SECTION 4 - EXPLODED VIEWS

DS-1200 G3 Service Manual Page 4a-1 Issue SECTION 4 - EXPLODED VIEWS Head Assembly Page 4a.1 Opener Assembly 4a-7 Continued for Track Pair, Feeders, Folders, Collator, Hi-Cap, 4a.2 Divert Assembly 4a- Std-Cap, Covers & Stands, O/P Processor, Flatbed Feeder, 4a.3 Divert Assy - Sub-Assys. 4a-12 Single O/L I/Face, Vertical Stacker, Schneider Conveyor 4a.3a Divert Assy - Sub Assys 4a-14 4a.4 Env. Conveyor Assy 4a-16 4a.5 Env. Conveyor: Sub Assys 4a-18 4a.6 Env. Opener Assy: Sub Assys 4a-20 4a.7 Insert Plate Hinged Assy 4a-22 4a.8 Handover Assy. 4a-24 4a. Handover Drive Assy 4a-26 4a. Handover Bridge Assy. 4a-28 4a.11 Turnover Assy. 4a-30 4a.12 Insert & Top Plate Options 4a-33 4a.13 Turnover Eject Kicker 4a-35 4a.14 Gearbox Assy 4a-37 4a.15 Kicker Assy. 4a-3 4a.16 Kicker Sub Assys 4a-42 4a. Finger Shaft Assy: Sub Assys 4a-44 4a.18 Wetter/Closer Assy 4a-46 4a.1 Wetter/Closer Sub Assys 4a-48 4a.20 Wetter Assy. 4a-50 4a.21 Carrier Assy. 4a-52 4a.22 Tower Base Assy. (Mk.2) 4a-54 4a.23 Wetter Pump Assy. 4a-56 Page 4a-1

DS-1200 G3 Service Manual Page 4a-2 Issue SECTION 4 - EXPLODED VIEWS (Contd.) Track Pair Feeders / Folder etc. Page 4b.1 Shuttle Assy. 4b-1 4c.1 Feeder Assy. 4c-1 4b.2 Idler Shaft Assy. 4b-3 4c.2 Feeder Sub-assys. 4c-4 4b.3 Shuttle Bed Assy. 4b-5 4c.3 Separator (Feeder) Assy. 4c-6 4b.3a Backstop Motor Assy. 4b-7 4c.4 Feeder Conveyor Assy. 4c-8 4b.4 Feed Interface Assy. 4b- 4c.5 Folder Assy. 4c-11 4b.5 Lower Conveyor Assy. 4b-11 4c.6 Fold Plate 1 / 3 Assy. 4c-15 4b.6 Upper Conveyor Assy. 4b-13 4c.7 Fold Plate 2 Assy. 4c- 4b.7 Idler Assy. 4b-15 4c.8 Folder Sub-assys. 4c-1 4b.8 Track Cassette Assy. 4b- 4c. Hi-Cap Feeder LH Front/Feed Area 4c-21 4b.8a Itrack Belt Guide Assy. (1200) 4b-1 4c. Hi-Cap Feeder Sub Assys. 1 4c-24 4b. Motor Bracket Assy. 4b-21 4c.11 Hi-Cap Feeder Sub Assys. 2 4c-26 4b. Solenoid Stop Assy. 4b-23 4c.12 Hi-Cap Separator Sub Assys. 3 4c-28 4b.11 Infeed Structure Assy. 4b-25 4c.13 Hi-Cap Feeder RH Front 4c-30 4b.12 Overguide Assy. 4b-27 4c.14 Hi-Cap Feeder LH/RH Rear 4c-32 4c.15 Hi-Cap Tray Lift Runners 4c-34 4c.16 Hi-Cap Paper Trolley 4c-36 4c. Runner Bracket Assy. 4c-38 4c.18 Collate Unit Assy. 4c-40 Continued for Std-Cap, Covers & Stands, O/P Processor, Flatbed Feeder, Single O/L I/Face, Vertical Stacker, Schneider Conveyor 4c.1 Collate Unit Sub Assys. 4c-42 4c.20 Collate Chassis Assy. 4c-44 Page 4a-2

DS-1200 G3 Service Manual Page 4a-3 Issue Feeders / Folder etc. (cont.) SECTION 4 - EXPLODED VIEWS (Contd.) Page 4c.21 Pocket Frame Assy. 4c-46 4c.21a Pocket Frame Sub Assys. 4c-48 4c.21b Pocket Kicker Assy. 4c-50 4c.22 Lower Conveyor Assy. (1200) 4c-52 4c.23 Lower Conveyor Sub Assys. (1200) 4c-54 4c.24 Upper Conveyor Assy. 4c-56 4c.25 Upper Conveyor Sub Assys. 4c-58 4c.26 AM5 Acc Reader Kit. 4c-60 4c.27 AM5 Acc Reader Kit. 4c-62 4c.28 Divert Assy. (Forms) 4c-64 4c.2 Divert Sub Assys. 1 4c-67 4c.30 Divert Sub Assys. 2 4c-6 4c.31 Divert Sub Assys. 3 4c-71 4c.32 Franker Interface Assy. 4c-73 4c.33 OMR/Barcode Reader Assy. 4c-75 4c.34 OMR/Barcode Reader Sub Assys. 4c-78 4c.35 OMR/Barcode Reader Sub Assys. 1 4c-80 4c.36 OMR/Barcode Reader Sub Assys. 2 4c-82 4c.37 OMR/Barcode Feeder Assy. 4c-84 4c.38 OMR/Barcode Feeder Sub Assys. 4c-86 Standard-Cap Feeder Page 4c.3 Standard-Cap Feeder LH/Feed Area 4c-88 4c.40 Standard-Cap Feeder Sub Assys 1 4c-1 4c.41 Standard-Cap Feeder Sub Assys 2 4c-3 4c.42 Standard-Cap Feeder Sub Assys 3 4c-5 4c.43 Standard-Cap Feeder RH Side 4c-7 4c.44 Runner Bracket Assy 4c- 4c.45 Add-on Drive Exp 4c-1 4c.46 Autoread Base Assy. 4c-3 4c.47 Autoread X Drive Assy 4c-5 4c.48 Autoread Camera Light Assy 4c-7 4c.4 Monitor 2 Arm Assy 4c- 4c.50 Computer Enclosure 4c-111 4c.51 Computer Enclosure MK2 4c-113 4c.52 Tecnau Cutter Interface Assy 4c-115 4c.53 Tecnau Lower Belt Assy 4c-1 4c.54 Tecnau Upper Belt Assy 4c-11 4c.55 Tecnau Clutch/Brake Assy 4c-121 4c.56 Tecnau Sub Assys 1-2 4c-123 4c.57 Tecnau Sub Assys 3-4 4c-125 4c.58 Tecnau Tension Plate Assy 4c-127 4c.5 Web calmer Fan Assy 4c-12 Continued for O/P Processor, Flatbed Feeder, Single O/L I/Face, Vertical Stacker, Schneider Conveyor Page 4a-3

DS-1200 G3 Service Manual Page 4a-4 Issue SECTION 4 - EXPLODED VIEWS (Contd.) 4c.60 Tecnau Upgrade Kit 4c-131 4d.12 Flat Material Feeder 4d-12 4c.61 Tecnau Cutter Trim Box 4c-133 4d.13 Flat Material Feeder (open) 4d-13 4c.62 1-UP HS Cutter OMR/BCR Kit 4c-135 4d.14 OMR/Barcode Folder 4d-14 4c.63 1-UP HS Cutter 2D Kit 4c-137 4d.15 Collator/Diverter 4d-15 4c.64 2-UP HS Cutter OMR/BCR 4c-13 4d.16 Collator Top Cover (open) 4d-16 4c.65 2-UP HS Cutter 2D Kit 4c-141 4d. Collator Latch 4d- 4c.66 Envelope Conveyor Pivoting Assy 4c-143 4d.18 Hi/Lo-Cap Feeder & Single OL 4d-18 4c.67 Envelope Feeder Pivoting Assy 4c-145 4d.1 Hi-Cap Feeder Top Cover (open) 4d-1 4c.68 Envelope Feeder Pivoting Sub Assys 4c-148 4d.20 Lo-Cap/SOL Top Cover (open) 4d-20 4c.6 Envelope Conveyor Lift Assy 4c-150 4d.21 Vertical Stacker 4d-21 4c.70 Adjustable Backstop Assy 4c-152 4d.22 Pivoting Conveyor Assembly (Closed) 4d-22 4c.71 Powered Lift Assy 4c-154 4d.23 Pivoting Conveyor Assembly (Open) 4d-23 4c.72 Non Powered Lift Assy 4c-156 4d.24 Pivoting Conveyor Assembly A4-1475-A 4d-24 Output Processor Page Covers & Stands Page 4f.1 Output Conveyor Brkts (Base) 4f-1 4d.1 Insert Head (closed) 4d-1 4f.2 Output Conveyor Brkts (WJ Pro) 4f-2 4d.2 Insert Head (open) 4d-2 4f.3 Output Processor Covers 4f-3 4d.3 Insert Head End 4d-3 4f.4 Output Processor Chassis 4f-4 4d.4 PC Components 4d-4 4f.5 Idle Roller Set Assy. 4f-5 4d.5 Monitor Arm 4d-5 4f.6 Fin Assy. 4f-6 4d.6 Insert Head Rear 4d-6 4f.7 Backstop Assy. 4f-7 4d.7 Track 4d-7 4f.8 Infeed Drive Shaft & Motor Assy. 4f-8 4d.8 Feeder/Folder (closed) 4d-8 4f. Drive Transfer Cassette Assy. 4f- 4d. Feeder/Folder (open) 4d- 4f. Feed Idle Roller Assy. 4f- 4d. Feeder/Folder Cover Structure 4d- 4d.11 Feeder Conveyor 4d-11 Continued for Flatbed Feeder, Single O/L I/Face, Schneider Conveyor Page 4a-4

DS-1200 G3 Service Manual Page 4a-5 Issue SECTION 4 - EXPLODED VIEWS (Contd.) 4f.11 WJ Pro Interface 4f-11 4g-7 Flatbed Feeder Sub-Assemblies 4 4g- 4f.12 WJ Pro Interface Stand 4f-12 4g-8 Separator (F B) Assembly 4g- 4f.13 Output Transfer Drive Assy A4-0820-A 4f-13 4g- Chassis Assembly 4g-11 4f.14 Idler Shaft Assy A2-1401-A 4f-15 4g- Output Pressure Assembly 4g-12 4f.15 Motor Bracket Assy A2-1404-A 4f- 4g-11 Turnover Assembly 4g-13 4f.16 Printer Interface Assy A7418A (Pt.1) 4f.1 4g-12 Turnover Drive Assembly 4g-14 4f.16 Printer Interface Assy A7418A (Pt.2) 4f.20 Single Online Interface Page 4f. Printer Interface Stand 4f.22 4h-1 Main Assembly (Pt.1) 4h-1 4f.18 Pressure Roller Assy Printer Interface 4f.23 4h-1 Main Assembly (Pt. 2) 4h-2 4f.1 Divert Conveyor A4588A (5 Part Drg.) 4f.24 4h-2 Upper Assembly 4h-5 4f.20 Output Camera Kit A7164A 4f.35 4h-3 Lower Conveyor Assembly 4h-7 4f.21 Output Verification Chassis Assembly (1) 4f.37 4h-4 Drive Shaft Assembly 4h- 4f.22 Output Verification Chassis Assembly (2) 4f.38 4h-5 Tensioner Bracket Assembly 4h- 4f.23 Output Verification Trans. Assy 4f.3 4h-6 Support Roller Assembly 4h- 4f.24 LVDT Thickness Checker Assy A4A-A000565 4f.40 4h-7 Stop Assembly 4h- 4f.25 Output Verification Idler Roller Set Assy 4f.41 4h-8 CEM 1-UP I/F Assembly 4h-12 4f.26 Output Verification Elect. Panel Checker Assy 4f.42 4h- Transfer I/F Assembly (Conv) 4h-13 Flatbed Feeder Page 4g-1 Flatbed Feeder Main Assembly 4g-1 4g-2 Long Conveyor Assembly 4g-4 4g-3 Feeder Pickup Assembly 4g-5 4g-4 Flatbed Feeder Sub-Assemblies 1 4g-6 4g-5 Flatbed Feeder Sub-Assemblies 2 4g-7 4g-6 Flatbed Feeder Sub-Assemblies 3 4g-8 Continued for Vertical Stacker, Schneider Conveyor Page 4a-5

DS-1200 G3 Service Manual Page 4a-6 Issue SECTION 4 - EXPLODED VIEWS (Contd.) Vertical Stacker Page 4j-1 Vertical Stacker Main Chassis 4j-1 4j-2 Rotary Brush Drive 4j-3 4j-3 Wheel Assembly 4j-5 4j-4 Insert Conveyor Motor Assy. A7278A 4j-7 4j-5 Sideguide Motor Assy. A727A 4j- 4j-6 Insert Track Conveyor Assy. A7277A 4j-11 4j-7 Wheel & Brush Drive 4j-13 4j-8 Platform Assy. 4j-15 4j- Stacker Covers. A7285A 4j- 4j- Stacking Conveyor Assy. A4674A 4j-1 4j-11 Paddle Assy. A328A 4j-21 4j-12 Drive Shaft Assy. A7287A 4j-23 4j-13 Belt Tension Shaft Assy. A7288A 4j-25 4j-14 Envelope Jog Assy. A7283A 4j-27 4j-15 Cast Gearbox Assy. A2570A 4j-2 4j-16 Vertical Stacker Stand A7286A 4j-30 4j- Track Conveyor Stand A32A 4j-32 4j-18 VS Side Tray Sorting Kit A3307A 4j-34 4j-1 VS Dual Ink Marker A3300A 4j-36 Schneider Conveyor Schneider Conveyor Parts Catalogue Schneider Conveyor Operator Manual Page 4a-6

DS-1200 G3 Service Manual Page 4a-7 Issue 76 51 64,71 42 40 54 55 40 47 65,71 1 0 86 64,71 75 63 6 38 65,71 1 A 71 12 84 22 46 38 E 70 76 34 2 5 51 21 21 58 36 D C 61,71 58 E 36 63 67,72 62 14 26 A 23 24 32 S1 S2 48 S3 6. SEE SEC. 4a.2 S4 SENSORS Item Description Part No. Ref. S1 No Flap Divert TX 182-443 5.32 S2 No Flap Divert RX 182-444 5.32 S3 Opener HP 1 TX 182-440 5.32 S4 Flap Detect TX 182-443 5.32 S5 Env. Entry RX 182-441 5.32 S6 Env. Entry TX 182-440 5.32 S7 Flap Detect RX 182-445 5.32 S8 Opener HP 1 RX 182-444 5.32 S Opener HP 2 RX 182-441 5.32 NOTE: FOR DETAILS OF FEED CONVEYOR SEE 4c-4, OR 4g-2 FOR LONG CONVEYOR. 2,3 64 64,71 35 43 3 4 75 5. SEE SEC. 4a.7 77,72 30 36 56 57. SEE SEC. 4a.6 S5 15 48 S6 S7 4. SEE SEC. 4a.6 64 85 34 8. SEE SEC. 4a.7 32 31 63,72 56 57 S8 33 48 3. SEE SEC. 4a.6 48 1 34 85 34 80 82 74 72,7 43 57 56 63,72 53 57 56 73 44 74 57 37 2 23 60 64 78 C D 11 5 66,71 28 72,81 83 S 7. SEE SEC. 4a.4 16 72,7 48 80 83 50 74 48 32 82 18 30 32 22 36 B 41 67,72 27 38 5 38 56 74 20 1 74 63,72 63 62 B 45 63 68,66,71 24 63 53 54 36 26 36 35 62 67,72 3 21 4 65,71 52 25 42 43 67 65,71 40 42 51 76 75 18 48 72,81 13 4 21 65,71 40 28 16 52 62 42 51 76 4a.1 - Opener Assembly A2-82-A Page 4a-7

1200 G3 Service Manual Page 4a-8 Issue 4a.1 - Opener Assembly A2-82-A Item Description Part No. Qty. Item Description Part No. Qty. 1 SOLENOID W/D -348 XH 181-130 1 2 WIRED REED SWITCH 4WXH (2/4) 182-44 1 3 DRIVE ROLLER SHAFT ASSY A2-20-A 1 4 ACCESS BRIDGE ASSY A2601A 1 5 DIVERT SHAFT ASSY A2602A 1 6 DIVERT ASSY A2-1168-A 1 7 ENV CONVEYOR ASSY A2-10-A 1 8 INSERT PLATE HINGED ASSY A2-83-A 1 DRIVEN ROLLER SHAFT ASSY A2-21-A 1 SOLENOID PLATE B650A 1 11 DIVERT COVER B B7122W 1 12 SOLENOID BRACKET B8216P 1 13 OPENER SIDE PLATE LH B2-60-P 1 14 OPENER SIDE PLATE RH B2-61-P 1 15 OPENER BRIDGE A B8260P 1 16 OPENER BRIDGE B B8261P 2 OPENER BRIDGE C B8262P 1 18 OPENER BRIDGE D B8263P 2 1 WASHER B8431P 2 20 STRUT POST LONG C2607A 1 21 12mm BRG HSG UNTAPPED C276A 5 22 HANDOVER STAND-OFF C2848P 2 23 LATCH PIN C280A 2 24 LATCH SPACER C225A 2 25 SLIDE WASHER C2-11-A 1 26 TENSIONER POST C3408A 2 27 IDLER PULLEY POST C3442A 1 28 E TRACK LOCATOR C4252A 2 2 IDLER BEARING POST C4282A 1 30 FIXING PLATE C63P 2 31 PIVOT PLATE RH C6-0414-P 1 32 SUPPORT PLATE C6-0416-P 8 33 SHAFT DRIVE C763A 1 34 SPACER M4 x E0333A 35 BEARING BALL 12mm E34A 4 36 BEARING BALL 12mm E54A 7 37 BEARING BALL 8x16x5mm E61A 2 38 BEARING FL 8x22x7mm E78A 4 3 WASHER PL WAVED 13mm DIA E4052A 2 40 PIN DOWEL 3 DIA x 18LG E508A 6 41 12XL IDLER PULLEY ASSY F0046A 1 42 PULLEY XL 16 x 12 BORE F1283A 4 43 BELT 0XL 037 F5005A 2 44 BELT 1XL 037 F5025A 1 45 GAS SPRING G0080A 1 46 SPRING WETTER G6A 1 47 SPRING SOLENOID G1165A 1 48 BRIDGE CLAMP G402A 14 4 WASHER SPRING G6001A 2 50 PIVOT PLATE LH C6-0415-P 1 51 M6 LOCK CAP P2521A 6 52 LOCK SPACER (1.7) P2526A 3 53 LOCK SPACER (13) P2525A 3 54 LOCK SPACER (4.5) P2524A 2 55 LOCK SPACER (2.8) P2523A 1 56 LOCK CUP P2522A 6 57 DOWEL PIN 4DIA x 20 E506A 6 58 BEARING PRELOAD SPRING E0346A 2 5 DIVERT COVER A B7121W 1 60 INTERLOCK BRACKET B3-1158-A 1 Page 4a-8

1200 G3 Service Manual Page 4a- Issue 4a.1 - Opener Assembly A2-82-A Item Description Part No. Qty. Item Description Part No. Qty. Fixings 61 M4 x 20mm SKT CAP HD SCREW E2513A A/R 62 M4 x 12mm POZI PAN HD T/T SCREW E2730A A/R 63 M5 x 12mm SKT CAP HD SCREW E2508A A/R 64 M4 x 8mm CAP HD SCREW E250A A/R 65 M4 x 12mm CAP HD SCREW E2575A A/R 66 M4 FULL NUT E3502A A/R 67 M5 x mm CAP HD SCREW E2516A A/R 68 M4 x 25mm SKT CAP HD SCREW E2522A A/R 6 M5 x 20mm CAP HD SCREW E2523A A/R 70 VINYL PROT N CAP 3.5 x 12.7 (BLACK) E0204A A/R 71 M4 WASHER E4011A A/R 72 M5 WASHER E4012A A/R 73 6mm E CLIP E507A A/R 74.5mm E CLIP E5073A A/R 75 12mm E CLIP E502A A/R 76 M6 x 12 CSK SKT HD SCREW E2721A A/R 77 M5 x 20 SKT CAP HD SCREW E2523A A/R 78 M4 x 8 POZI PAN HD FINISHING SCREW E2520A A/R 7 M5 x 16 SKT CAP HD SCREW E2606A A/R 80 M5 x 20 GRUB SCREW E2645A A/R 81 M5 x 30 SKT CAP HD SCREW E2634A A/R 82 ADJUSTOR BLOCK C6-04-A 2 83 ADJUSTOR PIN C3-0673-A 2 84 WASHER M20 INT SH/PROOF E4072A 1 85 M4 x 6mm CAP HD SCREW E2512A A/R 86 M3 x 6mm SLOT PAN HD SCREW E2651A A/R 0 PCB SPLITTER 3SENS 4 SOL 180-61 1 1 PCB ASSY INTERLOCK 180-70 1 2 PCB MODULE HYBRID MK2 180-812 1 3 PCB ASSY DAUGHTER BOARD 180-814 1 4 RIBBON BRACKET 2 B2-126-F 1 5 GROMMET STRIP x 25mm LG. E0281A 2 6 IDLER T BOLT C227A 1 Page 4a-

DS-1200 G3 Service Manual Page 4a- Issue 46,47 12 51 42,4 31 50 22 42,4 33 2 4 44,4 42,4 23 11 7. SEE SEC. 4a.3 28 32 14 40,47 48,4 43 40,47 42,4 27 1 30 4,52 24 32 45 1 28 14 8. SEE SEC. 4a.3 25 4,52 11 4,52 28 27 28 28 46,47 28 26 28 15 16. SEE SEC. 4a.3 14 4,52 5. SEE SEC. 4a.3a 42,4 13 51 20 28 21 28 4,52 18 42 23 44,4 42,4 41,4. SEE SEC. 4a.3 26 28 6. SEE SEC. 4a.3a 42,4 44,4 4a.2 - Divert Assembly A2-1168-A Page 4a-

1200 G3 Service Manual Page 4a-11 Issue 4a.2 - Divert Assembly A2-1168-A Item Description Part No. Qty. Item Description Part No. Qty. 1 SWITCH MAGNET SMALL 131-824 1 2 CABLE TIE 2.6 X 0mm 16-2 3 CBL CLAMP SMALL 16-114 4 4 PCB SPLITTER 3SENS 4SOL 180-61 1 5 HP1 SIDE GUIDE ASSY A2-1167-A 1 6 HP1 OVERGUIDE ASSY A2-116-A 1 7 OPENER ASSY A2618A 1 8 IDLER ROLLER SHAFT ASSY A261A 1 DIVERT ROLLER SHAFT ASSY A2621A 2 OPENER BACK STOP B2-62-A 1 11 OPENER FRONT STOP B2-63-A 2 12 DIVERT SIDE PLATE RH B8240P 1 13 DIVERT SIDE PLATE LH B8241P 1 14 DIVERT BRIDGE A B8242P 3 15 DIVERT BRIDGE B B8243P 1 16 DIVERT BRIDGE C B8244P 1 SPRING POST B8331P 1 18 GAS STRUT POST LONG C218A 1 1 SHAFT SENSOR C068A 1 20 SHAFT DIVERT ASSY. PIVOT C070A 1 21 CHASSIS SPACER C11A 1 22 OILITE FL 12x18x12mm E31A 2 23 BEARING FL 8x22x7mm E78A 2 24 SPRING SEPARATOR G1A 1 25 SPRING NO FOLD G18C 1 26 SPRING LIGHT PRESSURE (GREEN) G1111A 2 27 SPRING INTER. PRESSURE (YELLOW) G1116A 2 28 BRIDGE CLAMP G402A 2 PCB SPACER P2006A 2 30 OPENER SPRING POST P2387A 1 31 *OPENER LATCH B8316S 1 32 *LATCH PIVOT C288A 2 33 M4 x mm SPACER E0333A 2 Fixings 40 M5 x 16mm CAP HD SCREW E2606A A/R 41 M4 x 35mm CAP HD SCREW E2630A A/R 42 M4 x 12mm POZI PAN HD SCREW E2730A A/R 43 M4 x mm BUTTON HD SCREW E2625A A/R 44 M4 x 8mm CAP HD SCREW E250A A/R 45 M3 x 8mm POSI PAN HD T/T SCREW E27A A/R 46 M5 FULL NUT E3501A A/R 47 M5 WASHER E4012A A/R 48 M4 FULL NUT E3502A A/R 4 M4 WASHER E4011A A/R 50 12mm E CLIP E502A A/R 51.5mm E CLIP E5073A A/R 52 M4 x mm CAP HD SCREW E2507A A/R *NOTE: Items 31 & 32 are part of A2-82-A items list (see section 4a-1) for assembly purposes, shown on this drawing for clarity. Page 4a-11

DS-1200 G3 Service Manual Page 4a-12 Issue OPENER ASSEMBLY A2618A 4 4 3 IDLER ROLLER SHAFT ASSEMBLY A261A 48 1 2 4 DIVERT ROLLER SHAFT ASSEMBLY A2621A 12 48 48 5 4 23 48 21 48 14 15 13 13 11 15 14 48 12 50,51 48 48 24 26 25 20 25 22 26 24 48 23 4a.3 - Divert Assembly - Sub Assemblies Page 4a-12

DS-1200 G3 Service Manual Page 4a-13 Issue 4a.3 - Divert Assembly - Sub Assemblies Opener Assembly A2618A 1 1 OPENER C7333E 4 2 SHAFT OPENER PIVOT C06A 1 3 LINK PIN C071A 1 4 GROOVED PIN 058 2.5x14 E5078A 8 5 OPENER SPRING POST P2387A 1 Fixings 48.5mm E CLIP E5073A A/R 4 M4 NYLOC NUT E3505A A/R 50 M4 x 8 SKT CAP HD SCREW E250A A/R 51 M4 WASHER (FORM A) E4011A A/R Idler Roller Shaft Assembly A261A 1 ROLLER IDLER CORE C2780A 4 SHAFT IDLER ROLLER C067A 1 11 TYRE FEED WHEEL D000A 4 12 BEARING HSG T 8mm MIN D40A 1 13 BEARING BALL 8x16x5mm E61A 8 14 WASHER WAVED W61370 SPEC E4033A 8 15 WASHER 12.3 x 8.5 x 0.18 E4-007-A 8 Divert roller shaft Assembly A2621A 2 20 ROLLER IDLER CORE C2780A 2 21 SHAFT IDLER ROLLER C067A 1 22 TYRE FEED WHEEL D000A 2 23 BEARING HSG T 8mm MIN D40A 1 24 WASHER WAVED W61370 SPEC E4033A 4 25 BEARING BALL 8 x 16 x 5mm E61A 4 26 WASHER 12.3 x 8.5 x 0.18 E4-007-A 4 Page 4a-13

DS-1200 G3 Service Manual Page 4a-14 Issue SENSORS Item Description Part No. Ref. S1 Disc Sensor 180-68* 5.32 S2 Disc Sensor 180-68* 5.32 *Sensor/PCB part no. shown - loom is a separate item. 24 37, 41 41 2 S1 S2 37, 41 HP1 SIDE GUIDE ASSEMBLY A2-1167-A 4a.3a - Divert Assembly - Sub Assemblies Page 4a-14

1200 G3 Service Manual Page 4a-15 Issue 4a.3a - Divert Assembly - Sub Assemblies Item Description Part No. Qty. Item Description Part No. Qty. HP1 Side Guide Assy A2-1167-A 1 1 RIVET 3.5mm 2.0-3.0 GRIP 16-145 6 2 PCB STANDARD DISC SENSOR 180-68 2 3 PCB SPLITTER 5SENS 2SOL 180-704 1 4 SIDE GUIDE MOTOR ASSY 181-0840 1 5 GUIDANCE CHASSIS B2-142-A 1 6 SIDE GUIDE PLATE B2-1436-P 2 7 SG FLAG B2-1437-A 1 8 SIDE GUIDE LH B3-1213-A 1 SIDE GUIDE RH B3-1214-A 1 BUSH ASSEMBLY RH B4-043-A 1 11 BUSH ASSEMBLY LH B4-0440-A 1 12 DISC HUB ASSEMBLY B4430A 1 13 RUNNER 8mm RH C2-71-A 1 14 RUNNER 8mm LH C2-72-A 1 15 PCB SPACER C2-11-A 2 16 SG SHAFT C5-11-A 1 SG GUIDE SHAFT C5-1118-A 1 18 GUIDE CARRIER C6340A 2 1 T BEARING 8mm 12 sq D40A 1 20 T BEARING 6mm sq D76A 2 21 WASHER PL WAVED 13mm DIA E4052A 2 22 PULLEY XL 12x8mm F11A 1 23 PULLEY XL 12x6mm F1237A 1 24 BELT 0XL 037 F5000A 1 25 SIDE GUIDE SPRING G1-0265-A 2 26 SPACER P2007A 4 Fixings 35 M4 x 16mm C SK HD SCREW E2664A A/R 36 M4 x mm C SK HD SCREW E2537A A/R 37 M4 x 8mm POZI PAH HD SCREW E2720A A/R 38 M4 x 6mm CAP HD SCREW E2512A A/R 3 M4 x 4mm GRUB SCREW E2518A A/R 40 M4 FULL NUT E3502A A/R 41 M4 WASHER E4011A A/R 42 7.0 E CLIP E5076A A/R 43.5 E CLIP E5073A A/R 44 M4 NYLOC NUT E3505A A/R HP1 Overguide Assy A2-116-A 1 50 BEARING HOLDER (OPENER) B0-0213-A 6 51 OVERGUIDE B2-1430-A 1 52 SPRING PLATE LH B2-1438-A 1 53 SPRING PLATE RH B2-143-A 1 54 SENSOR RETAINER B3-28-A 1 55 INA BEARING NEEDLE ROLLER 3x6.5x6 E1-0155-A 6 56 PIN DOWEL 3 DIA x (m6) HARDENED E5-012-A 6 Page 4a-15

DS-1200 G3 Service Manual Page 4a-16 Issue 31 23 33 33 20 20 37 14 21 21 12 4. SEE SEC. 4a.5 33 22 33 33 33 8. SEE SEC. 4a.5 7. SEE SEC. 4a.5 35 18 14 37 35 21 35 21 12 35 37 16 1 14 18 15 14 1 20 40 32,34 11 2 13 15 6. SEE SEC. 4a.5 30 40 3 20 32,34 16 3 11 34,35 5 SEE SEC. 4a.5 4a.4 - Envelope Conveyor Assy. A2-10-A Page 4a-16

1200 G3 Service Manual Page 4a- Issue 4a.4 - Envelope Conveyor Assy. A2-10-A Item Description Part No. Qty. Item Description Part No. Qty. 1 CABLE TIE 2.6 X 0mm 16-2 A/R 2 PCB ASSY RIBBON SPLITTER 180-61 1 3 SOLENOID W/D -348 XH 181-130 2 4 TENSIONER BRKT ASSY A2614A 2 5 HP2 STOP ASSY A2-13-A 1 6 1ST ENV STOP ASSY A267A 1 7 CONVEYOR DRIVE SHAFT ASSY 1 See 4a-5 1 8 CONVEYOR TRANSPORT SHAFT ASSY 2 See 4a-5 1 ENV CONVEYOR CHASSIS B8214P 1 ENV CONV TOP PLATE B2-1431-A 1 11 SOLENOID BRACKET B8216P 2 12 TENSION BKT SLIDE WASHER C2776A 4 13 SPACER M4 x E0333A 2 14 BEARING FLANGED E77A 4 15 ROLL PIN 1/8x1/2 E5006A 2 16 BELT 2XL 037 F5013A 1 N/A 18 SPRING CONVEYOR G1162A 2 1 SPRING SOLENOID G1165A 2 20 CONVEYOR BELT 75mm G5043A 2 21 BRAKE SHIM G6028A 4 22 PLATE 1 R274P 1 23 PLATE 2 R275P 1 Fixings 30 M4 x 8mm POZI PAN HD SCREW E2624A A/R 31 M4 x 8mm CSK SKT HD SCREW E2535A A/R 32 M4 x 8mm CAP HD SCREW E250A A/R 33 M4 x mm CSK SKT HD SCREW E2537A A/R 34 M4 WASHER E4011A A/R 35 M4 NYLOC E3505A A/R 36 N/A 37 6mm E CLIP E507A A/R 38 N/A 3 N/A 40 WASHER M20 INT S/PROOF E4072A 2 NOTE: FOR OTHER COMPONENTS ON ENVELOPE CONVEYOR ASSY. NOT LISTED ABOVE SEE SECTION 4a.5 Page 4a-

DS-1200 G3 Service Manual Page 4a-18 Issue CONVEYOR TRANSPORT SHAFT ASSEMBLY 2 (REF) ORDER SPARES ASSY A3-0457-A CONVEYOR DRIVE SHAFT ASSEMBLY 1 (REF) ORDER SPARES ASSY A3-0456-A 68* 32* 25 38 68* 42* 44 43 46* TENSIONER BRACKET ASSY A2614A 41 35* 36* 43 1 61 64 2 3 61 4 5 6 64 ITEMS MARKED * ARE PART OF ASSY A2-10-A (SECTION 4a-4) 28* 2 33* 31 27 47* 26 3 37 43 34* 40 45 45 40 36* 34* 43 37 3 ITEMS MARKED * ARE PART OF ASSY A2-10-A (SECTION 4a-4) 52 60,62 53 31 27 33* 2 44 46* 41 42* 68* 51 62,67 63 55 63 54 56 62 66 50 60,62 25 ENVELOPE STOP ASSEMBLY A2-13-A 65 2 30 32* 68* 1 63 21 63 23 60,62 22 62 66 18 20 60,62 1st ENVELOPE STOP ASSEMBLY A267A 4a.5 Envelope Conveyor - Sub Assemblies Page 4a-18

1200 G3 Service Manual Page 4a-1 Issue 4a.5 - Envelope Conveyor - Sub Assemblies Item Description Part No. Qty. Item Description Part No. Qty. TENSIONER BRACKET ASSY A2614A x2 CONVEYOR TRANSPORT SHAFT ASSY 2 A3-0457-A (SPARES) x1 1 ENV CONV TENSION BRACKET B65P 1 2 ENV. CONV. IDLER ROLLER C2778A 1 3 SHAFT IDLER ROLLER C3378A 1 4 BEARING BALL 12mm E54A 1 5 WASHER PL WAVED 13mm DIA E4052A 1 6 WASHER SPRING G6001A 1 1ST ENVELOPE STOP A267A x1 18 ENV. STOP PLATE B7224A 1 1 RETURN PIN C2877A 1 20 ENVELOPE STOP SHAFT C041A 1 21 SPRING FINE PRESSURE G1137A 1 22 SOLENOID SPRING POST P2386A 1 23 4.5mm CIRCLIP E5081A 1 CONVEYOR DRIVE SHAFT ASSY 1 A3-0456-A (SPARES) x1 25 CONVEYOR DRIVE ROLLER C8130A 2 26 CONVEYOR DRIVE SHAFT C762A 1 27 BEARING BALL 12mm E54A 2 28 SPACER TUBE C4502A* 1 2 PIN DOWEL 3 DIA x 18LG (S/S) E508A 3 30 PULLEY XL 16 x 12 BORE F1283A 1 31 BEARING HOUSING 12mm MOD G4051A 2 32 M6 LOCK CAP P2521A* 2 33 LOCK SPACER (2.8) P2523A* 2 ITEMS MARKED * ARE PART ASSY. A2-10-A SEE ALSO SECTION 4a-4 34 LOCK SPACER (4.5) P2524A* 2 35 LOCK SPACER (1.7) P2526A* 1 36 LOCK SPACER (25) P2528A* 2 37 ROLLER CORE C277A 2 38 CONVEYOR TRANSPORT SHAFT C761A 1 3 TYRE FEED WHEEL D000A 2 40 BEARING BALL 12mm E34A 4 41 BEARING BALL 12mm E54A 2 42 M6 LOCK CAP P2521A* 2 43 PIN DOWEL 3 DIA x 18LG (S/S) E508A 4 44 PULLEY XL 16 x 12 BORE F1283A 2 45 BEARING HOUSING 12mm MOD G4051A 2 46 LOCK SPACER (2.8) P2523A* 3 47 SPACER TUBE (53) C4503A 1 ITEMS MARKED * ARE PART OF ASSY. A2-10-A SEE ALSO SECTION 4a-4 HP2 STOP ASSY A2-13-A x1 50 ENV. STOP PLATE B3-1211-A 1 51 WIDE STOP ADD ON B3-12-A 1 52 RETURN PIN C2877A 1 53 ENVELOPE STOP SHAFT C041A 1 54 4.5mm CIR CLIP E5081A 3 55 SPRING FINE PRESSURE G1137A 1 56 SOLENOID SPRING POST P2386A 1 Fixings 60 M4 x 8mm CAP HD SCREW E250A A/R 61 M4 x mm CSK HD SCREW E2537A A/R 62 M4 WASHER E4011A A/R 63 M5 WASHER E4012A A/R 64 12mm CIR CLIP E5025A A/R 65 12mm E CLIP E502A A/R 66 M4 FULL NUT E3502A A/R 67 M4 NYLOC NUT E3505A A/R 68 M6 x 12 SKT. CSK. HD SCREW E2721A A/R Page 4a-1

DS-1200 G3 Service Manual Page 4a-20 Issue 15 DRIVEN ROLLER SHAFT ASSEMBLY A2-21-A 22 41 20 31 42 32 40 12 11 14 * 41 14 24 26 23 1 21 15 23 26 24 41 41 IDLER ROLLER SHAFT ASSEMBLY A26A 33 30 13 16 43 40 2 *ITEM USED ON FLAP SENSOR ONLY 42 ACCESS BRIDGE ASSEMBLY A2601A See section 4a.7 for further Sub Assemblies 1 5 3 DRIVE ROLLER SHAFT ASSEMBLY A2-20-A 4 6 4a.6 Envelope Opener Assembly - Sub Assemblies Page 4a-20

1200 G3 Service Manual Page 4a-21 Issue 4a.6 - Envelope Opener Assembly - Sub Assemblies Item Description Part No. Qty. Item Description Part No. Qty. Drive Roller Shaft Assembly A2-20-A 1 1 ROLLER CORE C277A 4 2 SHAFT DRIVE ROLLER C5-04-A 1 3 TYRE FEED WHEEL D000A 4 4 PIN DOWEL 3 DIA x 16LG E5086A 1 5 PIN DOWEL 3 DIA x 18LG E508A 4 6 PULLEY XL 16 x 12 BORE F134A 1 Fixing 40 8mm CIRCLIP E5025A A/R 41.5mm E CLIP E5073A A/R 42 12mm E CLIP E502A A/R 43 M4 x 6mm GRUB SCREW E2505A A/R Access Bridge Assembly A2601A 1 IDLER ROLLER SHAFT ASSY A26A 1 11 ACCESS ENTRY BRIDGE B8264P 1 12 SHAFT PIVOT C076A 1 13 BEARING HSG T 8mm MIN D40A 1 14 SPRING PLUNGER E0350A 2 15 SPRING INTER. PRESSURE (YELLOW) G1116A 2 16 COLLAR C2-1118-A 1 SENSOR CLIP B0-0221-A 1 Idler Roller Shaft Assembly A26A 1 1 ROLLER IDLER CORE C2780A 4 20 SHAFT IDLE ROLLER C075A 1 21 FEED WHEEL TYRE D000A 4 22 BEARING HSG T 8mm MIN D40A 1 23 BEARING BALL 8x16x5mm E61A 8 24 WASHER WAVED W61370 SPEC E4033A 8 25 N/R 26 WASHER 12.3 x 8.5 x 0.18 E4-007-A 8 Driven Roller Shaft Assembly A2-21-A 1 30 ROLLER CORE C277A 4 31 SHAFT DRIVE ROLLER C5-04-A 1 32 TYRE FEED WHEEL D000A 4 33 PIN DOWEL 3 DIA x 18LG E508A 4 Page 4a-21

DS-1200 G3 Service Manual Page 4a-22 Issue SENSORS Item Description Part No. Ref. S1 Disc Sensor 180-68* 5.34 S2 Disc Sensor 180-68* 5.34 *Sensor/PCB part no. shown - loom is a separate item. 7 56 67 6 56 POSITION OF FLAT INSERT PLATE HINGED ASSY A2-83-A 6 55 67 13 24 55 2, 66 14 55 E 18 D 5 (5) HP2 OVERGUIDE ASSY A2-12-A 27 36 48, 4 (4) HP2 SIDE GUIDE ASSY A2-11-A 22 57 46 45 58 31 15 64 65 63 50 58 47 48, 4 A 1 63 55 25 32,62 47 45 50 58 21,62 60, 65 67 28 20 65 31 D 13 60, 65 27 36 C E 64 23 33 57 30 61 62 12 34 C 16 15 S1 11 5 A B 26 60, 65 2 66 S2 11 B 2 56 DIVERT SHAFT ASSEMBLY A2602A See section 4a.6 for further Sub Assemblies 3 1 35 4a.7 - Insert Plate Hinged Assembly - A2-83-A Page 4a-22

1200 G3 Service Manual Page 4a-23 Issue Item Description Part No. Qty. Item Description Part No. Qty. Divert Shaft Assembly A2602A 1 1 DIVERTER C6320A 8 2 SHAFT DIVERT C074A 1 3 GROOVED PIN 058 2.5x14 E5078A 8 Insert Plate Hinged Assembly A2-83-A 1 4 HP2 SIDE GUIDE ASSY A2-11-A 1 5 HP2 OVERGUIDE ASSY A2-12-A 1 6 INSERT PLATE PIVOT C34A 2 7 TOP PLATE BACK C7-042-E 1 HP2 Side Guide Assembly A2-11-A 1 RIVET 3.5 2.0-3.0 GRIP 16-145 4 11 PCB STANDARD DISK SENSOR 180-68 2 12 PCB SPLITTER 3 SENS 4 SOL 180-61 1 13 SIDE GUIDE MOTOR ASSY 181-0840 1 14 GUIDANCE CHASSIS 2 B2-1432-A 1 15 SIDE GUIDE PLATE B2-1436-P 2 16 SG FLAG B2-1437-A 1 SIDE GUIDE LH 2 B3-1215-A 1 18 SIDE GUIDE RH 2 B3-1216-A 1 1 BUSH ASSEMBLY RH B4-043-A 1 20 BUSH ASSEMBLY LH B4-0440-A 1 21 DISC HUB ASSEMBLY B4430A 1 22 RUNNER 8mm RH C2-71-A 1 23 RUNNER 8mm LH C2-72-A 1 24 PCB SPACER C2-11-A 2 25 SG SHAFT C5-11-A 1 26 SG GUIDE SHAFT C5-1118-A 1 27 GUIDE CARRIER C6340A 2 28 T BEARING 8mm 12SQ D40A 1 2 T BEARING 6mm SQ D76A 2 30 SPACER M4 x mm E0333A 2 31 WASHER PL WAVED 13mm DIA E4052A 2 32 PULLEY XL 12 x 8mm F11A 1 33 PULLEY XL 12 x 6mm F1237A 1 34 BELT 60XL 037 F5046A 1 35 S.G. SPRING 2 G1-0267-A 2 36 SPACER P2007A 4 4a.7 - Insert Plate Hinged Assembly - A2-83-A HP2 Overguide Assembly A2-12-A 1 45 BEARING HOLDER B0-0213-A 2 46 OVER GUIDE 2 B2-1440-A 1 47 SPRING PLATE 2 B2-1441-A 2 48 INA BEARING NEEDLE ROLLER 3x6..5x6 E1-0155-A 2 4 PIN DOWEL 3 DIA x E5-012-A 2 50 GUIDE SPRING 3 B0-0216-A 2 Fixings 55 M4 x 16mm C SK HD SCREW E2664A A/R 56 M4 x 12mm C SK HD SCREW E2564A A/R 57 M4 x 8mm C SK HD SCREW E2535A A/R 58 M4 x 8mm POZI C SK HD SCREW E2668A A/R 5 M4 x 8mm POSI PAN HD E2720A A/R 60 M4 x 8mm CAP HD SCREW E250A A/R 61 M4 x 16mm CAP HD SCREW E2664A A/R 62 M4 x 4mm GRUB SCREW E2518A A/R 63 M4 NYLOC NUT E3505A A/R 64 M4 NUT E3502A A/R 65 M4 WASHER E4011A A/R 66 7.0 E CLIP E5076A A/R 67.5 E CLIP E5073A A/R Page 4a-23

DS-1200 G3 Service Manual Page 4a-24 Issue 15 SEE SEC. 4a. S1 S2 S3 13, 31 2 2 2 25 1 2 14 32 32 23 SENSORS Item Description Part No. Ref. S1 H/Over Index RX 182-442 5.32 S2 H/Over Index TX 182-437 5.32 S3 H/Over Clock Flag 180-68* 5.32 S4 Doc at Insert RX 182-445 5.32 S5 Opener HP 2 TX (Env. Opener) 182-443 5.32 *Sensor/PCB part no. shown - loom is a separate item. SEE NOTE BELOW 8 25,27 32 2 30 2 3 2 14 4 23 28 14 S4 16 SEE SEC. 4a. 25,27 25,27 28 7 11 26 7 S5 14 25,27 5 25,27 23 6 5 28 NOTE: LOCATION OF NAME IDENTITY LABEL 25,27 5 5 25,27 23 6 5 11 25,27 5 4a.8 - Handover Assembly A2-7-A Page 4a-24

1200 G3 Service Manual Page 4a-25 Issue 4a.8 - Handover Assembly A2-7-A Item Description Part No. Qty. Item Description Part No. Qty. 1 MTR. STEP 3 STK S/S WIRED 181-0820 1 2 PCB ASSY A5 STEPPER 180-675 1 3 PCB BRACKET B73P 1 4 HANDOVER SIDE PLATE B8206A 2 5 HANDOVER SPACER C338P 6 6 ALIGNMENT POST C3433A 2 7 MOTOR ADJUST POST C4280A 2 8 SPACER M4 x mm E0333A 4 PULLEY ASSY F0047A 6 BELT T5 224T mm WIDE (1 PAIR) F504A 1 11 HANDOVER BELT GUIDE B8401P 2 12 HANDOVER STEPPER SUPPORT BKT. B2-1843-A 1 13 25 DIA X-Y COUPLER 8mm E0332A 1 14 PAWL PLATE B0-0207-A 8 15 RUBBER SEAL 2mm E0026A 15mm x 2 Assemblies 16 HANDOVER DRIVE ASSEMBLY See 4a. 1 HANDOVER BRIDGE ASSEMBLY See 4a. 1 Fixings 23 M4 x 12mm POZI PAN HD (T/T) SCREW E2730A A/R 24 M4 x mm POZI PAN HD SCREW E2638A A/R 25 M5 x mm CAP HD SCREW E2516A A/R 26 M5 x 60mm CAP HD SCREW E2768A A/R 27 M5 WASHER E4012A A/R 28 M4 x 6mm BUTTON HD SCREW E264A A/R 2 M4 x 6mm CAP HD SCREW E2512A A/R 30 M4 x 8 CAP HD SCREW E250A A/R 31 M3 x CAP HD SCREW E2500A A/R 32 M4 WASHER E4011A A/R Page 4a-25

DS-1200 G3 Service Manual Page 4a-26 Issue 7 27 3 33 25 11 15 7 DRIVE PULLEY ASSY A2606A 33 16 12 4 13 2 2 1 26,31 8 13 33 16 12 6 2,32 11 12 16 33 14 26,31 5 30,32 28,31 4a. - Handover Drive (Part of A2-7-A - See also 4a-8 & 4a-) Page 4a-26

1200 G3 Service Manual Page 4a-27 Issue 4a. - Handover Drive (Part of A2-7-A - See also 4a-8 & 4a-) Item Description Part No. Qty. Item Description Part No. Qty. 1 DISC SENSOR 180-68 1 2 PLASTIC RIVET 16-145 2 3 HUB & DISC ASSY B4340A 1 4 DISC SENSOR BRACKET B70P 1 5 MOTOR BRACKET B820P 1 6 SENSOR BAR C33A 1 7 MOTOR STAND OFF C4247A 4 8 SHAFT HANDOVER DRIVE C038A 1 25 DIA X-Y COUPLER 8mm E0332A 1 25 DIA TOURQUE DISC E0335A 1 11 BEARING BALL 12mm E54A 2 12 WASHER PL WAVED 13mm DIA E4052A 4 13 GROOVED PIN S80 3 x 18 LG E508A 4 14 BEARING HOUSING 12mm G4031A 1 15 BEARING HOUSING 12mm MOD G4051A 1 16 WASHER SPRING G6001A 4 PULLEY 24T T5 (DRIVE) F1302A 2 Fixings 25 M3 x mm CAP HD SCREW E2500A A/R 26 M4 x mm POZI PAN HD SCREW E2638A A/R 27 M4 x 12mm CSK HD SCREW E2564A A/R 28 M4 x 12mm CAP HD SCREW E2575A A/R 2 M5 x mm CAP HD SCREW E2516A A/R 30 M5 x 60mm CAP HD SCREW E2768A A/R 31 M4 WASHER E4011A A/R 32 M5 WASHER E4012A A/R 33 12mm E CLIP E502A A/R Page 4a-27

DS-1200 G3 Service Manual Page 4a-28 Issue 11 5 11, 12 2 6 12, 14 6 4 12, 14 3 4 12, 13 2 1 6 6, 12 4a. - Handover Bridge (Part of A2-7-A - See also 4a-8 & 4a-) Page 4a-28

1200 G3 Service Manual Page 4a-2 Issue 4a. - Handover Bridge (Part of A2-7-A - See also 4a-8 & 4a-) Item Description Part No. Qty. Item Description Part No. Qty. 1 DEFLECTOR B0124A 1 2 TIE BRACKET B8207P 2 3 OVERGUIDE B2-1433-A 1 4 BEARING HOLDER ASSY * A2-117-A 2 5 HANDOVER INSERT PLATE C7-0430-E 1 6 BRIDGE CLAMP G402A 4 Fixings M4 x mm POZI PAN HD SCREW E2638A A/R 11 M4 x mm CSK HD SCREW E2537A A/R 12 M4 WASHER E4011A A/R 13 M4 NUT E3502A A/R 14 M4 NYLOC NUT E3505A A/R * CONSISTS OF THE FOLLOWING ITEMS: BEARING HOLDER B0-0213-A 1 INA BEARING NEEDLE ROLLER 3x6.5x6 E1-0155-A 1 PIN DOWEL 3 DIA x (m6) E5-012-A 1 Page 4a-2

DS-1200 G3 Service Manual Page 4a-30 Issue 83 1 65 24 8 73 71 73 7 68 51 58 65 84 78 2 2 74 72 S1 2 58 84 65 1 2,4 84 20 *Sensor/PCB part no. shown - loom is a separate item. F 7 54 7 81 30 7 18 84 8 48 7 8 68 51 73 71 67 7 46 74 35 84,8 7 4 66 28 E 58 6 SENSORS Item Description Part No. Ref. S1 Env. Flap Clock Flag 180-68* 5.34 S2 Env. Flap RX 182-43 5.34 S3 T/Over Complete RX 182-445 5.34 S4 T/Over Index TX 182-440 5.34 S5 T/Over Index RX 182-442 5.34 S6 T/Over Complete TX 182-443 5.34 S7 T/Over Ej. Clk. Flag 180-68* 5.34 S8 T/O B/Stop Clk. Flag 180-62* 5.34 73 46 E 0 72 47 12 65 1 31 41 0 65 32 7 25 7 7 65 58 4 20 3,4 1,4 85 4 58 85 7 51 57 2 72 2,4 64 7 68 51 3 87 F 2 74 88,8 6 3 73 FOR DETAILS OF FRONT TOP PLATE ASSY'S & 2nd INSERT PLATES SEE SECTION 4a -11 S2 23 64 52 4 G 71 73 2,4 60 52 3 E E B 3 A 8 68 3,4 7 2,4 C 85 7 1 5 52 87 3,4 C 62 2,4 40 36 65 A 67 2,4 56 38 D 45 0 44 43 15 7 68 51 67 87 48 33 G 31 5 3 2 2 87 3 50 4 52 38 3 51 68 7 S4 48 2 11 48 7 62 S5 47 S6 84 2 54 2,4 30 24 1 48 2,4 67 87 52 0 5 65 S7 25 83 74 73 71 83 87 2,4 S3 6. SEE SEC. 4a.13 85,5 42 22 37 70 85,8 88,8 6 7 5 88,8 55 5 1 A 6 63 4 14 6 7 34 27 61 7 63 26 83 32 55 C 8 4a.11 - Turnover Assembly A2-80-A D 72 1 73 2,4 3 8 13 16 83 5 70 21 4 1 A 5. SEE SEC. 4a.14 85.8 B 85,8 S8 Page 4a-30

1200 G3 Service Manual Page 4a-31 Issue 1 Sep 2013 4a.11 - Turnover Assembly A2-80-A Item Description Part No. Qty. Item Description Part No. Qty. 1 PCB ASSY A5 STEPPER 180-675 1 2 PCB DISC SENSOR ASSY 180-68 1 3 MTR W/D -03 HYBRID 181-04 1 4 MOTOR STEP 3STK D/S WIRED 181-0830 1 5 GEARBOX ASSEMBLY (CAST) A2-14-A 1 6 TURNOVER EJECT KICKER A2633A 1 7 N/A 8 BRUSH EJECT G0128A 1 ENV. CHASSIS ASSEMBLY B4302P 1 ENV SUB PLATE ASSY LH B4316P 1 11 ENV SUB PLATE ASSY RH B43P 1 12 HUB & DISC ASSY 8mm B4318A 1 13 EJECT INPUT GUIDE B7184A 1 14 E BACK STOP R6242A 1 15 E PLATE B7186A 1 16 TURNOVER EJECT GUIDE B7240A 1 EJECT TOP PLATE B7241A 1 18 SENSOR/RIBBON BRACKET B3-40-P 1 1 GUIDE PLATE B7273A 2 20 SWING ARM B8227P 2 21 MOTOR SUPPORT B8228P 1 22 SLIDE SUPPORT R6243P 1 23 MOTOR BRACKET B8402P 1 24 WASHER B8431P 2 25 TRAY SPIGOT C2022C 2 26 IDLE POST C251A 1 27 BEARING BUSH C2520A 1 28 COLLAR RESTRICTOR 20 DIA C2557C 3 2 BEARING SPIGOT C2853A 4 30 ARBOR C2855P 2 31 LOCATING SHAFT C2881A 2 32 PULLEY POST C220A 2 33 ROLLER IDLER CORE C221A 2 34 SHAFT DRIVE C424A 1 35 SHAFT PIVOT C4251A 1 36 GUIDE POST C4267A 1 37 POSITION SLIDER D1-0086-A 1 38 TOP PLATE CLAMP C3468A 2 3 ROLLER FEED 35 x 12 C86A 3 40 FLAP SHAFT C051A 1 41 SHAFT IDLE C053A 1 42 SHAFT SLIDE C054A 1 43 E DRIVE SHAFT C764A 1 44 PULLEY SHAFT C056A 1 45 TYRE FEED WHEEL D000A 2 46 SPACER M4 x 15mm E034A 4 47 OILITE FL 8x12x6mm E33A 2 48 BEARING BALL 12mm E54A 6 4 BEARING FLANGED 12x21x5 E87A 4 50 WASHER PL WAVED 0.86 I/D E4051A 1 51 WASHER PL WAVED 13mm DIA E4052A 7 52 PIN DOWEL 3 DIA x 18LG E508A 8 53 N/A 54 PULLEY F0044E 2 55 PULLEY MXL 15x6mm F1230A 2 56 PULLEY LOCKING 12T XL F123P 1 57 PULLEY STS 30T S2M F124P 1 58 PULLEY ASSEMBLY F0-0068-A 6 5 PULLEY XL 24x12 DRIVE F1335A 3 60 PULLEY STS 30T S2M F1348A 1 61 GEAR SPUR 20Tx6mm 1.0M F4137A 1 62 BELT 120XL 037 F5011A 1 63 BELT 5MXL F5077A 1 64 BELT STS 0T 0-S2M-180 F5078A 1 65 BELT 506XL LOW MODULUS F53A 2 66 SPRING TORSION G13C 2 67 BEARING HOUSING 12mm MOD G4051A 4 68 WASHER SPRING G6001A 6 6 N/A 70 TURNOVER RESTRICTOR TAPE G6-0235-A 2 71 BOBBIN C288A 4 72 POST BOBBIN C3457A 4 73 BEARING BALL 8x16x5mm E61A 8 74 WASHER WAVED E4033A 4 76 N/A 77 N/A 78 EJECT LIGHT SHIELD B7660F 1 7 LH CAP SHIELD B3-1280-W 1 Page 4a-31

1200 G3 Service Manual Page 4a-32 Issue 4a.11 - Turnover Assembly A2-80-A Item Description Part No. Qty. Item Description Part No. Qty. Fixings 81 RIVET 3.5mm (2mm-3mm) 16-145 A/R 82 M3 x mm POZI PAN HD SCREW E2726A A/R 83 M4 x 8mm POZI PAN HD SCREW E2624A A/R 84 M4 x 8mm CAP HD SCREW E250A A/R 85 M4 x mm CAP HD SCREW E2507A A/R 86 M4 x 12mm POZI PAN HD SCREW E2581A A/R 87 M4 x 12mm CSK SKT HD SCREW E2564A A/R 88 M4 FULL NUT E3502A A/R 8 M4 WASHER E4011A A/R 0 M4 x 8mm GRUB SCREW E2520A A/R 1 M5 x mm CAP HD SCREW E2516A A/R 2 M5 x 12mm CAP HD SCREW E2508A A/R 3 M5 FULL NUT E3501A A/R 4 M5 WASHER E4012A A/R 5 3.5mm E CLIP E5055A A/R 6.5mm E CLIP E5073A A/R 7 12mm CIRCLIP E501A A/R 8 8mm E CLIP E5054A A/R LOCK CUP P2522A 2 0 LOCK SPACER P252A 2 1 M4 LOCK CAP P2520A 2 2 PIN DOWEL 4DIA x 20 E506A 2 3 M4 x CSK SKT HD SCREW E2537A A/R 4 RESTRICTOR TAPE WEDGE B300A 2 5 LOCKING KNOB P201A 2 6 M4 NYLOC NUT E3505A 2 7 M4 WASHER FORM C E4048A 2 Page 4a-32

DS-1200 G3 Service Manual Page 4a-33 Issue FOR TURNOVER ASSEMBLY DETAILS SEE SECTION 4a.11 30 21,23 22 8 31,34 26 30 21,23 12 7 11 31,34 33 12 7 33 11 7 33 12 25 20 33 24 25 20 24 25 24 32 33 20 33 FRONT TOP PLATE ASSEMBLY - A2-84-A 2nd INSERT PLATE (OPTIONAL) - A3-0418-A 4a.12 - Insert & Top Plate Options Page 4a-33

DS-1200 G3 Service Manual Page 4a-34 Issue 4a.12 - Insert & Top Plate Options Front Top Plate Assy A2-84-A x1 7 BEARING HOUSING B07A 3 8 SUPPORT LH C6372E 1 SUPPORT RH C6375E 1 TOP PLATE FRONT C7-0431-E 1 11 INA BEARING NEEDLE ROLLER 3x6.5x6 E1-0155-A 6 12 PIN DOWEL 3 DIA x 24LG E55A 3 Fixings 30 M3 x 8mm C SK SKT HD SCREW E2502A A/R 31 M4 x 8mm CAP HD SCREW E250A A/R 32 M4 x 8mm POZI PAN HD SCREW E2720A A/R 33 M4 x 4mm POZI PAN HD SCREW E2815A A/R 34 M4 WASHER E4011A A/R 2nd Insert Plate (OPTIONAL) A3-0418-A x1 20 BEARING HOUSING B07A 3 21 LOCK SCREW M4 C2404A 2 22 TOP PLATE FRONT C7-0431-E 1 23 LOCK LEVER (GREEN) D30A 2 24 INA BEARING NEEDLE ROLLER 3x6.5x6 E1-0155-A 6 25 PIN DOWEL 3 DIA x 24LG E55A 3 26 INSERT AREA GUIDE STRIP LONG G61A 1 Page 4a-34

DS-1200 G3 Service Manual Page 4a-35 Issue 30,34 33,34 11 30 35 30,34 3 24 36 2 11 8 30 30 11 7 30 SEE NOTE BELOW 36 1 4 1 22 1 40 13 6 14 NOTE: LOCATION OF NAME IDENTITY LABEL 16 20 32 18 13 5 21 4a.13 - Turnover Eject Kicker A2633A Page 4a-35

1200 G3 Service Manual Page 4a-36 Issue 4a.13 - Turnover Eject Kicker A2633A Item Description Part No. Qty. Item Description Part No. Qty. 1 RIVET 3.5 2.0-3.0 GRIP 16-145 4 2 MTR. STEP 3 STK S/S WIRED 181-0820 1 3 PCB ASSY A5 STEPPER 180-675 1 4 PCB ASSY DISC SENSOR 180-68 1 5 HUB & DISC ASSY 12mm B4308A 1 6 SENSOR BRACKET B7204P 1 7 EJECT CHASSIS B8230P 1 8 EJECT PCB BRACKET B8325P 1 IDLE POST C2852A 1 SHAFT EJECT C4250A 1 11 SPACER M4 x E0333A 4 12 N/R 13 BEARING FLANGED 12x21x5 E87A 2 14 WASHER PL WAVED 0.86 DIA E4051A 1 15 WASHER PL WAVED 13mm DIA E4052A 1 16 PIN DOWEL 3 DIA x 18LG E508A 1 PULLEY STS 30T S2M F124P 1 18 PULLEY T5 22T (DRIVE) F125A 1 1 PULLEY ASSEMBLY F0-0065-A 1 20 PULLEY STS 30T S2M F128E 1 21 BELT STS 0T 0-S2M-180 F5078A 1 22 BELT T5 0T mm WIDE F505A 1 23 WASHER SPRING G6001A 1 24 RH CAP SHIELD B3-127-W 1 Fixings 30 M4 x 6mm CAP HD SCREW E2512A A/R 31 M4 x 8mm CAP HD SCREW E250A A/R 32 M4 x 12mm CAP HD SCREW E2575A A/R 33 M4 NUT E3502A A/R 34 M4 WASHER E4011A A/R 35 M4 x 8mm POZI PAN HD SCREW E2720A A/R 36 M5 x 12 POZI PAN HD SCREW E2628A A/R 37 12mm CIRCLIP E501A A/R Page 4a-36

DS-1200 G3 Service Manual Page 4a-37 Issue 4a.14 - Gearbox Assy A2-14-A Page 4a-37

1200 G3 Service Manual Page 4a-38 Issue 4a.14 - Gearbox Assy A2-14-A Item Description Part No. Qty. Item Description Part No. Qty. 1 PCB ASSY A6 DC MTR BRD 180-683 1 2 PCB ASSY VANE SENSOR 180-62 1 3 MOTOR -813 2X2WXH WIRED 181-073 1 4 DRIVE DOG C2527A 1 5 SENSOR DISC C2613A 1 6 BEARING SPIGOT P2452A 1 7 MOTOR SPIGOT C2615A 1 8 GEAR SHAFT C324A 1 8x12x8mm PL. OILITE E28A 1 4x7x4mm PL. OILITE E74A 1 11 WORM GEAR F413A 1 12 HELICAL GEAR F4140A 1 13 T SPUR GEAR x 6mm F4136A 1 14 GEARBOX CASTING G4065A 1 Fixings 20 M3 x 3mm GRUB SCREW E2642A A/R 21 M3 x 20 SLOTTED PAN HD SCREW E2515A A/R 22 M3 x POZI PAN HD SCREW E2726A A/R Page 4a-38

DS-1200 G3 Service Manual Page 4a-3 Issue S1 74,78 13. SEE SEC. 4a.16 7, 3 1 13. SEE SEC. 4a.16 AF *Sensor/PCB part no. shown - loom is a separate item. 75,78 AD 38 52 52 35 71,77 45 36 34.71,77 AC 55 40 46 22 11.SEE SEC. 4a.16 74,78 AE 7 14. SEE SEC. 4a.16 80 71,77 60,61 38 25 P 45 76,78 N 58 53 63 62 80 6 71,77 4 R 16. SEE SEC. 4a.16 SENSORS Item Description Part No. Ref. S1 Ins. Backstop Home Flag 180-62* 5.33 S2 Env. Flap TX 182-443 5.33 S3 Ins. Fingers Flag 180-776* 5.33 S4 Ins. in Position TX 182-443 5.33 S5 Kickers Index RX 182-344 5.33 S6 Kickers index TX 182-340 5.33 AB AA 73,77 42 80 20 31 41 74,78 74,78 S 3 6 56 72 15. SEE SEC. 4a.16. SEE SEC. 4a. T U M 26 L 8 3 77,81 S3 5 50 X 4 70 15. SEE SEC. 4a.16 44 4 75,78 R 80 83 S4 74,78 31 G W 50 SEE K4A-A0013765 KICKER GAS SPRING STOP SETUP INSTRUCTIONS A 23 S 44 S5 L H 64 88 87 45 86 80 2 48 45 13. SEE SEC. 4a.16 S7 Insert Kicker Clock Flag 180-68* 5.33 4a.15 - Kicker Assembly A2-81-A 51 M AB S6 3 33 43 30 74,78 71,77 52 57 28 72 C 51 70 74,78 46 71,77 21 45 D B F 45 27 E 71,77 J 47 14. SEE SEC. 4a.16 K 7 53 58 73,77 74,78 41 80 72 40 24 42 36 80 37 63 62 80 14. SEE SEC. 4a.16 74,78 5 18 74,78 Page 4a-3

1200 G3 Service Manual Page 4a-40 Issue 4a.15 - Kicker Assembly A2-81-A Item Description Part No. Qty. Item Description Part No. Qty. 1 16-114 CABLE CLAMP SMALL 1 2 16-116 RIVET 5mm 3.5-4.5mm GRIP 3 16-145 RIVET 3.5mm 2.0-3.0mm GRIP 6 4 180-675 PCB ASSY A5 STEPPER 2 5 180-683 PCB ASSY A5 DC MTR BRD 1 6 180-68 PCB STANDARD DISC SENSOR 2 7 180-62 PCB ASSY VANE SENSOR 1 8 180-776 PCB WIDEBODY DISC SENSOR 1 181-05 MOTOR W/D -06 2WXH 1 A2-85-A FINGER SHAFT ASSY 1 11 A2-87-A KICKER BACKSTOP ASSY 1 12 A2-88-A STEPPER/PULLEY ASSY 1S 1 13 A2-8-A KICKER DRIVE SHAFT ASSY 1 14 F0-0065-A PULLEY ASSEMBLY 3 15 A2-1111-A TENSIONER ASSY KICKER 2 16 A2654A STEPPER / PULLEY ASSY 3S 1 B0011A FORM CONTROLLER FLAT 4in 2 18 B0132A SPRING INPUT GUIDE 1 1 B2-1266-P OVERGUIDE LH 1 20 B2-1267-P SENSOR BRACKET 1 21 B2-1268-P SUPPORT BRACKET 1 22 B2-1272-P INSERT KICKER BRACKET RH 1 23 B2-1274-P PCB BRACKET 1 24 B2-1276-P INSERT KICKER BRACKET LH 1 25 B2-127-A SENSOR PLATE ADJUST 1 26 B2-1280-P SENSOR BRACKET AJUST 1 27 B2-1282-P TENSION BRACKET MID 1 28 B2-1283-P GUIDE MID RIGHT 1 2 B2-1284-P GUIDE MID LEFT 1 30 B3-3-P SENSOR COVER KICKER 1 31 B3-1127-P COVER AM6 KICKER 1 32 B70P DISC SENSOR BRACKET 1 33 B718P SENSOR BRACKET 1 34 B8331P SPRING POST 1 35 B837F KICKER LATCH 1 36 B8431P WASHER 2 37 C2814A GUIDE POST SHORT 2 38 C216A LATCH PIVOT 2 3 C2A KICKER GUIDE 2 40 C218A GAS STRUT POST LONG 2 41 C2-1277-A BUSH KICKER PIVOT 2 42 C25A SHAFT IDLE 3 43 C3-0676-A SENSOR COVER POST 2 44 C4-0530-A SPACER BAR 8mm 2 45 C423A CHASSIS SPACER 7 46 C4240A GUIDE POST LONG 3 47 C012A SHAFT PIVOT 1 48 C118A SHAFT GAS STRUT 1 4 E0-05-A SPACER M4.5 O/D 3.2 2 50 E0333A SPACER M4 x 51 F51A BELT STS 1 0-S2M-220 2 52 F5154A BELT T5 136T mm WIDE 3 53 G0157A GAS SPRING 300N 2 54 G1-0288-A INSERT SPRING 1 55 G06A SPRING TRACTOR 1 56 G3-0481-A LABEL FINGER 1 57 G6146A RIBBON CLAMP 2 58 R235P KICKER SIDE PLATE 2 5 B2-2168-P FEED GUIDE 1 60 C2404A M4 LOCK SCREW 1 61 D30A LOCK LEVER 1 62 G6001A SPRING WASHER 3 63 E4052A WASHER WAVED 13 DIA 3 64 C6-043-P GAS SPRING STOP 1 65 B0-022-A GUIDE SPRING 2 Page 4a-40

1200 G3 Service Manual Page 4a-41 Issue 4a.15 - Kicker Assembly A2-81-A Item Description Part No. Qty. Item Description Part No. Qty. Fixings 70 M4 x 8 POZI PAN HD SCREW E2624A A/R 71 M4 x 8 CAP HD SCREW E250A A/R 72 M4 x 8 DIN THD FORM (TAPTITE) E2701A A/R 73 M4 x 35 CAP HD SCREW E2630A A/R 74 M5 x CAP HD SCREW E2616A A/R 75 M5 x 16 CAP HD. SCREW E2606A A/R 76 M5 FULL NUT E3501A A/R 77 M4 WASHER E4011A A/R 78 M5 WASHER E4012A A/R 7 7mm E CLIP E5076A A/R 80 12mm CIRCLIP E501A A/R 81 M4 NYLOC NUT E3505A A/R 82 M4 x 8 BUTTON HD SCREW E2544A A/R 83 M5 x 15mm CAP HD SCREW E2573A A/R 84 M4 x 8 GRUB SCREW E2520A A/R 85 M4 x 6 BUTTON HD SCREW E264A A/R 86 M6 x 16mm CAP HD SCREW E2504A A/R 87 M6 FULL NUT E3505A A/R 88 M6 WASHER E4026A A/R Page 4a-41

DS-1200 G3 Service Manual Page 4a-42 Issue 48 4 16 1 STEPPER/PULLEY ASSY 3S A2654A 21 35 47 2 32 TENSIONER ASSY A2-1111-A 31 25 12 15 18 13 36 30 51 26 IDLER PULLEY ASSY F0-0065-A KICKER DRIVE SHAFT ASSY A2-8-A 54 BACK STOP ASSEMBLY A2-121-A 21 53 41 STEPPER/PULLEY ASSY 1S A2-88-A 1 14 50 22 40 42 46 7 45,52 KICKER BACK STOP ASSY A2-87-A 18 15 8 21 1 3 12 20 4 50 8 1 2 4a.16 - Kicker Sub Assemblies Page 4a-42

1200 G3 Service Manual Page 4a-43 Issue 4a.16 - Kicker Sub Assemblies Item Description Part No. Qty. Item Description Part No. Qty. Kicker Backstop Assembly A2-87-A x1 1 BACKSTOP (ASSEMBLY) A2-121-A 1 2 LEADSCREW C418A 1 3 FLANGED BEARING 4mm BORE E77A 1 4 PIN DOWEL 3 DIA x LG (S/STEEL) E53A 1 Stepper / Pulley (1S) A2-88-A x1 7 MTR. STEP 1 STK S/S WIRED 181-0880 1 8 MOTOR SPACER C338A 3 PULLEY STS 15T S2M F128A 1 Kicker Drive Shaft Assy A2-8-A x1 12 PLATE DRIVE SHAFT B2-1278-A 2 13 DISC HUB ASSEMBLY B4-0437-A 1 14 DRIVE DOG MID C2-66-A 1 15 BEARING RING C2-67-A 2 16 DOG WASHER C2865A 1 SHAFT DRIVE KICKER C5-74-A 1 18 BEARING FL 12x21x5 E87A 2 1 PULLEY T5 22T F125A 3 20 PULLEY STS 30T S2M F128E 1 21 GEAR WASHER P244A 3 22 LOCK SPACER (13) P2525A 1 Stepper / Pulley (3S) A2654A x1 35 MTR. STEP 3 STK S/S WIRED 181-0820 1 36 PULLEY STS 15T S2M F124P 1 Back Stop Assembly A2-121-A x1 40 BOSS ASSEMBLY B4-0445-A 1 41 STOP ASSEMBLY B4-0446-A 1 42 WASHER WAVED 8.8 I/D E4033A 1 Fixings 45 M3 x 14mm CAP HD SCREW E2684A A/R 46 M4 x CSK HD SCREW E2537A A/R 47 M4 x 14mm CAP HD SCREW E2531A A/R 48 M5 x 12mm CAP HD SCREW E2508A A/R 4 M5 WASHER E4012A A/R 50 DOWEL PIN 3 x 18mm E508A A/R 51 CIRCLIP 4.5 E5081A A/R 52 M3 WASHER E400A A/R 53 M3 x mm CAP HD SCREW E2500A A/R 54 DOWEL PIN 3 x 16mm E5086A A/R Idler Pulley Assy F0-0065-A x1 25 BEARING BALL 12x28x8 E54A 1 26 PULLEY T5 22T F126A 1 Tensioner Assembly A2-1111-A x1 2 INSERT LOCATOR BOSS C3634A 1 30 PIN DOWEL 2 DIA x E57A 1 31 SPRING OMR SHAFT G1136A 1 32 INSERT BOSS P2436A 1 Page 4a-43

DS-1200 G3 Service Manual Page 4a-44 Issue 40 46,47 2 44 FINGER ASSEMBLY R H A2-78-A FINGER TIP KIT RH (SPARES) A2-11-A 15 14 41,43 18 FINGER ASSEMBLY MIDDLE A2-86-A 1 41,43 16 15 20 FINGER ASSEMBLY L H A2-77-A 45 6 4 48 21 22 20 41,43 11 MID FINGER BODY ASSY A2-115-A 37 34 32 35 40 41,43 FINGER SHAFT ASSEMBLY A2-85-A 3 5 48 4 7 8 45 45 12 13 11 FINGER TIP KIT LH (SPARES) A2-118-A 36 33 31 26 2 28 25 24 23 27 40 41,43 FINGER BODY ASSEMBLY A2-76-A NOTE: ASSEMBLE ALL PARTS TO SHAFT, C5-12-A (ITEM 5) BEFORE FITTING PIN, E5078A (ITEM 48). TO REMOVE PARTS FROM SHAFT REMOVE PIN E5078A FROM ONE END AND REPLACE WITH A NEW PIN ON RE-ASSEMBLY. 6 44 1 46,47 40 4a. - Finger Shaft Assembly - Sub Assemblies Page 4a-44

1200 G3 Service Manual Page 4a-45 Issue 4a. - Finger Shaft Assembly - Sub Assemblies Item Description Part No. Qty. Item Description Part No. Qty. Finger Shaft Assembly A2-85-A x1 Finger Body Assembly A2-76-A x1 1 AM6 FINGER ASSY (LH) A2-77-A 2 23 FINGER STOP B71P 1 2 AM6 FINGER ASSY (RH) A2-78-A 2 24 LOCK SCREW C2313A 1 3 AM6 FINGER ASSY MIDDLE A2-86-A 1 25 FINGER BODY C6-0424-A 1 4 FINGER END SHAFT C4-055-A 2 26 FINGER LEVER C6312A 1 5 FINGER STUB SHAFT C5-12-A 1 27 LOCK LEVER D30A 1 6 BEARING FLANGED E87A 2 28 PIN DOWEL 3 DIA x 18 E508A 1 7 PIN DOWEL E508A 1 2 SPRING FINGER G1161A 1 8 PULLEY STS 45T S2M F1-0442-E 1 J S T TOOL (REF ONLY) B0158A 1 Finger Assembly L.H A2-77-A x1 FINGER BODY ASSY A2-76-A 1 11 *FINGER PEG C2-75-A 2 12 *FINGER L.H D45A 1 13 *SPRING INDEX G46A 1 NOTE: STARRED ITEMS (*) ARE PART OF FINGER TIP KIT LH (SPARES) A2-118-A Mid Finger Body Assembly A2-115-A x1 31 FINGER STOP (MIDDLE) B3-1235-A 1 32 LOCK SCREW C2313A 1 33 FINGER BODY C6-0424-A 1 34 FINGER LEVER C6312A 1 35 LOCK LEVER D30A 1 36 PIN DOWEL 3 DIA x 18 E508A 1 37 SPRING FINGER G1161A 1 Finger Assembly R.H A2-78-A x1 14 FINGER BODY ASSY A2-76-A 1 15 *FINGER PEG C2-75-A 2 16 *FINGER R.H D46A 1 *SPRING INDEX G46A 1 NOTE: STARRED ITEMS (*) ARE PART OF FINGER TIP KIT RH (SPARES) A2-11-A Finger Assembly Middle A2-86-A x1 18 FINGER BODY ASSY A2-115-A 1 1 SENSOR VANE B2-1281-A 1 20 FINGER PEG C2-75-A 2 21 FINGER L.H D45A 1 22 SPRING INDEX G46A 1 Fixings 40 M3 x 6 CSK HD SCREW E2560A A/R 41 M4 x 6 CAP HD SCREW E2512A A/R 42 M4 x 12 SKT HD SCREW E2575A A/R 43 M4 WASHER E4011A A/R 44 12mm CIRCLIP E501A A/R 45 SHIM (12mm DIA) + G6-0233-A A/R 46 LOCK SCREW M4 C2404A A/R 47 LOCK LEVER D30A A/R 48 PIN GROOVED 2.5 x 14 E5078A A/R + FIT AS REQUIRED Page 4a-45

DS-1200 G3 Service Manual Page 4a-46 Issue 23 34 21 A 4 6. SEE SEC. 4a.21 A 50,55 58 15 51,53 47,53 16 27 24 3 1 A 22 1 50,55 31 4. SEE SEC. 4a.1 46 11 20 50,55 47,53 58 15 16 27 24 3 51,53 12 57 38 20 21 34 57 38 57 38 23 2 4 20 37 13 37 57 20 38 36 35 47,53 56 51 26 3 43 24 27 S2 5 44 45 53 51 16 47,53 15 58 S1 A 22 31 1 1 48 S3 1 50,55 5. SEE SEC. 4a.1 18 47,53 7. SEE SEC. 4a.20 3. SEE SEC. 4a.1 SENSORS Item Description Part No. Ref. S1 Closer RX 182-441 5.34 S2 Eject RX 182-445 5.34 S3 Closer TX 182-443 5.34 S4 Eject TX 182-443 5.34 3 24 27 26 16 47,53 28 S4 40 42 28 2 41 15 58 14 51,53 LOCATION OF NAME IDENTI- FICATION LABEL 4a.18 - Wetter / Closer Assembly A734A 25 52,54 47,53 45 30 32 33 8 Page 4a-46

1200 G3 Service Manual Page 4a-47 Issue 4a.18 - Wetter / Closer Assembly A734 A Item Description Part No. Qty. Item Description Part No. Qty. 1 MTR W/D -03 IN-LINE 181-050 1 40 LOCK SPACER (4.5) P2524A 1 2 SOLENOID W/D -348 XH 181-130 1 41 LOCK SPACER (13) P2525A 1 3 OUTFEED SHAFT ASSY A735A 1 42 LOCK SPACER (1.7) P2526A 1 4 INFEED SHAFT ASSY A737A 1 43 SENSOR PLATE B2-1881-A 1 5 CLOSER ASSY A2660A 1 44 PROTECTION FILM G6-0243-A 1 6 CARRIER ASSY A2661A 1 45 1/4 P CLIP 16-112 1 7 WETTER ASSY A7416A 1 8 CLOSER MOTOR ELEC COVER B341A 1 WETTER BOARD COVER B7306A 1 Fixings BUTTRESS B8370P 2 45 M3 x 14mm CAP HD SCREW E2684A A/R 11 WETTER TOP PLATE B8373A 1 46 M4 x 8mm POZI CSK HD SCREW E2668A A/R 12 MAIN CHASSIS R6244A 1 47 M4 x 12mm CAP HD SCREW E2575A A/R 13 SOLENOID BRACKET WETTER B8375P 1 48 M5 x 20mm CAP HD SCREW E2523A A/R 14 WETTER MOTOR PLATE R6245A 1 4 M5 x 20mm GRUB SCREW E2645A A/R 15 M6 LOCK CAP P2521A 4 50 M6 x 12mm CAP HD SCREW E2533A A/R 16 12mm BRG HSG UNTAPPED C276A 4 51 M4 FULL NUT E3502A A/R LOCATION STUB C201A 1 52 M5 FULL NUT E3501A A/R 18 LOCKING KNOB C202A 1 53 M4 WASHER E4011A A/R 1 CARRIER BEARING WASHER C203A 4 54 M5 WASHER E4012A A/R 20 SUPPORT POST VERTICAL C4273A 8 55 M6 WASHER E4026A A/R 21 CARRIER SUPPORT C4274A 2 56 M4 x 25mm CAP HD SCREW E2744A A/R 22 CARRIER BEARING BAR C4275A 2 57 M6 FULL NUT E3503A A/R 23 N.A.T. POST C4356A 2 58 M6 x 12mm CSK HD SCREW E2721A A/R 24 LOCK CAP P2522A 4 5 M3 x 8mm CSK SKT HD SCREW E2502A A/R 25 SNAP BUSHING.3mm I/D E0305A 2 26 BEARING PRELOAD SPRING E0346A 2 Notes: 27 BEARING BALL 12mm E54A 4 1) The following items form Wetter Closer Pressure Assy: A3226A 28 PIN DOWEL 3 DIA x 16(m6) S / STEEL E5086A 1 2 PULLEY TIMING 60T S2M F1288A 1 ITEMS: 21, 22, 23, 34, 4 30 PULLEY STS 15T S2M F1346P 1 31 BELT 232T x 1W XL F5076A 2 2) Item 33 - PCB Splitter 3 sens 4 sol - No.180-61 32 BELT STS 1 0-S2M-22 F51A 1 is part of Elec Kit A5 Wetter/Close No. 07-04 33 PCB SPLITTER 3 SENS 4 SOL 180-61 1 34 SPRING PRESSURE G25A 2 35 SPRING WETTER G6A 1 36 SPRING SOLENOID G1165A 1 37 WASHER M20 INT SH/PROOF E4072A 1 38 M6 SUPPORT POST C4507A 8 3 PIN DOWEL 4 DIA x 20mm (m6) E506A 4 Page 4a-47

DS-1200 G3 Service Manual Page 4a-48 Issue 21 24 38 22 20 15 OUTFEED SHAFT ASSEMBLY A735A 23 20 24 38 21 14 16 20 24 38 18 1 13 5 6 4 7 38 5 6 4 7 38 5 1,3 5 1,3 5 1,3 2 5 CLOSER ASSEMBLY A2660A 1 3 7 38 32 30 40,41,42 36,37 2 31 INFEED SHAFT ASSEMBLY A737A 35,37 12 18 38 4 4a.1 - Wetter / Closer Sub Assemblies Page 4a-48

1200 G3 Service Manual Page 4a-4 Issue 4a.1 - Wetter / Closer Assemblies Item Description Part No. Qty. Item Description Part No. Qty. Outfeed Shaft Assembly A735A x1 1 ROLLER CORE C288A 4 2 SHAFT OUTFEED C755A 1 3 TYRE FEED WHEEL D000A 4 4 WASHER PL WAVED 13mm DIA E4052A 3 5 PIN DOWEL 3 DIA x 16 (m6) S/S E5086A 6 6 PULLEY 24XL x 25 F1287A 2 7 WASHER SPRING G6001A 3 Infeed Shaft Assembly A737A x1 12 WETTER DIVERT OVERGUIDE B342A 13 WETTER DIVERT B343A 1 14 ROLLER CORE C288A 1 15 SHAFT INFEED C747A 1 16 TYRE FEED WHEEL D000A 1 N/R 18 BEARING FLANGED 12x21x5 E87A 2 1 WASHER PL WAVED 0.86 DIA E4051A 1 20 WASHER PL WAVED 13mm DIA E4052A 3 21 PIN DOWEL 3 DIA x 16 (m6) S/S E5086A 2 22 PULLEY 24XL x 25 F1287A 1 23 PULLEY ASSEMBLY F0-006-A 1 24 WASHER SPRING G6001A 3 Fixings 35 M4 x 8 POZI PAN HD SCREW E2624A A/R 36 M4 x 8 CAP HD SCREW E2507A A/R 37 M4 WASHER E4011A A/R 38 12mm CIRCLIP E501A A/R 3 N/R 40 M3 x 8 CAP HD. SCREW E2771A A/R 41 M3 FULL NUT E4065A A/R 42 M3 WASHER E361A A/R Closer Assembly A2660A x1 2 CLOSER OVERGUIDE SHIM B012A 1 30 CLOSER OVERGUIDE BRKT B8361A 1 31 CLOSER R15 B8371A 1 32 SPACER M4 x 15 E034A 4 Page 4a-4