 REP26.7 ROLL ASSY FEED (PL26.40) ............................................................... 96 REP26.8 HOLDER ASSY MSI (PL26.51) ............................................................ 97 REP26.9 ROLL ASSY FEED (PL26.72) ............................................................... 98 REP26.10 ROLL FEED MSI (PL26.75)................................................................ 99 27. 500 Paper Exit (25PPM) & Option Face Up .................................................. 100 REP27.1 CHUTE ASSY EXIT500 (PL27.3) ....................................................... 100 REP27.2 ROLL EXIT (PL27.11) ......................................................................... 101 REP27.3 CHUTE LOW ASSY (PL27.14), MOTOR ASSY EXIT (PL27.15) ....... 102 REP27.4 SENSOR FACE UP OPEN (PL27.25), SENSOR FULL STACK (PL27.26) ........................................................ 103 REP27.5 ROLL FU (PL27.44) ............................................................................ 104

4-3

DISASSEMBLY AND ADJUSTMENT Table of Contents
REP27.6 COVER ASSY REAR500 (PL27.44)................................................... 105 REP27.7 COVER DUP (PL27.53), TRAY FU (PL27.54).................................... 106 28. Option OCT ...................................................................................................... 107 REP28.1 OCT..................................................................................................... 107 REP28.2 COVER OCT (PL28.1), COVER REAR (PL28.4), TRAY ASSY OCT (PL28.43) DAMPER ASSY TRAY L (PL28.50), DAMPER ASSY TRAY R (PL28.51) ...................................................... 108 REP28.3 MOTOR ASSY OCT (PL28.7), SENSOR OCT (PL28.31) .................. 109 REP28.4 S/W REAR COVER (PL28.17), MOTOR ASSY OFFSET (PL28.22), PWBA OCT (PL28.27) ......................................................................... 110 REP28.5 ROLL OCT LOWER (PL28.18) ............................................................111 REP28.6 SOLENOID ASSY GATE (PL28.29).................................................... 112 REP28.7 ROLL OCT UPPER (PL28.39) ............................................................ 113 REP28.8 COVER FRONT (PL28.48) ................................................................. 114

4.3

Adjustment .................................................................................115

4.3.1 Collecting Log Information When Printer Controller Has a Fatal Error and Hangs Up............................... 115 4.3.1.1. 4.3.1.2. 4.3.1.3. 4.3.1.4. 4.3.1.5. 4.3.1.6. Overview ................................................................................................ 115 Errors Requiring Log Information Collection.......................................... 115 Tools Required for Log Information Collection ...................................... 115 Device Requirements for Log Information Collection ............................ 115 Procedure 1 for Collecting Log Information (Error 1: A fatal error has occurred.) ...................................................... 116 Procedure 2 for Collecting Log Information (Error 2: The error cannot be cleared with the device operating.)......... 118

4.3.2 Procedure for Upgrading ESS PWB Firmware ............................................. 121 4.3.2.1. 4.3.2.2. 4.3.2.3. 4.3.2.4. 4.3.2.5. Procedure .............................................................................................. 121 Overview of the Download Operation.................................................... 121 Download Time ...................................................................................... 122 DP 205/255/305 Requirements ............................................................. 122 Procedure .............................................................................................. 122

4-4

DISASSEMBLY AND ADJUSTMENT
4.1 Preface This section describes the procedures for removing and installing main parts in 14 items where the device parts correspond to parts lists. *1. Cover *2. 150/250/550 Paper Cassette/Option 250/550 Cassette *3. 550 Paper Cassette/Option 550 Cassette *4. 150 Paper Feeder *5. 250/550 Paper Feeder *6. Xero *7. 250 Paper Exit (20PPM) *8. Frame & Drive *9. Electrical *20. Option 250/550 Feeder *24. Option Duplex *26. Option MSI *27. 500 Paper Exit (25/30PPM) & Option Face Up *28. Option OCT NOTE When working on a part managed as a spare part but not described in the procedures, check the mounting status well before starting work. NOTE The options should basically be removed but may be left mounted if it is not necessary to remove them. 4.1.1 Before Work - Turn the power OFF and unplug the power cable from the outlet. - For work around FUSER ASSY, check that the FUSER ASSY and ambient temperatures are low enough. - Handle parts with great care. Excess force may damage or disable parts. - This device has many kinds of screws. Use them at correct positions. If a screw is used at a wrong position, the threaded hole may be damaged or any other problem may occur. - When working, wear a wrist band or any other grounding item to eliminate static electricity from the body. - Remove 150 PAPER CASSETTE, 250 PAPER CASSETTE, and the EP cartridge and place them where the work is not disturbed.

4-5

DISASSEMBLY AND ADJUSTMENT
4.1.2 Don'ts Do not remove the frame components shown below. Removing the components may cause device misalignment. If such components are removed or their screws are loosened by mistake, be sure to install or tighten them on a stable and solid horizontal surface.

4.1.3 Check after Work After work, check that COVER OPEN and LEVER LINK are connected securely. Then open and close COVER OPEN to see that it works smoothly.

4-6

DISASSEMBLY AND ADJUSTMENT
4.1.4 Notations in Procedures - "REP X.Y AAAAA" at the beginning of a procedure means that the procedure is for removing or replacing part AAAAA. - "(PL X.Y)" after a part name in a procedure means that the part corresponds to Item Y of Plate (PL) X in Section 5, "Parts List." You can check the shape, the mounting position, and others in Section 5. - In a procedure, directions are expressed as follows: Front: To this side when viewing the device from the front Rear: To the other side when viewing the device from the front Left: To the left-hand side when viewing the device from the front Right: To the right-hand side when viewing the device from the front

Rear

Left

Right Front

- In a procedure, a screw is described about the attachment position, color, characteristics, and under-head length. - If a procedure says " ..... Model," the work applies to the specified model only (not to other models). - "(REP X.Y)" in the middle or at the end of a procedure means that "REP X.Y" gives a related work procedure. - "(Fig. X.Y)" at the end of a procedure means that "Fig. X.Y" gives a reference illustration for REP X.Y. - "Z)" in an illustration corresponds to "Z)" in the work procedure. - A Phillips screwdriver is used to loosen an illustrated screw unless specified otherwise. - A black arrow in an illustration means that the part should be moved in the direction of the arrow. Numbered black arrows mean that the parts should be moved in order of the numbers. - A white arrow (FRONT) in an illustration indicates the front direction of the device. - For a connector (P/J) position, see Section 7, "Electrical Wiring Diagrams."

4-7

DISASSEMBLY AND ADJUSTMENT

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4-8

DISASSEMBLY AND ADJUSTMENT
4.2 Disassembling and Assembling

1. Cover REP1.1 OPERATION PANEL (PL1.1), COVER TOP ASSY (PL1.9), SWITCH I/L ASSY (PL1.15)
Removal 1. Remove COVER REAR250. (REP7.4) 2. Remove COVER REAR. (REP1.2) 3. Remove COVER LEFT. (REP1.5) 4. Remove 250 EXIT ASSY. (REP7.1) 5. Remove the two screws (silver, collar-head, 8 mm) securing OVER TOP ASSY. 6. Release LEVER LINK from the boss of COVER OPEN. NOTE When releasing LEVER LINK from the boss of COVER OPEN, open COVER OPEN and extend LEVER LINK. NOTE In the following procedure, care should be taken not to take OPERATION PANEL too far away from the main unit because they are connected through a harness. 7. Release the four front hooks of COVER TOP ASSY from COVER FRONT and remove COVER TOP ASSY from the main unit. 8. Disconnect the SWITCH I/L ASSY connectors (P/J144, P/J411) from the frame. 9. Release a harness from the OPERATION PANEL connector. 10. Release a harness from the clamps of SWITCH I/L ASSY and COVER TOP ASSY and remove COVER TOPASSY. 11. Release the two hooks of OPERATION PANEL and remove OPERATION PANEL from COVER TOP ASSY. 12. Remove the two screws (gold, tapped, 8 mm) securing SWITCH I/L ASSY, extract a harness from the COVER TOP ASSY hole, and remove SWITCH I/L ASSY.

4-9

DISASSEMBLY AND ADJUSTMENT

Replacement Perform removal steps in reverse order.

4-10

DISASSEMBLY AND ADJUSTMENT
REP1.2 COVER REAR (PL1.6)
Removal 1. Remove COVER REAR250. (REP7.4) 2. Remove the four screws (silver, collar-head, 8 mmx2; gold, tapped, 8 mmx2) securing COVER REAR. 3. Open COVER REAR as indicated by the arrow, release three hooks, and remove COVER REAR from the main unit.

Replacement Perform removal steps in reverse order. NOTE When replacing, identify two kinds of screws and attach them to the correct positions.

4-11

DISASSEMBLY AND ADJUSTMENT
REP1.3 COVER RIGHT (PL1.7)
Removal 1. Loosen one screw securing COVER RIGHT. 2. Slide COVER RIGHT in the direction of the arrow to release the three bottom hooks and the two rear hooks. 3. Slide COVER RIGHT downward to release the three top hooks and then remove COVER RIGHT from the main unit.

Replacement Perform removal steps in reverse order.

4-12

DISASSEMBLY AND ADJUSTMENT
REP1.4 COVER FRONT (PL1.8)
Removal 1. Remove COVER REAR250. (REP7.4) 2. Remove COVER REAR. (REP1.2) 3. Remove COVER LEFT. (REP1.5) 4. Remove 250 EXIT ASSY. (REP7.1) 5. Remove COVER TOP ASSY. (REP1.1) 6. While pressing the top two hooks of COVER FRONT, pull down COVER FRONT to the front. 7. By sliding in the direction of the arrow, release the bottom two hooks and remove COVER FRONT from the main unit.

Replacement Perform removal steps in reverse order.

4-13

DISASSEMBLY AND ADJUSTMENT
REP1.5 COVER LEFT (PL1.9)
Removal 1. Remove COVER REAR250. (REP7.4) 2. Remove COVER REAR. (REP1.2) 3. Slide COVER LEFT in the direction of the arrow to release the three bottom hooks and the two rear hooks. 4. By sliding down, release the three top hooks and remove COVER LEFT from the main unit.

Replacement Perform removal steps in reverse order.

4-14

DISASSEMBLY AND ADJUSTMENT
2. 150/250/550 Paper Cassette / Option 250/550 Cassette REP2.1 ROLL ASSY RETARD (PL2.4/3.4/3.4/21.4/23.4)
Removal 1. Unhook HOLDER RETARD with a screwdriver and lift it as indicated by the arrow to make free. 2. Unhook ROLL ASSY RETARD and remove it from SHAFT RETARD. NOTE When removing ROLL ASSY RETARD, do not hold its rubber section.

NOTE In addition to the above procedure, you may press HOLDER RETARD down to remove ROLL ASSY RETARD.

Replacement Perform removal steps in reverse order. NOTE Hook ROLL ASSY RETARD securely on the groove of SHAFT RETARD. NOTE After mounting, press HOLDER ASSY REATRD down to see that SPRING RETARD is not off.

4-15

DISASSEMBLY AND ADJUSTMENT
REP2.2 GEAR SECTOR (PL2.23/3.23/3.25/21.23/23.25), RACK SIZE (PL2.24/3. 24/3.25/21. 24/23.25), GUIDE END150/250 (PL2.28/3.28/3.29/21.28/23.29)
Removal 1. Remove COVER CST from the cassette body. 2. Release LOCK EXTENSION and extract the cassette extension. 3. Remove the five screws (gold, tapped, 6mm) securing COVER EXTENSION. 4. Remove COVER EXTENSION from HOUSING EXTENSION150/250/550. 5. While releasing RACK SIZE with the cassette on the front, remove RACK SIZE from HOUSING EXTENSION150/250/550. 6. Remove the screw (black, collar-head, 8mm) securing GEAR SECTOR. 7. Remove GEAR SECTOR from HOUSING EXTENSION150/250/550. 8. Unhook GUIDE END150/250/550 and remove it from HOUSING EXTENSION150/250/550. NOTE Note that excess force may damage the hook of GUIDE END150/250/550.

4-16

DISASSEMBLY AND ADJUSTMENT
Replacement Perform removal steps in reverse order. NOTE After replacement, move GUIDE END150/250/550 to see that LINK SWITCH SIZE moves smoothly. Note1 When replacing, set GUIDE END150/250/550 to A4 (portrait) as shown below and align on RACK SIZE and GEAR SECTOR for attachment as shown in the previous page.

Note2 When attaching COVER EXTENSION, check that COVER EXTENSION is secured by tabs at five sections of HOUSING EXTENSION150/250/550.

4-17

DISASSEMBLY AND ADJUSTMENT
REP2.3 PLATE ASSY BTM (PL2.35/3.36/3.45/21.36/23.45)
Removal 1. Remove COVER CST from the cassette body. 2. Release LOCK EXTENSION and extract the cassette extension. 3. Unhook GEAR PINION and detach it from HOUSING TOP150/250/550. 4. Release LEVER BTM LOCK and STOPPER GEAR and lift PLATE ASSY BTM. 5. Press the hook of HOUSING TOP150/250/550 down and slide GUIDE ASSY SD L inward to remove from HOUSING TOP150/250/550. 6. Press HOUSING TOP150/250/550 down and slide GUIDE ASSY SD R inward to remove from HOUSING TOP 150/250/550. 7. Remove the screw (gold, tapped, 8mm) securing PLATE GEAR LOCK on the GEAR PB R side. Unhook PLATE GEAR LOCK and remove it from HOUSING BASE150/250/550. NOTE Since the following procedure makes GEAR PB L, GEAR BTM ONEWAY, and GEAR LOCK ONEWAY free, care should be taken not to lose them. 8. Unhook GEAR PB R and remove it from SHAFT PB. 9. Release GEAR PB L and remove PLATE ASSY BTM, SHAFT PB, GEAR PB L, GEAR BTM ONEWAY, and GEAR LOCK ONEWAY together from HOUSING TOP150/250/550. 10. Extract SHAFT PB from PLATE ASSY BTM and remove GEAR PB L, GEAR BTM ONEWAY, and GEAR LOCK ONEWAY.

4-18

DISASSEMBLY AND ADJUSTMENT
Replacement Perform removal steps in reverse order. NOTE When replacing SPRING BTM UP150/250/550, align it with the bosses of PLATE ASSY BTM. NOTE When replacing GEAR PINION, extend GUIDE ASSY SD R and GUIDE ASSY SD L out completely. If GUIDE ASSY SD R and GUIDE ASSY SD L deviate from each other, side registration will be lost. NOTE When replacing PLATE GEAR LOCK, lift PLATE ASSY BTM. If PLATE ASSY BTM is tilted, a skew or a jam may occur. After work, check that PLATE ASSY BTM is not tilted.

4-19

DISASSEMBLY AND ADJUSTMENT
REP2.4 GEAR LEVER LOCK (PL2.17/3.17/21.17/23.17), LEVER BTM LOCK (PL2.18/3.18/21.18/23.18)
Removal 1. Remove COVER CST from the cassette body. 2. Release LOCK EXTENSION and extract the cassette extension. 3. Release LEVER BTM LOCK and STOPPER GEAR and lift PLATE ASSY BTM. 4. Remove the screw (gold, tapped, 8mm) securing PLATE GEAR LOCK on the GEAR PB R side. Unhook PLATE GEAR LOCK and remove it from HOUSING BASE150/250/550. 5. Unhook GEAR PB R and remove it from SHAFT PB. 6. Remove the screw (gold, tapped, 8mm) securing COVER BTM UP/COVER BTM UP550 and remove COVER BTM UP/COVER BTM UP550 from HOUSING BASE 150/250/550. 7. Remove GEAR LOCK PINION from HOUSING BASE 150/250/550. 8. Remove RACK BTM LOCK150/250/550 and SPRING BTM LOCK together from HOUSING BASE 150/250/ 550. 9. Remove GEAR LEVER LOCK from HOUSING BASE 150/250/550. 10. Remove LEVER BTM LOCK from HOUSING BASE 150/250/550. 11. Remove the two screws (black, collar-head, 8mm) securing STOPPER GEAR and remove STOPPER GEAR and SPRING STOPPER GEAR from HOUSING BASE 150/250/550. NOTE When removing and replacing STOPPER GEAR, care should be taken not to lose SPRING STOPPER GEAR.

4-20

DISASSEMBLY AND ADJUSTMENT
Replacement Perform removal steps in reverse order. NOTE When replacing, lift PLATE ASSY BTM. If PLATE ASSY BTM is tilted, a skew or a jam may occur. After work, check that PLATE ASSY BTM is not tilted. Note1 When replacing RACK BTM LOCK150/250/550, lift LEVER BTM LOCK. After work, press and release LEVER BTM LOCK to see that the convex of LEVER BTM LOCK hits the stopper of HOUSING BASE 150/250/550 and that is positioned on the stopper. Note2 When replacing STOPPER GEAR, press the SPRING STOPPER GEAR against the plate as shown in the figure.

4-21