Maximailer HD Service Manual

Transcription

1 Table Of Contents 1 Installation Instructions Safety Notes Detachable Items Machine Modules Machine Stands Assembly onto Stand Setting up the Machine PC Equipment Software and Firmware Installation Description of Operation General Description Track Collation Description Description of Insertion Head Insert Head Product Codes Component Identification Maintenance and Service Adjustments Health, safety & environment Conventions used in this manual Preventative maintenance guidance & schedule Information for engineers Removal of covers Drive side cover Operator side cover Internal black covers Front vertical cover Removal of envelope feeder Removal/adjustment of envelope separator Replacement of envelope conveyor belts Removal of collate pocket clam assembly Replacement of collate chains/pawls Removal of finger assembly Adjustment of fingers Removal of side guide adjust assembly Adjustment of side guides Removal of power supply Replacement of sealer rollers Removal of sealer assembly Adjustment of wetter lever Engineering mode Hardware setup Units setup Firmware download Diagnostics Recommended Spares Parts List Exploded Views Chassis Drive Side (Front) Chassis Drive Side (Rear) Chassis Operator Side Chassis Assembly Shaft Locations Envelope Feeder Assy A A Envelope Separator Assy A A Envelope Tractor Assy A A Envelope Feed Shaft Assy A A Envelope Conveyor Assy A A Page i

2 4.11 Envelope Conveyor Backstop Assy A A Collate Clam Assy A A Head Input Conveyor Upper Assy A A Head Input Conveyor Lower Assy A A Motor Assy A A (115V) / A A (230V) Sealer Assembly A A Split Shaft Sub Assys A / 1060 / 1061-A Finger Assembly A A Finger Bkt Op Assy A A Side Guide Adjust Assy A A Pawl Tension Bracket Assy A A Wetter Lever Assy A A Wetter Beam Assembly Wetter Tank Assy A A No Seal Assembly A A Head Ribbon Bkt. Assy Universal Head PSU Mains Input Pluggable Mains Input Hardwired External Float Switch A A Catch Tray Assy A A Inserter Head Covers Monitor Arm Lift Beam Assy A A Electrical & Circuit/Wiring Diagrams Sensors Sensors List Sensors Diagram, Operator Side Sensors Diagram, Drive Side Electrical Components Physical Locations of Components Control PCB Circuit Diagram Processor PCB Circuit Diagram Comms PCB Circuit Diagram Envelope Wetter PCB Circuit Diagram Expansion PCB Circuit Diagram Interlock PCB Circuit Diagram Stepper Motor PCB Circuit Diagram R/Splitter & Disk PCBs Circuit Diagrams Inserter Head Wiring Diagram Inserter Head Splitter PCB s Wiring Diagram Ins. Head PSU & Interlock Wiring Diagram Mains Input (pluggable) Wiring Diagram Mains Input (hardwired) Wiring Diagram Page ii

3 Installation Page 1-1 Section 1 Installation Instructions Sect. Page 1.1 Safety Notes Detachable Items Machine Modules Machine Stands Assembly onto Stand Setting up the Machine PC Equipment Software & Firmware Installation Page 1-1

4 Installation Page SAFETY NOTES Warning! Do not work inside the machine unless you are a trained mechanic or electrician. Stop the machine, and disconnect the power cord before you open the machine. Only a trained electrician should work with the electrical parts! A voltage of 120 Volts may be present inside this machine. The power source can produce enough voltage and current to be very dangerous! Warning! This machine is equipped with a three-pronged plug. One of the prongs on the plug provides a safety grounding feature. Be sure the plug is always connected to a properly wired three-prong outlet. Do not use a two-prong adapter without grounding the machine properly. Never remove the third prong from the plug. The safety grounding feature provides extra protection in the event of an electrical problem. The apparatus must be earthed. As the colors of the wires may not correspond with the colored markings identifying the terminals in your plug, proceed as follows: The wire which is coloured GREEN/YELLOW must be connected to the terminal in the plug which is marked by the letter E or by the safety earth symbol or coloured GREEN/YELLOW. The wire which is coloured BLUE must be connected to the terminal which is marked with the letter N. The wire which is coloured BROWN must be connected to the terminal which is marked with the letter L. Warning! The mains input supply is fused on both live and neutral sides. Service personnel should be aware that a mains voltage can exist even if no lighted neon shows. Warning! Most of the moving parts are protected by covers. Don t operate the machine unless all of the covers are in place. Opening covers include safety interlock switches. If a cover is opened, the switch will stop the machine from running. Don t try to bypass the interlocks, and don t use the machine if the interlocks are not working. Warning! Don t wear any loose clothing when you are working near the machine. If a bit of clothing becomes caught in one of the moving parts, you may be pulled into the machine very quickly. This force can be surprisingly powerful - you may not be able to resist it. Take care with neckties, sashes, long sleeves, or any other loose clothing. Dangling jewelry can also present a hazard. Remove any of these items of looselyfitting clothing, or tie the loose sections out of the way so they can t be caught by the machine. Long hair can also be dangerous when working near this type of machine. If you have long hair, tie it back or tuck it under a hat. Be especially careful around the folding rolls near the center of the machine. Caution! Keep the machine clean. Wipe off the outside of the cabinet from time to time to keep the paper dust from collecting. If you notice that paper dust is collecting inside the machine, open the covers and vacuum it out, or blow it out with an airduster. Caution! Keep the work area around the machine clean. Don t allow paper trim and waste to pile up. If the work area includes a lot of loose paper scraps, an operator may slip and fall. BEFORE DISASSEMBLING: THE MAIN POWER CABLE MUST REMAIN UNPLUGGED UNTIL END OF ASSEMBLY DO NOT TOUCH INSIDE POWER SUPPLY UNIT TO PREVENT ELECTRICAL DISCHARGE DUE TO CHARGED CAPACITOR. ALTHOUGH MANUFACTURER TAKES CARE TO REDUCE RIDGE DANGER, PLEASE HANDLE STEEL SHEETS CAREFULLY TO AVOID ALL RISKS OF CUTTING. IMPORTANT!! IN THE EVENT OF ANY EMERGENCY, OR TO STOP THE MACHINE FOR ANY OTHER REASON, OPEN ANY COVER. Page 1-2

5 Installation Page 1-3 Important! ELECTRICAL INSTALLATION NOTES THESE NOTES MUST BE READ PRIOR TO INSTALLING THIS MACHINE This equipment is supplied with a plugged power lead, or optionally an unterminated, three-core lead for connection to the mains supply. For an unterminated lead, the connection must only be made by a qualified electrician, or by a qualified Service Engineer. 1) This equipment must be earthed. 2) For continued protection against the risk of fire, fuses must only be replaced by those of the same type and rating. 3) Caution: This equipment is internally fused in both Live and Neutral leads. 4) Maximum input current is 10A for 115V and 6.3A for 230V. Maximum leakage current shall not exceed 5% of the input current. 5) Pluggable v Hardwired: By default, the machine is supplied in pluggable form for connection to a standard or domestic supply. The socket outlet shall be installed near the equipment and shall be easily accessible. If the machine is supplied in optional hardwired form, an appropriate disconnect device shall be provided as part of the building installation and be readily accessible. 230 Volt Machines Wire Colours: Live: Brown Neutral: Blue Earth: Green/Yellow 115 Volt Machines Wire Colours: Live: Brown Neutral: Blue Earth: Green/Yellow Caution High leakage current. An earth connection is essential before connecting to the supply. Page 1-3

6 Installation Page 1-5 Issue 2 Feb 2013 Installation Instructions 1.2 Detachable Items The machine is supplied on site with each module packaged separately and with stands supplied in flat-pack form. Check that the following detachable items are all present: Machine Modules Insertion Head Comms Lead, Long ( B) Qty. 1 Power Cable (Euro) ( P) Qty. 1 or Power Cable (UK) ( M) Qty. 1 or Power Cable UL (US) ( W) Qty. 1 Cleaning Kit (EU) A3104A ( R) Qty. 1 Cleaning Kit (US) A3187A ( Y) Qty. 1 Sealing Fluid 10L A0275A ( H) Qty. 1 Monitor Support Arm A A ( C) Qty. 1 PC DS ( M) Qty. 1 Touch Screen ( N) Qty. 1 USB to CAN Compact kit ( Q) Qty. 1 Operator Manual CD K A ( J) Qty. 1 Screw M5 x 10 Torx* E A ( S) Qty. 4 Stands (see 1.2 opposite) * Screws assembled to chassis flanges Machine Stands Stands are supplied as an Inserter Head unit, then further single or double units to accommodate added feeders, where applicable. Part Numbers A A (Part of ordered machine) - Inserter Head Stand A3240A ( B) - Feeder Stand (Double) A3241A ( C) - Feeder Stand (Single) A A ( Z) - Conveyor Stand (Optional) Unpack and assemble the stands using the supplied assembly instructions. For multiple units, connect them together using the supplied fasteners in the 4 corners of the mating faces. See also Fig. 1 on the following page. Output Conveyor (optional) Loom Conveyor 0.75M ( X) Qty. 1 Rollers A A ( P) Qty. 1 Deflector G A ( U) Qty. 1 Lobe Knob Black E A ( K) Qty. 2 Seal Roller Bracket Dr B G Qty. 1 Seal Roller Bracket Op B G Qty. 1 Output Cover (Conveyor) B G Qty. 1 Operator Manual K A Qty. 1 Important: Check that all covers are in place and undamaged. Check that all warning labels are in place and legible. Check that the mains lead and its connectors are sound and undamaged. Page 1-4

7 Installation Page Assembly ONTO STAND (See Fig. 2 overleaf) Apply the brakes to the Maximailer HD stand A A Lift the Maximailer HD head onto the stand, ensuring that the wetter tube passes through the hole in the top of the front section of the stand. Caution: The machine is extremely heavy and will require a number of people to lift it. Do not attempt to lift if you do not feel confident to do so Place the sealing fluid bottle and PC into the stand as shown. Do not connect the PC at this stage. Fig. 1 Add further combinations of A3240A or A3241A as required to suit the number of feed units. Page 1-5

8 Installation Page 1-7 Issue 2 Jan Screw all stands together and fit the supplied attachment bracket R2904T to the end stand. Note: Use holes marked L. This is required for the alignment of the wider Maximailer HD and the Datacard system - see Fig. 3. Maximailer HD Insert Head (supporting stand underneath) Datacard machine (shown connected to attachment bracket) Attachment bracket R2904T Wetter pipes passed through stand into bottle Fig. 3 End module stand Sealing Fluid PC Lift all feed modules (if applicable) and the DTI onto the stands. Assemble them together using the supplied screws - see Fig. 4 overleaf. Ensure the conversion plate is in place on the rear face of the Maximailer HD. Fig. 2 Page 1-6

9 Installation 1.4 Setting up the machine Operator side of Maximailer HD connected to module 1 Drive side of Maximailer HD connected to module Connect the power and comms cables for all modules as follows (see also section 1.5): Datacard machine to DTI serial lead Datacard machine to PC comms lead Cancard from PC to Maximailer HD Power leads between modules and then to Maximailer HD head Power lead from Maximailer HD head to mains supply Power lead to PC Power lead to Datacard machine Check the DIP switches on the head and module PCBs are set as shown in Fig. 5: Module 1 X 2 X DIP Switch ON Position Fig Attach the Datacard machine to the attachment bracket R2940T, as shown in Fig X X 4 X 5 X X 6 X X 7 X X X 8 X Fig. 5 Page 1-7

10 Installation Connect remaining PC leads to monitor and keyboard Switch the PC and the Maximailer HD ON Check the software/firmware version Check network connections between Maximailer HD PC and the Datacard machine Program the Maximailer HD with jobs and test run When all is satisfactory, replace all covers. Operator side of Maximailer HD connected to module 1 Drive side of Maximailer HD connected to module 1 Page 1-8

11 Installation Issue 2 Jan PC EQUIPMENT This section describes the fitting and connection of the PC, touchscreen monitor and keyboard. The PC is located in the cupboard below the inserter head so that the rear face lines up with the aperture on the inner wall, revealed after opening the rear door (see Fig. 2) Connect the cables as shown in Fig. 6 below (PC removed from cupboard for clarity). Run the cables inside the monitor stand, after removing its cover. Keyboard (USB) Mouse (USB) Connect the other side of the CAN card to Port B on the mains input unit as shown in Fig. 7 below. CAN card cable To INF or MPPC (for future development) To conveyor CAN (USB) Monitor (sound) Monitor (USB, touchscreen) Monitor (display) Diagnostic port Monitor Arm Fig. 7 Attach the monitor arm on the drive side by removing the back cover on the arm and slotting the keyhole mounts on the four studs at the desired height, and then tightening the nuts. 4 mounting nuts Fig. 6 Fig. 8 Run the monitor cables through the arm (see Fig. 8) and connect them to the PC as shown in Fig. 5. Replace the cover on the monitor arm. Page 1-9

12 Installation 1.6 SOFTWARE & FIRMWARE INSTALLATION The operating software is factory installed on the PC, but if it needs to be installed again (eg. a defective PC is replaced), it is supplied on disc packed with the PC. To install, proceed as shown below. 1 Switch on the PC and insert the installation disc into the PC drive. 2. In the directory labelled USB-CAN Driver, run the Setup.exe file in the Driver sub-directory. This will install the driver for the Trace Tool. 3. In the directory labelled PFETrace Tool_Vn-n, run the Setup.exe file. This will install Trace Tool which can be used for manual firmware upgrading. 3. In the directory labelled Rev_n.n.n.n, run the Setup.exe file. This will install the core operating software. Important: The core software must later be upgraded with the latest version which can be downloaded from 4. Close down the PC, insert the USB CAN and restart. Plug & Play will find the hardware and offer to search the web for drivers, or use recommended drivers. Select recommended drivers and when installed, follow the procedure below to install Minimon Click Start\All Programs\IXXAT\VCI 2.16\Minimon 32 (see opposite). Click button Page 1-10

13 Select USB to CAN Compact and click OK. Installation Select Config\Baudrate\List Set Baud rate to 500kBd 001C and click OK. Note USB to CAN Compact is now selected Minimon32 is now ready to use. Click OK and Minimon32 is now ready to run. Baud rate must now be set. Page 1-11

14 Description of Operation Page 2-1 Section 2 Description of Operation Sect. Page 2.1 General Description Track Collation Description Description of Insert Head Insert Head Product Codes Component Identification Page 2-1

15 Description of Operation Page 2-2 SECTION 2 DESCRIPTION OF OPERATION 2.1 General Description The machine is a high-volume folder/inserter capable of up to 200,000 cycles per month at a speed of up to 4800 filled envelopes per hour (DL/ No. 10 with 1 insert). It is of modular construction and consists of an insert head and either or both of: a Versatile Feeder and a Flex Folder This may be fitted with either 1 or 2 feed pods, each one having either a 1000-sheet tray or two 500-sheet trays. An optional accumulator for collating/diverting is available, this being fitted with a diverter tray. It is always fitted in the end station position. The insert head also includes a collator, as well as the envelope hopper, wetter and closer. Collation can be carried out a number of ways, depending upon the particular job. The software works out the optimum feed pattern, as well as the best feed units to use if more than one possibility exists. Collation possibilities are: 1. Using the accumulator in a Flex Folder - up to 24 forms (nonreading) or 25 forms (reading) are fed into the accumulator, folded and ejected on towards the insert head. (Note that the maximum that can be folded together is 8, with default of 5. Groups larger than max. folded setting will be split or diverted). 2. Collation on the track - a folded sheet or insert is timed to trailing-edge collate with the document fed from the following feed unit as the first document passes underneath. 3. At the insert head - all documents will arrive in the collation pocket, either individually or as a pack already collated by the above methods. The topmost item is the prime (address) document. The pack is then inserted in the envelope. 2.2 Track collation description Jobs with more than one feed unit will in most cases collate together as described in paragraph 2 above, and will arrive in the collation pocket as a pack, with the exception of the prime document, which will be fed on top of the pack as a separate item. The exception to this is if the prime station is No. 1, in which case the document would be finally collated on top of the pack from preceding feed units, then finally delivered to the collate pocket. Documents are trailing-edge located due to the pack being inserted by pushing it into the envelope with chain-driven pawls. Timing is controlled by the track control sensor located behind each hopper. The sequencing between the stages of machine operation is shown in the diagrams below, which begin part way through a complete cycle the preceding sequence of operations from the start of the cycle will have been similar, but with fewer documents having been gathered. Stage 1: Form 1 is fed from feeder 1 down onto the conveyor track. This form is trail edge collated with the upstream documents arriving from feeders 2 and 3. The feed timings for the collate operation are triggered when the trailing edge of the documents from feeders 2 and 3 pass through the track control sensor. Stage 2: The three collated documents (for pack 1) from feeders 1, 2 and 3 are driven into the collation pocket by the retard rollers. This roller set ensures that the final presentation of the collated pack is suitable for envelope insertion by slowing down whilst feeding. Form 1a is fed from insert feeder 2 down onto the conveyor track. This form is trail edge collated with the upstream document arriving from feeder 3. The feed timings for the collate operation are triggered when the trailing edge of the document from feeder 3 passes through the track control sensor. Form 1b is held stationary at the exit hold point of insert feeders 3 and 4. Page 2-2

16 Description of Operation Page 2-3 Fig. 3 Stage 3: Form 1 (prime/address carrying document for this pack) is driven into the collation pocket by the retard rollers. Form 1b (prime/address carrying document for a following pack) is fed from feeder 4 down onto the conveyor track. The feed operation between all stages is governed by software timings to set a controlled gap (pitch length) between the prime documents on the track. Form 1a held is stationary at the exit hold point sensor of insert feeder 1. After the prime document has been fed into the collation pocket on top of the 3 documents already collated, the pack is inserted into the envelope, described in more detail below. 2.3 Description of Insert Head (see Fig. 4 opposite, and section 2.3.2) The insert head includes the envelope hopper, collation pocket, insert fingers, wetter and closer. The insert pack arrives into the input conveyor, as monitored by the input conveyor sensor. When its trailing edge passes this sensor, the drive rollers ahead reduce speed as necessary to allow the collate pocket to clear. The pack is then driven into the collate pocket where it contacts a solenoid-actuated backstop to prevent overrun (there are 3 backstops, the one used being determined by the pack length). Its arrival is monitored by the collate pocket load sensor; the collate pocket sensor confirms it is in place in the pocket. Whilst the pack is feeding, an envelope will have been fed to the envelope feed sensor which acts a hold point if necessary, and then into the stationary deskew rollers which straightens any skew; the deskew rollers are controlled by the deskew sensor. The envelope tractor facilitates feeding of envelopes and operates on a pivot. When pushed forward by the envelope stack, the envelope conveyor sensor switches off the feed conveyor; as envelopes are fed and the tractor relaxes, the sensor is cleared and the conveyor starts again. The amount of delay before feeding restarts can be controlled in software. The envelope is then driven past the tilting flap opener and into place ready Page 2-3

17 Description of Operation Page 2-4 for insertion. Here it is held with the flap crease at the datum point shown in Fig. 4, timed from the trailing edge passing the deskew sensor and arriving at the envelope flap sensor. The solenoid-actuated insert fingers hold the envelope throat open. With the envelope then in place ready for the arriving pack, the backstop drops and the pack is driven into the envelope. Note that it is possible in the software to adjust whether the outer pair of fingers move forward first, or the inner pair. This can assist certain envelopes, depending on design. As the chain pawls are pushing the pack in, the pawls below the track are detected by the pawl position sensor which times precisely how long it take to push in the pack. At that point, the envelope is released. Just prior to release, the chain track pauses momentarily so that the tips of the pawls do not catch on the edge of the departing envelope. While insertion is taking place, the next envelope is fed into place and held at the deskew rollers ready for the next insertion. Timed from the leading edge of the envelope passing the wetter output detect sensor, the wetter beam is pulled down by solenoid action so that the flap is wetted by the wetter felt below. As the trailing edge passes this sensor, the beam will retract. The envelope is driven forward into the seal rollers. Due to the angle of the roller axis, the flap edge of the envelope is lifted up, forcing the flap downwards against the roller, at which point the rollers reverse to drive the envelope into the upper seal rollers, sealing the envelope flap - the reverse point is timed from the closer output sensor. The envelope leading edge reaches the closer seal sensor and the envelope reverses again to drive it out of the eject, monitored by the closer output sensor. This completes the cycle. See fig. 5 above. The insert finger widths and collate pocket side guides are automatically adjusted to suit the appropriate paper widths, as determined by the sizes set in the operating software. For the fingers, the finger datum (flag) sensor determines when the fingers are at their narrowest position. The finger disc sensor then clocks their movement to set them to the correct position. The finger out (flag) sensor is blocked when the fingers are in the relaxed position (out of the envelope). For the collate pocket, the guide datum (flag) sensor determines when the guides are at their widest position. The guide disc sensor then clocks their movement to set them to the correct position. See also section for Clutch/Brake, Motor and Solenoid identities Insert Head Product Codes Insert Head 230V: E2430ZZ Insert Head 115V: A2430ZZ ( B) ( T) Page 2-4

18 2.3.2 Components identification Shown below for reference are the locations of the clutches/brakes, motors and solenoids. Page 2-5 Issue 2 Jul 2012 Component side See following page for drive side Page 2-5

19 2.3.2 Components identification (cont.) Shown below for reference are the locations of the clutches/brakes, motors and solenoids. Page 2-6 Issue 2 Jul 2012 Drive side See previous page for component side Page 2-6

20 Section 3 Maintenance and Service Adjustments Maintenance and Servicing Sect. Page Sect. Page 3.1 Health, safety & environment Conventions used in this manual Preventative maintenance guidance & schedule Information for engineers Removal of covers Drive side cover Operator side cover Internal black covers Front vertical cover Removal of envelope feeder Removal/adjustment of envelope separator Adjustment of side guides Removal of power supply Replacement of sealer rollers Removal of sealer assembly Adjustment of wetter lever Engineering mode Hardware setup Units setup Firmware download Diagnostics Recommended Spares Parts List Replacement of envelope conveyor belts Removal of collate pocket clam assembly Replacement of collate chains/pawls Removal of finger assembly Adjustment of fingers Removal of side guide adjust assembly Page 3-1

21 Maintenance and Servicing 3.1 Health, safety and environment Safety instructions General This machine must be operated by competent personnel. The manufacturer accepts no responsibility for accidents or injuries caused by operation by incompetent personnel. Covers may only be opened by skilled persons, who know the risks involved. For safety reasons, the machine will not function with opened covers. Keep away long hair, fingers, jewelry, etc. from rotating and moving objects of the system. Switch off the system at the end of the day. Electrical safety Disconnect the mains power supply before performing any maintenance to any kind of mains power supply/high voltage related items. The power connection must be easily accessible, preferably close to the machine. For safety reasons it is essential that the machine is connected to a socket outlet with protective earth connection. Over-current protection in the equipment also relies on the branch circuit protection. Disconnect the machine from the power supply when it is not in use for a longer time. Potential hazard may exist to electronic hardware in conditions with static electricity. It is advised that, when handling electronic parts, an earth connected wrist band is used in order to be permanently discharged from static electricity End of life The objectives of the European Community s environment policy are, in particular, to preserve, protect and improve the quality of the environment, protect human health and utilise natural resources prudently and rationally. That policy is based on the precautionary principle and principles that preventive action should be taken, that environmental damage should as a priority be rectified at source. Separate collection of waste is the precondition to ensure reuse and recycling of waste that is generated at the disposal of electrical or electronical equipment and is necessary to achieve the chosen level of protection of human health and the environment in the European Community. More particularly, certain materials and components of waste electrical and electronical equipment needs selective treatment as their injudicious handling or disposing of on or into land, water or air would represent a major threat to the environment and human health. cont. Page 3-2

22 Maintenance and Servicing In order to facilitate collection and treatment separated from normal domestic waste, electrical and electronical equipment is marked with the following logo: 3.2 Conventions used in this manual Symbols Do not mix with normal domestic waste. Please use the subjoined return or collection system dedicated to electrical and electronical waste. Disconn being wi Draws to your attention a particular difficulty associated with this operation, or indicates a potential hazard with it. Equipment produced after August 13, 2005 Remem complet Indicates a piece of advice, tip or quick technique to assist in carrying out this operation. Not only are you by law not allowed to dispose of the waste equipment via other waste-streams, but we encourage you to actively contribute to the success of such collection and to the common good and better quality of life of present and future generations. For more information on the correct disposal of this product please contact your local dealer Orientation Throughout this manual, reference will be made to Operator and Drive side to indicate the side of the machine in question. These are defined as: Operator Side: Drive Side: The side of the machine where the operator normally stands, viewing the screen. The side covers can be opened by the operator. The opposite side to the Operator side. The side covers cannot be opened by the operator and are only able to be removed by the Engineer. Gear/ drive trains are located on this side. Page 3-3

23 Maintenance and Servicing 3.3 Preventative Maintenance Guidance and Schedule The Maintenance schedule on the following pages is applicable to the 200 series product range and must be strictly followed to guarantee machine performance and reliability. This schedule is based on a monthly cycle count of 200k / month which is considered the normal maximum. If the machine is running less than this, the PM visits should still be carried out with the same frequency, but fewer parts will be required. DS200 Duty Cycle 200k / Month = 2.4 million / year = PM every 500k. Minor at 500K and Major at 1000k. Click here to view the full PM Schedule. Service visit Number of cycles 1 500,000 x 2 1,000,000 x x 3 1,500,000 x Duty interval 500k 1mil 2mil 4mil 6mil 4 2,000,000 x x x 5 2,500,000 x 6 3,000,000 x x 7 3,500,000 x 8 4,000,000 x x x x 9 4,500,000 x 10 5,000,000 x x 11 5,500,000 x 12 6,000,000 x x x x Service visit Number of cycles 13 6,500,000 x 14 7,000,000 x x 15 7,500,000 x Duty interval 500k 1mil 2mil 4mil 6mil 16 8,000,000 x x x 17 8,500,000 x 18 9,000,000 x x 19 9,500,000 x 20 10,000,000 x x x x 21 10,500,000 x 22 11,000,000 x x 23 11,500,000 x 24 12,000,000 x x x x Page 3-4

24 Part No. or Assembly Location NISL No. Part No Required for ordering DS-200 Head 500k service visit Description Page Reference (Manual) C A Y none T BEARING HOUSING Clean and Oil Item Maintenance Required C A D none LOWER SEAL ROLLER 48 DIA Clean and remove any contamination C A U none LOWER SEAL ROLLER 25 DIA Clean and remove any contamination A A X none WET O/P SHAFT UPPER ASSY Clean and remove any contamination A A Z none WET O/P SHAFT LOWER ASSY Clean and remove any contamination F6023A S none CHAIN 1/4 PITCH 83 LINKS x2 clean pawl chain and inspect pawls for damage. Check chain links are in tact. Turn the pawl track by hand completely one cycle and check for any tight spots. A A U none C4 ENV TRACTOR ASSY x2 Clean C8194Ax2 check slots are still visible A A G none ENV FEED I/P SHAFT ASSY 4-19 SA2 Clean using water A A H none ENV OPENER I/P SHAFT ASSY 4-19 SA3 Clean A A J none ENV OPENER O/P SHAFT ASSY 4-19 SA4 Clean A A K none ENV FEED O/P SHAFT ASSY 4-19 SA5 Clean C8194A J none SLOTTED FEED WHEEL x2 Clean with water C A T none ENV FEED ROLLER x8 clean thoroughly with water A A C none INPUT SHAFT ASSY CLAM clean rollers with water A A A A none OPENER I/P SHAFT ASSY CL clean with water A A E none OPENER O/P SHAFT ASSY CL clean with water A A J none FELT ON FELT BRIDGE remove tank and clean and felt with water and refit

25 B A n/a none OUTPUT GUIDE remove bridge and clean (remove all paper duct/sealing fluid contamination from bridge and surrounding areas). Make sure sensor is DRY. misc - none All Gears on Drive and Operator side misc - none all sensors, clutches, brakes and solenoids various various Check all gears and lightly apply silicon grease - wipe any access. Turn the geartrain by hand and ensure all gear security. various various Check all sensors and functional - block /clear using paper. Then clean use air duster. Recalibrate if required. Then go into engineer screen and check all clutches, brakes and solenoids are functional. misc - none all sensors various various Check all settings, calibrations are correct. Check ALL jobs are set-up correctly and finally Run Min 1000 envelopes. Part No. or Assembly Location NISL No. Part No Required for ordering DS-200 Head 1000k service visit Description Page Reference (Manual) Item Maintenance Required B7708A E none SENSOR DISC Clean sensor disk with dry cloth - make sure all slots are clear J none COLL. POCKET BACKSTOP SHORT SOL J none COLL. POCKET BACKSTOP SHORT SOL J none COLL. POCKET BACKSTOP EXT. LNG. SOL Clean solenoid plunger with dry cloth and use air duster to blow away any debris in solenoid body a Clean solenoid plunger with dry cloth and use air duster to blow away any debris in solenoid body Clean solenoid plunger with dry cloth and use air duster to blow away any debris in solenoid body. G A P none COLLATE PANEL SPRING check springs are located within item 24 and the panel springs evenly. B A R none NARROW INSERT GUIDE check springs are intact and still spring evenly. These are designed to hold the insert flat in the collate pocket F6023A S none CHAIN 1/4 PITCH 83 LINKS x2 clean remove paper dust and apply light oil then dry. Rotate chain and check for tight spots. B A Y none SPRING PLATE 0.25mm check spring for damage and pressure E A A none BEARING NEEDLE 4 IDx8x x4 clean and check bearings rotate freely, apply light oil and DRY E A B none WASHER 4.06x7.24x x2 clean and check for wear C8135A A none SEPARATOR ROLLER x2 clean using water and check for even roller wear A A R none Envelope Tractor Assy 4-22 Check assembly pivots

26 F A R none 16T TRACTOR DRIVE GEAR Clean and grease gear. Check / Tighten grub screw that secures the gear onto the motor shaft A A M none ENV CONVEYOR BACKSTOP Ensure full travel of backstop from Max/Min. D A H none RUBBER WHEEL 40D 40 SHORE x2 clean with water C A n/a none T BEARING HOUSING Clean, apply light oil onto circlip groove where the bearing fits. F5119A A none BELT 140XL 037 POLYURETHANE Clean every 1 million C V n/a none LATCH HANDLE Check & Tighten screw handles if required D1040A J none T BEARING 8mm 12 SQ Clean, apply light oil onto circlip groove where the bearing fits. F5120A C none BELT 130XL 037 POLYURETHENE Clean every 1 million F1373A S none PULLEY 15T S2M MOTOR Clean and lubricate. Make sure pulley is retained securely onto shaft Tighten grub screws C A Y none T BEARING HOUSING x4 Clean, apply light oil onto circlip groove where the bearing fits. F4182A J none GEAR 35Tx8mm 1.0M x2 clean and oil gear H none SOLENOID W/D (MIDDLE) Clean solenoid plunger with dry cloth and use air duster to blow away any debris in solenoid body H none SOLENOID W/D (DR) a Clean solenoid plunger with dry cloth and use air duster to blow away any debris in solenoid body. D1040A J none T BEARING 8mm 12 SQ Clean & oil D1076A S none T BEARING 6mm 10 SQ Clean & oil C A n/a none FINGER BUSH clean C A n/a none FINGER NUT OPERATOR clean C A n/a none FINGER NUT DRIVES clean H none SOLENOID W/D XH Clean solenoid plunger with dry cloth and use air duster to blow away any debris in solenoid body.

27 H none SOLENOID W/D XH SDT2652L Clean solenoid plunger with dry cloth and use air duster to blow away any debris in solenoid body H none SOLENOID W/D XH Clean solenoid plunger with dry cloth and use air duster to blow away any debris in solenoid body. G A R G A* GUIDE TAPE LOWER x2 Replace A A T D0051A RESTRICTOR ARM ASSY 4-19 SA6 Item 66 D0051A SEPARATOR PAD to be secured using VHB TAPE E0448A 3M AS REQUIRED. A A U C8194A* C4 ENV TRACTOR ASSY x2 Item 11 C8194Ax2 to be replaced C8194A J C8194A* SLOTTED FEED WHEEL x2 Replace C A T none ENV FEED ROLLER x8 Clean with water C A C none UPPER SEAL ROLLER 48 DIA x2 clean with water A A J A A FELT ON FELT BRIDGE Replace Part No. or Assembly Location NISL No. Part No Required for ordering DS-200 Head 2000k service visit Description Page Reference (Manual) C A T C A* ENV FEED ROLLER x8 Replace Item Maintenance Required A A K none LENZE CLUTCH ASSY 4-4 SA1 Remove and clean item 4b with DRY cloth and use an air duster to blow away any debris. The air gap of 0.15mm should be set. Ensure the retaining collar is fitted correctly with the grub screw hole located furthest away from solenoid body. A A M none LENZE CLUTCH ASSY 30T 4-4 SA3 Remove and clean item 4a with DRY cloth and use an air duster to blow away any debris. The air gap of 0.15mm should be set. Ensure the retaining collar is fitted correctly with the grub screw hole located furthest away from solenoid body. A A K none LENZE CLUTCH ASSY 4-7 SA1 Remove and clean item 3 with DRY cloth and use an air duster to blow away any debris. The air gap of 0.15mm should be set. Ensure the retaining collar is fitted correctly with the grub screw hole located furthest away from solenoid body. A A M none LENZE CLUTCH ASSY 30T 4-10 SA1 Remove and clean item 3 with DRY cloth and use an air duster to blow away any debris. The air gap of 0.15mm should be set. Ensure the retaining collar is fitted correctly with the grub screw hole located furthest away from solenoid body.

28 A A L none INSERT PAWL TRACK BRAKE ASSY 4-10 SA2 Remove and clean item 4 with DRY cloth and use an air duster to blow away any debris. The air gap of 0.15mm should be set. Ensure the retaining collar is fitted correctly with the grub screw hole located furthest away from solenoid body. F C W none DRIVE SPROCKET 15T x2 Clean and ensure sprockets rotate freely on shaft F C B none IDLE SPROCKET 15T x2 Clean and ensure sprockets rotate freely on shaft A A n/a none Pawl Tension Bracket Assembly Clean and ensure sprockets rotate freely on shaft. Clean T- bearings and apply light oil A A n/a none SIDE GUIDE OPERATOR and 7 Check squareness of sideguides. Ensure adjustment of side from Max to Min. B A n/a none BELT TENSIONER BRACKET Item 26 T-bearing clean & oil G A n/a none BELT CONVEYOR(EAT-8P) 1165x Clean belts dry cloth F5007A L none BELT 200XL clean belts / pulleys - do not remove from machine F4150A X none GEAR 40Tx8mm 1.0M Grease gear and corresponding gears with silicon grease C A Y none T BEARING HOUSING Clean, apply light oil onto circlip groove where the bearing fits. C I n/a none Collate Pocket Handle Check & Tighten screw handles if required A A N none Pawl Tension bracket Assy 4-54 Remove & clean complete assy. Ensure sprockets are free turning and Clean, apply light oil onto circlip groove where the G6200A D G6200A GUIDE SHIM bearing fits Replace G A Z G A* SEPARATOR SHIELD Replace F5112A W none BELT 100-S2M-280 Inspect for wear - only replace if causing problems E A B none WASHER 4.06x7.24x x2 Replace C A C none UPPER SEAL ROLLER 48 DIA x2 Inspect for wear - only replace if causing problems C A U none LOWER SEAL ROLLER 25 DIA Inspect for wear - only replace if causing problems C A D none LOWER SEAL ROLLER 48 DIA Inspect for wear - only replace if causing problems

29 C A none none CONV. P. WHEEL SHAFT ASSY Inspect for wear - only replace if causing problems B A U none FINGER MIDDLE OP C Inspect for wear - only replace if causing problems B A T none FINGER MIDDLE DRIVES C Inspect for wear - only replace if causing problems B Z S none FINGER OUTER OPERATOR C Inspect for wear - only replace if causing problems B Z R none FINGER OUTER DRIVES C Inspect for wear - only replace if causing problems B A Y none SPRING PLATE 0.25mm Inspect for wear - only replace if causing problems A A P none SPLIT SHAFT OPERATOR 4-45 Inspect for wear - only replace if causing problems A A none SPLIT SHAFT DRIVES 4-45 Inspect for wear - only replace if causing problems N A A M none SPLIT SHAFT CENTRE 4-45 Inspect for wear - only replace if causing problems Part No. or Assembly Location NISL No. Part No Required for ordering DS-200 Head 4000k service visit Description Page Reference (Manual) Item Maintenance Required B A U none OPENER (ASSEMBLY) C clean and check for scratches. Adjust if necessary G0167A Z none EC30 CLUTCH PIN x4 Replace where EC30 clutch is used A A H none 32T GEAR/ROLLER CLUTCH ASSY 4-22 SA1 Clean and grease gear. Check the roller clutch bearing is secured onto the gear. F5120A C F5120A* BELT 130XL 037 POLYURETHENE replace after every 4 million F5119A A F5119A* BELT 140XL 037 POLYURETHANE replace after every 4 million D A H D A* RUBBER WHEEL 40D 40 SHORE x2 Replace A A E A A* OPENER O/P SHAFT ASSY CL Replace A A K A A* ENV FEED O/P SHAFT ASSY 4-19 SA5 Replace

30 A A J A A* ENV OPENER O/P SHAFT ASSY 4-19 SA4 Replace A A H A A* ENV OPENER I/P SHAFT ASSY 4-19 SA3 Replace A A G A A* ENV FEED I/P SHAFT ASSY 4-19 SA2 Replace A A Z A A* WET O/P SHAFT LOWER ASSY Replace A A X A A* WET O/P SHAFT UPPER ASSY Replace C8135A A C8135A SEPARATOR ROLLER x2 Replace C A need nisl none CONV. P. WHEEL SHAFT ASSY Inspect for wear and only replace if required E A A none BEARING NEEDLE 4 IDx8x x4 Inspect and only replace if causing problems Y none WETTER OUTPUT DRIVE CLUTCH remove and clean. Replace if causing Problems Y none COLLATE ENTRY FAST CLUTCH remove and clean. Replace if causing Problems X none ENV. LOWER DRIVE CLUTCH remove and clean. Replace if causing Problems X none COLLATE ENTRY BRAKE remove and clean. Replace if causing Problems X none INPUT CONVEYOR CLUTCH remove and clean. Replace if causing Problems X none ENV. UPPER DRIVE BRAKE remove and clean. Replace if causing Problems X none ENV. UPPER DRIVE BRAKE remove and clean. Replace if causing Problems Y none ENV. PICK UP CLUTCH remove and clean. Replace if causing Problems Part No. or Assembly Location NISL No. Part No Required for ordering DS-200 Head 6000k service visit Description Page Reference (Manual) Item Maintenance Required F6023A S F6023A CHAIN 1/4 PITCH 83 LINKS x2 Replace Chain & link - make sure the link is fitted in the correct direction as per manual

31 F A G F A PAWL CHAIN LINK x2 Replace C A F C A CHAIN ROLLER x2 Replace

32 Maintenance and Servicing 3.4 Information for Engineers Service Procedures and adjustments The procedures described on the following pages are the recommended methods to be employed when removing or replacing various items. Note that not all individual spare parts may be available for replacement; in some cases, only the assemblies containing those parts can be obtained. For further clarification, see section Tools required No special tools are required for service operation on the machine, though a variety of standard engineer s tools will be needed, including: Torx drivers & wrenches #10, #15, #20 & #25 Pozidrive screwdrivers #1 & #2 Set of metric Allen Keys Pointed (snipe) nosed pliers Right-angled bit drivers Side-cutters Nut drivers 5.5, 7 & 8mm JST connector removal tool B0158N ( U) E clip tool Facom Truarc 1813 In addition, a stock of cable-ties 100 x 2.6mm L Potential Hazards Take extreme care if running the machine with the covers open. To run with the covers open, a magnet will be needed to override the safety interlocks. A spare magnet such as fitted to the opening cover ( ) is most suitable. The machine is double-pole fused. This means that power may still be present even after switching off at the mains. Always disconnect the machine from the mains source before removing covers. Don t just switch off. Ensure the black inner covers on the operator side are in place when work is finished. These covers protect the operator from hazardous areas when the cover is opened. When removing items such as the envelope feeder assembly, note that some items are very heavy and lifting should not be undertaken unless you feel confident to do so. Seek assistance otherwise Electrical Connectors and Sensors Sensors are supplied as a cable assembly, with the sensor at one end and its two connectors at the other. All sensors (with the exception of flag or disc sensors) consist of a pair, Emitter and Receiver. The receiver is usually mounted below the emitter, though this can vary. All connectors are marked with the number of the appropriate PCB connector to which it joins Page 3-5

33 Maintenance and Servicing 3.5 Removal of Covers Some or all of the covers on the machine will need to be removed for service operations. In some cases where fixing screws are plainly visible, removal is self-explanatory. In less obvious cases, removal is described below. When service operations are complete, covers must be replaced fully failure to do so could result in a hazard to the operator Drive side cover Before removal of the drive side cover, the monitor arm must be removed first. 1 Remove the back cover on the monitor arm 2 Slacken the 4 nuts and lift the monitor arm off the machine. Place on the floor, taking care not to strain the cables. The nuts do not need to be removed fully. Note the original positions of the nuts so that the arm can be replaced at the same height Operator side cover 4 Lower the operator side cover and pivot the sealer assembly forward. Remove the screw indicated on the inside of the chassis. Note: the side cover may become loose at this point. 5 Drop the side cover down slightly to free the hooks on the lower edge and lift the cover off the machine. The operator side cover is in two parts: the front, opening part for operator access, and the rear, fixed part. 1 To remove the fixed cover, lower the front, opening part and remove the screw indicated. 3 Open the perspex top cover and remove the 2 screws indicated on the inside of the chassis drive side. 2 Open the perspex top cover and remove the 2 screws indicated on the inside of the chassis.. Note: the side cover may become loose at this point. 3 Drop the side cover down slightly to free the hooks on the lower edge and lift the cover off the machine. Page 3-6

34 Maintenance and Servicing 4 To remove the opening cover, lower the cover and remove the screw and pivot indicated. 5 Remove the nut and washers indicated to free the cover stay. Slide the cover off the pivot at the other end and lift it clear. Operator Side 3 Remove the 2 screws indicated, on both sides of the machine. Lift the cover away. Note: it may be convenient to remove the sealer assembly first (see section 3.17) Internal black covers These are fitted behind the opening operator cover to protect the operator from moving parts, and are visible in the picture above. Replacement is a reversal of removal. Ensure that the hooks on the lower edges are properly located. If these are misplaced, the cover may appear to be in place, but the lower part may still be loose. After removal, they must be replaced, including the screw shown in which also secures the fixed side cover Front vertical cover This is located above the sealer assembly. 1 Remove the internal black covers on the operator side, as described in and then take out the 2 screws securing the lower skirt. Lift the skirt away. 2 Remove the drive side cover, as described in Drive Side Page 3-7

35 Maintenance and Servicing 3.6 Removal of Envelope Feeder Remove the feeder 1 The envelope conveyor must be removed before the feeder assembly F is lifted out of the chassis. Drive side Fig. 1 C C C 2 Remove the screws marked C on both the drive and operator side (Figs 1 & 2) 3 Unclip the ribbon cable and lift it out of the way. 4 Disconnect the conveyor motor from the splitter PCB. 7 Remove the screws marked F on both the drive and operator sides (Figs 1 & 2). 8 Lift the feeder assembly out of the chassis. When placing the feeder assembly onto a surface, ensure the overguide underneath is not damaged. 9 Reassembly of the feeder and conveyor is a reverse of removal. Remember to reconnect the sensor cable at the inner edge of the conveyor. F F 10 For replacement of conveyor belts, see 3.8 Operator side Fig. 2 C C F F 5 Disconnect the ribbon cables from the PCB. 6 Open the sealer cover under the conveyor and lift the conveyor away from the feeder assembly. Tips for resolving feeding problems 1. Check separator gap and alignment. 2. Clean and calibrate all associated sensors. 3. Check all feed clutches/brakes. 4. Check, change feed wheel tyres. 5. Check separator shields for damage/misalignment. 6. Check separator rotation motors for correct operation. 7. Take trace and send to IPSS. Disconnect the sensor cable on the inner edge of the conveyor as it is being withdrawn. Page 3-8

36 Maintenance and Servicing 3.7 Removal/Adjustments of Separator The separator gap is operator adjustable by reaching in below the envelope feeder and turning the green knob. Turning the knob clockwise opens the gap (an indicator is pierced into the chassis adjacent to the knob). Removal of the separator assembly allows replacement of the separator rollers and also adjustment, if needed, of the shield. To remove, proceed as follows: 1 Remove the envelope conveyor assembly as described in 3.6. Fig. 3 2 Turn the green knob fully clockwise to back off the rollers and remove the 3 screws indicated in Fig Disconnect the motor cable at the connector on the chassis bridge, push the assembly forward to unhook the two lugs and lift it out of the chassis. Fig. 4 Set screw (one each side) 5 To replace the rollers, simply slacken the set screws and slide the rollers off the shaft. 6 To replace the motor, the assembly will have to be stripped to reach the screws. 7 To adjust the shield, slacken the screws indicated in Fig. 4 and move the shield as required. The shield is factory set in its lowest (fully forward) position and should not normally need adjustment. Certain problem envelopes that will not separate properly may benefit from moving the shield back. This is a trial and error method, but try setting it fully back to start. 8 Refitting the separator assembly is a reversal of removal. Remember to reset the separator gap, and check the roller alignment as described below. 4 With the assembly removed from the chassis, the rollers or motor can be replaced, or the roller shield can be adjusted (see opposite). Page 3-9

37 Maintenance and Servicing 3.8 Replacement of Envelope Conveyor Belts The envelope conveyor belts should not normally require replacement as they have a very long life, but if replacement is required due to damage etc, proceed as follows: 1 Remove the envelope conveyor assembly as described in Remove the end cover together with the backstop (2 screws underneath). Fig. 5 3 Turn the conveyor upside down and remove the springs on the rollers at the far end of the conveyor. 4 Now remove the roller carrier (see Fig. 5). This will allow the belt to be looped off over the side of the conveyor. 5 Fit the new belt in a reverse manner and replace the roller carrier and springs. 6 Repeat for the other belt. 7 Refit the end cover and reassemble the conveyor back on the machine. Remember to reconnect the motor cable onto the connector mounted on the chassis bridge. Belts may also be coloured black, not green as shown. Page 3-10

38 Maintenance and Servicing 3.9 Removal of Collate Pocket Clam Assembly The collate pocket clam assembly pivots on a spigot post each side. Removal entails taking out the spigot on the operator side only. Removing the assembly is quick to carry out, and allows much improved acces to the collate area. 1 On the drive side, trace the sensor cables for the assembly back to the chassis hole, detach them from the clips and disconnect them from the PCB. Fig. 6 2 On the operator side, remove the clutch/gear, idler and gear indicated in Fig. 6. Slacken the clutch locators to allow this. Note that the drive pin will come loose. Fig. 7 3 Remove the spigot indicated in Fig. 7 whilst holding the collate pocket clam assembly. Open the assembly and free it from the other spigot, then lift it out of the chassis, leading the chassis cable out as it is removed. 4 Reassembly is a reverse of removal. Page 3-11

39 Maintenance and Servicing 3.10 Replacement of collate chains or chain pawls Try not to let the chain slip on the sprockets as it is drawn round them, or the pawls will be misaligned. If this happens, see step 6. Before removing the collate chains, the Envelope Feeder (see 3.6) and Collate Pocket Clam (see 3.9) must be removed to allow access. The collate chains need checking as Preventative Maintenance only every 2 million envelopes and will not normally need replacing. However, if they break or otherwise become damaged, proceed as follows. The chains can be replaced complete with pawls, or one or more pawls only, retaining the chains. The chains must always be replaced as a pair. 1 Remove the insert panels this will allow the chains to flex sideways. Fig. 9 5 Use a screwdriver or similar tool to compress the spring tensioner. Fig. 8 2 At the pawl link, remove the spring clip on the outer side and pull out the rollers to separate the chain (see Fig. 8). Caution: jam the chain at the input end to prevent it sliding inside the chassis, or use a cable tie to join the 2 ends. 3 Use the link to connect one end of the new chain with Insert panel shown removed one end of the existing one. Maintaining chain tension, draw it round the pulleys until the other end appears on the chassis surface. F F 4 Jam the chain to hold it and separate the link to remove the old chain, using a cable tie to hold the ends together. Join the 2 ends of the new one. If necessary, the chain tension can be relieved by using a screwdriver (or other suitable tool) to compress the tensioner at the input end (see Fig. 9). Fig. 10 Pawl misalignment 6 If the chain pawls become misaligned, they can be brought back into line by the following procedure. 7 Slacken the screw indicated in Fig. 10 and remove the tension shaft. 8 Hold the forwardmost pawl, and using pointed nose pliers drag the other chain over the required number of sprocket teeth at the output end. When the pawls are aligned, replace the tension shaft. 9 Turn the chain by hand to check for free running. I all is well, replace the insert panels and run the machine to check that the chains operate correctly. Page 3-12

40 Maintenance and Servicing 3.11 Removal of Finger Assy Before removing the finger assembly, the envelope feeder assembly must be removed first - see section The finger assembly is withdrawn from the drive side of the chassis after disconnecting the pivot shaft on the operator side. Operator side Fig On the operator side, remove the E clip on the end of the pivot shaft. Remove the solenoid from the chassis by taking out the indicated screws. Remove the finger assy. 5 Withdraw the finger assembly from the chassis, folding the fingers clear of obstructions. Do not apply undue force when removing the assembly or the fingers may be damaged. 6 Reassembly is a reverse of removal. With the envelope feeder removed, the fingers should also be adjusted see the following section. Note: to adjust the inners fingers, the finger assembly must also be removed from the chassis. Solenoids and solenoid springs can be obtained as separate items, but the rest of the assembly can be obtained only as a complete spare. Drive side Backstop screw 3 On the drive side, remove the screws indicated. Fig Disconnect the ribbon cable from the PCB and unclip it from the finger chassis. Page 3-13

41 Maintenance and Servicing 3.12 Adjustment of fingers Only the outer fingers are adjusted with the finger assembly in-situ: it must be removed for the inner fingers. A setting gauge is required for this operation, located in the top corner of the drive-side chassis face: unscrew it to use Outer Fingers To avoid flexing of the actuator bar, the outer fingers are actuated by a solenoid on each side. The fingers are therefore individually adjusted. 6 Slacken the backstop screw and repeat steps 3 to 5 for the drive side (see Fig. 13a). 7 Check that the adjustments are correct by actuating both solenoids together and ensuring that the settings have not changed. It may be necessary to repeat the whole procedure 2 or 3 times. 8 When satisfied that the settings are correct, replace the top plates and the envelope feeder. The solenoids can be actuated in Engineer mode diagnostics. To operate the machine, close the top cover and place a magnet over the side cover interlock switch. Fig Remove the envelope feeder (see section 3.6). 2 In the insert area, remove the two front chassis top plates. Operator side Drive side Fig. 13a 3 On the operator side, attach the setting guage using the top plate screws (Fig. 13). 4 Turn down the backstop screw (see Fig. 12) so that the finger tip aligns with the top edge of the guide (arrowed). 5 Slacken the 2 screws securing the solenoid, pull in the plunger and slide it until free play is removed from the link. Tighten the screws. Note that a right-angled torx driver will be required for the screws. Page 3-14

42 Maintenance and Servicing Inner Fingers The inner fingers are adjusted using a special setting gauge with the finger assembly removed from the machine, as described in section The setting gauge is located in the top corner of the driveside chassis face: unscrew it to use. 1 After removing the finger assembly, attach the setting gauge as shown in Fig. 14 using 2 x M4 screws. 2 Pull in the solenoid to advance the fingers: the underside should be 1-1.5mm above the edge of the setting guage at the points indicated in Fig If adjustment is required, slacken the 2 screws securing the solenoid and slide it as required. Tighten the screws and check that the setting has not changed. 4 Replace the finger assembly in reverse order to removal. Remember Fig. 14 to replace the setting gauge when adjustment is complete Insertion Guidelines The following guidelines may also assist with insertion problems 1. Inspect documents looking for witness marks for crashing at envelope throat, indicating if fingers have not entered throat. 2. Check that document pack is correctly folded. 3. Check correct sizes are entered in document screens for all documents used in job. 4. Check envelope side guides are set correctly. 5. Check separator setting. 6. If using C4 envelopes, try adjusting the blower setting. 7. Check correct sizes entered in document screens for all documents used in job. 8. Programme a new job and see if it works. If it does compare finetuning settings. Try settings with the problem job. 9. Check sensor values in the unit then clean and calibrate. 10. Check all finger solenoids are working in Engineer Mode. 11. Check and set collate pocket side guide calibrations. 12. Check and set finger calibrations. 13. Run with side cover open in envelope only, with magnet on cover switch, check envelope stop position is correct. Flap crease should be at front datum point. 14. Run with side cover open in envelope only with magnet on cover switch, watch fingers for correct entry into envelope. 15. Try adjusting which fingers enter the envelope first in the fine tuning screens. cont. Page 3-15

43 Maintenance and Servicing Check static finger setup for outer finger home position and repeat step 13: Mark along the inner flap crease with pen. Wind envelope to insertion area by hand. Stop when outer flap crease reaches the back of the datum point. Check that the outer finger tips are just behind the flap crease when at rest. Adjust finger back stops if necessary. Check both sides of the machine. Check static finger set up for middle fingers. Find Best Fit for all the envelopes remembering that the envelope stop position is adjustable in the job and repeat step 13: Wind the envelope forward until the outer flap crease is at the front of the datum point. Energise the middle finger solenoid in diagnostics (cheat the cover switch with a magnet). Ensure the tips of the middle fingers have entered the envelope throat. Adjust the finger tips if required. Energise the outer fingers to check they work with the envelope at the front of the datum point. Repeat with any different style envelope the customer will be using. Check envelope length calibration in Units setup. Recalibrate Hybrid motor. Remove finger assembly and check finger setup. Take a trace and send to IPSS. Page 3-16

44 Maintenance and Servicing 3.13 Removal of Side Guide Adjust Assembly In order to remove the side guide assembly, the Power Supply Unit must be removed first see section 3.15 Motor cable Fig. 17 Drive Side 3 Remove the solenoid bracket screws to allow access for the side guide adjust assembly Fig. 17). It is not necessary to remove the bracket. The side adjust assembly consists of a motor-powered lead-screw and provides the mechanism for adjusting the side guides above the chassis surface in the collate area. It is removed from the drive side of the chassis. PCB Fig. 15 Fig. 16 Operator side The leadscrew shaft must first have the T bearing removed. This is located under the PCB on the operator side. 1 Remove the ribbon cables on the LH and upper edges of the PCB. Take out the screws and pull down the top of the PCB to reveal the T bearing (see Fig. 15). Remove the E clip and bearing. 2 Raise the collate clam assembly in the collate area and remove the side guide brackets and side guides, as shown in Fig. 16. These are attached to the side guide adjust assembly below. Solenoid bracket Adhesive tape Fig Disconnect the 2 disc sensor cables shown in Fig. 17 and also the motor cable. Remove the 2 screws indicated. Withdraw the assembly, reaching in through the chassis opening vacated by the PSU in order to hold the side guide carriers free of any obstructions. Replacement 5 Replacement can be awkward due to the side guide carriers swinging upside-down. To avoid this, use adhesive tape to hold the carriers to the lead-screw during reassembly as shown in Fig. 18. Reach in through the PSU opening to help guide the lead screw through the T bearing opening on the operator side. When the assembly is in place with the carriers the right way up, remove the tape. 6 Replace the T bearing and clip on the operator side, screw the PCB back into place and reconnect the cables. Also reconnect the cables on the drive side. 7 Replace the side guide brackets and side guides in the collate area. The side guides must now be adjusted see section Page 3-17

45 Maintenance and Servicing 3.14 Adjustment of Side Guides 3.15 Removal of Power Supply The side guide width is automatically set according to document size. However, the side guides are factory set to toe-in at the front. If the guides have to be removed or disturbed, the toe-in must be reset to toe-in at the front. A B 1 Open the collate pocket assembly in the collate area. Slacken the 2 screws indicated in Fig. 19 to allow the guides to swivel. Adjust the guides so that point B is 1.5mm (1/16 ) wider each side than point A. This is most easily achieved by placing a piece of paper between the guides and winding the gears by hand to move them. The gap can then be easily measured. Tighten the screws and check that the setting has not altered. The toe-in applies to all document sizes. 2 Re-check the calibration in Engineer Mode. A B Fig. 19 The power supply unit can be removed from the drive side of the machine after disconnecting cables on the operator side. Network Cable Fig. 20 Operator side The PSU must first be disconnected on the operator side. 1 Disconnect the two cables indicated in Fig. 20. Unplug the network cable to allow access for the PSU cables to pass through the opening. Drive side 2 Remove the 2 screws indicated in Fig. 21 and withdraw the PSU, feeding the connectors through the chassis opening on the operator side. Replacement Hold the cables and reach in the chassis opening on the drive side and feed the connectors through the opening Fig. 21 on the operator side. Push the PSU home. The lugs on the operator side must locate in the chassis plate before the PSU will fit. Tape or bind the cables together to assist with feeding them through the operator side opening. Page 3-18

46 Maintenance and Servicing 3.16 Replacement of Sealer Rollers There are four sealer rollers: two in the chassis, two in the opening sealer assembly. They should be checked for wear or damage at every site visit and replaced at 2 million envelopes. To remove the rollers, this can be done with the envelope feeder in place, but the sealer assembly will have to be removed first (see section 3.17), and also the envelope conveyor (see section 3.6). Having done so, proceed as follows. 3 Lift the rollers out of the chassis, utilising the access slots to do so. The lower roller can be removed by springing the surrounding metalwork slightly. When fitting the new rollers, take care not to damage the lower roller as it is refitted. Do not get grease on the rollers. Fig. 22 Drive side (chassis rollers) 1 Open the sealer assembly and remove the clutches, gears, E clips, bearings and waved washers indicated in Fig. 22. Slacken, but do not remove, the clutch location bracket to facilitate this. Fig. 24 Sealer Assembly Rollers 1 Open the sealer assembly and on both sides, remove the bearing springs shown in Fig. 24. alternatively, remove the sealer assembly (see section 3.17) 2 Remove the E clips on the ends of both sides of the uppermost roller only. Fig. 23 Operator side (chassis rollers) 2 Remove the clutch, gears, E clips, bearings and waved washers indicated in Fig. 23. Remove the screws for the float switch bracket to facilitate this, but do not remove the bracket. 3 The roller sub-chassis can now be lifted out of the sealer assembly and the rollers removed. 4 Reassemble in reverse order to replacement. Page 3-19

47 Maintenance and Servicing 3.17 Removal of Sealer Assembly 3.18 Adjustment of Wetter Lever The sealer assembly can be quickly removed for replacement of sealer rollers (see section 3.16). Proceed as follows. Fig Open the sealer assembly and remove the pivot screw on each side (Fig. 25 shows drive side - operator side is similar). 2 Lift the assembly out of the machine. Reassembly is a reverse of removal. The wetter lever is factory set so that when the solenoid is actuated, the wetter beam will just contact the wetter felt below. If the beam is set too low, splashing may occur; if set too high, flap wetting may not be sufficient. If required, adjust as shown below in Fig. 26. Fig. 26 Access hole 1 Lower the operator side cover. The wetter lever assembly is visible inside the cavity. 2 Slacken the 2 screws indicated. Insert a suitable rod or screwdriver into the access hole indicated to fully actuate the solenoid; this will lower the wetter beam. When replacing the pivot screws, insert a screwdriver or drift in one hole to align the assembly whilst fitting the other one. 3 Move the lever to adjust the wetter beam to the condition described above. Tighten the screws. Note: the wetter solenoid can also be actuated in Engineer mode/ Diagnostics, though it is better to operate it manually. Page 3-20

48 Maintenance and Servicing 3.19 ENGINEERING MODE To enter Engineering mode, select the Service button from the Menu on the Run screen Hardware Setup Configures the physical machine. When the machine is first set up, or if new units are added or altered (eg. a reader is added), Hardware Setup must be set to reflect each unit and its features. Engineering mode allows the following functions: Hardware Setup Units Setup Firmware Download Diagnostics External Devices Network Devices Reader Setup Machine ID Plug and Play Note: Engineering mode will only be available to personnel with appropriate access rights (set via the Users button from the Menu on the Run screen). Engineering mode applies to the whole machine, hence this section covers feed/fold modules, as well as the insert head. Modules not relevant to the actual machine setup should be ignored. To make changes select the Edit tab. Select each unit in turn in the lefthand column, choose the unit type in the centre column and select the required options in the right-hand column. Extra settings relating to readers are shown in the pane on the right-hand side. For Feed/fold units, the readers fitted are selected with the module highlighted, then the reader options for each hopper are selected with the module hopper highlighted. To view all settings without making changes, select the View tab and select each module or its hoppers. To add new modules to the end of the existing ones, use the button and configure to suit. cont. Page 3-21

49 Maintenance and Servicing To delete existing modules, use the button. Important: modules are deleted from the end. If a module is removed that is not the end module, all module settings after that one must be re-configured. However, in practice, when a module is added or removed, providing that the DIP switches have been correctly set, the modules can be automatically re-configured using Plug and Play (see later in this section for details) Units Setup This allows adjustment of various settings, depending upon the module selected using the button at the bottom. Note: These are global changes and will affect all jobs. For job specific changes, use fine tuning screen in the Run screen Settings tab This allows adjustment of various settings, depending upon the module. Module 0: Head adjustment of: Collate Pocket Cal & Fingers Cal: These settings are in addition to any changes made in Calibrations (see later in this section). Use if the settings need to be different from the calibrated sizes. Wetter Start: Adjusts the point at which the wetter beam drops to wet the flap (+ve = more wetting). In steps of 1mm. Note: this setting applies to the machine, and can be further adjusted for the job in Advanced. Page 3-22

50 Maintenance and Servicing Envelope Stop Position Cal: Adjusts envelope stop position. Positive = further forward towards exit direction. Envelope Insert Position Cal: Adjusts amount of insertion of insert pack into envelope. Positive = further forward past flap crease. Envelope Reverse Position Cal: Adjusts amount of envelope forward travel after flap wetting, before reversing to enter sealing rollers. Positive = further forward into rollers, towards exit direction. Envelope Seal Position Cal: amount of envelope travel into seal plate. Positive = further forward, away from exit direction. Envelope depth Measured: auto-measured depth of envelope, which will be displayed. Adjust up or down to suit actual envelope size. Positive = greater. Ins. Pawl Stop Position Cal: Adjusts stop position of insert pawls behind insert pack in collate pocket. If the pawls are stopped too high by the software, inserts entering the collate pocket will contact the tips, hence position must be adjusted back. Positive = further forward. Pocket Backstop Cal: As inserts enter the collate pocket, they contact a backstop to prevent overrun, and stop. The backstop is then lowered and the insert drives forward. This setting increases the time delay before the insert drives forward. Use if backstops are slow to drop for any reason, causing crashing. If set to Off, backstop remains lowered always. Flex Folder: adjustment of: a: settings of foldplates 1 & 3. Figure shown will be the setting for the job, and may be adjusted if required. Units are 0.1mm and positive = greater. To set up for the first time, or if parts have been replaced: 1. Set up a job with the following parameters: European: Envelope = C5 (162 x 229), Paper = A4 single sheet from top hopper, Fold = V. US: Envelope = No. 7 Booklet (159 x 244), Paper = Letter size single sheet from top hopper, Fold = V. 2. In the Adjust Fold Settings under Fold Settings in the Define Settings screen, select the number at the top of the fold module icon: check the Fold Plate Length settings in the dialog box (see below). For A4, F1 should be 148mm. For Letter, Length A should be 139mm. 3. Save the job and run. Measure the length of the first panel, which should be 148mm (A4) or 139mm (Letter). If not, exit Configuration and enter Units Setup in Engineering mode. Select the Flex Folder in the module box at the bottom of the screen: this will display the settings boxes for the foldplate calibrations (see following page). Page 3-23

51 Maintenance and Servicing Z fold: Z fold should not be used for setting the fold plates. Instead, set the plates using C fold as previously described, then switch the job to Z fold. If the plates are set correctly for C fold, they will be correct for Z fold also. b: calibration of no-fold blanking beams 1 & 3. Adjusts gap between tip of beam and fold roller. If forms are not entering a fold plate when they should, gap must be increased and vice versa. Units are 0.1mm of motor actuator which equates to 1mm at beam tip. Positive numbers only. c: alignment of leading edges when collating before feeding. Applies to feeders 2, 3 & 4 (where fitted). Units are 1mm and positive = further forward. 4. In Foldplate 1 Cal, enter the difference between the measured length and the length displayed in Configuration, ie. if the measured length is 152mm, select Change and enter -40 to change the length to 148mm. 5. Run the job to check the length is now correct (148mm in this case). C fold (see opposite for Z fold): These will be similar, except there will be two lengths to measure, and if necessary, recalibrate. Also, lengths are measured from the trailing edge (see below): Important: As the lengths are measured from the trailing edge, any change figure entered must be added, not subtracted, and vice versa. Eg. If the measured length was 103mm, enter 40 to change it to 99mm. Page 3-24

52 Maintenance and Servicing Calibrations tab When these options are selected, the motors for the settings will automatically adjust to the correct size. They should then be measured, and any difference should be corrected out using the adjustment boxes - positive numbers increase the width. Note that the measured distances should be 210mm/235mm exactly. Appropriate clearances will then be automatically applied by the software, which will suit most job applications. It it is required to alter the settings, use the adjustment boxes as described above. These settings will then remain until set otherwise. Note also that the collate pocket side guides are adjustable for taper and are factory set to taper intowards the closer end. The 210mm setting above applies to the narrowest point - the widest point is set to approx. 3-4mm wider either side. To adjust, slacken the screw near the middle of the guide and twist the guide to suit. This screen applies only to the insert head, and is used to set the collate pocket side guides to A4 size (210mm) and the width of the insert fingers to DL size (235mm). Note: there are calibration notches in the chassis bridge at 235mm, visible in the cavity below the envelope conveyor - the outer edges of the fingers should align with the centre of the notches (see below). Page 3-25

53 Hybrid Motor Calibrations tab Maintenance and Servicing This screen applies only to the insert head, and is used to calibrate and test the hybrid motor. This should not normally be required as the motor is factory calibrated, but if operating problems may indicate the motor, it should be carried out. The machine should be clear of stationery when doing so. When the Calibrate button is selected, the motor slowly increases in speed up to a maximum, and sets 4 calibration points as it does so: low, medium, normal & high. These unitless points are displayed in the Settings cell. The linear speed (of the paper), current and voltage are also displayed. Selecting the Speed button allows the motor to be tested at low, medium and normal speeds. The motor will continue running until Off is selected. Page 3-26

54 Maintenance and Servicing Firmware Download Firmware downloading allows selected units to be upgraded with selected files, usually sourced from the company website. Select the unit(s) to be upgraded and use the Files button to find the appropriate.am4 file(s). Note that each file includes the module name in the filename, ie. for head, 3P folder or feeder/2p folder/ Cardfolder. The lower windows show the version number and status of the file. These can be compared with the main window showing the same details for the current firmware in the unit. Normally, all modules should be ticked in the left-hand column and Broadcast Mode should be ticked also. This will allow multiple modules of similar type (feed/fold modules or Cardfolder) to be upgraded simultaneously, saving time; only untick if a module is specifically not to be upgraded. It does not matter if, for example, the head were ticked whilst feed/fold modules were being upgraded. When downloading, the righthand window shows download status in progress. Page 3-27

55 Maintenance and Servicing Diagnostics Diagnostics allows sensors to be calibrated and components (motors, clutches, brakes, solenoids etc) to be tested. The voltage and current drawn by the sensors is shown as a read-only display, and their clear or blocked status is indicated. Component tests will run each selected component to confirm it functions. Note: the screens may vary in appearance from that shown, depending upon the module type. Solenoids This includes other clutches, brakes and AC motors also. Allows various components to be switched on or off to test them and provide a readout of current rating. Components shown will depend upon type of unit selected and will include some or all of: clutches, brakes*, solenoids and indicator LEDs. Drive motor is also included for each module, as this must be switched on to test some other components. Motors Tests the DC motors for collate pocket, fingers and foldplates. Applies only to insert head and tower folder. The Fwd button toggles between forward, reverse and forward+reverse (alternating). Select the required direction, then On to start, Off to stop. The right-hand column indicates the status. Start Sync applies only to Tower Folder fold plates. It will cause the backstops to travel to the far end of the fold plate, then reset for the selected job. Select each module as required using the Select Unit button. When testing brakes, ensure no other devices are activated and test by switching the brake on, then attempting to turn its centre by hand to check it has actuated. Page 3-28

56 Maintenance and Servicing Analogue sensors Analogue sensors are those that respond over a graduated range, unlike digital sensors which are read as either On or Off. They are usually adustable. The screen displays the status of analogue sensors and allows their calibration. The read-only displays translate as follows: Example: T=2.6V I=44% R=12% C 0.2V Where T = Threshold voltage, generally over 2.5V (this is the switching votage between blocked and clear); I = effort of current required to read across the sensor halves (typically between 10% & 60%); R = Percentage of pot value on PCB, C (or B) = clear or blocked and sensor voltage, which should <0.5 clear, >4.5V blocked. Calibration Sensors can be calibrated individually or all together by using the Cal All (Paper sensors) button. Generally, the readings are best used as a comparison guide for like sensors from one machine to another. However, if a sensor has failed, the readings are likely to be very low or zero. Select each module as required using the Select Unit button. Page 3-29

57 Maintenance and Servicing Digital sensors Digital sensors are those that are read as either On or Off, unlike analogue sensors which respond over a graduated range. They are not adustable. The screen displays the On/Off status of each sensor. To check if a sensor is working, it should be On when blocked, Off when clear. Any sensor that does not respond this way should be replaced Covers Displays the status (open or closed) of all operator-opening covers and hopper interlocks. This will indicate if a reed switch has failed or is badly adjusted. Select each module as required using the Select Unit button. Select each module as required using the Select Unit button. Page 3-30

58 Maintenance and Servicing Power Displays the voltage or current drawn by each component. The component name indicates the nominal voltage/current, while the display indicates the actual rating. Miscellaneous Displays the total count for each module. For insert head, Feed Count 1 is the number of envelopes fed, Output Count is the number of filled envelopes ejected and Pack Count is the number of packs that have arrived at the collate area for insertion into the envelope. For tower folder, feed counts 1 to 4 relate to the hoppers, where hopper 4 is the hand-feed hopper. Select each module as required using the Select Unit button. Select each module as required using the Select Unit button. Page 3-31

59 Maintenance and Servicing Issue 2 Jan RECOMMENDED SPARE PARTS Shown below are the spare parts recommended to be held by Service Agents. Quantities shown are per machine. Consumable items are marked in the right-hand column: these might need to be ordered more frequently. To obtain a 230V list, order part number A A ( C). To obtain a 115V list, order part number A A ( D). ITEM P/N (NTL) P/N (SAP) DESCRIPTION QTY CONS. 1 A A Z MOTOR ASSY, 230V 1 or 1a A A Y MOTOR ASSY, 115V Z CLUTCH EC30LL CW 8m m 24V C MTR W/D IN-LINE G CLUTCH W/D WXH H BRAKE W/D WXH J SOLENOID W/D XH T LOOM C4 HYBRID MTR LINK Q PCB C4 ENV WETTER U PCB ASSY AM4 PROCESSOR T PCB ASSY AM4 CNTRL BRD R PCB SPLIT 5SEN 5SOL H/D W PCB WIDEBODY DISK SENSOR U PCB C4 EXPANSION A MTR ASSY PERISTALTIC 24V K LOOM EMITTER 200 SM M LOOM RECEIVER N/A 200 SM Q LOOM RECEIVER N/A 300 SM T LOOM EMITTER 200 XH U LOOM RECEIVER W/A 200 XH W LOOM EMITTER 300 XH B LOOM 4W-3W/3W XH 0.2M S LOOM A5 WETTER PROBE 1 Page 3-32

60 Maintenance and Servicing ITEM P/N (NTL) P/N (SAP) DESCRIPTION QTY CONS Y OPB715 WIRED SENSOR 2x3W Q LOOM C4 HEAD LINKS U LOOM C4 HEAD RIBBON SET K C4 HEAD PSU S PCB SPLIT 3SEN 4SOL H/D X LOOM RECEIVER W/A 300 XH Y LOOM RECEIVER N/A 300 XH V LOOM C4 ENV FDR LINK SET L OPB715 SENSOR 2x3W 250mm W WIRED 24V BLOWER SM G LOOM EMITTER 100 SM J LOOM RECEIVER N/A 100 SM X MTR W/D WSM S LOOM RECEIVER N/A 100 XH V LOOM RECEIVER N/A 200 XH N LOOM C4 INTERNAL COMMS 1 49 D A Y SOFT RUBBER WHEEL 40 DIA 4 x 40 F5119A A BELT 140XL 037 POLYURETH 1.5 x 41 F5120A C BELT 130XL 037 POLYURETH 1.5 x 42 C A C UPPER SEAL ROLLER 48DIA 2 x 43 D0045A U ROLLER TRANSPORT NOTCHED 2 x R LOOM X 2WXH H SOLENOID W/D XH M WIRED MTR X2WXH Y CLUTCH EC30LL CCW 8m m 24V 1 48 C8135A A SEPARATOR ROLLER 2 x 49 G A Z SEPARATOR SHIELD 1 x U WIRED MTR W SM 1 51 C8194A J SLOTTED FEED WHEEL 2 x 52 C A T ENV FEED ROLLER 10mm DIA 8 x 53 D A P RUBBER WHEEL 40 DIA 10 x Page 3-33

61 Maintenance and Servicing Issue 2 Jun 2013 ITEM P/N (NTL) P/N (SAP) DESCRIPTION QTY CONS. 54 D0051A K SEPARATOR PAD x 55 G0167A Z EC30 CLUTCH PIN 2 56 G A A GUIDE TAPE UPPER 2 x 57 G A R GUIDE TAPE LOWER 2 x 58 G A B FLAP GUIDE SHIM 2 x X MTR EMS 30RPM 24V 1 60 C8194A J SLOTTED FEED WHEEL 2 x 61 D0007A G TYRE JOGGLER 4 x 62 F5007A L BELT 200XL x 63 D0021A T ROLLER TRANSPORT 30x E0235A L O RING (12.1 X 1.6) 1 65 G A S WETTER FELT C G1117A X SPRING HEAVY PRESSURE 2 67 G0079A L CLUTCH PIN 2 68 G A Q SPRING LINK 1 69 C A E CLUTCH PLATE STANDARD 1 70 C A V CLUTCH PLATE 30T 1 71 C A F CHAIN ROLLER 8 72 C A W LOWER SPROCKET IDLE 1 73 C A D LOWER SEAL ROLLER 48 DIA 1 x 74 C A U LOWER SEAL ROLLER 25DIA 1 x 75 F A G PAWL CHAIN LINK 4 76 G A X SPRING CLIP SOLENOID 2 Page 3-34

62 Section 4 Exploded Views Exploded Views Section Description Page 4.1 Chassis Drive Side (Front) Chassis Drive Side (Rear) Chassis Operator Side Chassis Assembly Shaft Locations Envelope Feeder Assy A A Envelope Separator Assy A A Envelope Tractor Assy A A Envelope Feed Shaft Assy A A Envelope Conveyor Assy A A Envelope Conveyor Backstop Assy A A Collate Clam Assy A A Head Input Conveyor Upper Assy A A Head Input Conveyor Lower Assy A A Motor Assy A A (115V) / A A (230V) Sealer Assembly A A Split Shaft Sub Assys A / 1060 / 1061-A Section Description Page 4.18 Finger Assembly A A Finger Bkt Op Assy A A Side Guide Adjust Assy A A Pawl Tension Bracket Assy A A Wetter Lever Assy A A Wetter Beam Assembly Wetter Tank Assy A A No Seal Assembly A A Head Ribbon Bkt. Assy Universal Head PSU Mains Input Pluggable Mains Input Hardwired External Float Switch A A Catch Tray Assy A A Inserter Head Covers Monitor Arm Lift Beam Assy A A Page 4-1

63 Exploded Views Issue 5 Nov 2012 S1 H J K L F G F F H M A J C C A L K B E C D A M B C D F E SENSORS Item Description Ref. S1 Hybrid Motor Disc 5.12 G Chassis Drive Side (Front) Page 4-2

64 Exploded Views Issue 4 Jun 2012 Item Part No. Description Qty. Spares C MTR W/D IN-LINE 1 Y R PCB SPLITTER 5SEN 5SOL H/D (No.6) 1 Y N PCB ASSY HI-RES SENSOR 1 Y 4a CLOSER FORWARD DRIVE CLUTCH 1 N (See Spares Assy 1) 4b INSERT PAWL TRACK DRIVE CLUTCH 1 N (See Spares Assy 3) CLOSER REVERSE DRIVE BRAKE 1 N (See Spares Assy 2) Y WETTER OUTPUT DRIVE CLUTCH 1 Y 7 B A HEAD SIDE PLATE DRIVES 1 N 8 B A SENSOR DISC BRACKET 1 N 9 B A CLOSER CLUTCH BRACKET DRIVE 1 N 10 C A L IDLER POST LONG 4 Y 11 C A C COMPOUND IDLER POST 2 Y 12 C A D SENSOR DISC POST 1 Y 13 C A E CLUTCH PLATE STANDARD 2 Y (See Spares Assy 1) 14 C A CLUTCH PLATE 30T 1 N (See Spares Assy 3) 15 C A E GEAR CONNECTOR 1 Y 16 C A F BRAKE POST 2 Y 17 N/R 18 C A CLUTCH SPACER 3 N (See Spares Assy 1/2/3) 19 F A G GEAR 48T 1M 10ID 1 Y 20 F A H GEAR 40T 1M IDLER 2 Y 21 F A E GEAR 40T 1M 10ID 1 Y 22 F A J GEAR 48T IM IDLER 5 Y 23 F A N GEAR 30T IM CLUTCH 2 Y 24 F A P GEAR 25T IM IDLER 1 Y 25 F A D GEAR 25T 1M 10ID 2 Y 26 F A L GEAR 25/48T 1 Y 27 F A S ISSUE B GEAR 16T 1M 8ID 1 Y 28 E A V BEARING FL 10 x 22 x 7 A/R Y 29 E1061A B BEARING BALL 8 x 16 x 5 A/R Y 30 N/R 31 E A V KEY 2mm x 10 1 Y 32 B7708A E SENSOR DISC 1 Y 33 G6168A CLUTCH SHIM A/R N (See Spares Assy 2) 34 G0167A Z EC30 CLUTCH PIN 1 Y 35 C A MOTOR SPACER 4 N 36 A A R T BEARING HOUSING ASSEMBLY 1 Y 37 F A R GEAR 25T IM 6ID 1 Y 38 G A Z SEALER SPRING 1 Y R WIRED REED SW (CLOSER COVER) 1 Y 40 C A Z BRAKE BEARING HOLDER 1 Y 41 E1078A BEARING FL 8x22x7 1 Y Chassis Drive Side (Front) Page 4-3

65 Exploded Views Issue 3 Oct 2012 Item Part No. Description Qty. Spares Fixings 50 E A SCREW M3 x 6 TORX PAN HD 2 51 A A SCREW M3 x 6 CH HD 6 52 E2684A SCREW M3 x 14 CAP HD 1 53 E2782A SCREW 3mm PLAS-TECH E A SCREW M4 x 6 TORX PAN HD 2 55 E2826A SCREW M4 x 8 TORX PAN HD 4 56 E2507A SCREW M4 x 10 CAP HD 2 57 E2523A SCREW M5 x 20 CAP HD 2 58 E A 3mm SCHNORR WASHER 6 59 E4011A M4 WASHER 6 60 E3501A M5 FULL NUT 2 61 E5126A 3 DIA x 8 GROOVED PIN 3 62 E5103A 3 DIA x 10 DOWEL PIN 3 63 E5086A 3 DIA x 16 DOWEL PIN 6 64 E5073A 9.5mm E CLIP 3 65 E5092A 12mm E CLIP 6 66 E0475A WAVED WASHER 10.5 ID 3 67 E0367A WAVED WASHER 23 ID PLASTIC RIVET 3.5mm GRIP 4 69 E0425A WASHER 10.2 x 17 x E4033A WASHER WAVED 8.8 ID 1 71 E5110A 2.5 DIA x 16 DOWEL PIN 1 72 E2604A SCREW M3 x 10 CHEESE HD 2 73 E3557A M3 NYLOC NUT 2 74 E4012A M5 WASHER 4 75 E5003A CIRCLIP 7mm 1 76 E5105A 3 DIA x 24 DOWEL PIN 2 SEE FIXING KIT FOR THIS ASSEMBLY A A ( S) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY. Spares Assemblies SA1 A A K LENZE CLUTCH ASSY A/R SA2 A A L CLOSER REVERSE BRAKE ASSY A/R SA3 A A M LENZE CLUTCH ASSY 30T A/R Chassis Drive Side (Front) Page 4-4

66 Exploded Views Issue 5 Jun 2013 Note: Belt F5112A (Item 34) is also shown on Motor Assy. A A see (Section 4.15) Chassis Drive Side (Rear) Page 4-5

67 Exploded Views Issue 5 Jun 2013 Item Part No. Description Qty. Spares X COLLATE ENTRY BRAKE 1 Y 1a X INPUT CONVEYOR BRAKE 1 Y R PCB SPLITTER 5SEN 5SOL H/D (No.2) 1 Y 2a R PCB SPLITTER 5SEN 5SOL H/D (No.3) 1 Y COLL. POCKET ENTRY SLOW CLUTCH 1 N (See Spares Assy 1) J COLL. POCKET BACKSTOP SHORT SOL. 1 Y 4a J COLL. POCKET BACKSTOP LONG SOL. 1 Y 5 A A B I/P CONV STUB BRG ASSY 1 Y 6 B A HEAD SIDE PLATE DRIVES 1 N 7 B A PRIMARY DRIVE PLATE 1 N 8 B A CLUTCH LOCATOR SP SH 1 N 9 B A BACKSTOP SOL BRKT DRIVES 2 N 10 B A DUAL SOLENOID BRACKET 1 N 11 C A CONVEYOR BEARING HOUSING 1 N 12 C A L IDLER POST 2 Y 13 C A C COMPOUND IDLER POST 1 Y 14 C A CLUTCH PLATE STANDARD 1 N (See Spares Assy 1) 15 C A CONV PIVOT POST 1 M 16 C A CLUTCH SPACER 1 N (See Spares Assy 1) 17 C A PLATE POST 2 N 18 C A IJ PRIMARY DRIVE SHAFT 1 Y 19 C A K CONVEYOR DRIVE STUB 1 Y 20 F A G GEAR 48T 1M 10ID 2 Y 21 F A H GEAR 40T 1M IDLER 1 Y 22 F A E GEAR 40T 1M 10ID 3 Y 23 F A J GEAR 48T IM IDLER 2 Y 24 F A F GEAR 30T 1M 10ID 1 Y 25 F A D GEAR 25T 1M 10ID 1 Y 26 F A L GEAR 25/48T 1 Y 27 F1404A U PULLEY 104T S2M M/DRIVE 1 Y 28 E A U BEARING FL 10 x 22 x 7 A/R Y 29 E A L BEARING FL 10 x 19 x 8 A/R Y 30 E1061A B BEARING BALL 8 x 16 x 5 A/R Y 31 G0167A Z EC30 CLUTCH PIN 2 Y 32 R2874A BRAKE BRACKET 1 N 33 E1078A L BEARING FL 8 x 22 x 7 A/R Y 34 F5112A W BELT 100-S2M Y 35 G6168A S CLUTCH SHIM A/R Y 36 C A CLAM PIVOT POST DRIVES 1 N C CLIP RESTRAINT MEDIUM 1 Y 38 G A X SPRING CLIP SOLENOID 1 Y Chassis Drive Side (Rear) Page 4-6

68 Exploded Views Issue 3 Oct 2012 Fixings Item Part No. Description Qty. Spares 50 A SCREW M3 x 6 CH HD 3 51 E A SCREW M4 x 6 TORX PAN HD 2 52 E2826A SCREW M4 x 8 TORX PAN HD 2 53 E2507A SCREW M4 x 10 CAP HD 2 54 E A 3mm SCHNORR WASHER 3 55 E3505A M4 NYLOC NUT 4 56 E5103A 3 DIA x 10 DOWEL PIN 3 57 E5071A 3 DIA x 14 DOWEL PIN 1 58 E5086A 3 DIA x 16 DOWEL PIN 1 59 E5073A 9.5mm E CLIP 2 60 E5092A 12mm E CLIP 4 61 E0475A WAVED WASHER 10.5 ID 2 62 E0367A WAVED WASHER 23 ID 4 63 E4033A WAVED WASHER 8.8ID 1 64 E2834A SCREW M4 x 10 TORX CSK HD 2 65 E4026A M6 WASHER FORM A 1 66 E2829A SCREW M4 x 8 TORX PAN HD T/T 2 67 E4011A M4 WASHER 1 68 E5105A 3 DIA x 24 DOWEL PIN 3 Spares Assemblies SA1 A A K LENZE CLUTCH ASSY A/R SEE FIXING KIT FOR THIS ASSEMBLY A A ( S) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Chassis Drive Side (Rear) Page 4-7

69 Exploded Views Issue 5 Jun 2013 EE EE Z V W T R X Z T U S Y H U J N G P X Y R S N P H E F K DD CC BB L H E F J M K G BB L DD M CC Chassis Operator Side Page 4-8

70 Exploded Views Issue 3 Jun 2012 Item Part No. Description Qty. Spares X INPUT CONVEYOR CLUTCH 1 Y Y COLLATE ENTRY FAST CLUTCH 1 Y CLOSER REVERSE DRIVE CLUTCH 1 N (See Spares Assy 1) INSERT PAWL TRACK DRIVE BRAKE 1 N (See Spares Assy 2) / U PCB ASSY AM4 PROCESSOR 1 Y U PCB C4 EXPANSION 1 Y T PCB ASSY C4 CONTROL MK2 1 Y Q PCB C4 ENV. WETTER 1 Y R PCB SPLITTER (No.1) 1 Y F PCB MAXI DONGLE 1 Y J COLL. POCKET BACKSTOP EXT. LNG. SOL. 1 Y N TUBE CLEAR FOR PERI/PMP A/R Y 13 B A BACKSTOP SOLINOID BKT. OPERATOR 1 N 14 B A COVER BRACKET 2 N 15 B A COVER LINK ARM 1 N 16 B A CHASSIS LINK ARM 1 N 17 B A HEAD SIDE PLATE OP 1 N 18 B A CONVEYOR CLUTCH BRACKET 2 N 19 A A R T BEARING HOUSING ASSEMBLY 1 Y 20 B A GEAR SHIELD 1 N 21 C A IDLER POST SHORT 1 N 22 B A WETTER PIPE BKT. ASSEMBLY 1 N 23 C A E CLUTCH PLATE STANDARD 2 Y 24 C A CLUTCH PLATE 30T 1 N 25 C A CLUTCH SPACER 2 N (See Spares Assy 1 & 2) 26 C A G GEAR SPACER 1 Y 27 C A Y BRAKE SPACER 16mm 2 Y 28 C A BRAKE BEARING HOLDER 1 N (See Spares Assy 2) 29 A A CONVEYOR PIVOT POST 1 N 30 A A CLAM PIVOT POST OPERATOR 1 N 31 C A BRAKE KNOB 1 Y 32 G A FOOT SPIGOT 3 N 33 C A IDLER POST LONG 1 Y 34 C A C WETTER FUNNEL 1 Y 35 N/R 36 C A E LL SENSOR BLOCK 1 Y 37 C8078A V RUBBER FOOT 3 Y 38 D A MOULDED PAPER EJECT KNOB 1 Y 39 E0367A N WASHER WAVED 23mm I/D 8 Y 40 E0425A Q WASHER 10.2 x 17 x 2 1 Y 41 E0475A U WAVED WASHER EPL5 5 Y 42 E A V KEY 2mm SQ X101g RAD ENDS 1 Y Chassis Operator Side Page 4-9

71 Exploded Views Issue 6 Jun 2013 Item Part No. Description Qty. Spares 43 E A U BEARING BALL FL 10x22x6 15 Y 44 E1061A B BEARING BALL 8x16x5 4 Y 45 N/R 46 E A F PVC TUBE 8mm I/D 11mm O/D A/R Y 47 F A G GEAR 48T 1M 1OID 3 Y 48 F A H GEAR 40T 1M IDLER 4 Y 49 F A N GEAR 30T 1M CLUTCH 1 Y 50 F A D GEAR 25T 1M 1OID 1 Y 51 G0167A Z CLUTCH PIN 2 Y 52 G A SEALER SPRING 1 Y 53 G6168A S SHIM CLUTCH 1 Y Y REED SW SML SWSM 2 Y 55 G A X SPRING CLIP SOLENOID 1 Y MOTOR PUMP W/D 24V 1 Y Fixings 70 A SCREW M3 x 6 CH HD 3 71 E A SCREW M3 x 6 TORX PAN HD 2 72 E A SCREW M4 x 6 TORX PAN HD 8 73 E2829A SCREW M4 x 8 TORX PAN HD T/T 8 74 E2826A SCREW M4 x 8 TORX PAN HD 1 75 E2507A SCREW M4 x 10 CAP HD 2 76 E2809A SCREW M5 x 20 POZI PAN HD T/T 3 77 E3505A M4 NYLOC NUT 4 78 E4048A M4 WASHER FORM C 8 79 E A M3 SCHNORR WASHER 3 80 E5086A 3 DIA x 16 DOWEL PIN 1 81 E5103A 3 DIA x 10 DOWEL PIN 4 82 E5126A 3 DIA x 8 GROOVED PIN 2 83 E5092A 12mm E CLIP 6 84 E2505A SCREW M4 x 6 SOCKET SET 2 85 E2559A SCREW M3 x 10 PAN HD 2 86 E3557A M3 NYLOC NUT 2 87 E5003A CIRCLIP 7mm 1 88 E2503A SCREW M3 x 8 HEX SKT CAP HD 1 89 E5110A 2.5 DIA PIN x 16LG 1 90 E5105A 3 DIA x 24 DOWEL PIN 3 Spares Assemblies SA1 A A M LENZE CLUTCH ASSY 30T A/R SA2 A A* L INSERT PAWL TRACK BRAKE ASSY A/R Chassis Operator Side SEE FIXING KIT FOR THIS ASSEMBLY A A ( J) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY. * ASSY. A A IS SIMILAR TO SPARES ASSY. SA2 EXCEPT FOR 1TEMS 31,42,54 & 84 WHICH ARE NOT INCLUDED. Page 4-10

72 Exploded Views Issue 2 May 2012 S4 S12 S11 S9 SENSORS Item Description Ref. S1 Envelope Flap RX 5.12 S2 Collate Pocket Input RX 5.12 S3 Collate Pocket Load RX 5.12 S4 Collate Pocket TX 5.12 S5 Top Pawl RX 5.12 S6 Top Pawl TX 5.12 S7 Lower Pawl RX 5.12 S8 Lower Pawl TX 5.12 S9 Envelope Seal RX 5.12 S10 Envelope Seal TX 5.12 S11 Wetter Output RX 5.12 S12 Wetter Output TX 5.12 S13 Closer Output (reflective) 5.12 S3 S5 S6 S13 S1 S10 S8 S7 S Chassis Assembly Page 4-11

73 Exploded Views Item Part No. Description Qty. Spares 1 B A WETTER BRIDGE 1 N 2 B A INPUT BRIDGE 1 N 3 B A OUTPUT BRIDGE 1 N 4 B A HEAD SIDE PLATE DRIVES 1 N 5 B A HEAD SIDE PLATE OPS 1 N 6 B A MAIN BRIDGE 1 N 7 B A WIRE PROTECTOR BRACKET 1 N 8 B A SEALER PLATE 1 N 9 B A OUTPUT GUIDE BKT 1 N 10 B A WETTER SENSOR BKT 1 N 11 B A PIVOTING COLLATE PANEL 1 N 12 B A M CHAIN GUIDE INNER DRIVES 1 Y 13 B A N CHAIN GUIDE INNER OP 1 Y 14 B A CHAIN GUIDE OUTER DRIVES 1 N 15 B A CHAIN GUIDE OUTER OP 1 N 16 B A COLLATE POCKET SENSOR BKT (PART OF ) 1 N 17 B A SPLIT SHAFT COVER 2 N 18 B A COLLATE POCKET GUIDE OP 1 N 19 B A COLLATE POCKET GUIDE DR 1 N 20 B A HEAD UNDER COVER 1 N 21 B A WETTER TANK CHANNEL 1 N 22 B A INSERT PANEL CENTRE 1 N 23 B A INSERTION PANEL OP 1 N 24 B A INSERTION PANEL DRIVES 1 N 25 B A* SPECIAL OUTPUT GUIDE 1 N 26 B7696A SIDE GUIDE BRACKET 2 N 27 B A SPRING RETAINING PLATE 2 N 28 G A P COLLATE PANEL SPRING 2 Y 29 G A Q CHAIN TAPE 2 Y 30 B A R NARROW INSERT GUIDE 2 Y 31 P2190A S GUIDE SPIGOT 2 Y 32 B A OUTPUT SENSOR BRACKET 1 N 33 B A CONVEYOR SENSOR BRACKET 1 N 34 B A RIBBON PROTECTOR BRACKET 1 N 35 B A INSERTION SENSOR BRACKET (PART OF ) 1 N 36 B A PAWL SENSOR BRACKET 1 N 37 C9278A SENSOR POST 106mm 1 N PCB SPLITTER 3 SEN 4 SOL H/D (No.4) 1 N 39 B A CENTRAL BEARING BRACKET 1 N Chassis Assembly Page 4-12

74 Issue 2 May 2012 Exploded Views Item Part No. Description Qty. Spares 40 C A CENTRAL BEARING SUPPORT 1 N 41 E A BEARING FL 10x22x7 1 Y 42 E0291A A FOOT PUSH-IN 1 Y 43 G A R* CLOSER GUIDE TAPE 1 Y 44 B A CLAMP PLATE 1 N *Part of A A Q SPECIAL CLOSER GUIDE Fixings 50 E A SCREW M3 x 6 TORX CSK HD 2 51 E A SCREW M3 x 8 TORX CSK HD S/ST 6 52 E A SCREW M4 x 6 TORX PAN HD S/ST 4 53 E2826A SCREW M4 x 8 TORX PAN HD 4 54 E2829A SCREW M4 x 8 TORX PAN HD T/T 6 55 E3557A M3 NYLOC NUT 5 56 E3505A M4 NYLOC NUT 2 57 E0367A WAVED WASHER 23 I/D 1 58 E5092A 12mm E CLIP 1 59 E3630A M4 NUT S/ST 3 SEE FIXING KIT FOR THIS ASSEMBLY A A ( V) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Chassis Assembly Page 4-13

75 Exploded Views Issue 2 Feb Shaft Locations Page 4-14

76 Exploded Views Issue 3 Feb 2012 Item Part No. Description Qty. Spares 1 C A D LOWER SEAL ROLLER 48 DIA 1 y 2 C A U LOWER SEAL ROLLER 25 DIA 1 y 3 A A X WET O/P SHAFT UPPER ASSY 1 Y 4 C A Y IDLER SHAFT 2 Y 5 A A Z WET O/P SHAFT LOWER ASSY 1 Y 6 C A A SPROCKET DRIVE SHAFT 1 Y 7 C A W LOWER SPROCKET IDLE SHAFT 1 Y 8 C A B SLOW DOWN SHAFT 1 Y 9 F C W DRIVE SPROCKET 15T 2 Y 10 F C B IDLE SPROCKET 15T 2 Y 11 F A D GEAR 25T 1M 10ID 1 Y 12 C A PRESSURE WHEEL SHAFT 1 N 13 C A OPENER INPUT SHAFT 1 N 14 D A RUBBER WHEEL 40 DIA 2 N 15 D A SOFT RUBBER WHEEL 40 DIA 2 N 16 F6023A S CHAIN 1/4 PITCH 83 LINKS 4* Y 17 F A G PAWL CHAIN LINK 4* Y 18 C A F CHAIN ROLLER 8* Y 19 B A R INSERTION PAWL 4* Y 20 E A BEARING FL 10x19x5 4 Y *Per Machine Fixings 30 E2834A SCREW M4 x 10 TORX CSK M/C 1 31 E5092A 12mm E CLIP A/R 32 E5086A DOWEL PIN 3 DIA x 16LG 1 33 E5098A DOWEL PIN 3 DIA x 18LG 2 Spares Assembly SA1 A A P INSERTION PAWL ASSEMBLY Shaft Locations Page 4-15

77 Exploded Views Issue 4 Jan 2013 S5 S2 S3 S4 S1 SENSORS Item Description Ref. S1 Envelope Flap TX 5.12 S2 Envelope Feed TX 5.12 S3 Envelope Feed RX 5.12 S4 Envelope Deskew RX 5.12 S5 Envelope in Hopper 5.12 (Reflective) C4 Envelope Feeder Assy. - A A ( P) Page 4-16

78 Exploded Views Item Part No. Description Qty. Spares Y ENV. PICK UP CLUTCH 1 Y X ENV. UPPER DRIVE CLUTCH 1 Y X ENV. UPPER DRIVE BRAKE 1 Y X ENV. LOWER DRIVE CLUTCH 1 Y X ENV. LOWER DRIVE BRAKE 1 Y R PCB SPLITTER 5SEN 5SOL H/D (No.E4) 1 Y 7 A A C C4 ENV SEPARATOR ASSY 1 Y 8 A A U C4 ENV TRACTOR ASSY 1 Y 9 A A V C4 ENV FEED SHAFT ASSY 1 Y 10 A A X FLAP GRIP CLUTCH ASSY 1 Y 11 B A Y SPRING PLATE 0.25mm 1 Y 12 B A ENV INFEED BRIDGE ASSY 1 N 13 B A FLAP GRIP BRIDGE (ASSY) 1 N 14 B A ENVELOPE CLUTCH BRACKET 1 N 15 B A ENV. BRAKE & I/LOCK BKT. 1 N 16 B A ENV FEED SIDE PLATE DR 1 N 17 B A ENV FEED SIDE PLATE OP 1 N 18 B A ENVELOPE FEED BRIDGE UPPER 1 N 19 B A ENV FEED BRIDGE LOWER 1 N 20 B A UPPER ENVELOPE GUIDE 1 N 21 B A MOUNT PLATE OPERATOR 1 N 22 B A MOUNT PLATE DRIVES 1 N 23 B A SENSOR BRACKET 1 N 24 B A SENSOR BRACKET 1 N 25 P2247A MODULE LOCATION SPIGOT 3 N 26 B A ENVELOPE FLAP PLATE 1 N 27 B A INSERT GUIDE OPERATOR 1 N 28 B A INSERT GUIDE DRIVES 1 N 29 B A REFLECTIVE SENSOR BRACKET 1 N 30 C A E CLUTCH PLATE STANDARD 3 Y 31 C A E GEAR CONNECTOR 1 Y 32 C A G GEAR SPACER 2 Y 33 C A CLAM GUIDE SPIGOT 2 N 34 C A IDLER POST SHORT 1 N 35 C A BEARING STUB HOUSING 1 N 36 C A IDLER POST LONG 3 N 37 C A C COMPOUND IDLER POST 2 Y 38 C A Z ENV DRIVE STUB 1 Y 39 C A M FLAP GRIP ROLLER BAR 1 Y R PCB SPLITTER 5SEN 5SOL H/D (No.5) 1 Y 41 C A OPENER INPUT SHAFT 2 N 42 C A ENVELOPE STOP SHAFT 2 N 43 D A RUBBER WHEEL 40 DIA FOR 10mm DIA SHAFT 10 N (See Spares Assy 2, 3, 4 & 5) C4 Envelope Feeder Assy. - A A ( P) Page 4-17

79 Exploded Views Issue 5 Jan 2013 Item Part No. Description Qty. Spares 44 E0367A N WASHER WAVED 23mm ID EMOEPL20 8 Y 45 E0475A U WAVED WASHER EPL5 9 Y 46 E A U BEARING BALL FL 10x22x6 21 Y 47 E A BEARING BALL FL 10x19x5 2 N (See Spares Assy 1) 48 E A A BEARING NEEDLE 4 IDx8x8 4 Y 49 E1054A U BEARING BALL 12x28x8mm 1 Y 50 E1061A B BEARING BALL 8x16x5mm 4 Y 51 E1078A L BEARING FL 8x22x7mm 1 Y 52 E A B WASHER 4.06x7.24x Y 53 F A H GEAR 40T 1M IDLER 7 Y 54 F A J GEAR 48T 1M IDLER 1 Y 55 F A D GEAR 25T 1M 10ID 3 Y 56 F A L GEAR 25/48T 1M 1 Y 57 F A C GEAR 30T 1M IDLER 1 Y 58 G0167A Z EC30 CLUTCH PIN 5 Y 59 G4031A BEARING HOUSING 12mm 1 N 60 G4092A BRIDGE CLAMP 18 N 61 G A A GUIDE TAPE UPPER 2 Y 62 G A R GUIDE TAPE LOWER 4 Y 63 G A B FLAP GUIDE SHIM 2 Y 64 E0376A R BUSHING SHORTY (19 I/D) 1 Y 65 B A RESTRICTOR ARM 1 N (See Spares Assy 6) 66 D0051A SEPARATOR PAD N (See Spares Assy 6) C CLIP RESTRAINT MEDIUM 2 Y 68 C A CHASSIS TIE-BAR 1 N 69 E0446A F RBN CLIP RICHO TC Y 70 B A RESTRICTOR LATCH 1 N Y REED SWITCH SW SML SWSM 2 Y 72 E0214A WASHER SHOULDER 2 N 73 P2264A BRIDGE SPACER 2 N C4 Envelope Feeder Assy. - A A ( P) Page 4-18

80 Issue 2 Feb 2012 Item Part No. Description Qty. Spares Fixings 80 E A SCREW M3 x 6 TORX PAN HD 2 81 E2826A SCREW M4 x 8 TORX PAN HD 4 82 E2834A SCREW M4 x 10 TORX CSK HD 2 83 E2830A SCREW M4 x 12 TORX PAN HD T/T 8 84 E4009A M3 WASHER 6 85 E4011A M4 WASHER 8 86 E3557A M3 NYLOC NUT 4 87 E3505A M4 NYLOC NUT PLASTIC RIVET mm GRIP 2 89 E5126A 3 DIA x 8 GROOVED PIN 6 90 E5103A 3 DIA x 10 DOWEL PIN 6 91 E5086A 3 DIA x 16 DOWEL PIN 6 92 E5081A 4.5mm E CLIP 4 93 E5092A 12mm E CLIP PLASTIC RIVET 3.5 DIA mm GRIP 4 95 E A SCREW M4 x 6 TORX PAN HD 2 96 E5073A 9.5mm E CLIP PLASTIC RIVET 4mm mm GRIP 2 98 E2559A SCREW M3 x 10 PAN HD 2 99 E A SCREW SELF-TAP No. 4 x 1/ E2829A SCREW M4 x 8mm TORX PAN HD T/T 4 SEE FIXING KIT FOR THIS ASSEMBLY A A ( C) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY. Spares Assemblies SA1 ENV P/UP STUB BRG ASSY A A ( F) QTY. A/R SA2 ENV FEED I/P SHAFT ASSY A A ( G) QTY. A/R SA3 ENV OPENER I/P SHAFT ASSY A A ( H) QTY. A/R SA4 ENV OPENER O/P SHAFT ASSY A A ( J) QTY. A/R SA5 ENV FEED O/P SHAFT ASSY A A ( K) QTY. A/R SA6 RESTRICTOR ARM ASSY A A ( T) QTY. A/R C4 Envelope Feeder Assy. - A A ( P) Page 4-19

81 Exploded Views NOTE BRIDGE CLAMPS G4092A (ITEM 19) WITH M4 x 12 TORX HD SCREWS E2830A ( ITEM 34) ARE FITTED IN ALL LOCATIONS MARKED* DS200 Envelope Separator Assy. - A A ( C) Page 4-20

82 Exploded Views Item Part No. Description Qty. Spares U WIRED MTR W SM 1 Y 2 B A SEPARATOR SIDE PLATE 2 N 3 B A DS200 SEPARATOR BRACKET 1 N 4 B A SEPARATOR BRIDGE 1 N 5 B A SHIELD PROTECTOR PLATE 1 N 6 B A J SEPARATOR ACTUATOR ASSY 1 Y 7 C2755A X DRIVE ECCENTRIC 1 Y 8 C A SEPARATOR CLUTCH HOLDER 2 N 9 C I SEPARATOR ADJUSTOR KNOB BLUE 1 N 10 C3420A INNER TIE BAR 1 N 11 C A SEPARATOR WHEEL SHAFT 1 N 12 C A SEPARATOR ADJUSTOR SHAFT 1 N 13 C A SEPARATOR ADJUSTOR BLOCK 1 N 14 C8135A A SEPARATOR ROLLER 2 Y 15 E1068A D ROLLER CLUTCH 6x10x12mm 2 Y 16 E0062A A STEEL BALL 4mm DIA 1 Y 17 G A Z SEPARATOR SHIELD 1 Y 18 G1046A V SPRING INDEX 1 Y 19 G4092A BRIDGE CLAMP 4 N 20 G6150A N WASHER 2 Y 21 E1100A M NEEDLE ROLLER 6x10x8mm 1 Y Fixings 30 E A SCREW M2 x 5 TORX CSK HD 2 31 E A SCREW M3 x 6 TORX PAN HD 2 32 E2505A SCREW M4 x 6 SKT SET 4 33 E2826A SCREW M4 x 8 TORX PAN HD 4 34 E2830A SCREW M4 x 12 TORX PAN HD 2 35 E A SCREW M4 x 12 TORX CSK HD 2 36 E2517A SCREW M5 x 10 SKT SET 1 37 E A SCREW M5 x 10 TORX C SK HD 2 38 E5003A 7mm E CLIP D MS 4 39 E5092A 12mm E CLIP 1 SEE FIXING KIT FOR THIS ASSEMBLY A A G NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY. Spares Assemblies SA1 A A E CLUTCH LOCATOR OP ASSY A/R SA2 A A CLUTCH LOCATOR DR ASSY A/R SA3 A A D SEP ACTUATOR ASSY A/R DS200 Envelope Separator Assy. - A A ( C) Page 4-21

83 Exploded Views Issue 2 May 2012 SENSOR Item Description Ref. S1 Envelope Conveyor (Flag) C4 Envelope Tractor Assy. - A A ( R) Page 4-22

84 Exploded Views Item Part No. Description Qty. Spares PCB SENSOR FLAG 1 Y P MOTOR WIRED M SM 1 Y 3 B A TRACTOR MOUNT BRACKET 1 N 4 B A TRACTOR OVERGUIDE 1 N 5 B A TRACTOR MOUNT PLATE 1 N 6 C A Q TRACTOR PIVOT POST 1 Y 7 C A TRACTOR MOTOR STAND-OFF 3 N 8 C A TRACTOR BEARING SHAFT 1 N 9 C A TRACTOR FEED SHAFT 1 N 10 C A TRACTOR PIVOT SHAFT 1 N 11 C8194A J SLOTTED FEED WHEEL 2 Y 12 D1076A S T BEARING 6mm 10SQ 2 Y 13 E0367A N WASHER WAVED 23mm ID 2 Y 14 E1030A ROLLER CLUTCH 8x12x12mm 1 N (See Spares Assy 1) 15 E1061A B BEARING BALL 8x16x5mm 4 Y 16 E1078A L BEARING FL 8x22x7mm 2 Y 17 F A R 16T TRACTOR DRIVE GEAR 1 Y 18 F A 32T GEAR x 12mm BORE 1 N (See Spares Assy 1) 19 G1029A T SPRING D.D. 1 Y Fixings RIVET 3.5mm GRIP 2 31 E A SCREW M2 x 5 TORX CSK HD 2 32 E A SCREW M3 x 6 TORX CSK HD 2 33 E2518A SCREW M4 x 4 SKT SET 1 34 E2826A SCREW M4 x 8 TORX PAN HD 2 35 E A SCREW M4 x 25 TORX PAN HD 2 36 E3502A M4 FULL NUT 2 37 E3505A M4 NYLOC NUT 1 38 E5003A 7mm E CLIP 2 39 E5073A 9.5mm E CLIP 4 40 E5071A PIN DOWEL 3 DIA x 14 1 SEE FIXING KIT FOR THIS ASSEMBLY A A J NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY. Spares Assemblies SA1 A A H 32T GEAR/ROLLER CLUTCH ASSY A/R C4 Envelope Tractor Assy. - A A ( R) Page 4-23

85 Exploded Views C4 Envelope Feed Shaft Assy. - A A ( V) Page 4-24

86 Exploded Views Item Part No. Description Qty. Spares 1 C2653A G ENVELOPE FEED BEARING 1 Y 2 C2655A H BEARING NYLON 2 Y 3 C A ENVELOPE FEED SHAFT 1 N 4 C A T ENV FEED ROLLER 10mm DIA 8 Y 5 E5078A PIN GROOVED S8 2.5x14 1 N 6 E5079A C CIRCLIP E TYPE 6mm 1 Y 7 E5086A PIN DOWEL 3 DIA x 16(m6) SS 8 N 8 E5092A CIRCLIP E TYPE 12mm 8 N 9 G1139A K SPRING RELEASE 1 Y C4 Envelope Feed Shaft Assy. - A A ( V) Page 4-25

87 Exploded Views C C G H 48 6 C C D D J K 38 DS200 OFFSET GUIDE ASSY A A (OPTIONAL GUIDE KIT) 7 D D G 50 H J K (SEE NOTE) J 45 H H (SEE NOTE) (2) ENV. CONVEYOR BACKSTOP A A (SEE SECTION 4.11) 4 H H E J J E 50 G F E E F E J 17 F E F G F A F B A C C 49 NOTE BRIDGE CLAMPS G4092A WITH M4 x 12 TORX HD SCREWS E2827A ARE FITTED IN ALL LOCATIONS MARKED B NOTE: WHEN ASSEMBLING SIDE GUIDE SPACERS C A (ITEM 71) ONTO SIDE GUIDE OFFSET STUDS B A (ITEM 70) ENSURE THE SPACER THREAD COUNTERSINK IS FACING THE SIDE GUIDE STUDS. C C D D D D C4 Envelope Conveyor Assy. - A A ( P) Page 4-26

88 Exploded Views Item Part No. Description Qty. Spares X MTR W/D WSM (H1)J13 1 Y 2 A A Q ENV CONVEYOR BACKSTOP 1 Y 3 B A BELT TENSIONER BRACKET 2 N 4 B A ENV CONVEYOR CHASSIS 1 N 5 B A CONVEYOR BRIDGE 1 N 6 B A SIDE GUIDE OPERATOR 1 N 7 B A SIDE GUIDE DRIVES 1 N 8 B A CONV STRENGTHENING BKT 1 N 9 B A GEAR SUPPORT PLATE 1 N 10 B A SIDE GUIDE LOCATOR BRACKET 4 N 11 B G CONVEYOR UNDER COVER 1 N 12 B A CONVEYOR END CAP 1 N 13 B A CONVEYOR INFILL PLATE OP 1 N 14 B A CONVEYOR INFILL PLATE DR 1 N 15 C F SIDE GUIDE ADJUSTOR KNOB 1 Y 16 C A SEALER LATCH POST 2 Y 17 C A U CONVEYOR GEAR POST 2 Y 18 C A SCROLL SCREW 4 N 19 C A V ENV CONV DRIVE ROLLER 2 Y 20 C A W ENV CONV IDLER ROLLER 2 Y 21 C A SIDE GUIDE SLIDER 4 N 22 C A CONVEYOR DRIVE SHAFT 1 N 23 C A SIDE GUIDE ADJUST SHAFT 2 N 24 C A CONVEYOR TENSIONER SHAFT 2 N 25 D0007A G TYRE JOGGLER 4 Y 26 D1040A J T BEARING 8m m 12SQ 8 Y 27 E1102A S BEARING FL 8x19x6mm F698ZZ 2 Y 28 F A X PULLEY 12 XL x 8mm 2 Y 29 F A X GEAR 12 TOOTH CONVEYOR 1 Y 30 F4150A X GEAR 40Tx8mm 1.0M 2 Y 31 F4151A Y GEAR 48Tx8mm 1.0M 1 Y 32 F4152A Z GEAR 25Tx8mm 1.0M 2 Y 33 F4278A F GEAR 20T 1M x 6mm 1 Y 34 F5007A L BELT 200XL Y 35 G1117A X SPRING HEAVY PRESSURE 4 Y 36 G A BELT CONVEYOR(EAT-8P) 1165x60 1 Y 37 G6002A WASHER 4 N 38 B G Z CONVEYOR SKIRT OPERATOR 1 Y 39 B G A CONVEYOR SKIRT DRIVES 1 Y 40 B T J SIDE GUIDE INFILL PL OP 1 Y 41 B T K SIDE GUIDE INFILL PL DR 1 Y C4 Envelope Conveyor Assy. - A A ( P) Page 4-27

89 Exploded Views Item Part No. Description Qty. Spares Fixings 45 E A SCREW M4X12MM TORX CSK TAPTITE 2 46 E2505A SCREW M4 SOCKET SETx6 KCP 1 47 E2826A SCREW M4x8 TORX PAN HD 6 48 E2834A SCREW M4x10 TORX CSUNK HD 3 49 E3501A NUT M5 FULL BZP 2 50 E3505A NUT M4 NYLOC DIN 985 BZP 4 51 E4033A WASHER WAVED 8.89ID12.5OD0.18THICK 2 52 E5003A CIRCLIP 7m m 1 53 E5071A PIN DOWEL 3 DIA x 14(m6) 1 54 E5073A CIRCLIP 9.5mm E TYPE 3 55 E5074A PIN DOWEL 3 DIA x 8(m6) 2 56 E5123A PIN DOWEL 2.5 DIA x 10 m E5111A PIN DOWEL 3 DIA x 30 m6 1 SEE FIXING KIT FOR THIS ASSEMBLY A A ( Y) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY 70 B A SIDE GUIDE OFFSET 1 N 71 C A SIDE GUIDE SPACER 3 N 72 E A LOBE KNOB BLACK M4 3 N THESE PARTS ARE AN OPTIONAL GUIDE KIT FITTED AS REQUIRED C4 Envelope Conveyor Assy. - A A ( P) Page 4-28

90 Exploded Views B A D C B 21 A D C C4 Envelope Conveyor Backstop. - A A ( Q) Page 4-29

91 Exploded Views Item Part No. Description Qty. Spares 1 B0145A D SPRING GUIDE DAMPER 2 Y 2 B T BACKSTOP SUPPORT BRACKET 1 N 3 B T ENVELOPE BACK REST (OP) 1 N 4 B T ENVELOPE BACK REST (DR) 1 N 5 B G ENVELOPE BACKSTOP 1 Y 6 B G BACKSTOP HANDLE 1 N 7 B G BACKSTOP HANDLE BRACKET 1 N 8 C A P BACKSTOP SLIDER SPIGOT 4 Y 9 D A H RUBBER WHEEL 40D 40 SHORE 2 Y 10 E A K LOBE KNOB BLACK M6 x 16 2 Y 11 G1006A S SPRING TRACTOR 2 Y 12 G6176A X SIDE GUIDE TAPE 4 Y 13 R2392C H SPACER PLATE 2 Y Fixings 20 E A SCREW M3x6MM TORX PAN HD 2 21 E2826A SCREW M4x8 TORX PAN HD 2 22 E2746A SCREW M8x25 SKT CAP HD 2 23 E3505A NUT M4 NYLOC 4 24 E3525A NUT M8 NYLOC 2 25 E4011A M4 WASHER 2 26 E4026A M6 WASHER 2 27 E4044A M8 WASHER 2 SEE FIXING KIT FOR THIS ASSEMBLY A A ( Q) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY C4 Envelope Conveyor Backstop. - A A ( Q) Page 4-30

92 Exploded Views Issue 2 Jun 2012 N L J N M K L J NOTE 1) BRIDGE CLAMPS G4092A (ITEM 60) WITH M4 x 12 TORX HD SCREWS E2830A (ITEM 53) ARE FITTED IN ALL LOCATIONS MARKED 2) FOR LABEL COLLATE CLAM (ITEM 41) REFER TO LABEL SET - HEAD G A ( M) F H K M D B H C C G A E SENSORS Item Description Ref. S1 Collate Pocket RX 5.12 S2 Envelope Deskew TX 5.12 S3 Collate Pocket Load TX 5.12 A D E C4 Collate Clam Assy. - A A ( S) Page 4-31

93 Exploded Views Issue 2 Jun 2012 Item Part No. Description Qty. Spares B RIVET 4mm mm GRIP 2 Y W WIRED 24V BLOWER SM 1 Y 3 A A C INPUT SHAFT ASSY CLAM 1 Y 4 A A D OPENER I/P SHAFT ASSY CL 1 Y 5 A A E OPENER O/P SHAFT ASSY CL 1 Y 6 B A P COLLATE OVERGUIDE SPRING 2 Y 7 B A COLLATE CLAM ROOF ASSY 1 N 8 B A K OPENER (ASSEMBLY) C4 1 Y 9 B A COLLATE CLAM SIDE PL OP 1 N 10 B A COLLATE CLAM SIDE PL DR 1 N 11 B A COLLATE CLAM BRIDGE UPR 1 N 12 B A LATCH PLATE 2 N 13 B F COLLATE CLAM COVER 1 N 14 B A COLLATE SENSOR BRACKET 1 N 15 B A H COLLATE CENTRAL OVERGUIDE 1 Y 16 B A GUIDE LATCH BRACKET 1 N 17 B A BLOWER MOUNT BRACKET 1 N 18 A A R T BEARING HOUSING ASSEMBLY 6 Y 19 C A OVERGUIDE PIVOT SHAFT 1 N 20 C A OPENER PIVOT OPERATOR C4 1 N 21 C A OPENER PIVOT DRIVES C4 1 N 22 C I COLLATE CLAM HANDLE 1 N 23 C A COLLATE LATCH SHAFT 1 N 24 D A T CAP RECT VINYL 23x13x1.5 1 Y 25 E0291A A FOOT PUSH-IN 1 Y 26 E0375A M BUSH SNAP 12.7IDx6.4L 1 Y 27 N/R 28 E1108A B BEARING FLANGED 6x13x5 2 Y 29 G1025A J SPRING PRESSURE 6 Y 30 G1186A F CONVEYOR LATCH SPRING 1 Y 31 G1189A G LATCH SPRING LH 1 Y 32 G6028A Y SHIM BRAKE 4 Y 33 G6200A D GUIDE SHIM 1 Y 34 P2001A GUIDE SPIGOT 2 N 35 P2057A Z LATCH CLAMP SPIGOT 2 Y 36 B A OPENER STOP BKT 1 N 37 E0205A H M5 STOP CAP VINYL 1 Y 38 G1222A P TURNOVER SPRING 1 Y 39 C A OPENER STOP POST 1 N 40 E0003A L COVER STRIP 0.4M Y 41 G A* LABEL COLLATE CLAM 1 N C4 Collate Clam Assy. - A A ( S) FOR ITEM MARKED THUS(*), SEE NOTE 2 ON DRAWING. TO ORDER, QUOTE PART NO. G A ( M) Page 4-32

94 Exploded Views Item Part No. Description Qty. Spares Fixings 50 E2826A SCREW M4x8 TORX PAN HD E A SCREW M3x6 TORX CSK HD 2 52 N/R 53 E2830A SCREW M4x12 TORX PAN HD T/T 4 54 E2834A SCREW M4x10 TORX CSK HD 1 55 E3505A NUT M4 NYLOC 4 56 E4011A WASHER M E5003A CIRCLIP 7mm E TYPE 4 58 E5073A CIRCLIP 9.5mm E TYPE 2 59 E5081A CIRCLIP 4.5 E TYPE 2 60 G4092A BRIDGE CLAMP A/R SEE FIXING KIT FOR THIS ASSEMBLY A A ( J) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY C4 Collate Clam Assy. - A A ( S) Page 4-33

95 Exploded Views Issue 4 Jun 2012 X 57 SENSORS Item Description Ref. S1 Collate Pocket Input TX SA1 A C B A E SA C 56 G D J S1 G W F J 7 55 Y NOTE BRIDGE CLAMPS G4092A (ITEM 43) WITH M4 x 12 TORX HD SCREWS E2827A ARE FITTED IN ALL LOCATIONS MARKED H B 28 D K H W X P Y M 55 F A (x6) PULLEY 25T XL (ITEM 34) F5119A (x1.5) BELT SET 140XL O37 (ITEM 36) C A (x6) CONVEYOR WHEEL (ITEM 11) C A (x6) BELT BOBBIN (ITEM 10) C A (x6) CONVEYOR WHEEL (ITEM 11) Head Input Conveyor Upper A A ( X) Page 4-34

96 Exploded Views Issue 3 Jun 2012 Item Part No. Description Qty. Spares 1 B A CONVEYOR SIDE PLATE DR 1 N 2 B A CONVEYOR SIDE PLATE OP 1 N 3 B A BOBBIN BRACKET 6 N 4 B A LATCH CONVEYOR DRIVE 1 N 5 B A LATCH CONVEYOR OP 1 N 6 N/A 7 B A CONVEYOR BRIDGE 1 N 8 B9313A CENTRAL OVERGUIDE 4 N (See Spares Assy 2) 9 A A R T BEARING HOUSING ASSEMBLY 2 N (See Spares Assy 1) 10 C A L BELT BOBBIN 6 Y 11 C A M CONVEYOR WHEEL 12 Y 12 N/A 13 N/A 14 C2751A WASHER D SHAFT 2 N 15 C A N IDLER PIN 6 Y 16 C I LATCH HANDLE 1 N 17 C A CONVEYOR LATCH SHAFT 1 N 18 C A OVERGUIDE PIVOT SHAFT 1 N 19 C A IDLER PULLEY SHAFT 2 N 20 C A UPPER CONV. DRIVE SHAFT 10mm 1 N 21 C A CONV. P. WHEEL SHAFT 1 N 22 C9278A SENSOR POST 106mm 1 N 23 D A SOFT RUBBER WHEEL 40 DIA 4 N (See Spares Assy 1) 24 D1040A J T BEARING 8mm 12SQ 16 Y 25 E0367A N WASHER WAVED 23mm 12 Y 26 E0375A M BUSH SNAP 12.7I/D x 6.4L 1 Y 27 E0475A U WAVED WASHER EPL5 1 Y 28 E A U BEARING BALL FL 10 x 22 x 6 26 Y 29 E1078A L BEARING FL 8 x 22 x 7mm 12 Y 30 N/R BEARING BALL 6 x 13 x 5 4 N (See Spares Assy 1) 31 E1114A 32 E A V WAVY WASHER 6.73 I/D 0.76 H 9.32 O/D 2 Y 33 E4033A H WASHER WAVED 8.89 I/D,12.5 O/D 12 Y 34 F A B PULLEY 25T XL x 10 DIA 6 Y 35 F A E GEAR 40T 1M 10 I/D 1 Y 36 F5119A A BELT 140XL 037 POLYURETHANE 1.5 Y 37 G A P BELT TENSION SPRING 0.51 DIA 12 Y 38 G A SEALER SPRING 2 N (See Spares Assy 1) 39 G1182A C SPRING CONVEYOR 2 Y 40 G1184A B SPRING LATCH RH 1 Y Head Input Conveyor Upper - A A ( X) Page 4-35

97 Exploded Views Issue 2 Jan 2012 Item Part No. Description Qty. Spares 41 G1185A P SPRING LATCH LH 1 Y 42 G1206A OVERGUIDE SPRING 4 N (See Spares Assy 2) 43 G4092A BRIDGE CLAMP 6 N 44 G A G SPRING CONV. INPUT 2 Y 45 E0425A Q WASHER 10.2 x 2 1 Y Fixings 50 E2826A M4 x 8mm TORX PAN HD SCREW 2 51 E2832A M4 x 10mm TORX PAN HD SCREW 1 52 E2830A M4 x 12mm TORX PAN HD SCREW T/T 6 53 E A M4 x 16mm TORX PAN HD SCREW 2 54 E3505A M4 NYLOC NUT 2 55 E5092A 12mm E TYPE CIRCLIP 2 56 E5073A 9.5mm E TYPE CIRCLIP 6 57 E5076A 7mm E TYPE CIRCLIP 2 58 E5086A PIN DOWEL 3 DIA x 16mm 6 59 E5105A PIN DOWEL 3 DIA x 24mm 1 SEE FIXING KIT FOR THIS ASSEMBLY A A ( T) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY. Spares assemblies SA1 A A R CONV. P. WHEEL SHAFT ASSY A/R SA2 A A S CENTRAL OVERGUIDE ASSY A/R Head Input Conveyor Upper - A A ( X) Page 4-36

98 Exploded Views Issue 2 Mar A B 14 BELT FITTING DIAGRAM F A (x6) PULLEY 25T XL (ITEM 13) F5120A (x1.5) BELT SET 130XL O37 (ITEM 14) C A (x6) CONVEYOR WHEEL (ITEM 3) C4 Head Input Conv. Lower - A A ( D) Page 4-37

99 Exploded Views Item Part No. Description Qty. Spares 1 B A PULLEY IDLER BRACKET 6 N 2 B A LOWER CONVEYOR BODY 1 N 3 C A CONVEYOR WHEEL 6 N 4 N/R 5 C A BEARING POST 2 N 6 C A N IDLER PIN 6 Y 7 C A LOWER CONV. DR. SHAFT 1 N 8 D1040A J T BEARING 8mm 12 SQ. 12 Y 9 E0367A N WASHER WAVED 23mm ID 1 Y 10 E A U BEARING BALL FL 10x22x6 2 Y 11 E1078A L BEARING FL 8x22x7mm 12 Y 12 E4033A H WASHER WAVED 8.89ID, 12.5OD 12 Y 13 F A B PULLEY 25T XL x 10 BORE 6 Y 14 F5120A C BELT 130XL 037 POLYURETHENE 1.5 Y 15 G1111A S SPRING LIGHT PRESSURE 12 Y Fixings 20 E3505A M4 NYLOC NUT 1 21 E5092A 12mm E TYPE CIRCLIP 4 22 E5073A 9.5mm E TYPE CIRCLIP 4 23 E5086A PIN DOWEL 3 DIA x 16mm 2 24 N/R SEE FIXING KIT FOR THIS ASSEMBLY A A C NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY C4 Head Input Conv. Lower - A A ( D) Page 4-38

100 Exploded Views S1 SENSORS Item Description Ref. S1 AC Motor Disc 5.12 Note: Belt F5112A (Item 13) is also shown on Chassis Drive Side (Rear) see (Section 4.2) Motor Assy. - A A ( Y): 115V or A A ( Z): 230V Page 4-39

101 Exploded Views Item Part No. Description Qty. Spares MOTOR ASSEMBLY 115V: A A ( Y) G MOTOR W/D Y W PCB WIDEBODY DISK SENSOR 1 Y 3 B A TENSION BRACKET 1 N 4 B A MOTOR BRACKET 1 N 5 B A SINGLE SLOT DISC 1 N 6 C A BEARING POST 1 N 7 E0181A K FAN 2 5/8 DIA CCW 1 Y 8 E1061A B BEARING BALL 8x16x5mm 2 Y 9 E4033A H WASHER WAVED 8.89ID,12.5 OD 1 Y 10 F1373A S PULLEY 15T S2M MOTOR 1 Y 11 G1006A S SPRING TRACTOR 1 Y 12 P2448A W BELT IDLER 1 Y 13 F5112A W BELT 100-S2M Y Fixings 15 E A SCREW M5 x 10mm TORX PAN HD E2505A SCREW M4 x 6mm SOCKET SET 2 17 E2502A SCREW M3 x 8mm CSK HD E3505A M4 LOCKNUT 2 19 E5073A 9.5mm E CLIP 2 SEE FIXING KIT FOR THIS ASSEMBLY A A ( X) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY. See following page for 230V Motor Assy Motor Assy. - A A ( Y): 115V Page 4-40

102 Exploded Views Item Part No. Description Qty. Spares MOTOR ASSEMBLY 230V: A A ( Z) K MOTOR W/D Y W PCB WIDEBODY DISK SENSOR 1 Y 3 B A TENSION BRACKET 1 N 4 B A MOTOR BRACKET 1 N 5 B A SINGLE SLOT DISC 1 N 6 C A BEARING POST 1 N 7 E0181A K FAN 2 5/8 DIA CCW 1 Y 8 E1061A B BEARING BALL 8x16x5mm 2 Y 9 E4033A H WASHER WAVED 8.89ID,12.5 OD 1 Y 10 F1372A C PULLEY 18T S2M MOTOR 1 Y 11 G1006A S SPRING TRACTOR 1 Y 12 P2448A W BELT IDLER 1 Y 13 F5112A W BELT 100-S2M Y Fixings 15 E A SCREW M5 x 10mm TORX PAN HD E2505A SCREW M4 x 6mm SOCKET SET 2 17 E2502A SCREW M3 x 8mm CSK HD E3505A M4 LOCKNUT 2 19 E5073A 9.5mm E CLIP 2 SEE FIXING KIT FOR THIS ASSEMBLY A A ( X) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY. See previous page for 115V Motor Assy Motor Assy. - A A ( Z): 230V Page 4-41

103 Exploded Views Issue 5 Sep 2012 H H B M J M J A E G A G E C B F D C NOTE D BRIDGE CLAMPS G4092A (ITEM 27) WITH M4 x 12 TORX PAN HD F SCREWS E2827A (ITEM 36) ARE FITTED IN ALL LOCATIONS MARKED Sealer Assembly - A A ( V) Page 4-42

104 Exploded Views Issue 4 Sep 2012 Item Part No. Description Qty. Spares F SWITCH MAGNET SMALL 1 Y 2 B A SEALER ROLLER BKT ASSY 1 N 3 N/A 4 B F LATCH BRACKET 1 N 5 B A SEALER ASSY BRIDGE 1 N 6 B A SEALER LATCH ARM DR. 1 N 7 B A SEALER LATCH ARM OP. 1 N 8 B G SEALER SIDE ARM DR. 1 N 9 B G SEALER SIDE ARM OP. 1 N 10 B G W SEALER OUTFEED COVER 1 Y 11 B A GUIDE PLATE 1 N 12 A A R T BEARING HOUSING ASSEMBLY 4 Y 13 N/A 14 C A E SEALER ASSY PIVOT 2 Y 15 C A IDLER POST SHORT 1 N 16 C A SEALER LATCH PIVOT 1 N 17 C A C UPPER SEAL ROLLER 48 DIA 2 Y 18 E0367A N WASHER WAVED 23mm I/D 1 Y 19 E0475A U WAVED WASHER EPL5 1 Y 20 E A U BEARING BALL FL 10x22x6 4 Y 21 N/R 22 E A V WAVY WASHER 6.73 I/D 0.76H 4 Y 23 F A J GEAR 48T 1M IDLER 1 Y 24 F4182A J GEAR 35Tx8mm 1.0M 2 Y 25 G A Z SEALER SPRING 2 Y 26 G1091A A SPRING SEPARATOR 2 Y 27 G4092A U BRIDGE CLAMP 6 Y 28 G A F CLOSER SPRING 1.2 N/mm 2 Y 29 G A H AC FOAM SEALER OUFEED 1 Y 30 G A J AC FOAM OUTFEED UPPER 1 Y 31 B A F GUIDE SPRING 1 Y A EARTH BRAID 0.75M 1 Y Sealer Assembly - A A ( V) Page 4-43

105 Exploded Views Issue 2 Sep 2012 Item Part No. Description Qty. Spares Fixings 35 E A M5 x 10 TORX PAN HD SCREW 1 36 E2827A M4 x 12 TORX PAN HD SCREW 6 37 E2834A M4 x 10 TORX CSK HD SCREW 4 38 E A M4 x 12 TORX CSK HD SCREW 2 39 E A M3 x 8 TORX CSK HD SCREW 2 40 E2559A M3 x 10 PAN HD SCREW 2 41 E3505A M4 NYLOC NUT 2 42 E3557A M3 NYLOC NUT 2 43 E5071A PIN DOWEL 3 DIA x E5092A CIRCLIP 12mm E TYPE 2 45 E5073A CIRCLIP 9.5mm E TYPE 2 46 E5003A CIRCLIP 7.0mm E TYPE 4 47 G6028A BRAKE SHIM A/R 48 E2826A M4 x 8 TORX PAN HD SCREW 2 SEE FIXING KIT FOR THIS ASSEMBLY A A ( G) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Sealer Assembly - A A (911) FIXING KIT Page 4-44

106 Exploded Views SENSORS Item Description Ref. S1 Collate Pocket Load RX 5.12 S Split Shaft Sub-Assemblies A2-1059/1060/1061-A (911012M/ N/ P) Page 4-45

107 Exploded Views Item Part No. Description Qty. Spares A A P SPLIT SHAFT OPERATOR 1 Y 1 C4319A SPLIT SHAFT HOUSING 1 N 2 C A SPLIT SHAFT SHORT 1 N 3 D0045A ROLLER TRANSPORT NOTCHED 1 N 4 E0367A WASHER WAVED 23mm I/D 1 N 5 E A BEARING BALL FL 2 N 6 P2048A SPIGOT 2 N 7 B A SPLIT SHAFT COVER 1 N A A M SPLIT SHAFT CENTRE 1 Y 10 C A SPLIT SHAFT HOUSING 1 N 11 C A SPLIT SHAFT CENTRE 1 N 12 D0045A ROLLER TRANSPORT NOTCHED 2 N 13 E1102A BEARING FL 8x19x6mm 2 N 14 E4033A WASHER WAVED 1 N 15 F4152A GEAR 25Tx8mm 1.0M 1 N 16 G6028A SHIM BRAKE 1 N 17 B A COLLATE SENSOR BRACKET 1 N 18 C A COLLATE PANEL PIVOT 1 N 19 G1016A B SPRING 1 Y A A N SPLIT SHAFT DRIVES 1 Y 25 C4319A SPLIT SHAFT HOUSING 1 N 26 C A SPLIT SHAFT LONG 1 N 27 D0045A ROLLER TRANSPORT NOTCHED 1 N 28 E0367A WASHER WAVED 23mm I/D 1 N 29 E A BEARING BALL FL 2 N 30 P2048A SPIGOT 2 N 31 B A SPLIT SHAFT COVER 1 N Fixings 40 E2826A SCREW M4 x 8mm TORX PAN HD E5071A PIN DOWEL 3 DIA x 14mm 1 42 E5092A 12mm E TYPE CIRCLIP 2 43 E5073A 9.5mm E TYPE CIRCLIP 2 SEE FIXING KIT FOR THIS ASSEMBLY A A ( Q). ORDER THIS KIT FOR ANY ONE ASSY, OR ALL 3. NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Split Shaft Sub-Assemblies A2-1059/1060/1061-A (911012M/ N/ P) Page 4-46

108 Exploded Views NOTE BRIDGE CLAMPS G4092A (ITEM 48) WITH M4 x 12 TORX HD SCREWS E2830A ( ITEM 63) ARE FITTED IN ALL LOCATIONS MARKED SENSORS Item Description Ref. S1 Finger Datum (flag) 5.12 S2 Finger Disc 5.12 S1 S Finger Assembly - A A ( G) Page 4-47

109 Exploded Views Issue 2 Jan 2013 Item Part No. Description Qty. Spares E RIVET 3.5mm GRIP 4 Y M WIRED MOTOR 1 Y H SOLENOID W/D (MIDDLE) 1 Y 3a H SOLENOID W/D (DR) 1 Y S PCB SPLITTER 3 SEN 4 SOL H/D (No. 7) 1 Y 5 B A FINGER CHASSIS 1 N 6 B A FINGER STOP BRACKET DR 1 N 7 B A FINGER SOLENOID BRACKET 1 N 8 B A INNER SOLENOID BRACKET 1 N 9 B A SOLENOID SUPPORT BRACKET 1 N 10 B Z R FINGER OUTER DRIVES C4 1 Y 11 B Z S FINGER OUTER OPERATOR C4 1 Y 12 B A T FINGER MIDDLE DRIVES C4 1 Y 13 B A U FINGER MIDDLE OP C4 1 Y 14 B A FINGER SENSOR FLAG 1 N 15 B A FINGER DISK SENSOR BKT 1 N 16 B A V INSERTION FINGER SUPPORT 2 Y 17 B A INNER FINGER DRIVE BKT 1 N 18 B A E FINGER PIVOT BRACKET DR 1 Y 19 B A W FINGER S/GUIDE OPERATOR 1 Y 20 B A X FINGER S/GUIDE DRIVES 1 Y 21 B4330A DISC ASSEMBLY 1 N 22 B7433A SENSOR BRACKET 1 N 23 C A Y FINGER PIN C4 8 Y 24 C A Z FINGER SPACER 4 Y 25 C A FINGER BUSH 2 N 26 C A FINGER PIVOT 1 N 27 C A A SOLENOID PIN 1 Y 28 C A FINGER NUT OPERATOR 1 N 29 C A FINGER NUT DRIVES 1 N 30 C A B INNER FINGER DRIVE SHAFT 1 Y 31 C A INNER FINGER PIVOT 1 Y 32 C A ADJUSTMENT SHAFT 1 Y 33 C A FINGER ROD 1 Y 34 C A INNER FINGER BODY 2 Y 35 D1040A J T BEARING 8mm 12 SQ. 4 Y 36 D1076A S T BEARING 6mm 10 SQ. 2 Y 37 D1080A MOULDED FINGER BODY 2 N 38 E0204A R VINYL PROTN CAP 3.5x Y 39 E0291A A FOOT PUSH-IN 5 Y Finger Assembly - A A ( G) Page 4-48

110 Exploded Views Item Part No. Description Qty. Spares 40 E0375A BUSH SNAP 12.7 I/D x 6.4L 1 Y 41 F4175A E GEAR 45Tx6mm 0.7M 1 Y 42 F4176A F GEAR 35Tx6mm 0.7M 1 Y 43 G0079A L CLUTCH PIN 1 Y 44 G A Q SPRING LINK 1 Y 45 G A C FINGER SPRING C4 4 Y 46 G A K MIDDLE FINGERS SPRING 1 Y 47 G1152A L SPRING SOLENOID 1 Y 48 G4092A BRIDGE CLAMP 6 N 49 P2031A SHAFT ADAPTOR 1 N A SENSOR PCB FINGER DATUM (FLAG) 1 Y 50a A SENSOR PCB FINGER DISC 1 Y Fixings 60 E A M4 x 25mm TORX PAN HD SCREW 1 61 E2571A M3 x 5mm SOCKET SET SCREW 1 62 E2826A M4 x 8mm TORX PAN HD SCREW 6 63 E2830A M4 x 12mm TORX PAN HD SCREW 2 64 E3557A M3 NYLOC NUT 4 65 E4072A M20 WASHER INT SH/PROOF 2 66 E5073A CIRCLIP 9.5mm E TYPE 3 67 E5076A CIRCLIP 7mm E TYPE 2 68 E5082A PIN GROOVED 2.5 x E2774A M2 x 6mm POZI CSK HD SCREW 1 SEE FIXING KIT FOR THIS ASSEMBLY A A ( F) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Finger Assembly - A A ( G) Page 4-49

111 Exploded Views Finger Bkt. Op Assembly - A A ( L) Page 4-50

112 Exploded Views Issue 2 Jan 2013 Item Part No. Description Qty. Spares H SOLENOID W/D XH 1 Y 2 B A FINGER BRACKET OPERATOR 1 N 3 B A FINGER SOLENOID BRACKET 1 N 4 B A FINGER STOP BKT OPERATOR 1 N 5 B A D FINGER PIVOT BRACKET OP 1 Y 6 C A FINGER PIVOT 1 N 7 D1040A J T BEARING 8mm 12SQ 2 Y 8 E0204A VINYL PROTN CAP 3.5x N 9 G0079A L CLUTCH PIN 1 Y 10 G A Q SPRING LINK 1 Y 11 G1152A L SPRING SOLENOID 1 Y Fixings 20 E2826A SCREW M4 x 8mm TORX PAN HD 2 21 E A SCREW M4 x 25mm TORX PAN HD 1 22 E4072A WASHER M20 INT SH/PROOF 1 23 E4011A M4 WASHER 2 24 E3502A M4 FULL NUT 2 25 E5073A CIRCLIP 9.5mm E TYPE 2 SEE FIXING KIT FOR THIS ASSEMBLY A A ( K) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Finger Bkt. Op Assembly - A A ( L) Page 4-51

113 Exploded Views S2 S1 SENSORS Item Description Ref. S1 Side Guide Disc 5.12 S2 Side Guide Datum (flag) Side Guide Adjust Assembly - A A ( K) Page 4-52

114 Exploded Views Item Part No. Description Qty. Spares E RIVET 3.5mm GRIP 4 Y M WIRED MOTOR 1 Y W PCB WIDEBODY DISC SENSOR 2 Y 4 B4330A DISC ASSEMBLY 1 N 5 B7478A SIDEGUIDE MOTOR BRACKET 1 N 6 B7498A GUIDE CARRIER 2 N 7 C3476A FINGER NUT RH 1 N 8 C3477A FINGER NUT LH 1 N 9 C A ADJUSTMENT SHAFT 1 N 10 C6340A GUIDE CARRIER 2 N 11 D1076A S T BEARING 6mm 10SQ 1 Y 12 E A H O RING 6.1I/D x 9.3O/D 4 Y 13 F4175A E GEAR 45Tx6mm 0.7M 1 Y 14 F4176A F GEAR 35Tx6mm 0.7M 1 Y 15 P2031A SHAFT ADAPTOR 1 N 20 E2826A SCREW M4 x 8mm TORX PAN HD 2 21 E2571A SCREW M3 x 5mm SOCKET SET 2 22 E2774A SCREW M2 x 6mm POZI CSK HD 2 23 E5082A PIN GROOVED 2.5 DIA x 12mm 2 24 E5076A CIRCLIP 7mm E TYPE 4 SEE FIXING KIT FOR THIS ASSEMBLY A A ( J) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Spares Assemblies SA1 A A P GUIDE CARRIER ASSY RH A/R SA2 A A Q GUIDE CARRIER ASSY LH A/R Side Guide Adjust Assembly - A A ( K) Page 4-53

115 Exploded Views Pawl Tension Bracket Assy - A A ( N) Page 4-54

116 Exploded Views Item Part No. Description Qty. Spares 1 B A PAWL TENSION BRACKET 1 N 2 C A GEAR IDLER SHAFT 2 N 3 C A UPPER SPROCKET IDLE SHAFT 1 N 4 D1040A J T BEARING 8mm 12 SQ 6 Y 5 E1102A S BEARING FL 8x19x6mm 4 Y 6 F C B IDLE SPROCKET 15T 2 Y 7 F4156A B GEAR 30Tx8mm 1.0M 2 Y 8 G1117A X SPRING HEAVY PRESSURE 2 Y 9 G6028A Y SHIM BRAKE 2 Y 15 E3505A M4 NYLOC NUT 1 16 E5071A DOWEL PIN 3 DIA x 14mm 1 17 E5073A CIRCLIP 9.5mm E TYPE 2 SEE FIXING KIT FOR THIS ASSEMBLY A A ( M) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Pawl Tension Bracket Assy - A A ( N) Page 4-55

117 Exploded Views SENSORS Item Description Ref. S1 Wetter Down (flag) Wetter Lever Assy - A A ( W) Page 4-56

118 Exploded Views Item Part No. Description Qty. Spares E PLASTIC RIVET 3.5mm GRIP 2 Y H SOLENOID W/D XH SDT2652L628 1 Y 3 B A PIVOT ARM 1 N 4 B A WETTER SOLENOID BKT 1 N 5 B A WETTER LEVER 1 N 6 B A BEAM ADJ PLATE 1 N 7 C A BEARING SPIGOT 1 N 8 C A LEVER BEARING HOLDER 1 N 9 C A PIVOT BEARING HOLDER 1 N 10 C A BEARING SPIGOT 2 N 11 C A ACTUATOR ROD 1 N 12 E A A BEARING NEEDLE 4 IDx8x8 1 Y 13 E A J BEARING 5IDx7ODx10LONG 1 Y 14 E1088A Q BEARING BALL 4x12x4 SHLD 604ZZ 4 Y 15 G A P SPRING SOLENOID 1 Y A PCB WIDEBODY DISK SENSOR 1 Y Fixings 20 E A SCREW M4x6MM TORX PAN HD ST/STL 2 21 E A SCREW M4x16MM TORX CSK HD 2 22 E A SCREW M3x8 TORX PAN HD 4 23 E4011A WASHER M4 FORM A BZP 2 24 E5099A GROOVED PIN S80 3x18LG 1 SEE FIXING KIT FOR THIS ASSEMBLY A A ( Z) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Wetter Lever Assy - A A ( W) Page 4-57

119 Exploded Views DETAIL SHOWN IS PART OF WETTER LEVER ASSEMBLY (A A) SEE EXPLODED WIEW SECTION Wetter Beam Assembly Page 4-58

120 Exploded Views Issue1 Dec 2011 Item Part No. Description Qty. Spares 1 B A WETTING BEAM 1 N 2 C A D BEAM PIVOT BASE 2 Y 3 E1077A K FLANGED BEARING 4mm BORE 2 Y 4 E A M M4 x 6mm TORX PAN HD. SCREW 2 Y 5 E2826A A M4 x 8mm TORX PAN HD. SCREW 2 Y Wetter Beam Assembly Page 4-59

121 Exploded Views Wetter Tank Assy - A A ( D) Page 4-60

122 Exploded Views Item Part No. Description Qty. Spares A A 911 WETTER TANK ASSY 1 Y 1 A A FELT ON FELT BRIDGE 1 N 2 B A WETTER TANK 1 N 3 C3482A OVERFLOW PIPE 1 N 4 D A VINYL CAP 23x13x1.5 BLUE 1 N 5 E0235A O RING (12.1 x 1.6) 1 N 6 P2375A NUT M12 5mm 1 N A A J FELT ON FELT BRIDGE 1 Y RIVET 5mm mm GRIP 1 N 11 B A FELT BRIDGE ASSEMBLY 1 N 12 G A WETTER FELT C4 1 N B A FELT BRIDGE ASSY 15 B A FELT BRIDGE 2 1 N 16 B A FELT BRIDGE 1 1 N 17 C A SPACER RIVET 7 N Wetter Tank Assy - A A ( D) Page 4-61

123 Exploded Views Issue1 Dec No Seal Assembly - A A ( E) Page 4-62

124 Exploded Views Issue1 Dec 2011 Item Part No. Description Qty. Spares H SOLENOID W/D XH 1 Y 2 B A NO SEAL SOLENOID BKT 1 N 3 B A NO SEAL BRACKET 1 N 4 B A NO SEAL COMB 1 N 5 E0204A VINYL PROTN CAP 3.5 x N 6 E0253A INSERT FOOT N 7 E1077A K FLANGED BEARING 4mm BORE 2 Y 8 G0167A Z EC30 CLUTCH PIN 1 Y 9 G A Q SPRING LINK 1 Y 10 G1152A L SPRING SOLENOID 2 Y Fixings 15 E2827A SCREW M4 x 12mm TORX PAN HD 2 16 E2826A SCREW M4 x 8mm TORX PAN HD 2 17 E4072A WASHER M20 INTERNAL SH/PROOF 1 18 E4011A WASHER M4 4 SEE FIXING KIT FOR THIS ASSEMBLY A A ( C) NOTE: FIXINGS ARE NOT AVAILABLE INDIVIDUALLY No Seal Assembly - A A ( E) Page 4-63

125 Exploded Views Head Ribbon Bkt. Assy ( U) Page 4-64

126 Exploded Views Item Part No. Description Qty. Spares U LOOM C4 HEAD RIBBON SET 1 Y 2 B A RIBBON PLATE 1 N 3 B A RIBBON BRIDGE 1 N 4 E3505A Y M4 NYLOC NUT 2 Y 5 E4011A U M4 WASHER 2 Y Head Ribbon Bkt. Assy ( U) Page 4-65

127 Exploded Views C4 Universal Head PSU ( K) Page 4-66

128 Exploded Views C4 Mains Input Pluggable ( X) Page 4-67

129 Exploded Views C4 Mains Input Hardwired ( V) - Optional Page 4-68

130 Exploded Views C4 External Float Switch - A A ( J) Page 4-69

131 Exploded Views Item Part No. Description Qty. Spares TUBE CLEAR FOR PERI/PMP 0.4 M N CABLE TIE 200 x N FLOAT SWITCH WAND ASSY 1 N 4 E A PIPE CONNECTOR 5mm I/D 1 N NOTE: FOR REPLACEMENT, ONLY THE COMPLETE ASSY J CAN BE ORDERED C4 External Float Switch - A A ( J) Page 4-70

132 Exploded Views C4 Catch Tray Assy - A A ( D) Page 4-71

133 Exploded Views Item Part No. Description Qty. Spares 1 B H BACK STOP 1 N 2 B H SIDE GUIDE OP 1 N 3 B H SIDE GUIDE DR 1 N 4 B H TRAY BASE 1 N 5 E0330A WING BOLT NYLON M5 x 15 2 N 6 E4037A WASHER EXT FAN TAIL M5 2 N NOTE: FOR REPLACEMENT, ONLY THE COMPLETE ASSY. ( D) CAN BE ORDERED C4 Catch Tray Assy - A A ( D) Page 4-72

134 Exploded Views Operator Side Drive Side Inserter Head Covers Page 4-73

135 Exploded Views ITEM 1 A A ( Z) COVER ASSY OP ACCESS D/C SWITCH MAGNET SMALL 1 B T ACCESS COVER OP (ASSY) 1 B A COVER MAGNET BRACKET 1 E A STICK-ON BUMPER FOOT 2 E0176A MAGNETIC CATCH 200 SERIE 1 E A SCREW M3x8TORX PAN HD MC MACHINE 2 E3505A NUT M4 NYLOC DIN 985 BZP 2 E3557A NUT M3 NYLOC DIN 985 BZP 2 G A AC FOAM HEAD ACCESS OP 1 None of the above items are available individually ITEM 2 B T ( A) FIXED COVER OP (ASSY) 1 B A FIXED COVER OP 1 B A COVER BRACKET 1 B A COVER PLATE OP 1 None of the above items are available individually Separate Items Item Part Number Description Qty 5 B G E TRACTOR COVER LOWER 1 6 B G V OUTPUT COVER 1 7 B T F OUTPUT COVER SKIRT 1 8 B T G COVER SKIRT OP 1 9 B T H CONVERSION PLATE 1 10 B T J SIDE GUIDE INFILL PLATE OP 1 11 B T K SIDE GUIDE INFILL PLATE DR 1 12 B T L BACKSTOP SUPPORT BRACKET 1 13 B T M ENVELOPE BACKSTOP OP 1 14 B T N ENVELOPE BACKSTOP DR 1 ITEM 3 B T ( B) SIDE COVER DR (ASSY) 1 B A SIDE COVER DR 1 B A COVER BRACKET I/P 1 B A COVER BRACKET O/P 1 B A DRIVE COVER 1 B A COVER PLATE DR 1 None of the above items are available individually ITEM 4 B T ( C) TRACTOR COVER ASSY 1 B A TRACTOR COVER SHELL 1 B A TRACTOR COVER PLATE 1 E2618A S/CLINCH STUD M4x10 2 E2623A S/CLINCH STUD M4x8 BZP 2 E2729A S/CLINCH STUD M4x Inserter Head Covers Page 4-74

136 Issue 2 Feb ,21 22 IN 12 PLACES ,20 5 7,11 8,11 4 3,20 7,11 8,11 10,13 1,2 8,11 9 7, Monitor Arm Page 4-75