Section 4a Exploded Views (Inserter Head)

Section 4a Exploded Views (Inserter Head) Sect. Page 4a.1 Insert Head Assy. A5115A (Control Side)...4a-2 4a.2 Insert Head Assy. A5115A (Drive Side)...4a-5 4a.3 Insert Head Assy. A5115A (Main Sub-Assys.)...4a-7 4a.4 Primary Drive Assy. A7068A/A7069A/A7335A/A7336A...4a-9 4a.5 Head Upper Clam Assy. A7041A...4a-10 4a.6 Collate Pocket Clam Assy. A7060A...4a-11 4a.7 Sealer Cover Assy. A7046A...4a-12 4a.8 Side Guide Actuator Assy. A7047A...4a-13 4a.9 Side Guide Rack Assy. A7071A (Datacard A7354A)...4a-14 4a.10 Wetter Tank Assy. A7042A...4a-15 4a.11 Wetter Reservoir Assy. A7057A...4a-16 4a.12 Wetter Solenoid Brkt. (Drives) Assy. A7065A...4a-17 4a.13 Wetter Solenoid Brkt. (Operator) Assy. A7066A...4a-18 4a.14 Wetter Beam Assy. A7067A...4a-19 4a.15 Env. Feeder Assy. A7223A(220v) / A7224A(110v)...4a-20 4a.15a IMPORTANT NOTE FOR ORACLE JDE/SIEBEL SYSTEMS, PART NUMBERS SHOWN IN THIS MANUAL SHOULD BE CONVERTED AS FOLLOWS: PFE ORACLE JDE/SIEBEL B1-2345-A PFEB12345A B1234A PFEB1234A 123-456 PFE123456 Datacard Env. Feeder Assy. A2-1165-A/A2-1166-A...4a-21 4a.16 Envelope Separator Assemblies A7070A & A7353A...4a-22 Page 4a - 1 4a.17 Pocket Backstop Assy. A7058A...4a-23 4a.18 Finger Chassis Assy. A7055A (Alternative A7352A)...4a-24 4a.19 Finger Set A7056A...4a-25 Service Kit List...4a-26 4a.20 Finger Bracket Assy. A7062A...4a-27 4a.21 Sprocket Bracket Assy. A7059A...4a-27 4a.22 Split Shaft (Brake) Assy. A7063A...4a-28 4a.23 Split Shaft (Plain) Assy. A7064A...4a-29 4a.24 Feed Roller Shaft Assy. A2993A...4a-30 4a.25 Insert Roller Shaft Assy. A2994A...4a-30 4a.26 Opener Assemblies A7022A/A7413A...4a-30 4a.27 C/B Shaft Assy. A7023A...4a-31 4a.28 P. Wheel Shaft Assy. A7024A...4a-31 4a.29 Stub Housing Assy. A7038A...4a-31 4a.30 Lobed Feed Shaft Assy. A7073A (Datacard A7378A)...4a-32 4a.31 Envelope Clutch Shaft Assy. A2997A...4a-33 4a.32 Clutch/Brake Shaft Assy. A2998A...4a-33 4a.33 Flap Grip Roller Assy. A7072A/A2-1162-A/A2-1163-A/A2-1164-A...4a-34 4a.34 Control Panel Assy. A7260A...4a-35 4a.35 Head Covers A7045A...4a-36 4a.36 Maximailer Plus Upgrade...4a-37 4a.37 Envelope Pre-Feeder Assy. A7217A (Datacard A7355A)..4a-38 4a.38 Finger Set - Datacard A7356A (Optional)...4a-39 Page 4a - 1

Page 4a - 2 9 Apr 2011 17. SEE SEC 4a-12 W. SOL. BRACKET DRIVES ASSEMBLY A7065A S6 S7 15. SEE SEC 4a-22 SPLIT SHAFT (BRAKE) ASSEMBLY A7063A S13 12. SEE SEC 4a-17 POCKET BACKSTOP ASSEMBLY A7058A S14 16. SEE SEC 4a-23 SPLIT SHAFT (PLAIN) ASSEMBLY A7064A S8 S12 S9 S11 S4 S5 S17 19. SEE SEC 4a-14 WETTER BEAM ASSEMBLY A7067A S10 S15 S16 S18 13. SEE SEC 4a-21 SPROCKET BRACKET ASSEMBLY A7059A 11. SEE SEC 4a-8 SIDE GUIDE ACTUATOR ASSEMBLY A7047A 14. SEE SEC 4a-20 FINGER BRACKET ASSEMBLY A7062A RETRO FIT ONLY SENSORS Item Description Ref. S1 Closer Output 5.13 S2 Wetter Output RX 5.13 S3 Wetter Output TX 5.13 S4 Closer RX 5.13 S5 Closer TX 5.13 S6 Wetter Home Flag 5.13 S7 Main Motor Disc 5.13 S8 Collate Input RX 5.13 S9 Pawl Position TX 5.13 S10 Pawl Position RX 5.13 S11 Env. Flap RX 5.13 S12 Env. Insert TX 5.13 S13 Collate Pocket TX 5.13 S14 Coll. Pocket Load RX 5.13 S15 Side Guide Datum Flag 5.13 S16 Side Guide Disk 5.13 S3 S1 S2 104. SEE SEC 4a-28 P WHEEL SHAFT ASSEMBLY A7024A 103. SEE SEC 4a-27 CB SHAFT ASSEMBLY A7023A 10. SEE SEC 4a-10 WETTER TANK ASSEMBLY A7042A S17 Closer Cover Switch 5.13 4a.1 - Insert Head Assy. A5115A (Control Side) A A A 18. SEE SEC 4a-13 W. SOL. BKT. OPERATOR ASSEMBLY A7066A Page 4a - 2

Page 4a - 3 11 Nov 2011 Item Description Part No. Qty. Item Description Part No. Qty. 1 P CLIP 1/4 169-112 A/R 2 RIVET 3.5-4.5mm GRIP 169-128 A/R 3 SADDLE CLIP (SMALL) 169-140 A/R 4 SADDLE CLIP (LARGE) 169-141 A/R 5 CLUTCH, COLLATE ENTRY 179-213 1 6 CLUTCH, CLOSER REVERSE 179-214 1 6a BRAKE, CLOSER FORWARD 179-214 1 6b BRAKE, PAWL TRACK DRIVE 179-214 1 7 BRAKE, WETTER OUTPUT 181-127 1 7a CLUTCH, COLLATE POCKET FAST 181-127 1 8 WIRED REED SWITCH 3WXH 182-580 2 9 OPB715 WIRED SENSOR 2 x 3W 182-693 1 10 WETTER TANK ASSEMBLY A7042A 1 11 SIDE GUIDE ACTUATOR ASSY A7047A 1 12 POCKET BACKSTOPS ASSY A7058A 1 13 SPROCKET BKT ASSEMBLY A7059A 1 14 FINGER BKT OPERATOR ASSY A7062A 1 15 SPLIT SHAFT (BRAKE) ASSY A7063A 1 16 SPLIT SHAFT (PLAIN) ASSY A7064A 1 17 W.SOL.BKT ASSY DRIVES A7065A 1 18 W.SOL.BKT ASSY OPERATOR A7066A 1 19 WETTER BEAM ASSY A7067A 1 20 RIBBON CLIP RICHCO TC-30-1 E0446A 7 21 CHAIN PAWL B3-1478-A 4 22 SEAL PLATE B7455A 1 23 OUTPUT SENSOR BRACKET B7456A 1 24 TRIPLE CLUTCH BRACKET B7457A 1 25 SEALER SKI ASSY. B1889A 1 26 CENTRE PANEL B7468A 1 27 OP PANEL B7470A 1 28 DRIVES PANEL B7471A 1 29 OUTPUT SENSOR BRACKET B7488A** 1 30 OUTPUT COVER B7489S** 1 31 SPLIT SHAFT COVER B7507A 2 32 DOUBLE CLUTCH BRACKET B7509A 1 33 WIDE POCKET GUIDE LH* B9158A 1 34 WIDE POCKET GUIDE RH* B9159A 1 35 SIDE GUIDE BRACKET B7696A 2 36 TANK CHANNEL B7712A 1 37 HINGE STAY UPPER LH B7794A 1 * Narrow finger kit A3348A includes pocket guides B7694A (LH) & B7695A (RH). ** FOR DARK ENVELOPE KIT: A0-0644-A SENSOR BRACKET - Pt. No. B3-1544-A (OPTIONAL) OUTPUT COVER - Pt. No. B3-1543-S (OPTIONAL) 38 HINGE STAY LOWER B7796A 1 39 OUTPUT BRIDGE B8754A 1 40 HEAD SIDE PLATE B8761A 1 41 HEAD SIDE PLATE DRIVES B8762A 1 42 MAIN BRIDGE HEAD B8763A 1 43 FOOT SPIGOT G4-0149-A 4 44 IDLER POST C2586A 2 45 PIVOT POST CONVEYOR C3555A 2 46 SENSOR POST 77.5mm C4315A 1 47 HINGE PIN C4366A 2 48 BEARING T 6mm C6296A 1 49 HINGE C6358E 2 50 RUBBER FOOT C8078A 4 51 SEAL ROLLER (40 DIA) C8167A 1 52 SEAL ROLLER (25 DIA) C8168A 1 53 SHAFT WHEEL C9263A 2 54 SHAFT SPROCKET C9264A 1 55 SHAFT SPEED DOWN C9266A 1 56 SHAFT CONVEYOR DRIVE C9268A 1 57 SHAFT CONVEYOR IDLER C9274A 1 58 SENSOR POST 77.5mm C9278A 1 59 SHAFT IDLER C9418A 1 60 COVER PIVOT POST C9444A 1 61 BEARING T 8mm MIN D1040A 4 62 FOOT PUSH-IN HEYCO 086-2100 E0291A 1 63 WASHER WAVED 23mm ID E0367A 8 64 OILITE PL 8x12x12mm E1038A 1 65 BEARING FL. 8x22x7mm E1078A 8 66 PULLEY 25T XL x 8 DIA F1375A 8 67 JOCKEY SPROCKET F3004A 2 68 SPROCKET 15T F3044A 2 69 GEAR 48T x 8mm F4151A 7 70 GEAR 30T x 8mm F4156A 2 71 BELT 130XL 037 POLY 4 BELT F5120A 1 72 CHAIN 1/4 PITCH x 61 F6016A 4 73 CHAIN 1/4 SPECIAL C/LINK F6041A 4 74 WASHER G0000A 1 75 CLUTCH PIN G0079A 5 76 SPRING LIGHT PRESSURE (GREEN) G1111A 2 77 SPRING OMR SHAFT (BLUE) G1136A 2 4a.1 - Insert Head Assy. A5115A (Control Side) Page 4a - 3

Page 4a - 4 10 Jul 2011 Item Description Part No. Qty. Item Description Part No. Qty. 78 SPRING LINK G1180A 1 79 SPRING WETTER G1181A 2 80 BRIDGE CLAMPS G4092A A/R 81 CHAIN TAPE G6181A 2 82 VIEWING PANEL G7150A 1 83 SPROCKET HUB P2033A 2 84 LATCH SPIGOT SHORT P2065A 4 85 LATCH SPIGOT LONG P2066A 3 86 COVER STOP SPIGOT P2175A 1 87 GUIDE SPIGOT P2190A 2 88 COLLATE PIVOT POST P2212A 1 89 COLLATE PIVOT PEG P2213A 1 90 TRAY SPIGOT P2230A 2 91 PIPE SPOUT P2275A 1 92 STUD SPACER P2276A 1 93 BRAKE LOCATION SPLIT R2112A 1 94 CENTRE PLATE BRAKE R2113A 1 95 EDGE PLATE BRACKET R2114A 2 96 COLLATE BED BRACKET R2115A 1 97 MULTI CLUTCH BRACKET R2144A 1 98 SENSOR DISC BRACKET R2159A 1 99 WETTER BRIDGE R2174A 1 100 MAIN COVER HINGE BRACKET R2227F 1 101 TOP COVER HANDLE R2229F 1 102 HOSE BRACKET R2302A 1 103 CB SHAFT ASSEMBLY A7023A 1 104 P. WHEEL SHAFT ASSEMBLY A7024A 1 105 PCB, MOTOR DISC SENSOR 180-746 1 106 PCB, RIBBON SPLITTER 1 180-759 1 106a PCB, RIBBON SPLITTER 4 180-760 1 107 PCB, C4 CONTROL Mk.2 180-8360 1 108 PCB, AM4 PROCESSOR 180-720 1 109 M3 x 8mm POZI PAN HD T/T SCREW E2717A A/R 110 M3 x 8mm CSK HD ST/STL SCREW E2776A A/R 111 M3 x 12mm CSK SLOT HD SCREW E2590A A/R 112 M3 WASHER E4009A A/R 113 M3 NYLOC NUT E3557A A/R 114 M4 x 6mm SKT CAP HD SCREW E2512A A/R 115 M4 x 8mm POZI PAN HD T/T SCREW A/R 116 M4 x 8mm CAP HD SCREW E2509A A/R 117 M4 x 12mm POZI PAN HD T/T SCREW E2730A A/R 118 M4 x 12mm POZI PAN HD SCREW E2581A A/R 119 M4 x 12mm CSK SKT HD SCREW E2564A A/R 120 M4 x 12mm POZI HD T/T SCREW E2787A A/R 121 M4 x 20mm POZI PAN HD T/T SCREW E2716A A/R 122 M4 x 35mm POZI PAN HD SCREW ST. STL. E2833A A/R 123 M4 FULL NUT E3502A A/R 124 M4 NYLOC NUT E3505A A/R 125 M4 WASHER E4011A A/R 126 M5 x 20mm POZI PAN HD T/T SCREW E2809A A/R 127 M8 FULL NUT (BRASS) E3604A A/R 128 CIRCLIP 7mm E5003A A/R 129 E CLIP 9.5mm A/R 130 E CLIP 15.5mm E5100A A/R 131 PIN GROOVED 2.5 DIA x 14mm E5078A A/R 132 PIN DOWEL 3 DIA x 8mm E5074A A/R 133 PIN DOWEL 3 DIA x 14mm E5071A A/R 134 PIN EC30 P2232A A/R 135 NO SEAL BRACKET KIT A0-0503-A 1 136 M4 x 8 POZI PAN HD SS SCREW E2786A 2 137 CURRENT LABEL (MAXIMAILER + ONLY) G3444A 1 138 MAGNET 131-824 1 139 DOUBLE SIDED AHESIVE FOAM TAPE E0033A A/R 140 SPACER M4 x 15 E0349A 2 141 6mm FIBRE WASHER E4010A 2 142 LOOM, MAXI DONGLE LINK 182-745 1 143 DONGLE BRACKET R6053A 1 144a DONGLE PCB, MAXIMAILER STD 123-800* 1 144b DONGLE PCB, MAXIMAILER SE 2PF 123-801* 1 144c DONGLE PCB, MAXIMAILER SE 3PF 123-802* 1 144d DONGLE PCB, MAXI EXTRA FEATURES 123-803* 1 145 EC30 CLUTCH PIN G0167P A/R 146 BEARING FLANGED 8 x 22 x 25 x 7 SS E1137A 2 147 M4 NUT STAINLESS STEEL E3630A A/R 148 MAXI NO ENV. OVERGUIDE KIT A3-0368-A 1 149 PCB SHIELD G6201A 1 *Note 1: Dongle PCB varies according to machine configuration. Prior to ordering, contact Service Department for further advice. Note 2: Item 135 is an optional alternative to Item 25. 4a.1 - Insert Head Assy. A5115A (Control Side) Page 4a - 4

Page 4a - 5 29 16 37 22 30 11 34 MAXIMAILER PLUS ONLY (USE ITEM 29 IN PLACE OF ITEM 11) 31 13 38 8 1 33 2 4 2a 2a 1a 33 9 14 9 20 12 9 17 12 9 15 9 21 12 17 1537 25 15 3714 14 16 19 37 19 17 22 37 9 20 37 14 16 12 15 37 36 32 7 32 2a 38 19 37 35 20 37 36 35 16 19 19 39 38 2b 13 3 5 24 24 12 9 34 15 6 34 20 34 37 16 17 20 37 20 9 34 37 16 16 37 12 15 20 17 21 21 37 36 35 12 15 37 16 20 20 3 37 42/43 9 37 37 23 34 36 20 35 17 27 Use as required for clutch airgap of 0.15mm. 14 20 37 17 40 41 9 12 15 37 14 20 37 36 34 35 10 16 19 5 26 18 2 37 36 22 39 20 37 36 37 36 35 35 9 14 20 35 38 37 36 35 35 23 4 28. SEE SEC 4a-4 PRIMARY DRIVE ASSY. 6. SEE SEC 4a-29 STUB HOUSING ASSEMBLY (IN 2 POSNS) 23 4a.2 - Insert Head Assy. A5115A (Drive Side) Page 4a - 5

Page 4a - 6 Item Description Part No. Qty. Item Description Part No. Qty. 1 PCB, RIBBON SPLITTER 2 180-759 1 1a PCB, RIBBON SPLITTER 6 180-759 1 2 CLUTCH, PAWL TRACK DRIVE 179-214 1 2a BRAKE, CLOSER REVERSE 179-214 1 2b CLUTCH, CLOSER FORWARD 179-214 1 3 BRAKE, COLLATE ENTRY 181-117 1 4 CLUTCH, WETTER OUTPUT 181-127 1 5 CLUTCH, LENZE, COLL. POCK. ENTRY SLOW 181-132* 1 6 STUB HOUSING ASSEMBLY A7038A 2 7 SENSOR DISC 130 SLOT B7708A 1 8 HEAD SIDE PLATE DRIVE B8762A 1 9 IDLER POST C2586A 11 10 STUB SHAFT C4318A 1 11 CONVEYOR DRIVE SHAFT C4323A 1 12 WASHER WAVED 23mm ID x 8mm E0367A 8 13 SNAP BUSHING 17.5 x 11.5mm E0424A 2 14 OILITE PL. 8 x 12 x12mm E1038A 7 15 BEARING FL. 8 x 22 x 11.5mm E1078A 8 16 PIN DOWEL 3 x 14mm E5071A A/R 17 PIN DOWEL 3 x 8mm E5074A A/R 18 PULLEY V6 x 8 x 57mm F2083A 1 19 GEAR 40T x 8mm F4150A 6 20 GEAR 48T x 8mm F4151A 16 21 GEAR 25T x 8mm F4152A 3 22 GEAR 30T x 8mm F4156A 3 23 CLUTCH PIN G0079A 7 24 IDLER STAND OFF P2047A 2 25 SENSOR DISC HUB P2214A 1 26 CLUTCH WASHER P2225A 1 27 CLUTCH PLATE R2202A* 1 28 POLYCORD BELT 930mm F0052A 1 29 CONVEYOR BRAKE SHAFT C4429A 1 30 BRAKE BRACKET R2874A 1 31 CLUTCH EC30 CW 8mm 24V 179-213 1 Fixings 32 3mm PLAS-TECH 30 SCREW E2782A A/R 33 M4 x 6mm CAP HD SCREW E2512A A/R 34 M4 x 8mm POZI PAN HD T/T SCREW A/R 35 M4 x 35mm POZI PAN HD SCREW ST. STL. E2833A A/R 36 M4 WASHER E4011A A/R 37 9.5mm E CLIP A/R 38 EC30 CLUTCH PIN G0167P A/R 39 EC30 DOWEL PIN P2232A A/R 40 RIVET POP 2.4 DIA x 7.5L E0267A* A/R 41 CLUTCH DISC P2224A* 1 42 SHIM, BRAKE G6028A* A/R 43 SHIM, CLUTCH G6168A* A/R NOTE: Items marked * form Slow-down Clutch Assembly A7366A Page 4a - 6

Page 4a - 7 7/7A. SEE SEC 4a-4 PRIMARY DRIVE ASSEMBLY A7068A - (230v) / A7069 - (115v) A7335A - (230v) / A7336A - (115v) S22 S23 6. SEE SEC 4a-15 ENVELOPE FEEDER ASSEMBLY A7223A / A7224A FOR DATACARD ENVELOPE FEEDER ASSEMBLY - A2-1165-A / A2-1166-A SEE SEC. 4a-15a S24 S20 S21 S29 S28 S25 S26 S27 1. SEE SEC 4a-5 HEAD UPPER CLAM ASSEMBLY A7041A S30 S31 S19 3. SEE SEC 4a-18 FINGER CHASSIS ASSEMBLY A7055A (DATACARD A7352A) S32 5. SEE SEC 4a-6 COLLATE POCKET CLAM ASSEMBLY A7060A SENSORS Item Description Ref. S19 Finger Disc 5.13 S20 Fingers Out Flag 5.13 S21 Fingers Datum Flag 5.13 S22 Env. Loaded (Refl.) 5.13 S23 Deskew RX 5.13 S24 Deskew TX 5.13 S25 Envelope Width TX 5.13 S26 Envelope Width RX 5.13 S27 Side Cover Switch 5.13 S28 Envelope Insert RX 5.13 S29 Envelope Flap TX 5.13 S30 Collate Input TX 5.13 S31 Collate Pocket RX 5.13 S32 Coll. Pocket Load TX 5.13 S33 Wet. Fl. Level Switch 5.13 2. SEE SEC 4a-7 SEAL COVER ASSEMBLY A7046A 4a.3 - Insert Head Assy. A5115A (Main Sub Assemblies) S33 4. SEE SEC 4a-11 WETTER RESERVOIR ASSEMBLY A7057A Page 4a - 7

Page 4a - 8 Item Description Part No. Qty. Item Description Part No. Qty. 1 HEAD UPPER CLAM ASSEMBLY A7041A 1 2 SEAL COVER ASSEMBLY A7046A 1 3 FINGER CHASSIS ASSEMBLY A7055A 1 4 WETTER RESERVOIR ASSEMBLY A7057A 1 5 COLLATE POCKET CLAM ASSEMBLY A7060A 1 6 ENVELOPE FEEDER ASSEMBLY A7061A 1 7 PRIMARY DRIVE ASSEMBLY (220v) A7068A 1 7A PRIMARY DRIVE ASSEMBLY (110v) A7069A 1 8 HEAD SIDE PLATE B8761A 1 9 HEAD SIDE PLATE DRIVES B8762A 1 10 MAIN BRIDGE HEAD B8763A 1 11 PIVOT POST CONVEYOR C3555A 2 12 WASHER WAVED 8.89 x 12.5 x 0.18mm E4033A 2 13 BRIDGE CLAMP G4092A A/R 14 COVER PIVOT P2044A 2 15 COLLATE PIVOT POST P2212A 1 16 COLLATE PIVOT PEG P2213A 1 Fixings 20 M4 x 8mm POZI PAN HD SCREW E2624A A/R 21 M4 x 8mm POZI PAN HD T/T SCREW A/R 22 M4 x 12mm POZI PAN HD T/T SCREW E2730A A/R 23 M4 x 25mm POZI PAN HD T/T SCREW E2709A A/R 24 7mm E CLIP E5076A A/R Page 4a - 8

Page 4a - 9 11 Nov 2012 M4 x 35mm POZI PAN HD T/T SCREW E2702A A/R LABEL WARNING 125-328 (115V 60Hz) 125-329 (230V 50Hz) POLYCORD BELT 930mm F0052A SEE SEC 4a-2 INSERT HEAD 9.5mm 'E' CLIP A/R PULLEY V6 x 8 x 57mm F2083A DOWEL PIN M3 x 14mm E5071A LOOM 350mm EL HSG PLG 4W 183-7690 GEAR 48T x 8mm 1.0M F4151A IDLE POST C2586A M5 x 12mm POZI PAN HD SCREW E2628A A/R MOUNTING PLATE B8706A POST C4313A X3 A VINYL PROTN CAP 3.5 x 12.7mm E0204A BEARING HOUSING T 8mm D1040A X4 IDLER BRACKET B7419A IDLER STUB C3470A BEARING 8 x 22 x 7mm E1114A X2 230v SPRING INT. PRESSURE (YELLOW) G1116A X2 IDLER BRIDGE B7420A 230V 50Hz OR 115V 50Hz PULLEY 18T S2M MOTOR F1372A OR OR 115v SPRING HEAVY PRESSURE G1117A X2 115V 60Hz OR 230V 60Hz PULLEY 15T S2M MOTOR F1373A DOWEL PIN M3 x 8mm E5074A GEAR 25T x 8mm 1.0M F4152A SPACER P2029A M4 x 8mm POZI PAN HD T/T SCREW A/R POST C4313A X3 LOOM 350mm EL HSG PLG 4W 183-7690 M4 x 10mm SOCKET HD. SCREW E2507A A/R A SHAFT CLUTCH C9243A BELT 100-S2M-280 F5112A A M5 x 12mm POZI PAN HD SCREW E2628A A/R WASHER WAVED 23mm ID E0367A BEARING FL. 8 x 22 x 7mm E1078A X2 230v MOTOR W/D 179-072 4W JST CCW 181-0770 115v MOTOR W/D 179-073 4W JST CCW 181-5770 CLUTCH LENZE W/D 179-155 2WXH 181-128 PULLEY 104T S2M MAIN DRIVE F1404A FAN 2 5/8" DIA CCW E0181A CAPACITOR BRACKET B7421A X3 MOTOR PLATE B8705A 4a-4 Primary Drive Assy. A7068A (230V 50Hz), A7069A (115V 60Hz), A7335A (230V 60Hz), A7336A (115V 50Hz) Page 4a - 9

Page 4a - 10 9 May 2013 M4 x 8 POZI FINISHING SCREW E2720A REAR LATCH PLATE R2154A GEAR 30T x 8mm F4156A M4 x 8 TORX HD T/T SCREW E2829A 8mm T-BEARING D1040A SPRING CONVEYOR G1182A LATCH HANDLE CONV. C9429V SHAFT PULLEY DRIVE C9256A DOWEL PIN 3 DIA x 14 E5071A (P) (P) 8mm T-BEARING D1040A (P) SPRING TENSIONER G1183A 9.5mm E-CLIP DOWEL PIN 3 DIA x 14 E5071A PULLEY SHAFT C9251A PULLEY 25T XL x 8mm F1375A IDLER BOBBIN P2061A 9.5mm E-CLIP NOTE: PULLEYS MARKED (P) ARE PINNED USING A 3 DIA x 14 LONG DOWEL PIN (E5071A) SPRING TENSIONER G1183A WASHER 'D' SHAFT C2751A BELT 140 XL 037 F5119A M4 x 8 TORX HD SCREW 1005958X CONV. SIDE PLATE DRIVES R2153A (P) SPRING CONVEYOR G1182A SPRING OMR SHAFT G1136A (P) 8mm T-BEARING D1040A 8mm T-BEARING D1040A SPRING LATCH RH G1184A SPRING LATCH LH G1185A SHAFT LATCH PIVOT C9255A M4 x 8 TORX HD T/T SCREW E2829A TIE BAR C9253A SHAFT TYRE C9252A M4 x 8 POZI FINISHING SCREW E2720A TRAIL EDGE OVERGUIDE B7459A SHAFT OVERGUIDE PIVOT C9254A CENTRAL OVERGUIDE B9313A M4 x 16 POZI PAN HD E2562A M4 HALF NUT E3507A ROLLER TRANSPORT 40 x 15mm D0044A 4a-5 Head Upper Clam Assy. A7041A 9.5mm E-CLIP OVERGUIDE WEIGHT P2263A TRAIL EDGE OVERGUIDE B7459A 8mm T-BEARING D1040A 9.5mm E-CLIP OVERGUIDE SPRING G1206A M4 x 8 TORX PAN HD T/T SCREW E2829A CONV. SIDE PLATE OP R2152A SPRING OMR SHAFT G1136A FRONT LATCH PLATE R2155A Page 4a - 10

Page 4a - 11 M4 x 8 POZI FINISHING SCREW E2720A PUT LOCTITE 222 (N1001A) ON THREADS BEFORE ASSEMBLY POCKET SIDE PLATE DRIVES B8766A SPRING LATCH RH G1189A M4 x 8 POZI FINISHING SCREW E2720A LATCH HANDLE COLLATE C9430V M4 x 12 POZI PAN HD TAPTITE SCREW E2730A RUBBER WASHER G0000A ENV FEED SHAFT COVER B7742S (DATACARD B9317S) NOTE 1. - USE B1911S WHEN A7355A DATACARD TRACTOR FEED IS FITTED NOTE 2.- USE B1864S (SEE SECTION 4a-37) WHEN A7217A - 115V TRACTOR FEED IS FITTED. COVER STOP SPIGOT P2175A M4 x 10 TORX CSK HD SCREW E2834A BUSH SNAP E0296A M4 x 12 POZI PAN HD TAPTITE SCREW E2730A LATCH CLAMP SPIGOT P2057A M4 x 8 POZI FINISHING SCREW E2720A FRONT LATCH PLATE B8744A COLLATE ROOF COVER B7502F FEED ROLLER SHAFT ASSEMBLY A2993A 8mm T-BEARING (MINI) D1040A 9.5mm E-CLIP OPENER ASSEMBLY A7022A SPRING OMR SHAFT G1136A SPRING OMR SHAFT G1136A BRIDGE CLAMP G4092A CLAM BRIDGE R2160A M4 x 8 POZI PAN HD SCREW LATCH PIVOT SHAFT C9435A BRIDGE CLAMP G4092A SPRING LATCH LH G1186A POCKET SIDE PLATE OP B8767A M4 x 8 POZI FINISHING SCREW E2720A PUT LOCTITE 222 (N1001A) ON THREADS BEFORE ASSEMBLY FRONT LATCH PLATE B8744A M4 x 8 POZI PAN HD TAPTITE SCREW 8mm T-BEARING (MINI) D1040A 9.5mm E-CLIP OPENER STOP PLATE R2261A SPRING OMR SHAFT G1136A M4 x 10 TORX CSK HD SCREW E2834A LATCH CLAMP SPIGOT P2057A INSERT ROLLER SHAFT ASSEMBLY A2994A 9.5mm E-CLIP 3.5mm E-CLIP E5055A FINGER PIN P2148A SENSOR BRACKET B7707A 8mm T-BEARING (MINI) D1040A SPRING OMR SHAFT G1136A SLIP OVERGUIDE B7506A FINGER PIN P2148A 4a-6 Collate Pocket Clam Assy. A7060A M4 NUT E3502A M4 WASHER E4011A SPRING OVERGUIDE (0.25) B0157A GUIDE SHIM G6200A M4 WASHER E4011A x 2 RIVET 4mm 3.5-4.5 169-128 3.5mm E-CLIP E5055A SLIP OVERGUIDE B7506A COLLATE POCKET ROOF ASSY B1819A Page 4a - 11

Page 4a - 12 COVER ARM DRIVES ASSEMBLY B4374S M4 x 12mm POZI PAN HD T/T SCREW E2730A SWITCH MAGNET SMALL 131-824 M3 x 10mm CHEESE HD SCREW E2604A M3 NYLOC NUT E3557A M3 x 8mm POZI CSK HD SCREW E2502A COVER ARM INNER DRIVES R2239S M4 NYLOC NUT E3505A M4 x 8mm POZI PAN HD T/T SCREW 6mm 'E' CLIP E5079A SPRING D.D G1029C OUTPUT LATCH B8742F LATCH SHAFT C9439A SPRING D.D G1029C COVER CLAMP BOSS P2249A M4 x 8mm CSK SKT HD SCREW E2535A FRONT COVER G7149A CLOSER COVER UPPER B7454S 6mm 'E' CLIP E5079A M4 x 8mm POZI PAN HD T/T SCREW M4 NYLOC NUT E3505A M4 x 8mm POZI PAN HD T/T SCREW BRIDGE CLAMP G4092A SPRING OMR SHAFT (BLUE) G1136A M3 x 8mm POZI CSK HD SCREW E2502A COVER ARM INNER OP R2238S SPRING OMR SHAFT (BLUE) G1136A M4 x 8mm POZI PAN HD T/T SCREW COVER ARM OP ASSEMBLY B4375S CLOSER ROLLER BEARING P2226A M4 x 12mm POZI PAN HD T/T SCREW E2730A WETTER GUIDE B7941A (110V ONLY) OUTPUT ROLLER BRACKET B7458A COVER CLAMP BOSS P2249A M4 x 8mm CSK SKT HD SCREW E2535A M4 x 8mm POZI PAN HD T/T SCREW CLOSER COVER B7453S CLOSER OVERGUIDE B7731A BRIDGE CLAMP G4092A SPRING OMR SHAFT (BLUE) G1136A SPRING OMR SHAFT (BLUE) G1136A SEALER ROLLER TOP C8166A 4a-7 Sealer Cover Assy. A7046A SEALER ROLLER TOP C8166A SPRING OMR SHAFT (BLUE) G1136A Page 4a - 12

Page 4a - 13 9 Nov 2008 GEAR 45T x 6mm 0.7M F4175A RIVET 3.5mm 169-145 DISC SENSOR PCB 180-776 DOWEL PIN 2.5 DIA x 12 E5082A DOWEL PIN 2.5 DIA x 12 E5082A E-CLIP 7mm E5076A DISC ASSEMBLY B4330A GUIDE CARRIER B7498A GUIDE CARRIER EXTRUSION C6340A FINGER NUT LH C3477A RIVET 3.5mm 169-145 DISC SENSOR PCB 180-776 LEAD SCREW C9247A T-BEARING 6mm D1076A M2 x 6 CSK POZI E2774A GEAR 35T x 6mm 0.7M F4176A DOWEL PIN 2.5 DIA x 12 E5082A GRUB SCREW M3 x5 E2571A SHAFT ADAPTOR P2031A SIDE GUIDE MOTOR BRKT B7478A WIRED MOTOR 181-070 4a-8 Side Guide Actuator Assy. A7047A GUIDE CARRIER B7498A FINGER NUT RH C3476A GUIDE CARRIER EXTUSION C6340A M4 x 8 TAPTITE POZI Page 4a - 13

Page 4a - 14 BRIDGE CLAMP G4092A SIDE GUIDE SPACER P2041A SIDE GUIDE SLIDE BRACKET B7449A SIDE GUIDE SPACER P2041A SIDE GUIDE LOCKING BRACKET B7448A (USE SIDE GUIDE SLIDE BRACKET B7449A FOR DATACARD) BRIDGE CLAMP G4092A SIDE GUIDE RUNNER BRIDGE B8737A SPACER PLATE R6077A SPRING GUIDE DAMPER B0145A RACK PLATE B6697A M4 x 10 TORX PAN HD TAPTITE SCREW E2832A SPRING GUIDE DAMPER B0145A RACK BRIDGE D1052A M4 WASHER E4011A M4 NYLOC NUT E3505A M4 x 10 TORX PAN HD TAPTITE SCREW E2832A 4a-9 Side Guide Rack Assy. A7071A (Datacard A7354A) Page 4a - 14

Page 4a - 15 RIVET 5mm 169-115 G0135A WETTER FOAM CENTRE G0136A WETTER FOAM EDGE G0135A RIVET 5mm 169-115 WETTER TANK TOP B7462A M12 NUT 5mm P2375A WETTER TANK B7463A VINYL CAP D0054A OVERFLOW PIPE C3482A 'O' RING 12.1 x 1.6 E0235A 4a-10 Wetter Tank Assy. A7042A Page 4a - 15

Page 4a - 16 PIPE 'C' 125-432 (380mm) RIVET 5mm 169-115 RESERVOIR TOP B7479A E2786A M4 NUT E3502A 1/4" P-CLIP 169-112 MOTOR ASSY (PERISTALTIC) 181-048 TANK MOUTH B7713A E-CLIP 8mm E5090A PIPE 'B' 125-432 (650mm) PIPE 'B' 125-432 (650mm) RIVET 5mm 169-115 M4 x 8mm POZI PAN HD S/S T/T SCREW E2786A 1/4" P-CLIP 169-112 RUBBER WASHER TO BE FITTED ON THE INSIDE OF RESEVOIR PIVOT P2273A LOOM ASSY, FLOAT SW 182-567 TANK MOUTH B7811A WETTER RESERVOIR B7480A M3 STUD CAP E0227A PIPE 'C' 125-432 (380mm) PIVOT P2273A PIPE 'A' 125-432 (205 mm) PIPE CONNECTOR O RING E0169A 4a-11 Wetter Reservoir Assy. A7057A DRAIN NUT P2217A Page 4a - 16

Page 4a - 17 M4 x 12mm POZI PAN HD T/T SCREW E2730A RIVET 3.5mm 169-145 DISC SENSOR PCB 180-776 WETTER ACTUATOR B7441A WETTER PIVOT P2219A M4 x 8mm POZI PAN HD T/T SCREW WASHER PTFE E4070A WETTER ADJUST PLATE R2191A CLUTCH PIN G0079A M3 x 5mm CAP HD SCREW E2804A SOLENOID, WETTER DOWN 181-119 M3 WASHER E4009A WETTER BRACKET DRIVES B8727A 4a-12 Wetter Solenoid Brkt. (Drives) Assy. A7065A Page 4a - 17

Page 4a - 18 WETTER PIVOT P2219A WETTER BRACKET OP B8728A M4 x 12mm POZI PAN HD T/T SCREW E2730A M3 x 5mm CAP HD SCREW E2804A M3 WASHER E4009A SPRING LINK G1180A WETTER ACTUATOR B7441A WASHER PTFE E4070A WASHER PTFE E4070A SOLENOID, WETTER DOWN 181-142 CLUTCH PIN G0079A CLUTCH PIN G0079A SOLENOID, WETTER UP 181-142 VINYL CAP E0204A M3 x 5mm CAP HD SCREW E2804A M3 WASHER E4009A WETTER ADJUST PLATE R2191A 4a-13 Wetter Solenoid Brkt. (Operator) Assy. A7066A M4 x 8mm POZI PAN HD T/T SCREW Page 4a - 18

Page 4a - 19 WETTER STOP P2220A SHORTY BUSH 6.4ID x 9.5mm OD E0382A WETTER PIVOT PLATE DRIVES R2193A M4 x 8mm POZI PAN HD T/T SCREW B A WETTER BEAM C7356E M4 x 8mm POZI PAN HD SCREW E2724A M4 x 30mm POZI PAN HD T/T SCREW E2712A WETTER PIVOT PLATE OP R2192A WETTER PIN P2221A B A A SHORTY BUSH 6.4ID x 9.5mm OD E0382A M5 x 12mm POZI PAN HD T/T SCREW E2723A A WETTER STOP P2220A TUBE CLEAR FOR PERI/PMP 125-432 WETTER BEAM LOWER B7726A M4 x 8mm POZI PAN HD T/T SCREW M4 x 30mm POZI PAN HD T/T SCREW E2712A M5 x 12mm POZI PAN HD SCREW E2628A WETTER PIN P2221A 4a-14 Wetter Beam Assy. A7067A Page 4a - 19

Page 4a - 20 9 Feb 2012 CLUTCH, ENVELOPE DRIVE 181-104 CLUTCH PIN DOWEL PIN 3 x 8mm G0079A E5074A 9.5mm 'E' CLIP GEAR 25T x 8mm F4152A M4 x 35 POZI PAN HD TAPTITE SCREW E2702A M4 WASHER E4011A M4 x 35 POZI PAN HD TAPTITE SCREW E2702A GEAR 40T x 8mm F4150A ENVELOPE FEED JOINING PLATE B7494A CLUTCH, ENVELOPE PICKUP 181-105UL DOWEL PIN 3 x 8mm E5074A CLUTCH PIN G0079A CLUTCH LOCATOR B7469A WIRE CLIP (SML) 169-140 STUB HOUSING ASSEMBLY A7038A - SECTION 4a-29 M4 x 8mm POZI PAN HD T/T SCREW WIRE CLIP (SML) 169-140 CLUTCH LOCATOR B7469A BUSHING SHORTY E0375A ENV.FEED DRIVE SIDE PLATE B8757A M4 x 8mm POZI PAN HD T/T SCREW FEED STUB SHAFT C4317A OVERGUIDE (FITTED ON A7223A ONLY) B7723A LOCATION PLATE DRIVES R2179A FLAP GRIP ROLLER ASSY A7072A (A2-1162-A FITTED ON A7224A) - SECTION 4a-33 LOBED FEED SHAFT ASSY A7073A - SECTION 4a-30 ENV. SENSOR BRACKET R2636A (FITTED ON A7223A ONLY) SHAFT CLUTCH BRAKE ASSY A2998A - SECTION 4a-32 ENVELOPE CLUTCH SHAFT ASSY A2997A - SECTION 4a-31 ENV.FEED OP SIDE PLATE B8756A DOWEL PIN 3 x 14mm E5071A 9.5mm 'E' CLIP GEAR 30T x 8mm F4156A SIDE GUIDE LH B7450A M4 x 8 TORX CSK HD SCREW E2828A SIDE GUIDE RH B7451A LATCH POST C3560A SIDE GUIDE TAPE G6176A M4 x 12mm POZI PAN HD T/T SCREW E2730A ENVELOPE FEED TRAY B7496A BACKSTOP ROLLER C3657A (SEE NOTE BELOW) BACK REST PLATE B8891A ROLLER BAR C9734A 9.5mm 'E' CLIP NOTE: BACKSTOP ROLLER LIGHT C3660A IS AN ALTERNATIVE TO BACKSTOP ROLLER C3657A BEARING FLANGED 8mm E1078A IDLER POST C2586A SENSOR SUPPORT ASSEMBLY B1797A M3 x 20 SLOT PAN HD SCREW E2515A SKIFFY SPACER E0383A M3 NYLOC NUT E3557A LATCH POST C3560A WASHER WAVED 23mm ID E0367A M4 x 8mm POZI PAN HD T/T SCREW M4 x 8mm POZI PAN HD T/T SCREW SIDE GUIDE RACK ASSY A7071A - SECTION 4a-9 WIRE CLIP (SML) 169-140 ENVELOPE SEPARATOR ASSY A7070A - SECTION 4a-16 BRIDGE SPACER C2-1085-A BRIDGE CLAMP G4092A FINGER GUIDE TAPE LH G6210A (G6211A OPPOSITE) SEPARATOR SPRING G1091A M3 x 10 CHEESE HD SCREW E2604A M3 x 6 SKT CSK HD SCREW E2672A LOCK LEVER D1030A SIDE GUIDE LOCK SCREW P2040A BUSHING SHORTY E0375A 9.5mm 'E' CLIP LOCATION PLATE OP R2180A SIDE COVER REED SWITCH 182-572 PCB, RIBBON SPLITTER 5 180-759 BRAKE LOCATOR R2183A WIRE CLIP (SML) 169-140 CLUTCH PIN G0079A BRAKE, ENVELOPE DRIVE 181-155 4a-15 Envelope Feeder Assy. A7223A (220v) / A7224A (110v) M3 NUT E3500A M3 WASHER E4009A M4 x 15mm SPACER E0349A WIRE CLIP (MED) 169-141 M4 x 6 SKT CAP HD SCREW E2512A BUSHING SHORTY E0375A NOTES: 1. FOR DATACARD VERSION, SEE SECTION 4a.15a 2. FOR ENVELOPE PRE-FEEDER ASSEMBLY, USED ON ASSY. A7224A ONLY, SEE SECTION 4a.37 Page 4a - 20

Page 4a - 21 9 Feb 2012 M4 x 35 POZI PAN HD TAPTITE SCREW E2702A GEAR 40T x 8mm F4150A CLUTCH, ENVELOPE DRIVE 181-104 CLUTCH PIN MIN. CL. P2515A 9.5mm 'E' CLIP CLUTCH PIN G0079A WIRE CLIP (SML) ENVELOPE FEED JOINING PLATE B7494A 169-140 CLUTCH LOCATOR B7469A CLUTCH, ENVELOPE PICKUP 181-105UL DOWEL PIN 3 x 8mm E5074A CLUTCH PIN G0079A STUB HOUSING ASSEMBLY A7038A - SECTION 4a-29 M4 x 8mm POZI PAN HD T/T SCREW WIRE CLIP (SML) 169-140 CLUTCH LOCATOR B7469A BUSHING SHORTY E0375A FEED STUB SHAFT C4317A OVERGUIDE B7723A ENV.FEED DRIVE SIDE PLATE B8757A M4 x 8mm POZI PAN HD T/T SCREW LOCATION PLATE DRIVES R2179A FLAP GRIP ROLLER ASSY A2-1163-A FITTED ON A2-1166-A A2-1164-A FITTED ON A2-1165-A SECTION 4a-33 SHAFT CLUTCH BRAKE ASSY A2998A - SECTION 4a-32 NOTE: FOR ENVELOPE PRE-FEEDER ASSEMBLY, SEE SECTION 4a.37 LOBED FEED SHAFT ASSY A7378A - SECTION 4a-30 ENVELOPE CLUTCH SHAFT ASSY A2997A - SECTION 4a-31 GEAR 25T x 8mm F4152A M4 x 35 POZI PAN HD TAPTITE SCREW E2702A M4 WASHER E4011A BUSHING SHORTY E0375A ENV.FEED OP SIDE PLATE B8756A DOWEL PIN 3 x 14mm E5071A 9.5mm 'E' CLIP GEAR 30T x 8mm F4156A POLYESTER SHIM H0011A CUT TO LENGTH 296mm, FIX WITH TAPE E0188A BEARING FLANGED 8mm E1078A IDLER POST C2586A SIDE GUIDE LH B9331A WASHER WAVED 23mm ID E0367A M3 NUT E3500A M3 WASHER E4009A WIRE CLIP (MED) 169-141 M4 x 15mm SPACER E0349A PCB, RIBBON SPLITTER 5 180-759 M4 x 8 TORX CSK HD SCREW E2828A SIDE GUIDE TAPE G6176A M4 x 6 SKT CAP HD SCREW E2512A SIDE GUIDE RH B9332A M4 x 12mm POZI PAN HD T/T SCREW E2730A ENVELOPE FEED TRAY R6229A BACKSTOP ROLLER C3657A (SEE NOTE BELOW) LATCH POST C3560A 9.5mm 'E' CLIP BUSHING SHORTY E0375A WIRE CLIP (SML) 169-140 BRAKE LOCATOR R2183A BRAKE, ENVELOPE DRIVE 181-155 BACK REST PLATE R6194P CLUTCH PIN G0079A ROLLER BAR C9734A 9.5mm 'E' CLIP SIDE COVER REED SWITCH 182-572 LOCATION PLATE OP R2180A M3 x 10 CH HD SCREW E2604A NOTE: BACKSTOP ROLLER LIGHT C3660A IS AN ALTERNATIVE TO BACKSTOP ROLLER C3657A SENSOR SUPPORT ASSEMBLY B4427A M3 x 20 SLOT PAN HD SCREW E2515A SKIFFY SPACER E0383A M3 NYLOC NUT E3557A LATCH POST C3560A M4 x 8mm POZI PAN HD T/T SCREW M4 x 8mm POZI PAN HD T/T SCREW SIDE GUIDE RACK ASSY A7354A - SECTION 4a-9 SEPARATOR SPRING G1091A M3 x 6 SKT CSK HD SCREW E2672A BRIDGE CLAMP G4092A EASY-ADJUST ENV SEPARATOR ASSY A7353A - SECTION 4a-16 FINGER GUIDE TAPE LH G6210A (G6211A OPPOSITE) SIDE GUIDE LOCKING POST P2516A LOCK LEVER D1030A ENV GUIDE MOUNT BRACKET B2-1425-A ENVELOPE DESKEW SHIM G6-0224-A BRIDGE SPACER C2-1085-A 4a-15a Datacard Envelope Feeder Assy. A2-1165-A(220v) / A2-1166-A(110v) UPPER ENVELOPE GUIDE B2-1426-A RIVET 3.5mm 1.2-2.1 GRIP 169-1490 Page 4a - 21

Page 4a - 22 SEPARATOR PAD 45-55 D0051A 3M VHB TAPE E0448A SEPARATOR PAD 45-55 D0051A 3.5mm 'E' CLIP RIVET 3mm 1.2-2.1mm GRIP E5055A 169-126 ENV. DESKEW SHIM LOWER G6-0225-A SEPARATOR PLATE B7716A M4 x 16 HEX HD S/LOCK SCREW E2705A SEPARATOR PLATE B4426A SEPARATOR ADJ. KNOB P2518E SPRING INDEX G1046A M5 x 10 GRUB SCREW E2517A N.ROLLER PIN 4x14 E5124A WIRE CLIP (SMALL) 169-140 SEPARATOR ADJUSTOR C3661E M4 x 6 GRUB SCREW E2505A ENVELOPE SEPARATOR ASSY - A7070A (FITTED ON ENV. FEEDER ASSEMBLIES A7223A/A7224A SEE SECTION 4a-15) EASY ADJUST ENV. SEPARATOR ASSY - A7353A (FITTED ON DATACARD ENV. FEEDER ASSEMBLIES A2-1165-A/A2-1166-A SEE SECTION 4a-15a) 4a-16 Envelope Separator Assemblies. A7070A & A7353A Page 4a - 22

Page 4a - 23 BACKSTOP LONG B7474A M4 x 6 POZI CSK HD SCREW M4 x 8 POZI CSK HD SCREW E2563A E2668A INSERT FOOT E0253A FINGER ARM PIVOT C3557A INSERT FOOT E0253A M4 x 8 POZI PAN HD SCREW E2624A CENTRAL COLLATE BED B7499A BACKSTOP SHORT B7475A FINGER ARM PIVOT C3557A BACKSTOP RETURN SPRING G1199A WIRE CLIP 169-141 BACKSTOP BRACKET ASSY B4369A M4 x 8 POZI PAN HD SCREW E2624A 4.5mm E-CLIP E5055A WIRE CLIP 169-141 BACKSTOP RETURN SPRING G1199A M3 x 5 SKT CAP HD SCREW E2804A BACKSTOP BRACKET ASSY B4369A M3 WASHER E4009A M3 STUD CAP E0227A M4 x 16 POZI PAN HD SCREW E2714A CLUTCH PIN G0079A SOLENOID BACKSTOP BRACKET R2116A M4 x 6 SKT CAP HD SCREW E2512A CLUTCH PIN G0079A SOLENOID, LONG STOP 181-142 SOLENOID, SHORT STOP 181-142 PCB, RIBBON SPLITTER 3 180-758 M3 STUD CAP E0227A 4a-17 Pocket Backstop Assy. A7058A Page 4a - 23

Page 4a - 24 FINGER ARM DRIVES ASSY B4331A M2.5 x 12mm PIN GROOVED E5082A SPRING LINK G1180A 7mm 'E' CLIP E5076A CLUTCH PIN G0079A M2 x 6mm POZI CSK HD SCREW E2774A FINGER SOLENOID 2 181-142 GEAR 45T x 6mm F4175A FINGERS OUT SENSOR PCB 180-776 NOTE: ALTERNATIVE ASSEMBLY A7352A IS ALSO AVAILABLE. THIS ASSEMBLY IS AS SHOWN, EXCEPT FINGER SET A7056A IS REPLACED BY A7356A M4 x 10 POZI PAN SCREW E2519A M4 WASHER E4011A FINGER STOP DRIVES R6211A VINYL CAP E0204A SPRING SOLENOID G1152A B A A RIVET 3.5mm 169-145 PCB, RIBBON SPLITTER 7 180-760 M4 x 6mm CAP HD SCREW E2512A WIRED MOTOR 179-802 181-070 FINGER ARM PIVOT C3478A GEAR 35T x 6mm F4176A FINGER ROD C9246A SHAFT ADAPTOR P2031A M3 x 5 GRUB SCREW E2571A B 7mm 'E' CLIP E5076A DISC SENSOR PCB 180-689 RIVET 3.5mm 169-145 M4 x 8 POZI PAN SCREW M3 x 5mm CAP HD SCREW E2804A SENSOR BRACKET B7433A FINGER BRACKET B8882A FINGER SET* A7056A (STANDARD) A7356A (OPTIONAL) see Section 4a-38 *FINGER SET CONSISTS OF ALL FOUR FINGER ASSYS + LEAD SCREW C9247A 4a-18 Finger Chassis Assy. A7055A see also section 4a-38 FINGER SET* A7056A (STANDARD) A7356A (OPTIONAL) see Section 4a-38 BEARING 'T' 6mm D1076A 7mm 'E' CLIP E5076A LEAD SCREW* C9247A DISC ASSEMBLY B4330A FINGER FLAG B3-1058-A FINGER SET* A7056A (STANDARD) A7356A (OPTIONAL) see Section 4a-38 9.5mm 'E' CLIP FINGER DATUM SENSOR PCB 180-776 RIVET 3.5mm 169-145 FINGER SET* A7056A (STANDARD) A7356A (OPTIONAL) see Section 4a-38 Page 4a - 24

Page 4a - 25 WIDE FINGER PIN P2513A (SEE NOTE 3) FINGER NUT LH P2536A (SEE NOTE 3) FINGER BODY D1080A (SEE NOTE 3) FINGER DRIVES B9320A (SEE NOTE 3) FINGER BUSH P2537A (SEE NOTE 3) FINGER BODY D1080A (SEE NOTE 3) SPRING, FINGER G1252A Notes: 1 See also section 4a-38. for Finger Set with optional Overguide Kit 2. A7056A also includes leadscrew C9247A & finger flag B3-1058-A, shown in section 4a-18. 3. For pre-mar 2007 machines, use pin P2148A, Body C6338A, Finger Op. B9203A, Finger Dr. B9202A, Spring G1196A, Finger Nut LH C3477A, Finger Nut RH C3476A & Finger Bush C3475A. 4. For all machines with aluminium finger bodies, if body, nut or bush is required, order Finger Set A7056A. 5. See following page for Service Part Nos. SPACER, SKIFFFY E0561A 3.5mm 'E' CLIP E5055A FINGER PIN P2514A (NOTE 3) FINGER BUSH P2537A (SEE NOTE 3) MIDDLE FINGER SUPPORT B9323A FINGER BODY D1080A (SEE NOTE 3) 3.5mm 'E' CLIP E5055A FINGER PIN P2514A (NOTE 3) 9.5mm 'E' CLIP SPRING, FINGER G1252A (SEE NOTE 3) MIDDLE FINGER EXTENSION DRIVES B7638A SPRING, FINGER G1252A M3 NYLOC NUT E3557A FINGER NUT RH C3668A (SEE NOTE 3) 4a-19 Finger Set A7056A 3.5mm 'E' CLIP E5055A MIDDLE FINGER SUPPORT B9323A MIDDLE FINGER EXT. OPERATOR B7637A M3 NYLOC NUT WIDE FINGER PIN E3557A P2513A (SEE NOTE 3) FINGER BODY D1080A (SEE NOTE 3) SPACER, SKIFFFY E0561A SPRING, FINGER G1252A (SEE NOTE 3) FINGER OPERATOR B9319A (SEE NOTE 3) 3.5mm 'E' CLIP E5055A Page 4a - 25

Page 4a - 26 THE FOLLOWING SERVICE KITS ARE AVAILABLE FOR REPLACEMENT OR UPGRADE REPLACEMENT KITS UPGRADE KITS PRE MARCH 2007 ST. STEEL FINGER KIT 3 DIA. A7419A B9202A ST. STEEL FINGER DRIVES 3 DIA. QTY. 1 B9203A ST. STEEL FINGER OP 3 DIA. QTY. 1 WIDE FINGER KIT 3 DIA. A7421A B9324A WIDE FINGER DRIVES 3 DIA. QTY. 1 B9325A WIDE FINGER OP 3 DIA. QTY. 1 ADJUSTABLE FINGER OPERATOR 3 DIA. A7367A B7637A MIDDLE FINGER EXT OP QTY. 1 B9311A MIDDLE FINGER SUPPORT QTY. 1 E3557A NUT M3 NYLOC DIN 985 BZP QTY. 1 ADJUSTABLE FINGER DRIVES 3 DIA. A7368A B7638A MIDDLE FINGER EXT OP QTY. 1 B9311A MIDDLE FINGER SUPPORT QTY. 1 E3557A NUT M3 NYLOC DIN 985 BZP QTY. 1 POST MARCH 2007 ST. STEEL FINGER KIT 4 DIA. A7420A (Applies only to machines from serial nos. JAJ 9173 to JAW 0449) B9346A ST. STEEL FINGER OP 4 DIA. QTY. 1 B9347A ST. STEEL FINGER DR 4 DIA. QTY. 1 WIDE FINGER KIT 4 DIA. A7422A B9319A WIDE FINGER OP 4 DIA. QTY. 1 B9320A WIDE FINGER DR 4 DIA. QTY. 1 ADJUSTABLE FINGER OPERATOR 4 DIA. A7381A B7637A MIDDLE FINGER EXT OP QTY. 1 B9323A MIDDLE FINGER SUPPORT 4 DIA. QTY. 1 E3557A NUT M3 NYLOC DIN 985 BZP QTY. 1 ADJUSTABLE FINGER DRIVES 4 DIA. A7382A B7638A MIDDLE FINGER EXT OP QTY. 1 B9323A MIDDLE FINGER SUPPORT QTY. 1 E3557A NUT M3 NYLOC DIN 985 BZP QTY. 1 PRE MARCH 2007 WIDE FINGER UPGRADE KIT 3 DIA. A3287A B9158A WIDE POCKET GUIDE LH QTY. 1 B9159A WIDE POCKET GUIDE RH QTY. 1 B9324A WIDE FINGER UPGRADE OP QTY. 1 B9325A WIDE FINGER UPGRADE DR QTY. 1 E0383A SPACER 3.1x8x5 SKIFFY QTY. 2 E5055A CIRCLIP 3.5 D1500 QTY. 2 E5074A PIN DOWEL 3 DIA x 8 (m6) QTY. 1 G1196A SPRING FINGER QTY. 2 P2435A WIDE FINGER PIN QTY. 2 DEEP THROAT FINGER KIT 3 DIA. A3325A B9311A MIDDLE FINGER SUPPORT QTY. 2 B9321A FINGER EXTENSION XL DR QTY. 1 B9322A FINGER EXTENSION XL OP QTY. 1 E3557A NUT M3 NYLOC DIN 985 BZP QTY. 2 E5055A CIRCLIP 3.5 D1500 QTY. 2 G1196A SPRING FINGER QTY. 2 P2148A FINGER PIN QTY. 2 PRE APRIL 2008 WIDE FINGER UPGRADE KIT 4 DIA. A3353A B9158A WIDE POCKET GUIDE LH QTY. 1 B9159A WIDE POCKET GUIDE RH QTY. 1 B9319A WIDE FINGER OP 4 DIA. QTY. 1 B9320A WIDE FINGER DR 4 DIA. QTY. 1 E0561A SPACER 4.2x8x5 SKIFFY QTY. 2 E5055A CIRCLIP 3.5 D1500 QTY. 2 E5127A PIN DOWEL 4 DIA x 8 (m6) QTY. 1 G1252A SPRING FINGER 4 DIA. QTY. 2 P2513A WIDE FINGER PIN 4 DIA. QTY. 2 PRE APRIL 2008 (Cont.) DEEP THROAT FINGER KIT 4 DIA. A3354A B9321A FINGER EXTENSION XL DR QTY. 1 B9322A FINGER EXTENSION XL OP QTY. 1 B9323A MIDDLE FINGER SUPPORT 4 DIA. QTY. 2 E3557A NUT M3 NYLOC DIN 985 BZP QTY. 2 E5055A CIRCLIP 3.5 D1500 QTY. 2 G1252A SPRING FINGER 4 DIA. QTY. 2 P2514A FINGER PIN 4 DIA. QTY. 2 NARROW ENVELOPE FINGER KIT 4 DIA. A3348A B9326A NARROW ENV.FINGER OP QTY. 1 B9327A NARROW ENV.FINGER DR QTY. 1 E5055A CIRCLIP 3.5 D1500 QTY. 2 G1252A FINGER SPRING QTY. 2 P2514A FINGER PIN 4 DIA QTY. 2 NOTE: POST APRIL 2008 - ALL MACHINES ARE FITTED WITH FINGER SET A7056A AS STANDARD Z-FOLD WINDOW KIT A3347A B2-1427-A ENVELOPE DEFLECTOR Z-FOLD QTY. 1 C3-0709-A FINGER PIN OVERGUIDE 3 DIA QTY. 2 C4495A FINGER PIN OVERGUIDE 4 DIA QTY. 2 G6403A FINGER OVERGUIDE OP QTY. 1 C6404A FINGER OVERGUIDE DRIVES QTY. 1 E5055A CIRCLIP 3.5 D1500 QTY. 2 G6214A INSERT GUIDE QTY. 1 P2512A OVERGUIDE SPACER QTY. 2 See also Sections 4a-33 & 4a-38 for location of parts. Page 4a - 26

Page 4a - 27 FINGER BRACKET OP B7436A FINGER STOP OP R6210A VINYL CAP E0204A M4 x 10 POZI PAN HD SCREW E2519A M4 WASHER E4011A FINGER ARM PIVOT C3478A M4 x 8 POZI PAN HD SCREW FINGER ARM OP ASSY B4332A 7mm 'E' CLIP E5076A 4a-20 Finger Bracket Assy. A7062A M3 WASHER E4009A CLUTCH PIN G0079A M3 x 5 SKT CAP HD SCREW E2804A FINGER SOLENOID 1 181-142 SPRING SOLENOID G1152A SPRING LINK G1180A 4a-21 Sprocket Bracket Assy. A7059A M4 x 20mm POZI PAN HD T/T SCREW E2716A SPROCKET SPIGOT P2052A SPROCKET JOCKEY F3004A HEAVY PRESSURE SPRING G1117A 8mm T-BEARING (MINI) D1040A SPROCKET BRACKET B7472A M4 NYLOC NUT E3505A M4 WASHER E4011A 8mm T-BEARING (MINI) D1040A SPROCKET JOCKEY F3004A SPROCKET SPIGOT P2052A SHAFT SPRUNG C4351A M4 x 35mm POZI PAN HD SS SCREW E2833A HEAVY PRESSURE SPRING G1117A M4 x 20mm POZI PAN HD T/T SCREW E2716A Page 4a - 27

Page 4a - 28 BEARING FL. 8x22x7mm E1078A SPLIT SHAFT HOUSING C4319A WASHER WAVED 23mm ID E0367A 9.5mm 'E' CLIP BEARING FL. 8x22x7mm E1078A 9.5mm 'E' CLIP SHAFT SPLIT BRAKE C9417A ROLLER TRANSPORT NOTCHED D0045A SPIGOT P2048A M4 x 12mm POZI PAN HD T/T SCREW E2730A SPIGOT P2048A 4a-22 Split Shaft (Brake) Assy. A7063A Page 4a - 28

Page 4a - 29 9.5mm 'E' CLIP BEARING FL. 8x22x7mm E1078A WASHER WAVED 23mm ID E0367A SPLIT SHAFT HOUSING C4319A SHAFT SPLIT C9267A ROLLER TRANSPORT NOTCHED D0045A 9.5mm 'E' CLIP SPIGOT P2048A M4 x 12mm POZI PAN HD T/T SCREW E2730A SPIGOT P2048A BEARING FL. 8x22x7mm E1078A 4a-23 Split Shaft (Plain) Assy. A7064A Page 4a - 29

Page 4a - 30 ROLLER SHAFT C9276A ROLLER SHAFT C9276A ROLLER SHAFT C9276A ROLLER SHAFT C9276A ROLLER TRANSPORT D0021A ROLLER TRANSPORT D0021A 4a-24 Feed Roller Shaft Assy. A2993A 4a-25 Insert Roller Shaft Assy. A2994A ENV OPENER PIVOT STUB C4320A ENVELOPE FLAP OPENER C7383A ENV OPENER PIVOT STUB C4320A CURLED FLAP SHIM G6-0227-A & 3M VHB TAPE E0448A ENVELOPE FLAP OPENER C7383A ENV OPENER STOP C4360A VINYL CAP E0204A ENV OPENER STOP C4360A VINYL CAP E0204A ENV OPENER PIVOT STUB C4320A OPENER ASSEMBLY. - A7022A ENV OPENER PIVOT STUB C4320A NOTE: OPENER ASSY. - A7413A IS SUPPLIED IN ITS ASSEMBLED CONDITION, AND IS AN ALTERNATIVE TO OPENER ASSY. - A7022A 4a-26 Opener Assemblies A7022A & A7413A Page 4a - 30

Page 4a - 31 ROLLER TRANSPORT 40 x 15 D0044A ROLLER TRANSPORT 30 x 8mm D0021A C9262A SHAFT P. WHEEL C9265A ROLLER TRANSPORT 40 x 15 D0044A ROLLER TRANSPORT 30 x 8mm D0021A 4a-27 C/B Shaft Assy. A7023A 4a-28 P. Wheel Shaft Assy. A7024A STUB HOUSING C3483A BEARING BALL 8 x 16 x 5mm E1061A BEARING BALL 8 x 16 x 5mm E1061A 4a-29 Stub Housing Assy. A7038A Page 4a - 31

Page 4a - 32 ENV FEED JOG TYRE D0052A 9.5mm E-CLIP ROLLER ENVELOPE FEED C8098A (HI-GRIP ROLLER C8193A - OPTIONAL EXTRA) (SLOTTED ROLLER C8194A - OPTIONAL EXTRA) FEED WHEEL CORE D1042A 2.5 x 14mm PIN E5078A 9.5mm E-CLIP WASHER SHOULDER E0214A 9.5mm E-CLIP ROLLER ENVELOPE FEED C8098A (HI-GRIP ROLLER C8193A - OPTIONAL EXTRA) (SLOTTED ROLLER C8194A - OPTIONAL EXTRA) 9.5mm E-CLIP WASHER SHOULDER E0214A ROLLER ENVELOPE FEED C8098A (HI-GRIP ROLLER C8193A - OPTIONAL EXTRA) (SLOTTED ROLLER C8194A - OPTIONAL EXTRA) 9.5mm E-CLIP 3 x 14mm PIN E5071A 2.5 x 14mm PIN E5078A FEED WHEEL CORE D1042A ENV FEED JOG TYRE D0052A ENV FEED SHAFT C9257A (DATACARD C9745A) 9.5mm E-CLIP NOTE: DATACARD ALSO SUPPLIED WITH 6 x C8194A SLOTTED FEED WHEEL (NOT PART OF A7378A). BEARING NYLON C2655A SPRING RELEASE G1139A BEARING NYLON C2655A ENV. FEED BEARING C2653A E-CLIP 6mm E5079A 4a-30 Lobed Feed Shaft Assy. A7073A (Datacard A7378A) Page 4a - 32

Page 4a - 33 ENVELOPE CLUTCH SHAFT C9437A C9262A ROLLER TRANSPORT 40 x 15mm D0044A ROLLER TRANSPORT 40 x 15 D0044A ROLLER TRANSPORT 40 x 15mm D0044A ROLLER TRANSPORT 40 x 15 4a-31 Envelope Clutch Shaft Assy. A2997A 4a-32 Clutch/Brake Shaft Assy. A2998A Page 4a - 33

Page 4a - 34 ENV FLAP SHIM DRIVES G6-0217-A (FITTED ON A2-1162-A & A2-1163-A ONLY) UNDER PLATE OPERATOR R2176A ENVELOPE SHIM G6180A EDGE DEFLECTOR B7714A GUIDE BAR SPACER P2364A ENVELOPE GUIDE BAR C9436A WIRE PLATE B7827A M4 x 6 SKT. CSK HD SCREW E2655A ENVELOPE DEFLECTOR R2175A B2-1427-A (FITTED ON A2-1163-A ONLY) SPRING PLATE 0.25mm B0159A ADHESIVE M4 x 6 POZI CSK HD SCREW E2563A 3 EDGE DEFLECTOR B7714A ENV FLAP SHIM OPERATOR G6-0216-A (FITTED ON A2-1162-A & A2-1163-A ONLY) BEARING 6 x 8 x 13.8mm E1070A FLAP ROLLER BAR C4363A BEARING 6 x 8 x 13.8mm E1070A M3 WASHER E4009A M3 NUT E3500A UNDER PLATE DRIVES R2178A UNDER PLATE CENTRE R2177A INSERT GUIDE G6214A (FITTED ON A2-1163-A & A2-1164-A ONLY - OPTIONAL) M3 x 6 SLOT PAN HD SCREW E2651A 4a-33 Flap Grip Roller Assy. A7072A(220v)/A2-1162-A(110v) & (A2-1163-A(110v)/A2-1164-A(220v) Datacard) Page 4a - 34

Page 4a - 35 4a-34 Control Panel Assy. A7260A Page 4a - 35

Page 4a - 36 9 Mar 2011 4a-35 Head Covers A7045A Page 4a - 36

Page 4a - 37 10 Jul 2012 4a-36 Maximailer Plus Upgrade Page 4a - 37

Page 4a - 38 BEARING FL. 8 x 19 x 6mm E1102A SIDE ARM DRIVES R2771A PULLEY 12XL x 8 F1424A DOWEL PIN 2.5 x 5mm E5080A BEARING FL. 8 x 19 x 6mm E1102A 2.5 x 14mm PIN E5078A ROLLER ENVELOPE FEED C8098A SPACER BAR C4414A 3 x 14mm PIN E5071A TRACTOR SHAFT C9610A (DATACARD C9744A) BELT 100XL 025 F5152A DRIVEN SHAFT C9611A 3 x 14mm PIN E5071A DRIVE SIDE ARM OP R2770A SPRING RELEASE G1139A BEARING NYLON C2655A ENV. FEED BEARING C2653A UNLESS STATED OTHERWISE, ALL 'E' CLIPS 9.5mm 6mm E-CLIP E5079A PULLEY 28XL x 12 F1423A ROLLER CLUTCH 8x12x12mm E1030A ROLLER ENVELOPE FEED C8098A 4a-37 Envelope Feed Tractor (Pre-Feeder) Assy. A7217A (Datacard A7355A) Page 4a - 38

Page 4a - 39 Notes: 1 See also section 4a-19. for Finger Set A7056A 2. A7356A also includes leadscrew C9247A & finger flag B3-1058-A, shown in section 4a-18. 3. For pre-mar 2007 machines, use pin P2148A, Body C6338A, Finger Op. B9203A, Finger Dr. B9202A, Spring G1196A, Finger Nut LH C3477A, Finger Nut RH C3476A & Finger Bush C3475A. 4. For all machines with aluminium finger bodies, if body, nut or bush is required, order Finger Set A7356A. 5. See page 27 for Service Part Nos. 4a-38 Finger Set - Datacard A7356A (Optional) Page 4a - 39