1. 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 13 th March 2006 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 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”.

2. 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 13 th March 2006 2nd level Motor with electronics protected with potting compound and silicone New level Motor with electronics fully protected with potting compound Motor Electronics – different levels of protection can be checked by removing the end cap 1st level Motor with electronics slightly protected with potting compound

3. 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 13 th March 2006 Old level Switchbox – No raised part for the new switch New level Switchbox – Raised part for the new switch Switch box differences - seen from inside the frame

4. 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 13 th March 2006 Switch and Buttons The new switch is one piece and has a dust cover OLDNEW The old switch is seven pieces and has no dust cover

5. 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 13 th March 2006 Part is now angled Up-lock plate differences OLDNEW

6. 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 13 th 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.

7. 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 13 th March 2006 609681-00610021-00 609918-00609919-00 868319-06 230v 868319-07 115v Parts to be made obsolete and scrapped 605786-00 Modified here to fit new switch 606279-00 606195-00868979-00627055-11

8. 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 13 th March 2006 Parts to be carried over Cable clamp and screws Switch cover, pin & spring Mains Cable and Connector Block 115 Volt Mains Cable, Module and Connector Block 230 Volt

9. 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 13 th March 2006 New Parts for procedure “A”. Kit part number 869216-00 Modified here to fit new switch

10. 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 13 th March 2006 Modified here to fit new switch New Parts for procedure “B”. Kit part number 869216-01 for 230 Volt Kit part number 869216-02 for 115 Volt

11. 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 13 th March 2006 Procedure “A” – All 230 Volt units with a DC less than 200549-11 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.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 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. 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 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.

12. 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 13 th 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.

13. 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 13 th March 2006

14. 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 13 th March 2006

15. 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 13 th March 2006