Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
This bulletin details the changes required to bring the D27105 up to current production
levels. One of the following procedures must be carried out on all D27105’s with date codes
up to week 200604-11 that come in for repair, unless the switch box is at the new level, this
will indicate that the one of the following procedures has already been carried out or that the
parts are already at the latest level.
The date code is located on the motor.
For all 230 volt units where the date code is less than 200549-11 carry out procedure “A”.
For all 230 volt units with a date code between 200549-11 and 200603-11 carry out
procedure “B”.
For all 115 volt units where the date code is less than 200604-11 carry out procedure “B”.
Contents
1. Motor, switch box, switch, lock plate and guard lever differences
2. Parts to be made obsolete and scrapped
3. Parts to be carried over
4. New parts for Procedure “A”
869216-00 230 Volt Only
5. New parts for Procedure “B”
869216-01 230 Volt, 869216-02 115 Volt
6. Repair procedure “A”
7. Repair procedure “B”
8. Wiring diagrams
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
Motor Electronics – different levels of protection can be
checked by removing the end cap
1st level Motor with
electronics slightly
protected with potting
compound
2nd level Motor with
electronics protected
with potting compound
and silicone
New level Motor with
electronics fully
protected with potting
compound
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
Switch box differences - seen from inside the frame
Old level Switchbox – No raised part
for the new switch
New level Switchbox – Raised part
for the new switch
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
Switch and Buttons
OLD
The old switch is seven pieces and
has no dust cover
NEW
The new switch is one piece and has
a dust cover
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
Up-lock plate differences
OLD
NEW
Part is now angled
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
Guard lever
The difference in the old and new levers is not visually obvious. The way to test
the lever is to remove it from the unit and try to bend it in the middle, the faulty
one will bend easily.
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
Parts to be made obsolete and scrapped
605786-00
HOUSING SA SWITCH The sw itch housing, guard
606195-00
LINKAGE SA GUARD
606279-00
UP-LOCK PLATE
868979-00
MOTOR SA
609919-00
609918-00
610021-00
609681-00
627055-11
linkage, up-lock plate and
motor have all been modified
and are no longer usable,
how ever the part numbers
remain the same so all old
stock must be scrapped
868319-06 230v
868319-07 115v
609681-00
609918-00
609919-00
610021-00
868319-06
868319-07
627055-11
SPRING
BUTTON RED
BUTTON GREEN
PLUNGER
SWITCH
SWITCH
WIRE HARNESS
Scrap
Scrap
Scrap
Scrap
Scrap
Scrap
Scrap
Modified here to fit new switch
605786-00
606195-00
606279-00
868979-00
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
Parts to be carried over
115 Volt
Mains Cable and
Connector Block
Cable clamp and screws
230 Volt
Mains Cable, Module and
Connector Block
Switch cover, pin & spring
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
New Parts for procedure “A”. Kit part number 869216-00
Modified here to fit new
switch
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
New Parts for procedure “B”. Kit part number 869216-01 for 230 Volt
Kit part number 869216-02 for 115 Volt
Modified here to fit new
switch
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
Procedure “A” – All 230 Volt units with a DC less than 200549-11
1.
2.
3.
4.
5.
6.
7.
Ensure unit is not plugged into a power supply.
Remove the handle cover protecting the wiring.
Take note of how the handle is wired. Disconnect the wires connecting the switch box to the motor wiring and
handle switch.
Discard the PCB if present as it is no longer required.
Remove the cable clamp in the handle.
Remove the screws securing the switch box to the frame.
Take note of how the switchbox and switch is wired. Disassemble the switch box. Remove the following
9.
10.
parts which are to be used in the new switchbox (Cable clamp, screws, red switch cover, pin, spring, Module, Connector Block
and the Mains Cable). The switch harness cable is to be replaced.
Fit the new switch into the protective boot and connect the wires to the terminals using the correct wiring diagram Rev 4 at the
back of this bulletin. Please note: The wiring of the new switch is identical to the old switch.
Fit the carry over parts to the new switch box.
Reassemble the switch box and fit to the frame.
11.
Remove the old motor and fit the new one. Check
12.
13.
14.
15.
16.
Reconnect the wires to the motor and handle switch using the correct wiring diagram Rev 4 at the back of this bulletin.
Fit new Guard lever and up-lock plate.
Carry out all relevant safety and electrical checks before connecting to the power supply.
Plug in and check switches, motor and guard action all function correctly.
Disconnect from the power supply if any adjustments are required.
8.
belt tension before removing as correctly retensioning the drive belt is critical.
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
Procedure “B” – All 230 Volt units with a DC between 200549-11 and 200603-11
All 115 Volt units with a DC less than 200604-11
1. Ensure unit is not plugged into a power supply.
2. Remove the handle cover protecting the wiring.
3. Take note of how the handle is wired. Disconnect the wires connecting the switch box to the motor
wiring and handle switch.
4. Remove the cable clamp in the handle.
6. Remove the screws securing the switch box to the frame.
7. Take note of how the switchbox and switch is wired. Disassemble the switch box. Remove the
following parts which are to be used in the new switchbox (Cable clamp, screws, red switch cover, pin, spring,
module in the 230v, Connector Block and the Mains Cable). The switch harness cable is
to be replaced.
8. Fit the new switch into the protective boot and connect the wires to the terminals using the correct wiring
diagram Rev 4 at the back of this bulletin. Please note: The wiring of the new switch is identical to the old switch.
9. Fit the carry over parts to the new switch box.
10. Reassemble the switch box and fit to the frame.
12. Reconnect the wires to the motor and handle switch using the correct wiring diagram Rev 4 at the back of this bulletin.
13. Fit new Guard lever and up-lock plate.
14. Carry out all relevant safety and electrical checks before connecting to the power supply.
15. Plug in and check switches, motor and guard action all function correctly.
16. Disconnect from the power supply if any adjustments are required.
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006
Service Bulletin 161
SUBJECT:
Upgrade to current production level
UNITS:
D27105
DATE CODE RANGE: All units up to date code 200604-11 to be
checked
ISSUED BY:
Steve Hurt 13th March 2006