Service Bulletin 161 SUBJECT: Upgrade to current production level

Transcription

1 This bulletin details the changes required to bring the up to current production levels. One of the following procedures must be carried out on all s with date codes up to week that come in for repair, unless the switch box is at the new level, this will indicate that the one of the following procedures has already been carried out or that the parts are already at the latest level. The date code is located on the motor. For all 230 volt units where the date code is less than carry out procedure A. For all 230 volt units with a date code between and carry out procedure B. For all 115 volt units where the date code is less than carry out procedure B. Contents 1. Motor, switch box, switch, lock plate and guard lever differences 2. Parts to be made obsolete and scrapped 3. Parts to be carried over 4. New parts for Procedure A Volt Only 5. New parts for Procedure B Volt, Volt 6. Repair procedure A 7. Repair procedure B 8. Wiring diagrams

2 Motor Electronics different levels of protection can be by removing the end cap 1st level Motor with electronics slightly protected with potting compound 2nd level Motor with electronics protected with potting compound and silicone New level Motor with electronics fully protected with potting compound

3 Switch box differences - seen from inside the frame Old level Switchbox No raised part for the new switch New level Switchbox Raised part for the new switch

4 Switch and Buttons OLD NEW The old switch is seven pieces and has no dust cover The new switch is one piece and has a dust cover

5 Up-lock plate differences OLD NEW Part is now angled

6 Guard lever The difference in the old and new levers is not visually obvious. The way to test the lever is to remove it from the unit and try to bend it in the middle, the faulty one will bend easily.

7 Parts to be made obsolete and scrapped HOUSING SA SWITCH LINKAGE SA GUARD UP-LOCK PLATE MOTOR SA The switch housing, guard linkage, up-lock plate and motor have all been modified and are no longer usable, however the part numbers remain the same so all old stock must be scrapped SPRING Scrap BUTTON RED Scrap BUTTON GREEN Scrap PLUNGER Scrap SWITCH Scrap SWITCH Scrap WIRE HARNESS Scrap v v Modified here to fit new switch

8 Parts to be carried over 115 Volt Mains Cable and Connector Block Cable clamp and screws 230 Volt Mains Cable, Module and Connector Block Switch cover, pin & spring

9 New Parts for procedure A. Kit part number Modified here to fit new switch

10 New Parts for procedure B. Kit part number for 230 Volt Kit part number for 115 Volt Modified here to fit new switch

11 Procedure A All 230 Volt units with a DC less than Ensure unit is not plugged into a power supply. 2. Remove the handle cover protecting the wiring. 3. Take note of how the handle is wired. Disconnect the wires connecting the switch box to the motor wiring and handle switch. 4. Discard the PCB if present as it is no longer required. 5. Remove the cable clamp in the handle. 6. Remove the screws securing the switch box to the frame. 7. Take note of how the switchbox and switch is wired. Disassemble the switch box. Remove the following parts which are to be used in the new switchbox (Cable clamp, screws, red switch cover, pin, spring, Module, Connector Block and the Mains Cable). The switch harness cable is to be replaced. 8. Fit the new switch into the protective boot and connect the wires to the terminals using the correct wiring diagram Rev 4 at the back of this bulletin. Please note: The wiring of the new switch is identical to the old switch. 9. Fit the carry over parts to the new switch box. 10. Reassemble the switch box and fit to the frame. 11. Remove the old motor and fit the new one. Check belt tension before removing as correctly retensioning the drive belt is critical. 12. Reconnect the wires to the motor and handle switch using the correct wiring diagram Rev 4 at the back of this bulletin. 13. Fit new Guard lever and up-lock plate. 14. Carry out all relevant safety and electrical checks before connecting to the power supply. 15. Plug in and check switches, motor and guard action all function correctly. 16. Disconnect from the power supply if any adjustments are required.

12 Procedure B All 230 Volt units with a DC between and All 115 Volt units with a DC less than Ensure unit is not plugged into a power supply. 2. Remove the handle cover protecting the wiring. 3. Take note of how the handle is wired. Disconnect the wires connecting the switch box to the motor wiring and handle switch. 4. Remove the cable clamp in the handle. 6. Remove the screws securing the switch box to the frame. 7. Take note of how the switchbox and switch is wired. Disassemble the switch box. Remove the following parts which are to be used in the new switchbox (Cable clamp, screws, red switch cover, pin, spring, module in the 230v, Connector Block and the Mains Cable). The switch harness cable is to be replaced. 8. Fit the new switch into the protective boot and connect the wires to the terminals using the correct wiring diagram Rev 4 at the back of this bulletin. Please note: The wiring of the new switch is identical to the old switch. 9. Fit the carry over parts to the new switch box. 10. Reassemble the switch box and fit to the frame. 12. Reconnect the wires to the motor and handle switch using the correct wiring diagram Rev 4 at the back of this bulletin. 13. Fit new Guard lever and up-lock plate. 14. Carry out all relevant safety and electrical checks before connecting to the power supply. 15. Plug in and check switches, motor and guard action all function correctly. 16. Disconnect from the power supply if any adjustments are required.

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