The Full Issue of This Service Bulletin Can Be Seen on Www

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

The full issue of this Service Bulletin can be seen on www.2helpU.com under the Catalogue number D27105

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”.

Procedure “A” – All 230 Volt units with a DC less than 200549-11. Part number 869216-00

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. Discard the PCB if present as it is no longer required.

5. Remove the cable clamp in the handle.

6. Remove the screws securing the switch box to the frame.

7. Take note of how the switchbox and switch is wired. Disassemble the switch box. Remove the

following parts which are to be used in the new switchbox (Cable clamp, screws, red switch cover, pin,

spring, Module, Connector Block and the Mains Cable). The switch harness cable is to be replaced.

8. Fit the new switch into the protective boot and connect the wires to the terminals using the correct wiring

diagram (see www.2HelpU.com D27105). Please note: The wiring of the new switch is identical

to the old switch.

9. Fit the carry over parts to the new switch box.

10. Reassemble the switch box and fit to the frame.

11. Remove the old motor and fit the new one. Check belt tension before removing as correctly

re-tensioning the drive belt is critical.

12. Reconnect the wires to the motor and handle switch using the correct wiring diagram.

(see www.2HelpU.com D27105).

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.

Procedure “B” – All 230 Volt units with a DC between 200549-11 and 200603-11. Part number 869216-01

All 115 Volt units with a DC less than 200604-11 Part number 869216-02