Kodak EKTAGRAPHIC III ATS, EKTAGRAPHIC III KKE PLUS, EKTAGRAPHIC III AMT, EKTAGRAPHIC III KKA, EKTAGRAPHIC III E-PLUS SLIDE User Manual

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{ServiceManual}{Production}{KodakServiceSupport}

Publication No. SM4530-1

30APR96

SERVICE MANUAL for the

Kodak Ektagraphic III Painted and Non-Painted PROJECTORS

Models A, KKA, JA, ATS, AM, AMT, JAMT, B, BR, E, E-PLUS SLIDE, J-E PLUS, and KKE PLUS

Kodak Home Page on Internet

Intranet

Table of Contents

A100_0001HA

© Eastman Kodak Company, 1999

PLEASE NOTE The information contained herein is based on the experience and knowledge relating to the subject matter gained by Eastman Kodak Company prior to publication.

No patent license is granted by this information.

Eastman Kodak Company reserves the right to change this information without notice, and makes no warranty, express or implied, with respect to this information. Kodak shall not be liable for any loss or damage, including consequential or special damages, resulting from any use of this information, even if loss or damage is caused by Kodak’s negligence or other fault.

This equipment includes parts and assemblies sensitive to damage from electrostatic discharge. Use caution to prevent damage during all service procedures.

Table of Contents

 

Description

Page

Replacements and Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Replacing the LOWER HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

4

Installing the LOWER HOUSING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . .

4

Replacing the FAN SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Installing the FAN SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Replacing the MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Installing the MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Replacing the WORM PULLEY and MECHANISM BELT . . . . . . . . . . . . . . . . .

8

Installing the WORM PULLEY and MECHANISM BELT . . . . . . . . . . . . . . . . . .

9

Replacing the THERMAL FUSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Installing the THERMAL FUSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Replacing the LAMP MODULE RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . .

11

Installing the LAMP MODULE RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Replacing the CYCLE SOLENOID ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .

12

Installing the CYCLE SOLENOID ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

12

Replacing the MECHANISM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Installing the MECHANISM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Replacing the AUTO-FOCUS BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . .

14

Installing the AUTO-FOCUS BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . .

14

Replacing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY . . .

15

Installing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY . . . .

17

Replacing the LAMP SOCKET TERMINAL ASSEMBLY, N.P. . . . . . . . . . . . . .

18

Installing the LAMP SOCKET TERMINAL ASSEMBLY . . . . . . . . . . . . . . . . . . .

18

Replacing the LAMP SOCKET TERMINAL ASSEMBLY, Painted Models . . . .

19

Installing the LAMP SOCKET TERMINAL ASSEMBLY, Painted Models . . . . .

20

Replacing the LENS MOUNT ASSEMBLY - Auto Focus Model . . . . . . . . . . . .

20

Installing the LENS MOUNT ASSEMBLY - Auto Focus Models . . . . . . . . . . . .

20

Replacing the LENS MOUNT ASSEMBLY - Non Auto Focus Model. . . . . . . . .

21

Installing the LENS MOUNT ASSEMBLY - Non Auto Focus Model . . . . . . . . .

21

Replacing the AUTO-FOCUS SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . .

22

Installing the AUTO-FOCUS SWITCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . . .

22

Replacing the FOCUS SHAFT ASSEMBLY - Auto Focus Models. . . . . . . . . . .

23

Installing the FOCUS SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

Replacing the FOCUS SHAFT ASSEMBLY - Non Auto-Focus Models. . . . . . .

24

Installing the FOCUS SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

Adjusting the CYCLE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

Adjusting the INDEXER LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .

27

Adjusting the SLIDE LIFT LEVER MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

2

30APR96 – SM4530-1

Adjusting the SLIDE LIFT LEVER POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

Adjusting the ZERO POSITION SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

Adjusting the Focus Light Path - Auto Focus Models . . . . . . . . . . . . . . . . . . . . .

31

Adjusting the NULL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

Adjusting the PHOTOCELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

Adjusting the CLAMP PAD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

Adjusting the DARK SHUTTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

MAIN MOTOR Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

9-PIN SPECIAL APPLICATION PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

PHOTOCELL Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

5-PIN REMOTE CORD PLUG Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

SMALL COMPONENT BOARD ASSEMBLY 256809 Voltages . . . . . . . . . . . . .

46

Voltage Specifications - General Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

Power, Illumination, and Cooling Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . .

47

Slide Transport Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

Focus Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

SM4530-1 – 30APR96

3

SERVICE MANUAL

Section 1: Replacements and Installations

Replacing the LOWER HOUSING ASSEMBLY

Warning

Dangerous Voltage

[1]Disconnect the main power.

[2]Remove the PROJECTION LENS.

[3]Remove the LAMP MODULE ASSEMBLY.

[4]Remove the 6 Torx SCREWS (for N.P. models) (or 6 Phillips SCREWS for Painted Models) from the LOWER HOUSING ASSEMBLY.

[5]Pull the LOWER HOUSING ASSEMBLY off the TOP HOUSING.

Installing the LOWER HOUSING ASSEMBLY

LOWER HOUSING

SCREW (6)

A100_0012HCA

A100_0012HA

LAMP MODULE

[1] Do the replacement procedure for the LOWER HOUSING ASSEMBLY in reverse order.

4

30APR96 – SM4530-1

Replacements and Installations

Replacing the FAN SHAFT ASSEMBLY

WIRE TIE (not shown)

BR and KK models

BLOWER COVER WIRE TIE

GRILLE ASSEMBLY

A100_0013HCA

A100_0013HA

Warning

Dangerous Voltage

[1]Disconnect the main power.

[2]Do the replacement procedure for the LOWER HOUSING ASSEMBLY.

[3]Cut the 3 WIRE TIES:

1 on BLOWER COVER wires

2 on SMALL CIRCUIT BOARD between the MOTOR and MECHANISM ASSEMBLY

[4]Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD.

[5]Pull the SMALL CIRCUIT BOARD up.

[6]Remove the Torx SCREW from the BLOWER COVER ASSEMBLY.

[7]Lift the GRILLE ASSEMBLY in front of the BLOWER COVER ASSEMBLY up.

[8]Loosen the Torx SCREW on the right track of the LOWER LIGHT BAFFLE ASSEMBLY appoximately half way.

[9]Lift the LOWER LIGHT BAFFLE ASSEMBLY off the TAB on the BLOWER COVER ASSEMBLY.

[10]Remove the 2 long Torx SCREWS from the BLOWER COVER ASSEMBLY.

SM4530-1 – 30APR96

5

SERVICE MANUAL

MOTOR

SCREW

FAN

 

 

 

RETAINER

 

 

FAN CAP

 

CLIP

 

 

 

 

 

 

 

FAN PLATE

 

 

E-RING

 

ASSEMBLY

 

 

 

 

 

 

 

SPRING

 

FAN

SCREW (3)

 

 

 

BELT

 

WASHER

 

 

 

FAN

 

 

 

 

 

MECHANISM

 

BLOWER

 

 

 

ASSEMBLY

 

 

BELT

 

SCREW

 

 

 

 

WASHER

 

 

 

 

 

 

 

 

CORK

 

 

 

 

WASHER

FAN PLATE

Painted PROJECTOR

A008_0172HCA

A008_0172HA

[11]Lift the BLOWER COVER ASSEMBLY up.

[12]Remove the 3 Hex 1/4 in. SCREWS from the MOTOR.

[13]Lift the MOTOR until you observe the FAN BELT and MECHANISM BELT.

[14]Remove the FAN BELT and MECHANISM BELT off the MOTOR PULLEY. Use SPRING HOOK TL-1165.

Caution

Move the MOTOR to allow access to the parts; wires are still connected to the MOTOR. Do not cause damage to the MOTOR wires.

[15]N.P. only: Remove the RETAINER CLIP from the FAN SHAFT.

[16]Painted Models only: Remove the FAN CAP, E-RING, SPRING, and WASHER.

[17]Pull the FAN up and off the FAN SHAFT to allow access to the FAN BELT.

[18]Remove the FAN BELT.

[19]N.P. only: Remove the 3 Torx SCREWS from the FAN SHAFT ASSEMBLY.

[20]Lift and remove the FAN SHAFT ASSEMBLY.

6

30APR96 – SM4530-1

Replacements and Installations

Installing the FAN SHAFT ASSEMBLY

FAN BELT

MECHANISM BELT

 

A091_4015BCA

A091_4015BA

Important

When installing the FAN and MECHANISM BELTS, install the MECHANISM BELT on the small MOTOR PULLEY, and the FAN BELT on the large MOTOR PULLEY.

[1] Do the removal procedure for the FAN BELT and SHAFT in reverse order.

Replacing the MOTOR

SCREW (3)

 

Warning

Dangerous Voltage

[1]

Disconnect the main power.

[2]

Do the replacement procedure for the LOWER

 

HOUSING ASSEMBLY.

[3]

Disconnect all wires from the MOTOR.

[4]

Cut the 2 WIRE TIES on the SMALL CIRCUIT

 

BOARD between the MOTOR and MECHANISM

MOTOR

ASSEMBLY.

 

[5]

Disconnect the 2 wires from the CYCLE

 

SOLENOID on the SMALL CIRCUIT BOARD.

[6]

Pull the SMALL CIRCUIT BOARD up.

[7]

Disconnect all wires on the MOTOR.

[8]

Remove 3 Hex 1/4 in. SCREWS from the MOTOR.

[9]

Lift the MOTOR up to allow access to the FAN and

 

MECHANISM BELTS.

[10]

Remove the FAN and MECHANISM BELTS from

 

the MOTOR PULLEY.

[11]

Remove the MOTOR.

A091_4016GCA

A091_4016GA

SM4530-1 – 30APR96

7

SERVICE MANUAL

Installing the MOTOR

FAN BELT

MECHANISM BELT

 

A091_4015BCA

A091_4015BA

Important

When installing the FAN and MECHANISM BELTS, install the MECHANISM BELT on the small MOTOR PULLEY, and the FAN BELT on the large MOTOR PULLEY.

[1] Do the replacement procedure for the MOTOR in reverse order.

Replacing the WORM PULLEY and MECHANISM BELT

WORM PULLEY

SCREW

MECHANISM

BELT

Warning

Dangerous Voltage

[1]Disconnect the main power.

[2]Do the replacement procedure for the LOWER HOUSING ASSEMBLY.

[3]Do the replacement procedure for the MOTOR except do not disconnect the wires from the MOTOR.

[4]Remove the Torx SCREW (on N.P. models) (or Hex SCREW on Painted Models) from the WORM PULLEY ASSEMBLY.

[5]Move the TAB on the WORM PULLEY ASSEMBLY out.

[6]Remove the WORM PULLEY ASSEMBLY and MECHANISM BELT.

A091_4017GCA

A091_4017GA

8

30APR96 – SM4530-1

Replacements and Installations

Installing the WORM PULLEY and MECHANISM BELT

FAN BELT

MECHANISM BELT

 

A091_4015BCA

A091_4015BA

Important

When installing the FAN and MECHANISM BELTS, install the MECHANISM BELT on the small MOTOR PULLEY, and the FAN BELT on the large MOTOR PULLEY.

[1] Do the replacement procedure for the WORM PULLEY and MECHANISM BELT in reverse order.

Replacing the THERMAL FUSE ASSEMBLY

Warning

Dangerous Voltage

[1]Disconnect the main power.

[2]Do the replacement procedure for the LOWER HOUSING ASSEMBLY.

[3]Cut and remove the necessary WIRE TIES.

[4]Remove the black wire from the THERMAL FUSE ASSEMBLY on the POWER SWITCH.

[5]Remove the gray wire from the THERMAL FUSE ASSEMBLY from the POWER CORD.

[6]Loosen the Torx SCREW on the PREHEAT DUCT approximately half way.

[7]Pull the THERMAL FUSE ASSEMBLY out of hole of the LOWER LIGHT BAFFLE ASSEMBLY.

SM4530-1 – 30APR96

9

SERVICE MANUAL

Installing the THERMAL FUSE ASSEMBLY

[1] Do the replacement procedure for the THERMAL FUSE ASSEMBLY in reverse order.

SCREW

PRE-HEAT DUCT

A100_0015GCA

A100_0015GA

THERMAL FUSE POWER SWITCH

10

30APR96 – SM4530-1

Kodak EKTAGRAPHIC III ATS, EKTAGRAPHIC III KKE PLUS, EKTAGRAPHIC III AMT, EKTAGRAPHIC III KKA, EKTAGRAPHIC III E-PLUS SLIDE User Manual

Replacements and Installations

Replacing the LAMP MODULE RECEPTACLE

SCREW (2)

PRE-HEAT DUCT

SCREW (2)

LOWER LIGHT BAFFLE

LAMP MODULE

RECEPTACLE

BLOWER COVER

ASSEMBLY

A100_0016HCA

A100_0016HA

SCREW (not shown)

Warning

Dangerous Voltage

[1]Disconnect the main power.

[2]Do the replacement procedure for the LOWER HOUSING ASSEMBLY.

[3]Cut and remove the necessary WIRE TIES.

[4]Remove the 2 Torx SCREWS on the left side of the LOWER LIGHT BAFFLE ASSEMBLY.

[5]Loosen the Torx SCREW on the right side of the LOWER LIGHT BAFFLE ASSEMBLY approximately 1/2 way.

[6]Lift and remove the LOWER LIGHT BAFFLE ASSEMBLY.

[7]Lift the GRILLE ASSEMBLY up.

[8]Remove the 2 long Torx from the BLOWER COVER ASSEMBLY.

[9]Lift the BLOWER COVER ASSEMBLY up.

[10]Lift and move the PREHEAT DUCT up.

[11]To remove the LAMP MODULE RECEPTACLE from the PREHEAT DUCT, compress the 2 TABS on the LAMP MODULE RECEPTACLE.

Installing the LAMP MODULE RECEPTACLE

Warning

Dangerous Voltage

[1]Disconnect the main power.

[2]Do the replacement procedure for the LAMP MODULE RECEPTACLE in reverse order.

SM4530-1 – 30APR96

11

SERVICE MANUAL

Replacing the CYCLE SOLENOID ASSEMBLY

 

 

 

Warning

 

 

Dangerous Voltage

 

 

[1]

Disconnect the main power.

 

 

[2]

Do the replacement procedures for the LOWER

CYCLE SOLENOID

 

 

HOUSING ASSEMBLY and the MOTOR.

SCREW (2)

[3]

Cut and remove the necessary WIRE TIES.

 

 

 

[4]

Disconnect the 2 wires from the CYCLE

CYCLE

 

 

SOLENOID on the SMALL CIRCUIT BOARD.

 

[5]

Pull the SMALL CIRCUIT BOARD up.

SOLENOID

 

 

[6]

Remove the Torx SCREW (for N.P. models) (or

PLUNGER

 

 

 

 

Hex SCREW for Painted Models) from the WORM

 

 

 

PULLEY SHAFT.

 

 

[7]

Move the TAB on the WORM PULLEY

 

 

 

ASSEMBLY out of the MECHANISM ASSEMBLY.

 

 

[8]

Lift and remove the WORM PULLEY ASSEMBLY.

 

 

[9]

Remove the 2 Torx 1/4 in. SCREWS from the 2

 

 

 

CYCLE SOLENOID GROMMETS.

 

 

[10]

Pull the CYCLE SOLENOID ASSEMBLY up and

 

 

 

out.

 

 

[11]

If necessary, remove the CYCLE SOLENOID

 

A100_0017GCA

 

PLUNGER ASSEMBLY.

 

 

 

A100_0017GA

Installing the CYCLE SOLENOID ASSEMBLY

Important

Do the adjustment for the CYCLE SOLENOID ASSEMBLY. See the Adjustments section.

[1] Do the replacement procedure for the CYCLE SOLENOID ASSEMBLY in reverse order.

12

30APR96 – SM4530-1

Replacements and Installations

Replacing the MECHANISM ASSEMBLY

SCREW (3)

SCREW

 

DARK

LENS

SHUTTER

SWITCH

MOUNT

 

MECHANISM

ASSEMBLY

SCREW

FOCUS KNOB

 

AUTO FOCUS

A091_4022CCA

DEFEAT SWITCH

(not shown)

A091_4022CA

Warning

Dangerous Voltage

[1]Disconnect the main power.

[2]Do the replacement procedure for the LOWER HOUSING ASSEMBLY.

[3]Cut and remove the necessary WIRE TIES.

[4]Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD.

[5]Pull the SMALL CIRCUIT BOARD up.

[6]Disconnect all wires connected to the MECHANISM ASSEMBLY:

1 yellow wire from CYCLE SWITCH

1 orange wire from WIRE NUT

1 green wire from POWER CORD

2 green ground wires from the lower MECHANISM ASSEMBLY

[7]Remove the FOCUS KNOB from the FRONT PANEL.

Important

For Auto-Focus models only, disconnect the short, gray wire connected to the AUTO-FOCUS DEFEAT SWITCH.

[8]Remove the 3 Torx SCREWS from the LENS MOUNT ASSEMBLY.

[9]Lift and move the LENS MOUNT ASSEMBLY up.

[10]Do the replacement procedure for the MOTOR.

[11]Remove the 3 Torx SCREWS from the MECHANISM ASSEMBLY.

[12]Loosen the SCREW on the STABILIZER WALL approximately half way.

[13]Remove the SCREW from the DARK SHUTTER SWITCH and remove the SWITCH.

Caution

There might be a bind between the SELECT LEVER and the SELECT BUTTON when removing the MECHANISM ASSEMBLY. Do not use force; this might cause damage to the SELECT BUTTON.

[14] Remove the MECHANISM ASSEMBLY.

SM4530-1 – 30APR96

13

SERVICE MANUAL

Installing the MECHANISM ASSEMBLY

Important

To insert the SELECT BUTTON into the hole in the SELECT LEVER when installing the MECHANISM ASSEMBLY, hold the SELECT BUTTON completely down.

[1] Do the removal procedure for the MECHANISM ASSEMBLY in reverse order.

Replacing the AUTO-FOCUS BRACKET ASSEMBLY

SCREW

SCREW (2)

 

WORM

PULLEY

 

AUTO

 

CYCLE

FOCUS

SCREW

BRACKET

 

SOLENOID

ASSEMBLY

 

A091_4023BCA

A091_4023BA

Warning

Dangerous Voltage

[1]Disconnect the main power.

[2]Do the replacement procedure for the LOWER HOUSING ASSEMBLY.

[3]Cut and remove the necessary WIRE TIES.

[4]Disconnect the 2 wires from the CYCLE SOLENOID on the SMALL CIRCUIT BOARD.

[5]Pull the SMALL CIRCUIT BOARD up.

[6]Do the replacement procedure for the MECHANISM ASSEMBLY.

[7]Remove the Torx SCREW (on N.P. models) (or Hex SCREW on Painted Models) from the WORM PULLEY.

[8]Remove the WORM PULLEY.

[9]Remove the 2 Hex SCREWS from the CYCLE SOLENOID.

[10]Remove the CYCLE SOLENOID.

[11]Remove the Phillips SCREW from the AUTO-FOCUS BRACKET ASSEMBLY.

[12]Pull and remove the AUTO-FOCUS BRACKET ASSEMBLY through the hole where the CYCLE SOLENOID was.

Installing the AUTO-FOCUS BRACKET ASSEMBLY

[1] Do the replacement procedure for the AUTO-FOCUS BRACKET ASSEMBLY in reverse order.

14

30APR96 – SM4530-1

Replacements and Installations

Replacing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY

LIFT LEVER

LIFT LEVER

SHAFT

 

STYLE 1

RETARD

SPRING

E-RING

BEARING

STYLE 2

RETARD

SPRING

BEARING

 

NUT

A008_0173HCA

 

E-RING

CAM STACK ASSEMBLY

A008_0173HA

 

Warning

Dangerous Voltage

[1]Disconnect the main power.

[2]Do the replacement procedure for the MECHANISM ASSEMBLY.

[3]Remove the INDEXER LEVER ASSEMBLY from the TOP PLATE of the MECHANISM ASSEMBLY.

[4]Remove the Torx SCREW (on N.P. models) (or Hex SCREW on Painted Models) from the WORM PULLEY ASSEMBLY.

[5]Remove the WORM PULLEY ASSEMBLY.

[6]Remove the DIRECTION LEVER LINK from the DIRECTION LEVER.

[7]Remove the DIRECTION LEVER SPRING from the DIRECTION LEVER.

[8]Disconnect the LIFT LEVER SPRING from LIFT LEVER on the TOP PLATE of the MECHANISM ASSEMBLY.

[9]Remove the RETARD SPRING.

[10]Remove the 7 Torx SCREWS (on N.P. models) (or Hex SCREWS on Painted Models) from the TOP PLATE of the MECHANISM ASSEMBLY.

[11]Remove the TOP PLATE.

SM4530-1 – 30APR96

15

SERVICE MANUAL

[12] Remove the LIGHT BAFFLE.

LIFT LEVER

LIFT LEVER

 

SHAFT

 

SELECT LEVER

E-RING

BEARING

SELECT

LEVER

SPRING

 

 

NUT

CAM STACK ASSEMBLY

TAB

E-RING

 

[13]Remove the NUT from the LIFT LEVER SHAFT.

[14]Remove the LIFT LEVER and SHAFT.

[15]Remove the 2 E-RINGS from the 2 CAM SHAFT BEARINGS.

[16]Remove the 2 CAM SHAFT BEARINGS.

[17]Press and hold the SELECT LEVER down.

[18]Remove the CAM STACK ASSEMBLY.

[19]Disconnect the SELECT LEVER SPRING from the TAB and remove the SELECT LEVER.

BEARING

A008_0174HCA

A008_0174HA

16

30APR96 – SM4530-1

Replacements and Installations

HALF-CYCLE

LEVER

HALF-CYCLE

LEVER SPRING

CYCLE

LEVER

PLUNGER

SPRING

PLUNGER

CYCLE

SOLENOID

SCREW (2)

INDEX LEVER

and SPRING (not shown)

E-RING (2)

A091_0009CCA

A091_0009CA

[20]Remove the 2 SCREWS from the CYCLE SOLENOID.

[21]Remove the CYCLE SOLENOID.

[22]Slide the PLUNGER and PLUNGER SPRING off the CYCLE LEVER.

[23]Remove the HALF CYCLE SPRING between the CYCLE LEVER ASSEMBLY and the HALF CYCLE LEVER.

[24]Disconnect the INDEX LEVER SPRING from the MECHANISM ASSEMBLY.

[25]Push the INDEX LEVER back.

[26]Remove the 2 E-RINGS:

1 on the CYCLE LEVER ASSEMBLY

1 on the HALF CYCLE LEVER

Caution

Keep both the CYCLE LEVER ASSEMBLY and the HALF CYCLE LEVER together and observe the orientation of both LEVERS.

[27]Slide both the CYCLE LEVER and HALF CYCLE LEVER off the SHAFT.

Installing the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY

Caution

Keep both the CYCLE LEVER ASSEMBLY and the HALF CYCLE LEVER together and observe the orientation of both LEVERS.

[1]Do the replacement procedure for the CAM STACK ASSEMBLY and CYCLE LEVER ASSEMBLY in reverse order.

SM4530-1 – 30APR96

17

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