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Maximailer HD Service Manual Issue 2 Dec 2011

Table Of Contents 3.10 Replacement of collate chains/pawls.................................................. 3-12


3.11 Removal of finger assembly................................................................ 3-13
1 Installation Instructions............................................................................. 1.1
3.12 Adjustment of fingers........................................................................... 3-14
1-1 Safety Notes ....................................................................................... 1-2
3.13 Removal of side guide adjust assembly.............................................. 3-16
1-2 Detachable Items.................................................................................. 1-5
3.14 Adjustment of side guides................................................................... 3-17
1-2.1 Machine Modules......................................................................... 1-5
3.15 Removal of power supply.................................................................... 3-17
1-2.2 Machine Stands........................................................................... 1-5
3.16 Removal of sealer rollers.................................................................... 3-18
1-3 Machine Assembly................................................................................. 1-6
3.17 Removal of sealer assembly............................................................... 3-19
1-3.1 Connecting the Units.................................................................... 1-6
3.18 Adjustment of wetter lever................................................................... 3-19
1-3.2 PC Equipment.............................................................................. 1-8
3.19 Engineering mode............................................................................... 3-20
2 Description of Operation........................................................................... 2.1
3.19.1 Hardware setup.......................................................................... 3-20
2-1 General Description.............................................................................. 2-2
3.19.2 Units setup................................................................................. 3-21
2-2 Track Collation Description................................................................... 2-2
3.19.3 Firmware download.................................................................... 3-27
2-3 Description of Insertion Head................................................................ 2-3
3.19.4 Diagnostics................................................................................. 3-28
2-4 Description of Insert Feeder.................................................................. 2-5
3.20 Recommended Spares Parts List....................................................... 3-31
2-5 Description of Tower Folder.................................................................. 2-6
4 Exploded Views ....................................................................................... 4.1
3 Service Operations and Adjustments...................................................... 2.1
4.1 Chassis Drive Side (Front)..................................................................... 4-2
3.1 Health, safety & environment................................................................. 3-2
4.2 Chassis Drive Side (Rear)...................................................................... 4-5
3.2 Conventions used in this manual........................................................... 3-3
4.3 Chassis Operator Side........................................................................... 4-8
3.3 Preventative maintenance guidance & schedule................................... 3-4
4.4 Chassis Assembly.................................................................................. 4-11
3.4 Information for engineers....................................................................... 3-5
4.5 Shaft Locations...................................................................................... 4-14
3.5 Removal of covers................................................................................. 3-6
4.6 Envelope Feeder Assy A2-1064-A......................................................... 4-16
3.5.1 Drive side cover........................................................................... 3-6
4.7 Envelope Separator Assy A2-1065-A..................................................... 4-19
3.5.2 Operator side cover...................................................................... 3-6
4.8 Envelope Tractor Assy A2-1067-A.......................................................... 4-21
3.5.3 Internal black covers.................................................................... 3-7
4.9 Envelope Feed Shaft Assy A2-1068-A................................................... 4-23
3.5.4 Front vertical cover....................................................................... 3-7
4.10 Envelope Conveyor Assy A2-1066-A.................................................. 4-25
3.6 Removal of envelope feeder.................................................................. 3-8
4.11 Envelope Conveyor Backstop Assy A2-1200-A................................... 4-28
3.7 Removal/adjustment of envelope separator........................................... 3-9
4.12 Collate Pocket Clam Assy A2-1069-A................................................. 4-30
3.8 Replacement of envelope conveyor belts.............................................. 3-10
4.13 Head Input Conveyor Upper Assy A2-1054-A..................................... 4-33
3.9 Removal of collate pocket clam assembly............................................. 3-11
Page i
Maximailer HD Service Manual Issue 2 Dec 2011

4.14 Head Input Conveyor Lower Assy A2-1055-A..................................... 4-36 5.8 Interlock PCB Circuit Diagram.............................................................. 5-21
4.15 Motor Assy A2-1056-A (115V) / A2-1057-A (230V)............................. 4-38 5.9 Stepper Motor PCB Circuit Diagram..................................................... 5-22
4.16 Sealer Assembly A2-1058-A . ............................................................. 4-41 5.10 R/Splitter & Disk PCBs Circuit Diagrams............................................ 5-23
4.17 Split Shaft Sub Assys A2-1059 / 1060 / 1061-A ................................. 4-44 5.11 Inserter Head Wiring Diagram............................................................. 5-24
4.18 Finger Assembly A2-1062-A . ............................................................. 4-46 5.12 Inserter Head Splitter PCB’s Wiring Diagram..................................... 5-25
4.19 Finger Bkt Op Assy A2-1073-A . ......................................................... 4-49 5.13 Ins. Head PSU & Interlock Wiring Diagram......................................... 5-26
4.20 Side Guide Adjust Assy A2-1063-A .................................................... 4-51
4.21 Pawl Tension Bracket Assy A2-1072-A .............................................. 4-53
4.22 Wetter Lever Assy A2-1352-A............................................................. 4-55
4.23 Wetter Beam Assembly ...................................................................... 4-57
4.24 Wetter Tank Assy A2-1070-A............................................................... 4-59
4.25 No Seal Assembly A2-1214-A ............................................................ 4-61
4.26 Head Ribbon Bkt. Assy 184-2260....................................................... 4-63
4.27 Universal Head PSU 184-2150 .......................................................... 4-65
4.28 Mains Input Hardwired 184-2250........................................................ 4-66
4.29 Head Covers ..................................................................................... 4-67
4.30 External Float Switch A3-0421-A . ...................................................... 4-70
4.31 Lift Beam Assy A2-1520-A................................................................... 4-72
5 Electrical & Circuits................................................................................... 5.1
5.1 Sensors ....................................................................................... 5-2
5.1.1 Sensors List................................................................................. 5-2
5.1.2 Sensors Diagram, Operator Side................................................. 5-4
5.1.3 Sensors Diagram, Drive Side....................................................... 5-5
5.2 Electrical Components.......................................................................... 5-6
5.2.1 Physical Locations of Components.............................................. 5-8
5.3 Control PCB Circuit Diagram................................................................ 5-14
5.4 Processor PCB Circuit Diagram............................................................ 5-17
5.5 Comms PCB Circuit Diagram................................................................. 5-18
5.6 Wetter PCB Circuit Diagram.................................................................. 5-19
5.7 Expansion PCB Circuit Diagram........................................................... 5-20
Page ii
Maximailer HD Service Manual Installation Page 1 - 1 Issue 1 Mar 2010

Section 1
Installation
Instructions

Sect. Page

1.1 Safety Notes............................................................................1-2

1.2 Detachable Items.....................................................................1-4

1.3 Assemblty of HD Head onto Stand..........................................1-5

1.4 Setting up the Machine............................................................1-7

Page 1 - 1
Maximailer HD Service Manual Installation Page 1 - 2 Issue 1 Mar 2010

1.1 SAFETY NOTES Warning! Most of the moving parts are


protected by covers. Don’t operate the machine BEFORE DISASSEMBLING:
Warning! Do not work inside the machine unless all of the covers are in place. Opening cov- THE MAIN POWER CABLE MUST
unless you are a trained mechanic or electrician. ers include safety interlock switches. If a cover REMAIN UNPLUGGED UNTIL
Stop the machine, and disconnect the power cord is opened, the switch will stop the machine from END OF ASSEMBLY
before you open the machine. Only a trained running. Don’t try to bypass the interlocks, and
electrician should work with the electrical parts! don’t use the machine if the interlocks are not
A voltage of 120 Volts may be present inside this working.
machine. The power source can produce enough DO NOT TOUCH INSIDE POWER
voltage and current to be very dangerous! Warning! Don’t wear any loose clothing when SUPPLY UNIT TO PREVENT
you are working near the machine. If a bit of ELECTRICAL DISCHARGE DUE TO
Warning! This machine is equipped with a clothing becomes caught in one of the moving CHARGED CAPACITOR.
three-pronged plug. One of the prongs on the parts, you may be pulled into the machine very
plug provides a safety grounding feature. Be quickly. This force can be surprisingly power-
sure the plug is always connected to a properly ful - you may not be able to resist it. Take care
wired three-prong outlet. Do not use a two-prong with neckties, sashes, long sleeves, or any other ALTHOUGH MANUFACTURER
adapter without grounding the machine properly. loose clothing. Dangling jewelry can also present TAKES CARE TO REDUCE RIDGE
Never remove the third prong from the plug. The a hazard. Remove any of these items of loosely- DANGER, PLEASE HANDLE STEEL
safety grounding feature provides extra protec- fitting clothing, or tie the loose sections out of SHEETS CAREFULLY TO AVOID ALL
tion in the event of an electrical problem. The the way so they can’t be caught by the machine. RISKS OF CUTTING.
apparatus must be earthed. Long hair can also be dangerous when working
As the colors of the wires may not correspond near this type of machine. If you have long hair,
with the colored markings identifying the termi- tie it back or tuck it under a hat. Be especially
nals in your plug, proceed as follows: careful around the folding rolls near the center of IMPORTANT!!
The wire which is colored GREEN must be con- the machine.
nected to the terminal in the plug which is IN THE EVENT OF ANY EMERGENCY,
marked by the letter E or by the safety earth Caution! Keep the machine clean. Wipe OR TO STOP THE MACHINE FOR ANY
symbol or colored GREEN. off the outside of the cabinet from time to time to
keep the paper dust from collecting. If you notice
OTHER REASON, STRIKE THE RED
The wire which is colored WHITE must be con-
nected to the terminal which is marked with the that paper dust is collecting inside the machine, EMERGENCY STOP KNOB NEXT TO
letter N. open the covers and vacuum it out, or blow it out THE CONTROL PANEL
The wire which is colored BLACK must be con- with an airduster.
nected to the terminal which is marked with the
letter L. Caution! Keep the work area around the
machine clean. Don’t allow paper trim and waste
Warning! The mains input supply is fused to pile up. If the work area includes a lot of loose
on both live and neutral sides. Service personnel paper scraps, an operator may slip and fall.
should be aware that a mains voltage can exist
even if no lighted neon shows.

Page 1 - 2
Maximailer HD Service Manual Installation Page 1 - 3 Issue 1 Mar 2010

Important!

ELECTRICAL INSTALLATION NOTES


THESE NOTES MUST BE READ PRIOR TO INSTALLING THIS MACHINE

This equipment is supplied with an unterminated, three-core lead for connection to the mains supply. The connection
must only be made by a qualified electrician, or by a qualified Service Engineer.

1) This equipment must be earthed.


2) For continued protection against the risk of fire, fuses must only be replaced by those of the
same type and rating.
3) Caution: This equipment is internally fused in both Live and Neutral leads.
4) Maximum input current is 10A for 115V and 6.3A for 230V. Maximum leakage current shall not
exceed 5% of the input current.
5) Euro only: An appropriate disconnect device shall be provided as part of the building installation
and be readily accessible.
6) Euro and US/Can: Where the plug is fitted, the socket outlet shall be installed near the equip-
ment and shall be easily accessible.

230 Volt Machines


Wire Colours:
Live: Brown
Neutral: Blue
Earth: Green/Yellow

115 Volt Machines


Wire Colours:
Live: Brown
Neutral: Blue
Earth: Green/Yellow

Caution
High leakage current. An earth connection is essential before connecting to the supply.

Page 1 - 3
Maximailer HD Service Manual Installation Page 1 - 4 Issue 2 Sept 2011

Installation Instructions 1.2.1 Stand Assembly


Note: This secton covers installation of a complete Maximailer HD, Stands are supplied dependent upon machine configuration. Usage is as
and assumes a DTI is to be fitted with optional feeders. shown in Fig. 1 below.
1.2 Detachable Items
Insert Feed Feed Feed Feed Feed Feed Feed
3-P Folder
The machine is supplied on site with each module packaged separately and Head Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7

with stands supplied in flat-pack form. Check that the following de- A3-0417-A
A7048A =+A3239A
A3241A

tachable items are all present: A3-0417-A


A7049A + A3240A
= A3239A + A3241A

A3-0417-A
A7050A + A3241A
= A3239A + A3240A
+ A3240A
Insertion Head
A7051AA3-0417-A
= A3239A ++ A3240A
A3240Ax+A3241A
2
Comms Lead, Long 160-511 Qty. 1
A3-0417-A
A7259A+=A3241A ++
(A3240A
(A3240xx2)
Plug IEC60309 Yel 16A 168-347 (US) Qty. 1 A3239A 2)

or A3-0417-A
A7256A = A3239A + A3240A
+ (A3240 x 2) x+ 3A3241A

Plug IEC60309 Blu 16A 168-346 (EURO) Qty. 1 A3-0417-A


A7257A + A3241A
= A3239A + (A3240A
+ (A3240 x 3)x 3)
PC Fittings Kit A7226A Qty. 1
Fig. 1
A7256A = A3239A + (A3240 x 3) + A3241A
Set of Castors E0563A Qty. 2
Catch Tray (non-conveyor) R2211T Qty. 1
Screw, M5 x 10 E2516A Qty. 4 Unpack and assemble the stands using the supplied assembly instructions.
Operator Manual K1-0271-A Qty. 1 If the machine uses more than one stand, join these together using the
Stands (see 1.2 opposite) supplied fasteners in the 4 corners of the mating faces.
Declaration of Conformity (230v only)

Feeder (single and dual)


Comms Lead, Short 160-510 Qty. 1
Screw, M5 x 10 Cap E2516A Qty. 1
Infill Cover R2263S Qty. 1

Output Conveyor (optional)


Mains Lead 162-210 (UK) Qty. 1
or Mains Lead 162-321 (US) Qty. 1
or Mains Lead 162-311 (EURO) Qty. 1
DIN Lead 182-707 Qty. 1
Operator Manual K1-0283-A Qty. 1

Important: Check that all covers are in place and undamaged. Check
that all warning labels are in place and legible (see section x for locations).
Check that the mains lead and its connectors are sound and undamaged.

Page 1 - 4
Maximailer HD Service Manual Installation Page 1 - 5 Issue 1 Mar 2010

1.3 Assembly of Maximailer HD head onto stand

1.3.1 Assemble the HD head stand to the single stand supplied; this will
replace the previous Maximailer Plus stand that supported a single
Maximailer HD module as well as the insert head.
Insert Head
1.3.2 Lift the Maximailer HD head onto the stand, ensuring that the
wetter tube passes through the hole in the top of the front section
of the stand.

Caution: The machine is extremely heavy


and will require a number of people to
Maximailer HD lift it. Do not attempt to lift if you do not
Head Stand feel confident to do so.

Wetter pipes passed


through stand into bottle

1.3.3 Place the sealing fluid bottle and PC into the stand as shown. Do
not connect the PC at this stage.

PC
Sealing
Fluid

Page 1 - 5
Maximailer HD Service Manual Installation Page 1 - 6 Issue 1 Mar 2010

1.3.4. Screw all stands together and fit the supplied attachment bracket
R2904T to the end stand. Note: Use holes marked ‘L’. This is
Datacard machine required for the alignment of the wider Maximailer HD and Datac-
(shown connected ard system.
to attachment
bracket)
1.3.5 Lift all feed modules (if applicable) and the DTI onto the stands.
Assemble them together using the supplied screws.

Attachment
bracket R2904T

End module
stand

Note: Viewed from above

Operator side Drive side of


of Maximailer Maximailer HD
HD connected connected to
to module 1 module 1

1.3.6
Attach the Datacard machine to the attachment bracket R2940T,
as shown opposite.
cont.

Page 1 - 6
Maximailer HD Service Manual Installation Page 1 - 7 Issue 1 Mar 2010

1.4 Setting up the machine 1.4.6 Check network connections between Maximailer HD PC and the
Datacard machine.
1.4.1 Connect the power and comms cables for all modules as follows:
1.4.7 Program the Maximailer HD with jobs and test run.
• Datacard machine to DTI serial lead
• Datacard machine to PC comms lead 1.4.8 When all is satisfactory, replace all covers.
• Cancard from PC to Maximailer HD
• Power leads between modules and then to Maximailer HD head
• Power lead from Maximailer HD head to mains supply
• Power lead to PC
• Power lead to Datacard machine

1.4.2 Check the DIP switches on the head and module PCBs are set as
follows:

Module DIP Switch ON Position


1 2 3 4

1 X

2 X

3 X X

4 X

5 X X

6 X X

7 X X X

8 X

1.4.3 Connect remaining PC leads to monitor and keyboard.

1.4.4 Switch the PC and the Maximailer HD ON.

1.4.5 Check the software/firmware version.

Page 1 - 7
Maximailer HD Service Manual Description of Operation Page 2 - 1 Issue 1 Mar 2010

Section 2
Description
of
Operation

Sect. Page

2.1 General Description.................................................................2-2

2.2 Track Collation Description......................................................2-2

2.3 Description of Insertion Head...................................................2-3

2.4 Description of Insert Feeder.....................................................2-5

2.5 Description of Tower Folder.....................................................2-6

2.6 Description of Feeder Folder...................................................2-7

Page 2 - 1
Maximailer HD Service Manual Description of Operation Page 2 - 2 Issue 1 Mar 2010

SECTION 2 DESCRIPTION OF OPERATION The sequencing between the stages of machine operation is shown in the
diagrams below, which begin part way through a complete cycle – the
2.1 General Description preceding sequence of operations from the start of the cycle will have been
The machine is a high-volume folder/inserter capable of up to 200,000 cy- similar, but with fewer documents having been gathered.
cles per month at a speed of up to 4500 filled envelopes per hour (DL with
1 insert). It is of modular construction and consists of an insert head and
any or all of a: insert feeder; b: tower feeder; c: mark reading feeder; d:
feeder folder; d: tower folder (with built-in tower). This may be fitted with
either 1 or 3 trays and an optional accumulator for collating/diverting, with
or without a diverter tray. It is always fitted in the end station position.
The insert head also includes a collator, as well as the envelope hopper,
wetter and closer.
Stage 1: Form 1 is fed from feeder 1 down onto the conveyor track. This
Collation can be carried out a number of ways, depending upon the particu- form is trail edge collated with the upstream documents arriving from feed-
lar job. The software works out the optimum feed pattern, as well as the ers 2 and 3. The feed timings for the collate operation are triggered when
best feed units to use if more than one possibility exists. Collation possibili- the trailing edge of the documents from feeders 2 and 3 pass through the
ties are: track control sensor.
1. Using the accumulator in a 3-tray, tower folder - 3 forms are fed
into the accumulator, folded and ejected on towards the insert
head.
2. Collation on the track - a folded sheet or insert is timed to trail-
ing-edge collate with the document fed from the following feed
unit as the first document passes underneath.
3. At the insert head - all documents will arrive in the collation
pocket, either individually or as a pack already collated by the
above methods. The topmost item is the prime (address) docu-
ment. The pack is then inserted in the envelope. Stage 2: The three collated documents (for pack 1) from feeders 1, 2 and
3 are driven into the collation pocket by the retard rollers. This roller set
2.2 Track collation description ensures that the final presentation of the collated pack is suitable for enve-
Jobs with more than one feed unit will in most cases collate together as lope insertion by slowing down whilst feeding.
described in paragraph 2 above, and will arrive in the collation pocket as a Form 1a is fed from insert feeder 2 down onto the conveyor track. This
pack, with the exception of the prime document, which will be fed on top form is trail edge collated with the upstream document arriving from feeder
of the pack as a separate item. The exception to this is if the prime station 3. The feed timings for the collate operation are triggered when the trailing
is No. 1, in which case the document would be finally collated on top of the edge of the document from feeder 3 passes through the track control sen-
pack from preceding feed units, then finally delivered to the collate pocket. sor.
Documents are trailing-edge located due to the pack being inserted by Form 1b is held stationary at the exit hold point of insert feeders 3 and 4.
pushing it into the envelope with chain-driven pawls. Timing is controlled by
the track conrol sensor located behind each hopper.

Page 2 - 2
Maximailer HD Service Manual Description of Operation Page 2 - 3 Issue 1 Mar 2010

Whilst the pack is feeding, an envelope will have been fed to the envelope
feed sensor which acts a hold point if necessary, and then into the station-
ary deskew rollers which straightens any skew; the deskew rollers are con-
trolled by the deskew sensor.
The envelope tractor facilitates feeding of envelopes and operates on a
Fig. 3 pivot. When pushed forward by the envelope stack, the envelope conveyor
sensor switches off the feed conveyor; as envelopes are fed and the tractor
Stage 3: Form 1 (prime/address carrying document for this pack) is relaxes, the sensor is cleared and the conveyor starts again. The amount of
driven into the collation pocket by the retard rollers. delay before feeding restarts can be controlled in software.
Form 1b (prime/address carrying document for a following pack) is fed from The envelope is then driven past the tilting flap opener and into place ready
feeder 4 down onto the conveyor track.
The feed operation between all stages
is governed by software timings to set
a controlled gap (pitch length) between
the prime documents on the track.
Form 1a held is stationary at the exit
hold point sensor of insert feeder 1.
After the prime document has been fed
into the collation pocket on top of the 3
documents already collated, the pack is
inserted into the envelope, described in
more detail below.
2.3 Description of Insert Head (see
Fig. 4 opposite)
The insert head includes the envelope
hopper, collation pocket, insert fingers,
wetter and closer. The insert pack ar-
rives into the input conveyor, as moni-
tored by the input conveyor sensor.
When its trailing edge passes this sen-
sor, the drive rollers ahead reduce speed
as necessary to allow the collate pocket
to clear. The pack is then driven into
the collate pocket where it contacts a
solenoid-actuated backstop to prevent
overrun (there are 3 backstops, the
one used being determined by the pack
length). Its arrival is monitored by the
collate pocket load sensor; the collate
pocket sensor confirms it is in place in
the pocket.
Page 2 - 3
Maximailer HD Service Manual Description of Operation Page 2 - 4 Issue 1 Mar 2010

for insertion. Here it is held with the flap crease at the datum point shown finger out (flag) sensor is blocked when the fingers are in the relaxed posi-
in Fig. 4, timed from the trailing edge passing the deskew sensor and ar- tion (out of the envelope).
riving at the envelope flap sensor. The solenoid-actuated insert fingers hold
For the collate pocket, the guide datum (flag) sensor determines when the
the envelope throat open. With the envelope then in place ready for the ar-
guides are at their widest position. The guide disc sensor then clocks their
riving pack, the backstop drops and the pack is driven into the envelope.
movement to set them to the correct position.
Note that it is possible in the software to adjust whether the outer pair of
fingers move forward first, or the inner pair. This can assist certain enve-
lopes, depending on design.
As the chain pawls are pushing the pack in, the pawls below the track are
detected by the pawl position sensor which times precisely how long it take
to push in the pack. At that point, the envelope is released.
Just prior to release, the chain track pauses momentarily so that the tips of
the pawls do not catch on the edge of the departing envelope. While in-
sertion is taking place, the next envelope is fed into place and held at the
deskew rollers ready for the next insertion.
Timed from the leading edge of the envelope passing the wetter output
detect sensor, the wetter beam is pulled down by solenoid action so that the
flap is wetted by the wetter felt below. As the trailing edge passes this sen-
sor, the beam will retract.
The envelope is driven forward
into the seal rollers. Due to the
angle of the roller axis, the flap
edge of the envelope is lifted
up, forcing the flap downwards
against the roller, at which point
the rollers reverse to drive the
envelope into the upper seal
rollers, sealing the envelope flap
- the reverse point is timed from
the closer output sensor. The
envelope leading edge reaches
the closer seal sensor and the
envelope reverses again to drive
it out of the eject, monitored by
the closer output sensor. This
completes the cycle. See fig. 5 above.
The insert finger widths and collate pocket side guides are automatically
adjusted to suit the appropriate paper widths, as determined by the sizes
set in the operating software. For the fingers, the finger datum (flag) sensor
determines when the fingers are at their narrowest position. The finger disc
sensor then clocks their movement to set them to the correct position. The
Page 2 - 4
Maximailer HD Service Manual Description of Operation Page 2 - 5 Issue 1 Mar 2010

2.4 Description of Insert Feeder (see Fig. 6 opposite)


Insert feeders on the machine are fitted with a top feed hopper capable
of holding up to 300 reply paid envelopes or 150 2mm thick booklets. The
separator has 4 manual settings, each one automatically adjusting for a
range of thicknesses. 2 slotted sensors use a simple binary code to moni-
tor the separator setting to the software which will then flag an error if the
measured thickness of the insert is outside the range of the setting.
Operation
Inserts feed through the separator and up to the stationary deskew roll-
ers ahead. This straightens any skew, and as the leading edge is detected
by the deskew sensor, the drive clutch actuates to drive the insert forward
to the hold point sensor where it is stopped by the drive brake just ahead
of this point. The double document sensor is also located next to the hold
point, and if required, a calibration cycle will be performed to guage the
document length and thickness, otherwise the DD sensor will detect if a
double has been fed.
When the path ahead is clear, drive will again engage to move the insert
forward to the track feed sensor where it is halted. The paper width sensor
(located to one side) is used by Select & Go to detect if the insert width is
too wide for the envelope - if it is, an error will be flagged. If the insert is
to be collated with one from the following feed unit (as described in sec-
tion 2.2), it will wait at the track feed sensor until the following insert has
reached it (timed from the track sensor). They will then be fed together
with trailing edges collated into the conveyor of the next feed unit, or the
insert head conveyor.
All feed unit conveyors can operate independently, but normally move in
unison and will only stop if for any reason an expected insert for collation
has failed to arrive at the exit hold point sensor - this would only be result
of a fault condition such as a paper jam or hopper empty. Fig. 6

Page 2 - 5
Maximailer HD Service Manual Description of Operation Page 2 - 6 Issue 1 Mar 2010

2.5 Description of Tower Folder (see Fig. 7 below) Operation


The 3-plate tower folder may be fitted with either 1 or 3 feeder trays. If A form feeds through the pre-feed rollers, monitored by the pre-feed sensor
OMR or Barcode reading is being used, the reader is fitted to either or both and up to the deskew and double document sensors, mounted side-by-side.
of feeders 1 or 2, top or bottom read (barcode reader on feeder 1, bottom The leading edge is driven into the stationary rollers ahead to correct any
read only). An accumulator may optionally be fitted to allow up to 8 sheets skew. The deskew sensor also acts as a hold point. When the path ahead is
of 80 gsm paper to be folded together, or it may be used as a diverter for clear, the drive is engaged to the rollers to feed the form fowards. As soon
hand-removal. As a further option, a divert tray may be fitted for forms to as the trailing edge is clear of the pre-feed sensor, the next form starts to
be diverted into. move towards hold point (deskew), thus allowing minimum time delay be-
tween forms.
A hand-feed daily post tray is fitted to allow up to 8 sheets of 80gsm paper,
stapled or not, to be folded and inserted If an OMR or barcode head is fitted, the OMR Gate paper sensor detects the
leading edge of the forms and times the start of the marks from the dis-
The folder unit allows for a wide range of fold options on forms up to 16”
tance input by the user – the timing operation is carried out by the encoder
(406mm) length and it can be opened up for jam clearance.
(disk) sensor.
The form travels towards the accumulator, and if further forms
in hoppers 2 & 3 are part of the OMR group, they will also be fed
into the accumulator, following hopper 1 form. Their entry into
the accumulator is monitored by the collate tray sensor, and are
prevented from sliding forward by the collation gate.
Up to 8 forms can be folded together in this way, and when all
are in the accumulator, the collation gate drops by solenoid ac-
tion and the conveyor belts drive the forms into the folder. If
there are more than 8 forms (up to 12) in the group, these can
be diverted to the diverter tray (if fitted), or held in the accumu-
lator for removal.
If 3 or fewer non-OMR forms are to be folded together, they are
not by default directed by the solenoid into the accumulator, but
pass directly to the folder. They will be leading-edge collated, ie.
as form 1 passes hopper 2, that form will be fed so the leading
edges align, and then on to hopper 3 where the same occurs.
Non-OMR groups can also be directed in software to use the ac-
cumulator and be folded together, or they can be collated on the
track one at a time, or if 3 or fewer, folded together as described
above.
The forms are fed into fold plate 1 or 2 (depending upon fold
type) where the leading edge contacts the motor driven end
stop, forming a buckle. This buckle is driven through the next set
of fold rollers and into the next fold plate where a similar action
is performed. They are then finally driven out onto the track,
their exit being monitored by the track exit sensor.
Fig. 7
Page 2 - 6
Maximailer HD Service Manual Description of Operation Page 2 - 7 Issue 1 Mar 2010

Fold plate settings are automatic in operation, set by the data input in the 2.6 Description of Feeder Folder (see Fig. 8 below)
job setup, or more usually by the automeasure facility using standard form
The 2 plate feeder folder is fitted with a top feed hopper capable of holding
sizes. Fold plate that are not used are blanked off by a no-fold beam actu-
up to 500 sheets of 80gsm paper. The hopper and separator are identical to
ated by a lug attached to the motor-driven end stop.
the upper hopper of the tower folder.
The accumulator can also be used for diverting forms for subsequent hand
The unit is available as either an end unit, or in-line (mounted on the
removal (the cover over the conveyor can be raised), or if the optional di-
track), the difference being a blanking cover fitted to the rear of the end
verter tray is fitted at the top end of the accumulator, the forms will be fed
unit and no conveyor is fitted. An optional handfeed slot may be specified,
directly into it - passing the divert bin sensor confirms their presence. Note
located in front of the paper hopper – this can fold up to 3 sheets of 80gsm
that diverted forms will always pass into the divert tray if it is fitted.
(C or Z) or 5 sheets (V). Stapled sheets must be Z fold only.
The accumulator is an optional item, and if it not fitted there is no divert
facility, and a maximum of 3 forms can be folded together. If more than 3
forms are to be fed, these will be folded singly and fed onto the track one
after the other, then collated together in the collate pocket in the insert
head.
Daily post
This function will be enabled if ‘Handfeed’ is selected in the job setup. When
the Run button is then pressed, the machine will await a group of up to 8
forms, stapled or not, to be inserted into the daily post hopper. When these
pass the daily post sensor, they will be automatically fed, and the machine
will await the next group. Forms from other feeders in the tower folder can
be collated with the daily post (up to the maximum of 8 of 80gsm), and
forms from other feed units can also be included in the job.

Fig. 8
Page 2 - 7
Maximailer HD Service Manual Description of Operation Page 2 - 8 Issue 1 Mar 2010

The machine may be fitted with either OMR or barcode, top or bottom read- barcode head is fitted, shortform option is not available with either. In use,
ing, vertical or horizontal barcode for top reading, but horizontal only for both fold plates are blanked off by the no-fold beams. For forms clearance
bottom reading. An optional shortform upgrade can be fitted so the folder in the event of a crash, the rear roller shaft can be pivoted backwards after
can double as a feeder, but this cannot be Barcode or OMR enabled. removing the hopper. Shortform option can be specified with the unit or
retrofitted (A3302A).
Operation
Handfeed option
A form feeds through the pre-feed rollers, monitored by the pre-feed sensor
and up to the deskew and double document sensors, mounted side-by-side. This is fitted in front of the unit, as shown in Fig. 8. It allows folding of up
The leading edge is driven into the stationary rollers ahead to correct any to 3 sheets of 80gsm (C or Z) or 5 sheets (V). Stapled sheets must be Z
skew. The deskew sensor also acts as a hold point. When the path ahead is fold only. In operation, handfeed (daily post) is selected in the job. When
clear, the drive is engaged to the rollers to feed the form forwards. As soon the machine is started, the operator is prompted to feed the paper, detected
as the trailing edge is clear of the pre-feed sensor, the next form starts to by a reflective sensor. The machine will wait for up to 1½ minutes for paper
move towards hold point (deskew), thus allowing minimum time delay be- to be inserted in the handfeed hopper, after which it will switch off. Hand-
tween forms. feed option can be specified with the unit or retrofitted (A3301A).
If an OMR head is fitted, the OMR Gate paper sensor detects the leading
edge of the forms and times the start of the marks from the distance input
by the user: the timing operation is carried out by the encoder (tacho) fit-
ted to the end of the feed roller shaft just ahead of the DD/Deskew sensors.
If a barcode reader is fitted, no sensor or tacho is required or fitted, and a
different, shorter feed shaft is used. After reading any marks/barcode, the
form is fed into fold plate 1 whose backstop is motor-driven to be set short
(ie. approx. 1/3 form length) for C fold, or long (approx. 2/3 form length)
for Z fold. When the leading edge contacts the backstop, the form buckles
and drives the buckle into the nip of the first fold rollers. It is driven into
the second fold plate (set short for both C and Z fold) where it buckles
again and is fed, fully folded, towards the exit path where it is held by a
brake at the track feed sensor. For V fold, the form is driven into fold plate
1, set to half form length, and the buckle is driven into the first set of fold
rollers. The no-fold beam for fold plate 2 is solenoid-actuated to bypass the
fold plate, so the folded form is driven towards the exit path as for C or Z
fold.
For in-line units a conveyor is fitted, where forms approaching from the
unit behind are fed through, monitored by the track sensor. This is timed
in conjunction with the track exit sensor so the folded form is trailing-edge
collated with the preceding document, as described in section 2.2.
For end units, no conveyor is fitted and the unit normally feeds the prime
document. This travels through the machine to be fed on top of the collated
pack in the collate pocket in the insert head.
Shortform option
This option allows the folder to be used as a feeder by the addition of the
two roller shafts shown in Fig. 8. As these are placed where the OMR or
Page 2 - 8
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

Section 3
Maintenance
and
Service Adjustments
Sect. Page Sect. Page

3.1 Health, safety & environment...................................................3-2 3.14 Adjustment of side guides........................................................3-17

3.2 Conventions used in this manual.............................................3-3 3.15 Removal of power supply.........................................................3-17

3.3 Preventative maintenance guidance & schedule.....................3-4 3.16 Removal of sealer rollers.........................................................3-18

3.4 Information for engineers.........................................................3-5 3.17 Removal of sealer assembly....................................................3-19

3.5 Removal of covers...................................................................3-6 3.18 Engineering mode....................................................................3-20

3.5.1 Drive side cover..................................................................3-6 3.18.1 Hardware setup...................................................................3-20

3.5.2 Front vertical cover.............................................................3-6 3.18.2 Units setup..........................................................................3-21

3.5.3 Drive side lower skirt...........................................................3-7 3.18.3 Firmware download.............................................................3-27

3.5.4 Upper cover........................................................................3-7 3.18.4 Diagnostics.........................................................................3-28

3.6 Removal of envelope feeder....................................................3-8 3.27 Recommended Spares Parts List............................................3-31

3.7 Removal/adjustment of envelope separator............................3-9

3.8 Replacement of envelope conveyor belts................................3-10

3.9 Removal of collate pocket clam assembly...............................3-11

3.10 Replacement of collate chains/pawls.......................................3-12

3.11 Removal of finger assembly.....................................................3-13

3.12 Adjustment of fingers...............................................................3-14

3.13 Removal of side guide adjust assembly...................................3-16


Page 3 - 1
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.1 Health, safety and environment 3.1.2 End of life

3.1.2 Safety instructions The objectives of the European Community’s environment policy are, in
particular, to preserve, protect and improve the quality of the environment,
3.1.1.1 General protect human health and utilise natural resources prudently and rationally.
• This machine must be operated by competent personnel. That policy is based on the precautionary principle and principles that pre-
ventive action should be taken, that environmental damage should as a
The manufacturer accepts no responsibility for accidents or injuries priority be rectified at source.
caused by operation by incompetent personnel.
Separate collection of waste is the precondition to ensure reuse and recy-
• Covers may only be opened by skilled persons, who know the risks cling of waste that is generated at the disposal of electrical or electronical
involved. equipment and is necessary to achieve the chosen level of protection of hu-
For safety reasons, the machine will not function with opened cov- man health and the environment in the European Community.
ers. More particularly, certain materials and components of waste electrical and
• Keep away long hair, fingers, jewelry, etc. from rotating and mov- electronical equipment needs selective treatment as their injudicious han-
ing objects of the system. dling or disposing of on or into land, water or air would represent a major
threat to the environment and human health.
• Switch off the system at the end of the day.
cont.
3.1.1.2 Electrical safety
• Disconnect the mains power supply before performing any mainte-
nance to any kind of mains power supply/high voltage related items.
• The power connection must be easily accessible, preferably close
to the machine.
• For safety reasons it is essential that the machine is connected to a
socket outlet with protective earth connection.
• Over-current protection in the equipment also relies on the branch
circuit protection.
• Disconnect the machine from the power supply when it is not in
use for a longer time.
• Potential hazard may exist to electronic hardware in conditions
with static electricity. It is advised that, when handling electronic
parts, an earth connected wrist band is used in order to be perma-
nently discharged from static electricity.

Page 3 - 2
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

In order to facilitate collection and treatment separated from normal 3.2 Conventions used in this manual
domestic waste, electrical and electronical equipment is marked with the
following logo: 3.2.1 Symbols

Do not mix with normal domestic waste.


Please use the subjoined return or
Draws to your attention a particular difficulty as-
Disconn sociated with this operation, or indicates a potential
collection system dedicated to electrical
and electronical waste.
being wi hazard with it.

Indicates a piece of advice, tip or quick technique to


Equipment produced after
August 13, 2005  Remem
complet
assist in carrying out this operation.

3.2.2 Orientation
Not only are you by law not allowed to dispose of the waste equipment via Throughout this manual, reference will be made to Operator and Drive side
other waste-streams, but we encourage you to actively contribute to the to indicate the side of the machine in question. These are defined as:
success of such collection and to the common good and better quality of life
of present and future generations. Operator Side: The side of the machine where the operator
normally stands, viewing the screen. The side
For more information on the correct disposal of this product please contact covers can be opened by the operator.
your local dealer. Drive Side: The opposite side to the Operator side. The side
covers cannot be opened by the operator and are
only able to be removed by the Engineer. Gear/
drive trains are located on this side.

Page 3 - 3
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.3 Preventative Maintenance Guidance and Schedule

The Maintenance schedule on the following pages is applicable to the Maximailer HD product range and must be strictly followed to guaran-
tee machine performance and reliability.

This schedule is based on a monthly cycle count of 350k / month which is considered the normal maximum. If the machine is running less
than this, the PM visits should still be carried out with the same frequency, but fewer parts will be required.

• DS300 (Maxi HD)—Duty Cycle 350k / Month = 4.2 million / year = 4 PMV / year (pm every 3 months)

• DS200 (Maxi HD)—Duty Cycle 200k / Month = 2.4 million / year = 2 PMV / year (pm every 6 months)

• DS100/140 Feeders –Duty Cycle 200k / Month = 2.4 million / year = 2 PMV / year (pm every 6 months)

Note: If feeders are running at same duty cycle as the machine = 4 PMV / year (pm every 3 months).

Click here to view the full PM Schedule.

Page 3 - 4
ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete
Complete Interval Cycle (Page)

A1 Remove envelope conveyor and backstop Pulleys –Replace after 4million


Clean all spring loaded bearings and Regrease 30mins Belts-Replace after 6million
Clean shaft and regrease Bearings-Replace after 8million
Check side guides are movingly freely
Clean shafts
and regrease

Clean and
regrease all
spring loaded
bearings

Ensure side
guides are
tapered to feed
the envelope
freely into
envelope
pickup

A2 Remove envelope feed assembly Slotted feed wheel---C8194A


Check all feed tyres –replace if needed 45mins Replace after 2million
Clean and check gears on track assembly Feed tyres-C8-0209A
Clean and grease bearings Replace after 2million

Clean all
feed tyres-
replace if
needed
ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete

A2 cont Clean and check gears on track assembly 10mins Gears---Inspect and replace if worn
Clean and grease bearings after 4 million
Lenze clutches-Inspect after 2million
A3 Remove separator from envelope feed assembly 15mins separator roller---C8135A
Check separator roller Replace after 4 million
Check separator shield Shield ---D164_03A
Replace roller or shield if worn or damaged Replace after 4 million

Separator rollers
and shield

A4 Check flap guide tapes on flap grip assembly 10mins Flap guide shim---G6-0223-A
(Replace if required) Inspect after 2 million
Check and clean needle bearings ensuring no tight spots Needle bearings---
Inspect after 2 million

Needle bearings
ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete

Flap guide shims-


Replace after 1million
A4 contd
Flap guide shims

A5 Wetter Section Lower seal roller (48 dia) C8-0206-A


Clean silicone rollers and check for wear 15mins Inspect and Replace after 2 million
Replace if worn Lower seal Roller (25 dia) C8-0207-A
Clean and grease all bearings.

Upper seal roller –C8-0208-A


Replace after 2 million
ITEM Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete

A6 Clean wetter tank and replace felt . 10mins Wetter Felt--- G0-0181-A
Replace after 1 million

Wetter felt

A7 Remove collate pocket assembly. 30mins Bearings--Inspect at 2 million


Clean all feed rollers Rollers—Inspect at 2million
Check, clean and grease all bearings

Spring loaded
bearings
ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete
Complete Interval cycle (Page)

A8 Remove upper Input conveyor assembly 30mins Belts 140 XL---F5120A


Check and clean all upper transport belts (4 in set 6 belts required)
Inspect and clean after 500,000

Upper transport belts

Clean and regrease sprung loaded bearings


Clean feed rollers
Rollers—
Feed rollers Inspect after 2 million

Bearings—
Inspect after 2 million

Sprung loaded bearings


ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete
Complete Interval cycle (Page)

A9 Clean lower input conveyor belts 10mins Belt 130XL ---F5120-A


Inspect after 2 million

Lower input conveyor


belts

Sprung loaded Sprung loaded bearings and


Bearings springs—
Inspect after 2 million
ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete
Complete Interval cycle (Page)

Lead screw—
A10 Check , clean and regrease finger assembly 30mins
Inspect after 4 million
Ensure fingers are not sticking on lead screw shaft or
Catching on frame of machine
(remove and check if needed)

Lead screw

Check inner and outer finger tips for wear


(replace if needed)
Inner finger tips---
Inspect and replace after 1 million

Outer finger tips---


Inspect and replace if needed after 2
million

Outer and inner


Finger tips
ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete
Complete Interval cycle (Page)

A11 Clean wetter solenoid with dry cloth and air duster 5mins
to remove dust particles . Wetter solenoid—
Inspect after 2million

Wetter Solenoid

A12 Clean pawl chain 10mins


Check gears and tension on pawl chain Chain—
Inspect after 2 million
Lightly grease chain
Track Pawl---
Chain and Track Inspect after 2 million
Pawl
ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete
Complete Interval cycle (Page)

A13 Clean all sensors (both transmitter and receiver) 10mins Replace when faulty
With approved air duster

A14 Check all gears 30mins Replace when faulty


Check pins are intact
Clean and lightly grease gears

A15 Vacuum all areas to remove internal dust 5mins

A16 Refit Input conveyor assembly 5mins


(ensuring connector is plugged in)

A17 Refit collate assembly 5mins


(ensuring all connections are securely fitted)

A18 Refit envelope feed section 10mins


(ensuring all connectors are securely fitted)

A19 Refit envelope conveyor 10mins


` (Checking connector is pushed fully in )

A20 Engineer calibrations –Calibrate sensors and check 15mins


All are working

A21 Engineer Calibrations—Check fingers (to 235) 10mins


Check collate pocket size
ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete
Complete Interval Cycle (Page)

A22 Engineer settings – Check Motors work 5mins

A23 Engineer settings—check clutch ,brake and solenoids 15mins


All work

A24 Inspect cables for any damage (replace if needed) 5mins

A25 Run in envelope only mode checking for envelope stop 10mins
position and good envelope feed.

A26 Run customers job –check finger setup ,feeding, 15mins


Insertion, wetting and closing

A27 Refit all covers and clean. 15mins


Run machine machine to make sure no covers are
Rubbing.
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.4 Information for Engineers 3.4.4 Potential Hazards


3.4.1 Service Procedures and adjustments Take extreme care if running the machine with the covers open. To
run with the covers open, a magnet will be needed to override the safety
The procedures described on the following pages are the recommended interlocks. A spare magnet such as fitted to the opening cover (131-824) is
methods to be employed when removing or replacing various items. most suitable.
Note that not all individual spare parts may be available for replacement;
in some cases, only the assemblies containing those parts can be obtained.
For further clarification, see section 4. The machine is double-pole fused. This means that power may
still be present even after switching off at the mains.

3.4.2 Tools required


Always disconnect the machine from the mains source before re-
No special tools are required for service operation on the machine, though a moving covers. Don’t just switch off.
variety of standard engineer’s tools will be needed, including:
Ensure the black inner covers on the operator side are in place when work
is finished. These covers protect the operator from hazardous areas when
• Torx drivers #10, #15, #20 & #25 the cover is opened.

• Pozidrive screwdrivers #1 & #2 When removing items such as the envelope feeder assembly, note that
some items are very heavy and lifting should not be undertaken unless you
• Set of metric Allen Keys feel confident to do so. Seek assistance otherwise.
• Pointed (snipe) nosed pliers
• Right-angled bit drivers
• Side-cutters
• In addition, a stock of cable-ties 100 x 2.6mm 169-102

3.4.3 Electrical Connectors and Sensors


Sensors are supplied as a cable assembly, with the sensor at one end and
its two connectors at the other. All sensors (with the exception of flag or
disc sensors) consist of a pair, Emitter and Receiver. The receiver is usually
mounted below the emitter, though this can vary.
All connectors are marked with the number of the appropriate PCB connec-
tor to which it joins

Page 3 - 5
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.5 Removal of covers


Some or all of the covers on the machine will need to be removed for ser-
vice operations. In some cases where fixing screws are plainly visible, re-
moval is self-explanatory. In less obvious cases, removal is described below.
Visible after opening perspex
When service operations are complete, covers must be replaced
top cover.
fully – failure to do so could result in a hazard to the operator.
3.5.1 Drive side cover
Open the perspex top cover and hinge open the sealer assembly (below the
envelope conveyor). Remove the screws shown below, accessed from inside
the chassis face.

When screws are removed, lift the cover upwards of the lower location lugs
and lift it off.
3.5.2 Front vertical cover
Visible inside sealer cavity, This is located below the sealer and provides access to the wetter piping
after opening the sealer. and no-seal solenoid.
First remove the drive-side cover as above and open the side cover on the
operator side.

On the operator side, remove


the screw indicated, located
below the idler gear

Visible below envelope


separator.

cont.

Page 3 - 6
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.5.4 Upper Cover


This is located on the operator side by the perspex cover and covers the
Expansion PCB. It is secured by 5 screws and removal is shown below.
On the drive side, remove the
screw indicated (uppermost).
Also shown is one of the
lower skirt screws (see 3.5.3
below).

Open the perspex cover and


remove the 3 fixed screws.
Note that the 2 screws in
keyhole slots only need to be
With the screws removed, lift the cover upwards to release 2 hooked lugs slackened.
and lift it out. When replacing, ensue the hooks are properlay located.

3.5.3 Drive side lower skirt


This is located below the drive side cover, which must be removed first in
order to access the screws (see 3.5.1). Most other covers will either not require removal, or should not present a
problem to do so.
The skirt is secured with 2 screws and 1 nyloc nut. The front screw is shown
in the figure above, the other is located in a similar manner midway; the
nut is located at the back end. 2 hooked lugs on the lower edge secure the
bottom of the skirt.
When replacing the skirt, ensure the lugs are properly hooked onto the
chassis before replacing the screws/nut.

Page 3 - 7
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.6 Removal of Envelope Feeder

1 The envelope conveyor must be removed before the feeder assembly Remove the 6 Remove the screws marked ‘F’ on both the
is lifted out of the chassis. feeder drive and operator sides (Figs 1 & 2).

7 Lift the feeder assembly out of the chassis.


Drive side Fig. 1
2 Remove the screws
marked ‘C’ on both the drive When placing the feeder assembly onto a surface, ensure
C C
F and operator side (Figs 1 & 2) the overguide underneath is not damaged.
C

3 Unclip the ribbon cable


and lift it out of the way.
8 Reassembly of the feeder and conveyor is a
reverse of removal. Remember to recon-
F nect the sensor cable at the inner edge
F of the conveyor.

9 For replacement of conveyor belts, see 3.8.

Fig. 2 4 Disconnect the ribbon


Operator side cables from the PCB.
C
C

5 Open the sealer cover under the conveyor and lift the conveyor away
from the feeder assembly.

Disconnect the sensor cable on the inner edge of the con-


veyor as it is being withdrawn.
Page 3 - 8
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.7 Removal/Adjustments of Separator


Fig. 4 5 To replace the rollers,
simply slacken the set screws
The separator gap is operator adjustable by reaching in below the envelope and slide the rollers off the
feeder and turning the green knob. Turning the knob clockwise opens the shaft.
gap.
Removal of the separator assembly allows replacement of the separator 6 To replace the motor,
rollers and also adjustment, if needed, of the shield. the assembly will have to be
stripped to reach the screws.
To remove, proceed as follows:
7 To adjust the shield,
1 Remove the envelope conveyor assembly as described in 3.6. slacken the screws indicated in
Fig. 4 and move the shield as
required.

Fig. 3 2 Turn the green knob fully


clockwise to back off the roll- The shield is factory set in its lowest (fully forward) position and should not
ers and remove the 3 screws normally need adjustment. Certain problem envelopes that will not separate
indicated in Fig. 3. properly may benefit from moving the shield back. This is a trial and error
method, but try setting it fully back to start.

8 Refitting the separator assembly is a reversal of removal. Remember


3 Disconnect the motor to reset the separator gap.
cable at the connector on the
chassis bridge, push the as-
sembly forward to unhook the
two lugs and lift it out of the
chassis.

4 With the assembly removed from the chassis, the rollers or motor can
be replaced, or the roller shield can be adjusted (see opposite).

Page 3 - 9
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.8 Replacement of Envelope Conveyor Belts

The envelope conveyor belts should not normally require replacement as


they have a very long life, but if replacement is required due to damage
etc, proceed as follows:

1 Remove the envelope conveyor assembly as described in 3.6.

2 Remove the end cover together with the backstop (2 screws under-
neath).

Fig. 5 3 Turn the conveyor upside


down and remove the springs
on the rollers at the far end
of the conveyor.

4 Now remove the roller


carrier (see Fig. 5). This will
allow the belt to be looped off
over the side of the conveyor.

5 Fit the new belt in a


reverse manner and replace
the roller carrier and springs.

6 Repeat for the other belt.

7 Refit the end cover and reassemble the conveyor back on the ma-
chine.

Remember to reconnect the motor cable onto the connec-


tor mounted on the chassis bridge.

Page 3 - 10
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.9 Removal of Collate Pocket Clam Assembly

The collate pocket clam assembly pivots on a spigot post each side. Remov-
al entails taking out the spigot on the operator side only.
Removing the assembly is quick to carry out, and allows much improved ac-
ces to the collate area.

1 On the drive side, trace the sensor cables for the assembly back to
the chassis hole, detach them from the clips and disconnect them
from the PCB.

Fig. 6
2 On the operator side,
remove the clutch/gear, idler
and gear indicated in Fig. 6.
Slacken the clutch locators to
allow this.

Fig. 7 3 Remove the spigot indi-


cated in Fig. 7 whilst holding
the collate pocket clam as-
sembly. Free the assembly
from the other spigot and lift
it out of the chassis, leading
the chassis cable out as it is
removed.

4 Reassembly is a reverse
of removal.

Page 3 - 11
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.10 Replacement of collate chains or chain pawls Fig. 9 5 Use a screwdriver or simi-
lar tool to compress the spring
tensioner.

Before removing the collate chains, the Envelope Feeder


(see 3.6) and Collate Pocket Clam (see 3.9) must be re-
moved to allow access.

The collate chains need checking as Preventative Maintenance only every


2 million envelopes and will not normally need replacing. However, if they
break or otherwise become damaged, proceed as follows.
The chains can be replaced complete with pawls, or one or more pawls only,
retaining the chains. The chains must always be replaced as a pair.

1 Remove the insert panels – this will allow the chains to flex sideways.
Pawl misalignment
2 At the pawl link, remove Fig. 10
Fig. 8 the spring clip on the outer 6 If the chain pawls be-
side and pull out the rollers to come misaligned, they can be
separate the chain (see Fig. brought back into line by the
8). Caution: jam the chain following procedure.
at the input end to prevent
it sliding inside the chassis. 7 Slacken the screw indicat-
ed in Fig. 10 and release the
3 Use the link to connect tension shaft.
one end of the new chain with
one end of the existing one. 8 Hold the forwardmost
maintaining chain tension, pawl, and using pointed nose
Insert panel shown
dtoraw it round the pulleys pliers drag the other chain
removed
until the other end appears on over the required number of
the chassis surface. sprocket teeth at the output end. When the pawls are aligned, replace
the tension shaft.
4 Jam the chain to hold it and separate the link to remove the old chain.
Join the 2 ends of the newFone.FIf necessary, the chain tension can be 9 Replace the insert panels and run the machine to check that the
relieved by using a screwdriver (or other suitable tool) to compress chains operate correctly.
the tensioner at the input end (see Fig. 9).

Try not to let the chain slip on the sprockets as it is drawn


round them, or the pawls will be misaligned. If this hap-
pens, see step 6.

Page 3 - 12
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.11 Removal of Finger Assy


Remove the 5 Withdraw the finger assembly from the chas-
finger assy. sis, folding the fingers clear of obstructions.
Do not apply undue force when remov-
ing the assembly or the fingers may be
Before removing the finger assembly, the envelope feeder damaged.
assembly must be removed first - see previous section.
6 Reassembly is a reverse of removal. With the
envelope feeder removed, the fingers should
also be adjusted – see the following section.
1 The finger assembly is withdrawn from the drive side of the chassis Note: to adjust the inners fingers, the finger
after disconnecting the pivot shaft on the operator side. assembly must also be removed from the
chassis.
2 On the operator side, re- Solenoids and solenoid springs can be ob-
Operator side Fig. 11 move the ‘E’ clip on the end of tained as separate items, but the rest of the
the pivot shaft. assembly can be obtained only as a complete
Do not remove the solenoid spare.
from the chassis.

3 On the drive side, remove


Drive side Backstop
screw the screws indicated.

4 Disconnect the ribbon


cable from the PCB and unclip
Fig. 12 it from the finger chassis.

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Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.12 Adjustment of fingers


5 Slacken the backstop screw and repeat steps 2 to 4 to adjust the
other side.

6 Check that the adjustments are correct by actuating both solenoids


together and ensuring that the settings have not changed. If necessary,
Only the outer fingers are adjusted with the finger assem- make corrections.
bly in-situ: it must be removed for the inner fingers.
Note: as an alternative to using the backstop screws, the solenoid can be
be compressed by hand, and with the screws loosened, adjusted as de-
scribed whilst holding the straight-edge in place.
Outer Fingers
To avoid flexing of the actuator bar, the outer fingers are actuated by a so-


lenoid on each side. The fingers are therefore individually adjusted. The solenoids can be actuated in Engineer mode diagnostics.
To operate the machine, close the top cover and place a mag-
1 Ensure the envelope net over the side cover interlock switch.
Fig. 13 feeder is removed (see section
3.6).

2 On the side not being


adjusted, turn down the back-
stop screw shown in Fig. 12
so that the pivot lever is fully
raised. Be careful not to
strain it. Lock the screw.

3 On the side being ad-


justed, pull down the solenoid
by hand so the fingers are
fully forward. The top surface
of the fingers should now be at the same level as the centre insert plate. To
check, prop the insert plate with a screwdriver or similar to prevent it com-
pressing the springs and place a straight-edge so that it is flat on the plate,
as shown in Fig. 13. The finger should be at the same level as the plate at
the point indicated.

4 If adjustment is required, slacken the 2 screws securing the so-


lenoid, and while still compressed, slide it so that the finger just touches
the straight edge and tighten the screws. Note that a right-angled torx
driver will be required for the screws.

Page 3 - 14
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

Inner Fingers
The inner fingers are adjusted using a special setting gauge with the finger
assembly removed from the machine, as described in section 3.11.

The setting gauge is located in the top corner of the drive-


side chassis face: unscrew it to use.

1 After removing the finger


Fig. 14 assembly, attach the setting
gauge as shown in Fig. 14 us-
ing 2 x M4 screws.

2 Pull in the solenoid to


advance the fingers: the un-
derside should be 1 - 1.5mm
above the edge of the setting
guage at the points indicated
in Fig. 14.

3 If adjustment is required,
slacken the 2 screws securing
the solenoid and slide it as required. Tighten the screws and check that the
setting has not changed.

4 Replace the finger assembly in reverse order to removal.

 Remember to replace the setting gauge when adjustment is


complete.

Page 3 - 15
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

Motor Drive Side


3.13 Removal of Side Guide Adjust Assembly Fig. 17
cable
3 Remove the solenoid
bracket screws to allow access
for the side guide adjust as-
In order to remove the side guide assembly, the Power sembly Fig. 17). It is not nec-
Supply Unit must be removed first – see section 3.15 essary to remove the bracket.

4 Disconnect the 2 disc


Solenoid sensor cables shown in Fig.
The side adjust assembly consists of a motor-powered lead-screw and pro- bracket 17 and also the motor cable.
vides the mechanism for adjusting the side guides above the chassis sur- Remove the 2 screws indi-
face in the collate area. It is removed from the drive side of the chassis. cated. Withdraw the assem-
bly, reaching in through the
Operator side chassis opening vacated by
Fig. 15
The leadscrew shaft must first the PSU in order to hold the
have the ‘T’ bearing removed. side guide carriers free of any
This is located under the PCB obstructions.
on the operator side. Replacement
Fig. 18
1 Remove the ribbon cables 5 Replacement can be
on the LH and upper edges of awkward due to the side
the PCB. Take out the screws guide carriers swinging up-
and pull down the top of the side-down. To avoid this, use
PCB PCB to reveal the ‘T’ bearing adhesive tape to hold the car-
(see Fig. 15). Remove the ‘E’ riers to the lead-screw during
clip and bearing. reassembly as shown in Fig.
Adhesive 18. Reach in through the PSU
tape
opening to help guide the lead
2 Raise the collate clam as- screw through the ‘T’ bearing
Fig. 16 sembly in the collate area and opening on the operator side.
remove the side guide brack- When the assembly is in place
ets and side guides, as shown with the carriers the right way up, remove the tape.
in Fig. 16. These are attached
to the side guide adjust as- 6 Replace the ‘T’ bearing and clip on the operator side, screw the PCB
sembly below. back into place and reconnect the cables. Also reconnect the cables on the
drive side.

7 Replace the side guide brackets and side guides in the collate area.
The side guides must now be adjusted – see section 3.14.

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Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.14 Adjustment of Side Guides 3.15 Removal of Power Supply

The side guide width is automatically set according to document size. How- The power supply unit can be removed from the drive side of the machine
ever, the side guides are factory set to toe-in at the front. If the guides after disconnecting cables on the operator side.
have to be removed or disturbed, the toe-in must be reset to toe-in at the
Operator side
front. Fig. 20
The PSU must first be discon-
nected on the operator side.
A A 1 Open the collate pocket
assembly in the collate area.
1 Disconnect the two cables
Network indicated in Fig. 20. Unplug
Fig. 19 Slacken the 2 screws indi- Cable
the network cable to allow
cated in Fig. 19 to allow the
access for the PSU cables to
guides to swivel.
pass through the opening.
Adjust the guides so that
point B is 1.5mm (1/16”)
wider each side than point A.
This is most easily achieved Drive side
by placing a piece of pa-

B
per between the guides and 2 Remove the 2 screws indi-
B winding the gears by hand to cated in Fig. 21 and withdraw
move them. The gap can then the PSU, feeding the connec-
be easily measured. tors through the chassis open-
Tighten the screws and check that the setting has not altered. The toe-in ing on the operator side.
applies to all document sizes. Replacement
Hold the cables and reach in
the chassis opening on the
drive side and feed the con-
Fig. 21 nectors through the opening
on the operator side. Push the
PSU home. The lugs on the
operator side must locate in the chassis plate before the PSU will fit.

 Tape or bind the cables together to assist with feeding them


through the operator side opening.

Page 3 - 17
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.16 Replacement of Sealer Rollers


3 Lift the rollers out of the chassis, utilising the access slots to do so.
The lower roller can be removed by ‘springing’ the surrounding metalwork
slightly.

There are four sealer rollers: two in the chassis, two in the opening sealer
assembly. They should be checked for wear or damage at every site visit
and replaced at 2 million envelopes. When fitting the new rollers, take care not to damage the
To remove the rollers, this can be done with the envelope feeder in place, lower roller as it is refitted. Do not get grease on the rollers.
but the sealer assembly will have to be removed first (see section 3.17).
Having done so, proceed as follows.

Drive side (chassis rollers) Sealer Assembly Rollers


Fig. 22 Fig. 24
1 Open the sealer assem- 1 Open the sealer assembly
bly and remove the clutches, and on both sides, remove the
gears, ‘E’ clips, bearings and bearing springs shown in Fig.
waved washers indicated in 24.
Fig. 22. Slacken, but do not
remove, the clutch location 2 Remove the ‘E’ clips on
bracket to facilitate this. the ends of both sides of the
uppermost roller only.

3 The roller sub-chassis can


now be lifted out of the sealer
assembly and the rollers re-
moved.

4 Reassemble in reverse order to replacement.


Fig. 23 Operator side (chassis
rollers)

2 Remove the clutch, gears,


‘E’ clips, bearings and waved
washers indicated in Fig. 23.
Remove the screws for the
float switch bracket to facili-
tate this, but do not remove
the bracket.

Page 3 - 18
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.17 Removal of Sealer Assembly

The sealer assembly can be quickly removed for replacement of sealer roll-
ers (see section 3.16). Proceed as follows.

Fig. 25 1 Open the sealer assembly


and remove the pivot screw
on each side (Fig. 25 shows
drive side - operator side is
similar).

2 Lift the assembly out of


the machine.
Reassembly is a reverse of
removal.

 When replacing the pivot screws, insert a screwdriver or drift in


one hole to align the assembly whilst fitting the other one.

Page 3 - 19
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.18 ENGINEERING MODE 3.18.1 Hardware Setup


To enter Engineering mode, select the ‘Engineering’ button from the setup Configures the physical machine. When the machine is first set up, or if new
screen. units are added or altered (eg. a reader is added), Hardware Setup must
be set to reflect each unit and its features.

Engineering mode allows the following functions:


• Hardware Setup
• Units Setup
• Firmware Download
• Diagnostics
• Reader Setup
• Machine ID
• Plug and Play

Note:
Engineering mode will only be available to personnel
with appropriate access rights.
Engineering mode applies to the whole machine, To make changes select the Edit tab. Select each unit in turn in the left-
hence this section covers feed/fold modules, as well hand column, choose the unit type in the centre column and select the
as the insert head. Modules not relevant to the actual required options in the right-hand column. Extra settings relating to readers
machine setup should be ignored. are shown in the pane on the right-hand side. For Feed/fold units, the read-
ers fitted are selected with the module highlighted, then the reader options
for each hopper are selected with the module hopper highlighted.
To view all settings without making changes, select the View tab and select
each module or its hoppers.
To add new modules to the end of the existing ones, use the button
and configure to suit.
cont.

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Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.18.2 Units Setup


To delete existing modules, use the button. Important: modules are
deleted from the end. If a module is removed that is not the end module, This allows adjustment of various settings, depending upon the module se-
all module settings after that one must be re-configured. lected using the button at the bottom.
However, in practice, when a module is added or removed, providing that
the DIP switches have been correctly set, the modules can be automatically
re-configured using Plug and Play (see later in this section for details).

Settings tab
This allows adjustment of various settings, depending upon the module.
Module 0: Head adjustment of:
Collate Pocket Cal & Fingers Cal: These settings are in addition to any
changes made in ‘Calibrations’ (see later in this section). Use if the
settings need to be different from the calibrated sizes.
Wetter Start: Adjusts the point at which the wetter beam drops to wet
the flap (+ve = more wetting). In steps of 1mm. Note: this setting
applies to the machine, and can be further adjusted for the job in ‘Ad-
vanced’.
Envelope Stop Position Cal: Adjusts envelope stop position. Positive =
further forward towards exit direction.

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Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

Envelope Insert Position Cal: Adjusts amount of insertion of insert 2. In the configuration screen, select the number at the top of
pack into envelope. Positive = further forward past flap crease. the fold module icon: check the Fold Plate Length settings in the
dialog box (see below). For A4, F1 should be 149mm and F2 &
Envelope Reverse Position Cal: Adjusts amount of envelope forward
F3 should be 0. For Letter, Length A should be 140mm and F2 &
travel after flap wetting, before reversing to enter sealing rollers. Posi-
F3 should be 0.
tive = further forward into rollers, towards exit direction..
Envelope Seal Position Cal: amount of envelope travel into seal roll-
ers. Positive = further forward, away from exit direction.
Envelope depth Measured: auto-measured depth of envelope, which
will be displayed. Adjust up or down to suit actual envelope size. Posi-
tive = greater.
Ins. Pawl Stop Position Cal: Adjusts stop position of insert pawls be-
hind insert pack in collate pocket. If the pawls are stopped too high by
the software, inserts entering the collate pocket will contact the tips,
hence position must be adjusted back. Positive = further forward.
Pocket Backstop Cal: As inserts enter the collate pocket, they contact
a backstop to prevent overrun, and stop. The backstop is then lowered
and the insert drives forward. This setting increases the time delay
before the insert drives forward. Use if backstops are slow to drop for
any reason, causing crashing. If set to Off, backstop remains lowered
always.
Feeders (dual only): Collate Feeder 2 Cal: Moves the form in hopper
2 to adjust collate point. Positive = further forward, in steps of 1mm.
Feeder Folder: Folplate 1/2 Cal. & No Fold 1/2 cal: These are the
same as 1 & 2 of the 3-Plate folder (see below). 3. Save the job and run. Measure the length of the first panel,
which should be 149mm (A4) or 140mm (Letter). If not, exit
Tower Folder: adjustment of:
Configuration and enter Units Setup in Engineering mode. Select
a: settings of foldplates 1, 2 & 3. Figure shown will be the set- the Tower Folder in the module box at the bottom of the screen:
ting for the job, and may be adjusted if required. Units are 1mm and this will display the settings boxes for the foldplate calibrations
positive = greater. To set up for the first time, or if parts have been (see following page).
replaced:
1. Set up a job with the following parameters:
European: Envelope = C5 (162 x 229), Paper = A4 single sheet from
top hopper, Fold = V.
US: Envelope = No. 7 Booklet (159 x 244), Paper = Letter size single
sheet from top hopper, Fold = V.

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Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

4. In Foldplate 1 Cal, enter the difference between the meas-


ured length and the length displayed in Configuration, ie. if the
measured length is 152mm, select ‘Change’ and enter -3. 6. Set F1 and F3 to 0 – this will blank off foldplates 1 & 3.
5. Run the job to check the length is now correct (149mm in 7. Repeat steps 3 to 5 for Foldplate 2 Cal.
this case).
7. Repeat for foldplate 3, except that F1 & F3 are set to 0, and
6. To calibrate foldplate 2, return to Configuration and enter the make any necessary corrections for Foldplate 3 Cal.
dialog box described in step 2. Change the fold type to ‘Custom
b: calibration of no-fold blanking beams 1, 2 & 3. Adjusts gap
Fold’ and hit the Fold Plate Lengths button to open the Foldplate
between tip of beam and fold roller. If forms are not entering a fold
Settings box (see opposite).
plate when they should, gap must be increased and vice versa. Units
are 0.1mm of motor actuator which equates to 1mm at beam tip.
Positive numbers only.
c: alignment of leading edges when collating before feeding.
Applies to feeders 2 & 3. Units are 1mm and positive = further for-
ward.
Cardfolder: adjustment of:
FP1 Up Cal: Controls paper travel into FP1 in ‘up’ position. Positive =
further. Factory default = 4. (Mk.1/2).
FP1 Down Cal: Controls paper travel into FP1 in ‘down’ position. Posi-
tive = further. Factory default = 0. (Mk.1/2).
FP2 Up/Down Cal: As for FP1. Factory defaults = 0 & 0. (Mk.1 only).

Page 3 - 23
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

FP2 Clockwise Cal: Controls paper travel into FP2 for CW rotation,
(from operator side). Positive = further. Factory default = 0. (Mk.2
only).
FP2 Counter CW Cal: Controls paper travel into FP2 for CCW rotation,
(from operator side). Positive = further. Factory default = 0. (Mk.2
only).
Up Detent CW: Controls detent landing position for cassette home
position. Positive increases rotation. Factory default = 0. (Mk.2 only).
Down Detent CW: Controls detent landing position for cassette after
180° rotation. Positive increases rotation. Factory default = 0. (Mk.2
only).
Up/Down Detent Counter CW: As for CW, but rotating Counter CW.
Factory defaults = -4 & -3. (Mk.2 only).
Conclusion of Settings section.

Page 3 - 24
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

Calibrations tab Note also that the collate pocket side guides are adjustable
for taper and are factory set to taper intowards the closer
end. The 210mm setting above applies to the narrowest
point - the widest point is set to approx. 3-4mm wider either
side. Specific jobs may require a diferrent setting; to adjust,
slacken the screw near the middle of the guide and twist the
guide to suit.

This screen applies only to the insert head, and is used


to set the collate pocket side guides and the insert fingers
to A4 size (210mm). When these options are selected, the
motors for the settings will automatically adjust to the cor-
rect size. They should then be measured, and any difference
should be corrected out using the adjustment boxes - posi-
tive numbers increase the width.
Note that the measured distances should be 210mm exactly.
Appropriate clearances will then be automatically applied by
the software, which will suit most job applications. It it is
required to alter the settings, use the adjustment boxes as
described above. These settings will then remain until set
otherwise.

Page 3 - 25
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

Hybrid Motor Calibrations tab

Calibrating

54/76/94/116

984mm/s

0.51

24.0V

This screen applies only to the insert head, and is used


to calibrate and test the hybrid motor. This should not nor-
mally be required as the motor is factory calibrated, but if
operating problems may indicate the motor, it should be
carried out. The machine should be clear of stationery when
doing so.
When the Calibrate button is selected, the motor slowly
increases in speed up to a maximum, and sets 4 calibration
points as it does so: low, medium, normal & high. These
unitless points are displayed in the ‘Settings’ cell. The linear
speed (of the paper), current and voltage are also displayed.
Selecting the Speed button allows the motor to be tested
at low, medium and normal speeds. The motor will continue
running until ‘Off’ is selected.

Page 3 - 26
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.18.3 Firmware Download Change Params: this is a legacy feature and should not normally
be required unless a different CAN type were used. The default set-
Firmware downloading allows selected units to be upgraded with se-
tings are:
lected files, usually sourced from the company website.
USB CAN
Select the unit(s) to be upgraded and use the ‘Files’ button to find
the appropriate .am4 file(s). Note that each file includes the module Packet 4
name in the filename, ie. for head, 3P folder or feeder/2P folder/
Send Interval 1
Cardfolder. The lower windows show the version number and status
of the file. These can be compared with the main window showing O/Flow Timeout 10
the same details for the current firmware in the unit. When downloading is complete, select Exit.
Normally, all modules should be ticked in the left-hand column and
Broadcast Mode should be ticked also. This will allow multiple mod-
ules of similar type (feed/fold modules or Cardfolder) to be upgraded
simultaneously, saving time; only untick if a module is specifically
not to be upgraded. It does not matter if, for example, the head
were ticked whilst feed/fold modules were being upgraded.
When downloading, the righthand window shows download status in
progress.

Page 3 - 27
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

3.18.4 Diagnostics Motors


Diagnostics allows sensors to be calibrated and components (motors, Tests the DC motors for collate pocket, fingers and foldplates. Ap-
clutches, brakes, solenoids etc) to be tested. The voltage and cur- plies only to insert head and tower folder.
rent drawn by the sensors is shown as a read-only display, and their
clear or blocked status is indicated. Component tests will run each
selected component to confirm it functions.
Note: the screens may vary in appearance from that shown, de-
pending upon the module type.
Solenoids
This includes other clutches, brakes and AC motors also. Allows vari-
ous components to be switched on or off to test them and provide
a readout of current rating. Components shown will depend upon
type of unit selected and will include some or all of: clutches, brakes,
solenoids and indicator LEDs. Drive motor is also included for each
module, as this must be switched on to test some other components.

The Fwd button toggles between forward, reverse and


forward+reverse (alternating). Select the required direction, then On
to start, Off to stop. The right-hand column indicates the status.
Start Sync applies only to Tower Folder fold plates. It will cause the
backstops to travel to the far end of the fold plate, then reset for the
selected job.
Select each module as required using the Select Unit button.
Analogue sensors

Page 3 - 28
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

Analoque sensors are those that respond over a graduated range, Sensors can be calibrated individually or all together by using the
unlike digital sensors which are read as either On or Off. They are Cal All (Paper sensors) button.
usually adustable.
Generally, the readings are best used as a comparison guide for
The screen displays the status of analogue sensors and allows their like sensors from one machine to another. However, if a sensor has
calibration. The read-only displays translate as follows: failed, the readings are likely to be very low or zero.
Example: T=2.6V I=222% R=12% C 0.2V Select each module as required using the Select Unit button.
Where T = Threshold voltage, generally over 2.5V, I = ‘effort’ of Digital sensors
current required to read across the sensor halves, R = Percentage
of pot value on PCB, C (or B) = clear or blocked and sensor voltage,
which should <0.5 clear, >4.5V blocked.

Calibration

Page 3 - 29
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

Analoque sensors are those that respond over a graduated range, Sensors can be calibrated individually or all together by using the
unlike digital sensors which are read as either On or Off. They are Cal All (Paper sensors) button.
usually adustable.
Generally, the readings are best used as a comparison guide for
The screen displays the status of analogue sensors and allows their like sensors from one machine to another. However, if a sensor has
calibration. The read-only displays translate as follows: failed, the readings are likely to be very low or zero.
Example: T=2.6V I=222% R=12% C 0.2V Select each module as required using the Select Unit button.
Where T = Threshold voltage, generally over 2.5V, I = ‘effort’ of Digital sensors
current required to read across the sensor halves, R = Percentage
of pot value on PCB, C (or B) = clear or blocked and sensor voltage,
which should <0.5 clear, >4.5V blocked.

Calibration

Page 3 - 29
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

Analoque sensors are those that are read as either On or Off, unlike Covers
digital sensors which respond over a graduated range. They are not
Displays the status (open or closed) of all operator-opening covers
adustable.
and hopper interlocks. This will indicate if a reed switch has failed or
The screen displays the On/Off status of each sensor. To check if a is badly adjusted.
sensor is working, it should be On when blocked, Off when clear. Any
semnsor that does not respond this way should be replaced

Select each module as required using the Select Unit button.

Select each module as required using the Select Unit button.

Page 3 - 30
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010

Power Miscellaneous
Displays the voltage or current drawn by each component. The com- Displays the total count for each module. For insert head, Feed
ponent name indicates the nominal voltage/current, while the display Count 1 is the number of envelopes fed, Output Count is the number
indicates the actual rating. of filled envelopes ejected and Pack Count is the number of packs
that have arrived at the collate area for insertion into the envelope.
For tower folder, feed counts 1 to 4 relate to the hoppers, where
hopper 4 is the hand-feed hopper.

Select each module as required using the Select Unit button.

Select each module as required using the Select Unit button.

Page 3 - 31
Maximailer HD Service Manual Maintenance and Servicing Issue 3 May 2010

3.19 RECOMMENDED SPARE PARTS


Shown below are the spare parts recommended to be held by Service
Agents. Quantities shown are per machine.
Consumable items are marked in the right-hand column: these might need
to be ordered more frequently.
To obtain a 230V list, order part number A0-0530-A (9110259C).
To obtain a 115V list, order part number A0-0531-A (9110260D).

ITEM P/N (PFE) P/N (SAP) DESCRIPTION QTY CONS.


1 A2-1057-A 9110112Z MOTOR ASSY, 230V 1
or
1a A2-1056-A 9110111Y MOTOR ASSY, 115V 1
2 179-109 9108382Z CLUTCH EC30LL CW 8mm 24V 1
3 181-050 9100779C MTR W/D 179-093 IN-LINE 1
4 181-128 9100807G CLUTCH W/D 179-155 2WXH 1
5 181-129 9100808H BRAKE W/D 179-105 2WXH 1
6 181-1600 9109569J SOLENOID W/D 179-3540 XH 1
7 182-8450 9109554T LOOM C4 HYBRID MTR LINK 1
8 180-702 9100715L PCB ASSY ENV WETTER 1
9 180-720 9100723U PCB ASSY AM4 PROCESSOR 1
10 180-721 9109914T PCB ASSY AM4 CNTRL BRD 1
11 180-759 9100744R PCB SPLIT 5SEN 5SOL H/D 1
12 180-776 9110109W PCB WIDEBODY DISK SENSOR 1
13 180-8300 9100723U PCB C4 EXPANSION 1
14 181-048 9110257A MTR ASSY PERISTALTIC 24V 1
15 182-340 9100978K LOOM EMITTER 200 SM 1
16 182-342 9100980M LOOM RECEIVER N/A 200 SM 1
17 182-345 9100983Q LOOM RECEIVER N/A 300 SM 1
18 182-440 9101010T LOOM EMITTER 200 XH 1
19 182-441 9101011U LOOM RECEIVER W/A 200 XH 1
20 182-443 9101013W LOOM EMITTER 300 XH 1
21 182-451 9101018B LOOM 4W-3W/3W XH 0.2M 1
22 182-495 9101033S LOOM A5 WETTER PROBE 1
Page 3 - 32
Maximailer HD Service Manual Maintenance and Servicing Issue 2 Mar 2010

ITEM P/N (PFE) P/N (SAP) DESCRIPTION QTY CONS.


23 182-693 9101087Y OPB715 WIRED SENSOR 2x3W 1
24 182-8320 9109815Q LOOM C4 HEAD LINKS 1
25 182-8330 9109555U LOOM C4 HEAD RIBBON SET 1
26 184-2150 9109570K C4 HEAD PSU 1
27 180-760 9100745S PCB SPLIT 3SEN 4SOL H/D 1
28 182-444 9101014X LOOM RECEIVER W/A 300 XH 1
29 182-445 9101015Y LOOM RECEIVER N/A 300 XH 1
30 182-8300 9109556V LOOM C4 ENV FDR LINK SET 1
31 182-8310 9109571L OPB715 SENSOR 2x3W 250mm 1
32 181-1630 9109557W WIRED 24V BLOWER SM 1
33 182-337 9100975G LOOM EMITTER 100 SM 1
34 182-339 9100977J LOOM RECEIVER N/A 100 SM 1
35 182-8340 9109572M LOOM 4WXH-4WSM 0.1M 1
36 181-0870 9109558X MTR W/D 179-056 2WSM 1
37 182-439 9101009S LOOM RECEIVER N/A 100 XH 1
38 182-442 9101012V LOOM RECEIVER N/A 200 XH 1
39 182-8460 9109573N LOOM C4 INTERNAL COMMS 1
40 D0-0063-A 9109559Y SOFT RUBBER WHEEL 40 DIA 4 x

41 F5119A 9104497A BELT 140XL 037 POLYURETH 1.5 x

42 F5120A 9104499C BELT 130XL 037 POLYURETH 1.5 x

43 C8-0208-A 9109563C UPPER SEAL ROLLER 48DIA 2 x

44 D0045A 9105523U ROLLER TRANSPORT NOTCHED 2 x

45 182-8220 9109552R LOOM 300 2 X 2WXH 1


46 181-1610 9109568H SOLENOID W/D 179-3550 XH 2
47 179-3550 9109569J SOL SDT2652L628 1
48 181-070 9100788M WIRED MTR 179-802 2X2WXH 1
49 179-110 9108383Y CLUTCH EC30LL CCW 8mm24V 1
50 C8135A 9103513A SEPARATOR ROLLER 2 x

51 G1-0280-A 9109560Z SEPARATOR SHIELD 1 x

52 181-0850 9108955U WIRED MTR 179-802 2W SM 1


53 C8194A 9103545J SLOTTED FEED WHEEL 2 x

Page 3 - 33
Maximailer HD Service Manual Maintenance and Servicing Issue 3 Aug 2011

ITEM P/N (PFE) P/N (SAP) DESCRIPTION QTY CONS.


54 C8-0209-A 9109578T ENV FEED ROLLER 10mm DIA 8 x

55 D0-0062-A 9109574P RUBBER WHEEL 40 DIA 10 x

56 D0051A 9103618K SEPARATOR PAD 45-55 1 x

57 G0167A 9105600Z EC30 CLUTCH PIN 2


58 G6-0220-A 9109561A GUIDE TAPE UPPER 2 x

59 G6-0221-A 9109576R GUIDE TAPE LOWER 2 x

60 G6-0223-A 9109562B FLAP GUIDE SHIM 2 x

61 179-056 9105296H MTR EMS 30RPM 24V 1


62 C8098A 9108237W ROLLER ENVELOPE FEED 2 x

63 D0007A 9103591G TYRE JOGGLER 4 x

64 F5007A 9104435L BELT 200XL 037 1 x

65 G5074A 9107157W BELT CONVEYOR(HAT-5E) 1 x

66 D0021A 9103602T ROLLER TRANSPORT 30x8 8


67 E0235A 9103763L O RING (12.1 X 1.6) 1
68 G0-0181-A 9109577S WETTER FELT C4 1
69 G1117A 9104686X SPRING HEAVY PRESSURE 2
70 G0079A 9104579L CLUTCH PIN 2
71 G1-0256-A 9109575Q SPRING LINK 1
72 C2-1024-A 9109565E CLUTCH PLATE STANDARD 1
73 C2-1025-A 9109580V CLUTCH PLATE 30T 1
74 C2-1064-A 9109566F CHAIN ROLLER 8
75 C5-1066-A 9109581W LOWER SPROCKET IDLE 1
76 C8-0206-A 9109564D LOWER SEAL ROLLER 48 DIA 1 x

77 C8-0207-A 9109579U LOWER SEAL ROLLER 25DIA 1 x

78 F6-0054-A 9109567G PAWL CHAIN LINK 4


79 182-417 9105287y reed sw sml 3wsm (ul) 1
80 182-418 9105294f reed sw 3wxh (ul) 1

Page 3 - 34
Maximailer HD Service Manual Exploded Views Issue 4 Dec 2011

Section 4
Exploded
Views
Section Description Page

Section Description Page 4.16 Sealer Assembly A2-1058-A ...................................................4-41

4.1 Chassis Drive Side (Front).......................................................4-2 4.17 Split Shaft Sub Assys A2-1059 / 1060 / 1061-A ......................4-44

4.2 Chassis Drive Side (Rear).......................................................4-5 4.18 Finger Assembly A2-1062-A . ..................................................4-46

4.3 Chassis Operator Side.............................................................4-8 4.19 Finger Bkt Op Assy A2-1073-A ...............................................4-49

4.4 Chassis Assembly....................................................................4-11 4.20 Side Guide Adjust Assy A2-1063-A .........................................4-51

4.5 Shaft Locations........................................................................4-14 4.21 Pawl Tension Bracket Assy A2-1072-A ...................................4-53

4.6 Envelope Feeder Assy A2-1064-A...........................................4-16 4.22 Wetter Lever Assy A2-1352-A..................................................4-55

4.7 Envelope Separator Assy A2-1065-A.......................................4-19 4.23 Wetter Beam Assembly . .........................................................4-57

4.8 Envelope Tractor Assy A2-1067-A...........................................4-21 4.24 Wetter Tank Assy A2-1070-A....................................................4-59

4.9 Envelope Feed Shaft Assy A2-1068-A.....................................4-23 4.25 No Seal Assembly A2-1214-A .................................................4-61

4.10 Envelope Conveyor Assy A2-1066-A.......................................4-25 4.26 Head Ribbon Bkt. Assy 184-2260............................................4-63

4.11 Envelope Conveyor Backstop Assy A2-1200-A.......................4-28 4.27 Universal Head PSU 184-2150 ...............................................4-65

4.12 Collate Pocket Clam Assy A2-1069-A......................................4-30 4.28 Mains Input Hardwired 184-2250.............................................4-66

4.13 Head Input Conveyor Upper Assy A2-1054-A..........................4-33 4.29 Head Covers ...........................................................................4-67

4.14 Head Input Conveyor Lower Assy A2-1055-A..........................4-36 4.30 External Float Switch A3-0421-A ............................................4-70

4.15 Motor Assy A2-1056-A (115V) / A2-1057-A (230V)..................4-38 4.31 Lift Beam Assembly A2-1520-A . .............................................4-72

Page 4-1
Maximailer HD Service Manual Exploded Views Issue 5 Feb 2011

S1

NOTE:
FOR CONNECTOR PANEL DETAILS,
SEE SECTION 4-28.

SENSORS
Item Description
Ref.
S1 Hybrid Motor Disc 5.12

4.1 - Chassis Drive Side (Front)


Page 4-2
Maximailer HD Service Manual Exploded Views Issue 6 Feb 2012

Item Part No. Description Qty. Spares


1 181-050 9100779C MTR W/D 179-093 IN-LINE 1 Y
2 180-759 9100744R PCB SPLITTER 5SEN 5SOL H/D (No.6) 1 Y
3 180-746 9100741N PCB ASSY HI-RES SENSOR 1 Y
4a 181-128 CLOSER FORWARD DRIVE CLUTCH 1 N (See Spares Assy 1)
4b 181-128 INSERT PAWL TRACK DRIVE CLUTCH 1 N (See Spares Assy 3)
5 181-129 CLOSER REVERSE DRIVE BRAKE 1 N (See Spares Assy 2)
6 179-110 9108383Y WETTER OUTPUT DRIVE CLUTCH 1 Y
7 B2-1203-A HEAD SIDE PLATE DRIVES 1 N
8 B2-1187-A SENSOR DISC BRACKET 1 N
9 B2-1178-A CLOSER CLUTCH BRACKET DRIVE 1 N
10 C3-0681-A 9109970B IDLER POST 4 Y
11 C3-0682-A 9109971C COMPOUND IDLER POST 1 Y
12 C3-0683-A 9109972D SENSOR DISC POST 1 Y
13 C2-1024-A 9109565E CLUTCH PLATE STANDARD 2 Y (See Spares Assy 1)
14 C2-1025-A CLUTCH PLATE 30T 1 N (See Spares Assy 3)
15 C2-1026-A 9109973E GEAR CONNECTOR 1 Y
16 C2-1031-A 9109974F BRAKE POST 2 Y
17 C2-1029-A 9109975G GEAR SPACER 4 Y
18 C2-1027-A CLUTCH SPACER 3 N (See Spares Assy 1/2/3)
19 F4-0292-A 9109977J GEAR 48T 1M 10ID 1 Y
20 F4-0293-A 9109978K GEAR 40T 1M IDLER 2 Y
21 F4-0294-A 9109979L GEAR 40T 1M 10ID 1 Y
22 F4-0295-A 9109980M GEAR 48T IM IDLER 5 Y
23 F4-0296-A 9109981N GEAR 30T IM CLUTCH 2 Y
24 F4-0297-A 9109982P GEAR 25T IM IDLER 1 Y
25 F4-0299-A 9109983Q GEAR 25T 1M 10ID 2 Y
26 F4-0302-A 9109986T GEAR 25/48T 1 Y
27 F4-0301-A 9109985S ISSUE B GEAR 16T 1M 8ID 1 Y
28 E1-0138-A 9109987U BEARING FL 10 x 22 x 6 A/R Y
29 E1061A 9103826B BEARING BALL 8 x 16 x 5 A/R Y
30 E1107A 9105507C BEARING BALL 6 x 13 x 5 A/R Y
31 E0-0597-A 9109988V KEY 2mm x 10 1 Y
32 B7708A 9105533E SENSOR DISC 1 Y
33 G6168A CLUTCH SHIM A/R N (See Spares Assy 2)
34 G0167A 9105600Z EC30 CLUTCH PIN 1 Y
35 C2-1033-A MOTOR SPACER 4 N
36 C2-1028-A 9109991Y ‘T’ BEARING HOUSING 1 Y
37 F4-0300-A 9109984R GEAR 25T IM 6ID 1 Y
38 G1-0258-A 9109992Z SEALER SPRING 1 Y
39 182-494 9101032R WIRED REED SW (CLOSER COVER) 1 Y
40 C2-1032-A 9110016Z BRAKE BEARING HOLDER 1 Y
4.1 - Chassis Drive Side (Front)
Page 4-3
Maximailer HD Service Manual Exploded Views Issue 3 Sept 2010

Fixings
Item Part No. Description Qty. Spares
50 E2-0839-A SCREW M3 x 6 TORX PAN HD 2
51 E2651A SCREW M3 x 6 PAN HD 6
52 E2684A SCREW M3 x 14 CAP HD 1
53 E2782A SCREW 3mm PLAS-TECH 30 3
54 E2-0836-A SCREW M4 x 6 TORX PAN HD 2
55 E2826A SCREW M4 x 8 TORX PAN HD 4
56 E2507A SCREW M4 x 10 CAP HD 2
57 E2523A SCREW M5 x 20 CAP HD 2
58 E4-0078-A 3mm SCHNORR WASHER 6
59 E4011A M4 WASHER 6 SEE FIXING KIT FOR THIS ASSEMBLY
60 E3501A M5 FULL NUT 2 A0-0541-A (9110009S)
61 E5126A 3 DIA x 8 GROOVED PIN 3 NOTE: FIXINGS ARE NOT AVAILABLE
62 E5103A 3 DIA x 10 DOWEL PIN 3 INDIVIDUALLY.
63 E5086A 3 DIA x 16 DOWEL PIN 6
64 E5073A 9.5mm ‘E’ CLIP 3
65 E5092A 12mm ‘E’CLIP 6
66 E0475A WAVED WASHER 10.5 ID 3
67 E0367A WAVED WASHER 23 ID 4
68 169-145 PLASTIC RIVET 3.5mm 2.0 - 3.0 GRIP 4
69 E0425A WASHER 10.2 x 17 x 2 1
70 E4033A WASHER WAVED 8.8 ID 1
71 E5110A 2.5 DIA x 16 DOWEL PIN 1
72 E2604A SCREW M3 x 10 CHEESE HD 2
73 E3557A M3 NYLOC NUT 2

Spares Assemblies

SA1 A0-0553-A 9110050K LENZE CLUTCH ASSY A/R


SA2 A0-0554-A 9110051L CLOSER REVERSE BRAKE ASSY A/R
SA3 A0-0555-A 9110052M LENZE CLUTCH ASSY 30T A/R

4.1 - Chassis Drive Side (Front)


Page 4-4
Maximailer HD Service Manual Exploded Views Issue 4 Mar 2012

Note: Belt F5112A (Item 34) is also shown on


Motor Assy. A2-1056-A see (Section 4.15)

4.2 - Chassis Drive Side (Rear) Page 4-5


Maximailer HD Service Manual Exploded Views Issue 4 Jan 2011

Item Part No. Description Qty. Spares


1 179-109 9108382X COLLATE ENTRY BRAKE 1 Y
1a 179-109 9108382X INPUT CONVEYOR BRAKE 1 Y
2 180-759 9100744R PCB SPLITTER 5SEN 5SOL H/D (No.2) 1 Y
2a 180-759 9100744R PCB SPLITTER 5SEN 5SOL H/D (No.3) 1 Y
3 181-128 COLL. POCKET ENTRY SLOW CLUTCH 1 N (See Spares Assy 1)
4 181-1600 9109569J COLL. POCKET BACKSTOP SHORT SOL. 1 Y
4a 181-1600 9109569J COLL. POCKET BACKSTOP LONG SOL. 1 Y
5 A2-1302-A 9109994B I/P CONV STUB BRG ASSY 1 Y
6 B2-1203-A HEAD SIDE PLATE DRIVES 1 N
7 B2-1148-A PRIMARY DRIVE PLATE 1 N
8 B2-1198-A CLUTCH LOCATOR SP SH 1 N
9 B2-1260-A BACKSTOP SOL BRKT DRIVES 2 N
10 B2-1264-A DUAL SOLENOID BRACKET 1 N
11 C2-1038-A CONVEYOR BEARING HOUSING 1 N
12 C3-0681-A 9109970B IDLER POST 2 Y
13 C3-0682-A 9109971C COMPOUND IDLER POST 1 Y
14 C2-1024-A CLUTCH PLATE STANDARD 1 N (See Spares Assy 1)
15 C2-1029-A 9109975G GEAR SPACER 3 Y
16 C2-1027-A CLUTCH SPACER 1 N (See Spares Assy 1)
17 C4-0515-A PLATE POST 2 N
18 C4-0517-A 911000IJ PRIMARY DRIVE SHAFT 1 Y
19 C4-0519-A 9110002K CONVEYOR DRIVE STUB 1 Y
20 F4-0292-A 9109977J GEAR 48T 1M 10ID 2 Y
21 F4-0293-A 9109978K GEAR 40T 1M IDLER 1 Y
22 F4-0294-A 9109979L GEAR 40T 1M 10ID 3 Y
23 F4-0295-A 9109980M GEAR 48T IM IDLER 2 Y
24 F4-0298-A 9109993A GEAR 30T 1M 10ID 1 Y
25 F4-0299-A 9109983Q GEAR 25T 1M 10ID 1 Y
26 F4-0302-A 9109986T GEAR 25/48T 1 Y
27 F1404A 9107011U PULLEY 104T S2M M/DRIVE 1 Y
28 E1-0138-A 9109987U BEARING FL 10 x 22 x 6 A/R Y
29 E1-0139-A 9110003L BEARING FL 10 x 19 x 8 A/R Y
30 E1061A 9103826B BEARING BALL 8 x 16 x 5 A/R Y
31 G0167A 9105600Z EC30 CLUTCH PIN 1 Y
32 R2874A BRAKE BRACKET 1 N
33 E1078A 9103835L BEARING FL 8 x 22 x 7 A/R Y
34 F5112A 9104493W BELT 100-S2M-280 1 Y

4.2 - Chassis Drive Side (Rear)


Page 4-6
Maximailer HD Service Manual Exploded Views Issue 3 Sept 2010

Fixings
Item Part No. Description Qty. Spares
50 E2651A SCREW M3 x 6 PAN HD 3
51 E2-0836-A SCREW M4 x 6 TORX PAN HD 2
52 E2826A SCREW M4 x 8 TORX PAN HD 2
53 E2507A SCREW M4 x 10 CAP HD 2
54 E4-0078-A 3mm SCHNORR WASHER 3
55 E3505A M4 NYLOC NUT 4
56 E5103A 3 DIA x 10 DOWEL PIN 3 SEE FIXING KIT FOR THIS ASSEMBLY
57 E5071A 3 DIA x 14 DOWEL PIN 1 A0-0541-A (9110009S)
58 E5086A 3 DIA x 16 DOWEL PIN 4 NOTE: FIXINGS ARE NOT AVAILABLE
59 E5073A 9.5mm ‘E’ CLIP 2 INDIVIDUALLY.
60 E5092A 12mm ‘E’CLIP 4
61 E0475A WAVED WASHER 10.5 ID 2
62 E0367A WAVED WASHER 23 ID 4
63 E4033A WAVED WASHER 8.8ID 1
64 E2834A SCREW M4 x 10 TORX CSK HD 2

Spares Assemblies

SA1 A0-0553-A 9110050K LENZE CLUTCH ASSY A/R

4.2 - Chassis Drive Side (Rear)


Page 4-7
Maximailer HD Service Manual Exploded Views Issue 4 Aug 2011

4.3 - Chassis Operator Side


Page 4-8
Maximailer HD Service Manual Exploded Views Issue 4 Nov 2011

Item Part No. Description Qty. Spares

1 179-109 9108382X INPUT CONVEYOR CLUTCH 1 Y


2 179-110 9108383Y COLLATE ENTRY FAST CLUTCH 2 Y
3 181-128 CLOSER REVERSE DRIVE CLUTCH 1 N (See Spares Assy 1)
4 181-129 INSERT PAWL TRACK DRIVE BRAKE 1 N (See Spares Assy 2)
5 180-720/7 9100723U PCB ASSY AM4 PROCESSOR 1 Y
6 180-8300 9108643U PCB C4 EXPANSION 1 Y
7 180-8360 9109914T PCB ASSY C4 CONTROL MK2 1 Y
8 180-702 9100715L PCB ENV. WETTER 1 Y
9 180-759 9100744R PCB SPLITTER (No.1) 1 Y
10 180-8320 9109590F PCB MAXI DONGLE 1 Y
11 181-1600 9109569J COLL. POCKET BACKSTOP EXT. LNG. SOL. 1 Y
12 125-432 9100213N TUBE CLEAR FOR PERI/PMP A/R Y
13 B2-1263-A BACKSTOP SOLINOID BKT. OPERATOR 1 N
14 B2-1291-A COVER PIVOT BKT. LH 1 N
15 B2-1293-A SCISSOR STAY 1 2 N
16 B2-1294-A SCISSOR STAY 2 RH 1 N
17 B2-1295-A SCISSOR STAY 2 LH 1 N
18 B2-1313-A COVER PIVOT BKT RH 1 N
19 B2-1853-A WETTER BRAKE BRACKET 1 N
20 B3-1230-A GEAR SHIELD 1 N
21 B3-1232-A FLANGE PLATE 1 N
22 B4-0447-A WETTER PIPE BKT. ASSEMBLY 1 N
23 C2-1024-A 9109565E CLUTCH PLATE STANDARD 2 Y
24 C2-1025-A CLUTCH PLATE 30T 1 N
25 C2-1027-A CLUTCH SPACER 2 N (See Spares Assy 1 & 2)
26 C2-1029-A 9109975G GEAR SPACER 3 Y
27 C2-1030-A 9110015Y BRAKE SPACER 16mm 2 Y
28 C2-1032-A BRAKE BEARING HOLDER 1 N (See Spares Assy 2)
29 A2-1489-A CLAM. PIVOT POST OP. 2 N
30 C2-1107-A 9110017A SPRING ADJUST CAM 2 Y
31 C2-1178-E 9110018B BRAKE KNOB 1 Y
32 G4-0149-A FOOT SPIGOT 3 N
33 C3-0681-A 9109970B IDLER POST 2 Y
34 C3-0688-A 9110019C WETTER FUNNEL 1 Y
35 C3-0697-A 9110020D STAY SPACER 2 Y
36 C4-0544-A 9110021E LL SENSOR BLOCK 1 Y
37 C8078A 9105500V RUBBER FOOT 3 Y
38 D1077A 9105874K MOULDED PAPER EJECT KNOB 1 Y
39 E0367A 9103789N WASHER WAVED 23mm I/D 8 Y
40 E0425A 9110007Q WASHER 10.2 x 17 x 2 1 Y
41 E0475A 9103795U WAVED WASHER EPL5 4 Y

4.3 - Chassis Operator Side Page 4-9


Maximailer HD Service Manual Exploded Views Issue 5 Aug 2011

Item Part No. Description Qty. Spares


42 E0-0597-A 9109988V KEY 2mm SQ X101g RAD ENDS 1 Y
43 E1-0138-A 9109987U BEARING BALL FL 10x22x6 15 Y
44 E1061A 9103826B BEARING BALL 8x16x5 4 Y
45 E0291A 9105793A FOOT PUSH-IN 2 Y
46 E0-0602-A 9110022F PVC TUBE 8mm I/D 11mm O/D A/R Y
47 F4-0292-A 9109977J GEAR 48T 1M 1OID 3 Y
48 F4-0293-A 9109978K GEAR 40T 1M IDLER 4 Y
49 F4-0296-A 9109981N GEAR 30T 1M CLUTCH 1 Y
50 F4-0299-A 9109983Q GEAR 25T 1M 1OID 1 Y
51 G0167A 9105600Z CLUTCH PIN 3 Y
52 G1-0278-A 9110023G SPRING TORSION LH 1 Y
53 G1-0279-A 9110024H SPRING TORSION RH 1 Y
54 G6168A 9104921S SHIM CLUTCH 1 Y
55 P2247A 9105998P MODULE LOCATION SPIGOT 1 Y
56 B2-1155-A CONVEYOR CLUTCH BRACKET 2 N
57 B2-1204-A HEAD SIDE PLATE OP 1 N
58 182-417 9105287Y REED SW SML SWSM 1 Y
59 182-418 9105294F REED SW 3WHH (UL) 1 Y
60 181-0890 MOTOR PUMP W/D 24V 1 Y
61 A2-1490-A CONVEYOR PIVOT POST 1 N
Fixings
70 E2651A SCREW M3 x 6 PAN HD 3
71 E2-0839-A SCREW M3 x 6 TORX PAN HD 2
72 E2-0836-A SCREW M4 x 6 TORX PAN HD 8
73 E2829A SCREW M4 x 8 TORX PAN HD T/T 8
74 E2826A SCREW M4 x 8 TORX PAN HD 4
75 E2507A SCREW M4 x 10 CAP HD 2
76 E2809A SCREW M5 x 20 POZI PAN HD T/T 3
77 E3505A M4 NYLOC NUT 4 SEE FIXING KIT FOR THIS ASSEMBLY
78 E4048A M4 WASHER FORM ‘C’ 8 A0-0542-A (9110025J)
79 E4-0078-A M3 SCHNORR WASHER 3 NOTE: FIXINGS ARE NOT AVAILABLE
80 E5086A 3 DIA x 16 DOWEL PIN 4 INDIVIDUALLY.
81 E5103A 3 DIA x 10 DOWEL PIN 4
82 E5126A 3 DIA x 8 GROOVED PIN 2
83 E5092A 12mm ‘E’ CLIP 6
84 E2505A SCREW M4 x 6 SOCKET SET 2
85 E2559A SCREW M3 x 10 PAN HD 2
86 E3557A M3 NYLOC NUT 2
* ASSY. A2-1299-A IS SIMILAR TO SPARES
Spares Assemblies ASSY. SA2 EXCEPT FOR 1TEMS 31,42,54 &
SA1 A0-0555-A 9110052M LENZE CLUTCH ASSY 30T A/R 84 WHICH ARE NOT INCLUDED.
SA2 A0-0545-A* 9110027L INSERT PAWL TRACK BRAKE ASSY A/R
4.3 - Chassis Operator Side Page 4-10
Maximailer HD Service Manual Exploded Views Issue 4 Oct 2011

SENSORS
Item Description Ref.
S1 Envelope Flap RX 5.12
S2 Collate Pocket Input RX 5.12
S3 Collate Pocket Load RX 5.12
S4 Collate Pocket TX 5.12
S11 S5 Top Pawl RX 5.12
S6 Top Pawl TX 5.12
S7 Lower Pawl RX 5.12
S8 Lower Pawl TX 5.12
S9 Envelope Seal RX 5.12
S10 Envelope Seal TX 5.12
S11 Wetter Output RX 5.12
S12 Wetter Output TX 5.12
S4 S12 S13 Closer Output (reflective) 5.12
S9

S3
S13
S5 S6

S1

S10

S8

S7

S2

4.4 - Chassis Assembly


Page 4-11
Maximailer HD Service Manual Exploded Views Issue 3 Aug 2011

Item Part No. Description Qty. Spares


1 B2-1195-A WETTER BRIDGE 1 N
2 B2-1199-A INPUT BRIDGE 1 N
3 B2-1200-A OUTPUT BRIDGE 1 N
4 B2-1203-A HEAD SIDE PLATE DRIVES 1 N
5 B2-1204-A HEAD SIDE PLATE OPS 1 N
6 B2-1216-A MAIN BRIDGE 1 N
7 B2-1242-A WIRE PROTECTOR BRACKET 1 N
8 B2-1941-A SEAL PLATE 1 N
9 B2-1734-A OUTPUT GUIDE BKT 1 N
10 B3-1090-A WETTER SENSOR BKT 1 N
11 B3-1098-A PIVOTING COLLATE PANEL 1 N
12 B3-1106-A 9110028M CHAIN GUIDE INNER DRIVES 1 Y
13 B3-1115-A 9110029N CHAIN GUIDE INNER OP 1 Y
14 B3-1116-A CHAIN GUIDE OUTER DRIVES 1 N
15 B3-1117-A CHAIN GUIDE OUTER OP 1 N
16 B3-1121-A COLLATE POCKET SENSOR BKT (PART OF 184-2270) 1 N
17 B3-1123-A SPLIT SHAFT COVER 2 N
18 B3-1124-A COLLATE POCKET GUIDE OP 1 N
19 B3-1125-A COLLATE POCKET GUIDE DR 1 N
20 B3-1140-A HEAD UNDER COVER 1 N
21 B3-1232-A FLANGE PLATE 1 N
22 B3-1242-A INSERT PANEL CENTRE 1 N
23 B3-1245-A INSERTION PANEL OP 1 N
24 B3-1246-A INSERTION PANEL DRIVES 1 N
25 B3-1346-A OUTPUT GUIDE 1 N
26 B7696A SIDE GUIDE BRACKET 2 N
27 B3-1122-A SPRING RETAINING PLATE 2 N
28 G1-0261-A 9110030P COLLATE PANEL SPRING 2 Y
29 G6-0218-A 9110031Q CHAIN TAPE 2 Y
30 B0-0203-A 9110032R NARROW INSERT GUIDE 2 Y
31 P2190A 9110033S GUIDE SPIGOT 2 Y
32 B3-1088-A OUTPUT SENSOR BRACKET 1 N
33 B3-1055-A CONVEYOR SENSOR BRACKET 1 N
34 B2-1253-A RIBBON PROTECTOR BRACKET 1 N
35 B2-1256-A INSERTION SENSOR BRACKET (PART OF 184-2280) 1 N
36 B2-1259-A PAWL SENSOR BRACKET 1 N
37 C9278A SENSOR POST 106mm 1 N
38 180-760 PCB SPLITTER 3 SEN 4 SOL H/D (No.4) 1
39 E0291A 9115793A FOOT PUSH-IN 1 Y
40 B2-1197-A WETTER TANK CHANNEL 1 N

4.4 - Chassis Assembly Page 4-12


Maximailer HD Service Manual Exploded Views Issue 2 Feb 2012

Item Part No. Description Qty. Spares


Fixings
50 E2-0848-A SCREW M3 x 6 TORX CSK HD 2
51 E2-0842-A SCREW M3 x 8 TORX CSK HD S/ST 6
52 E2-0836-A SCREW M4 x 6 TORX PAN HD S/ST 4
53 E2826A SCREW M4 x 8 TORX PAN HD 4 SEE FIXING KIT FOR THIS ASSEMBLY
54 E2829A SCREW M4 x 8 TORX PAN HD T/T 6 A0-0543-A (9110036V)
55 E3557A M3 NYLOC NUT 4 NOTE: FIXINGS ARE NOT AVAILABLE
56 E3505A M4 NYLOC NUT INDIVIDUALLY.

4.4 - Chassis Assembly


Page 4-13
Maximailer HD Service Manual Exploded Views Issue 5 Feb 2012

4.5 - Shaft Locations Page 4-14


Maximailer HD Service Manual Exploded Views Issue 5 Feb 2012

Item Part No. Description Qty. Spares

1 C8-0206-A 9109564D LOWER SEAL ROLLER 48 DIA 1 y


2 C8-0207-A 9109579U LOWER SEAL ROLLER 25 DIA 1 y
3 A2-1305-A 9110038X WET O/P SHAFT UPPER ASSY 1 Y
4 C5-1022-A 9110039Y IDLER SHAFT 2 Y
5 A2-1306-A 9110040Z WET O/P SHAFT LOWER ASSY 1 Y
6 C5-1017-A 9110041A SPROCKET DRIVE SHAFT 1 Y
7 C5-1066-A 9109581W LOWER SPROCKET IDLE SHAFT 1 Y
8 C5-1020-A 9110042B SLOW DOWN SHAFT 1 Y
9 F3-0045-C 9110037W DRIVE SPROCKET 15T 2 Y
10 F3-0046-C 9110090B IDLE SPROCKET 15T 2 Y
11 F4-0299-A 9109983Q GEAR 25T 1M 10ID 1 Y
12 C5-1019-A PRESSURE WHEEL SHAFT 1 N
13 C5-1122-A OPENER INPUT SHAFT 1 N
14 D0-0062-A RUBBER WHEEL 40 DIA 2 N
15 D0-0063-A SOFT RUBBER WHEEL 40 DIA 2 N
16 F6023A 9106577S CHAIN 1/4” PITCH 83 LINKS 4* Y
17 F6-0054-A 9109567G PAWL CHAIN LINK 4* Y
18 C2-1064-A 9109566F CHAIN ROLLER 8* Y
19 B3-1340-A 9110320R INSERTION PAWL 4* Y

*Per Machine

30 E2834A SCREW M4 x 10 TORX CSK M/C 1


31 E5092A 12mm ‘E’ CLIP A/R
32 E5086A DOWEL PIN 3 DIA x 16LG 1
33 E5098A DOWEL PIN 3 DIA x 18LG 2


Spares Assembly

SA1 A0-0688-A 9112526P INSERTION PAWL ASSEMBLY A/R

4.5 - Shaft Locations


Page 4-15
Maximailer HD Service Manual Exploded Views Issue 5 Sep 2011

S5
S2

S3

S4

S1

SENSORS
Item Description Ref.
S1 Envelope Flap TX 5.12
S2 Envelope Feed TX 5.12
S3 Envelope Feed RX 5.12
S4 Envelope Deskew RX 5.12
S5 Envelope in Hopper 5.12
(Reflective)

4.6 - C4 Envelope Feeder Assy. - A2-1064-A (9110075L) Page 4-16


Maximailer HD Service Manual Exploded Views Issue 5 Sep 2011

Item Part No. Description Qty. Spares


1 179-109 9108383Y ENV. PICK UP CLUTCH 1 Y
2 179-109 9108382X ENV. UPPER DRIVE CLUTCH 1 Y
3 179-109 9108382X ENV. UPPER DRIVE BRAKE 1 Y
4 179-110 9108382X ENV. LOWER DRIVE CLUTCH 1 Y
5 179-109 9108382X ENV. LOWER DRIVE BRAKE 1 Y
6 180-759 9100744R PCB SPLITTER 5SEN 5SOL H/D (No.E4) 1 Y
7 A2-1065-A 9109900D C4 ENV SEPARATOR ASSY 1 Y
8 A2-1067-A 9110059U C4 ENV TRACTOR ASSY 1 Y
9 A2-1068-A 9110060V C4 ENV FEED SHAFT ASSY 1 Y
10 A2-1281-A 9110062X FLAP GRIP CLUTCH ASSY 1 Y
11 B0-0205-A 9110063Y SPRING PLATE 0.25mm 1 Y
12 B1-0937-A ENV INFEED BRIDGE ASSY 1 N
13 B1-0975-A FLAP GRIP BRIDGE (ASSY) 1 N
14 B2-2039-A ENVELOPE CLUTCH BRACKET 1 N
15 B2-1214-A ENVELOPE BRAKE PLATE 1 N
16 B2-1217-A ENV FEED SIDE PLATE DR 1 N
17 B2-1218-A ENV FEED SIDE PLATE OP 1 N
18 B2-1219-A ENVELOPE FEED BRIDGE UPPER 1 N
19 B2-1224-A ENV FEED BRIDGE LOWER 1 N
20 B2-1225-A UPPER ENVELOPE GUIDE 1 N
21 B2-1229-A MOUNT PLATE OPERATOR 1 N
22 B2-1230-A MOUNT PLATE DRIVES 1 N
23 B2-1240-A SENSOR BRACKET 1 N
24 B2-1270-A SENSOR BRACKET 1 N
25 B2-1296-A COVER LATCH BRACKET 1 N
26 B2-1603-A ENVELOPE FLAP PLATE 1 N
27 B2-1630-A INSERT GUIDE OPERATOR 1 N
28 B2-1631-A INSERT GUIDE DRIVES 1 N
29 B3-1237-A REFLECTIVE SENSOR BRACKET 1 N
30 C2-1024-A 9109565E CLUTCH PLATE STANDARD 3 Y
31 C2-1026-A 9109973E GEAR CONNECTOR 1 Y
32 C2-1029-A 9109975G GEAR SPACER 6 Y
33 C2-1056-A CLAM GUIDE SPIGOT 2 N
34 C2-1057-A CLAM LATCH SPIGOT 2 N
35 C3-0680-A BEARING STUB HOUSING 1 N
36 C2-1199-A IDLER POST SHORT 1 N
37 C3-0682-A 9109971C COMPOUND IDLER POST 2 Y
38 C4-0516-A 9110064Z ENV DRIVE STUB 1 Y
39 C4-0522-A FLAP GRIP ROLLER BAR 1 N
40 180-759 9100744R PCB SPLITTER 5SEN 5SOL H/D (No.5) 1 Y
41 C5-1122-A OPENER INPUT SHAFT 2 N
42 C5-1194-A ENVELOPE STOP SHAFT 2 N
43 D0-0062-A RUBBER WHEEL 40 DIA FOR 10mm DIA SHAFT 10 N (See Spares Assy 2, 3, 4 & 5)
44 E0367A 9103789N WASHER WAVED 23mm ID EMOEPL20 8 Y
4.6 - C4 Envelope Feeder Assy. - A2-1064-A (9110075L) Page 4-17
Maximailer HD Service Manual Exploded Views Issue 4 Sep 2011

Item Part No. Description Qty. Spares


45 E0475A 9103795U WAVED WASHER EPL5 9 Y
46 E1-0138-A 9109987U BEARING BALL FL 10x22x6 21 Y
47 E1-0139-A BEARING BALL FL 10x19x5 2 N (See Spares Assy 1)
48 E1-0140-A 9110065A BEARING NEEDLE 4 IDx8x8 4 Y
49 E1054A 9103819U BEARING BALL 12x28x8mm 1 Y
50 E1061A 9103826B BEARING BALL 8x16x5mm 4 Y
51 E1078A 9103835L BEARING FL 8x22x7mm 1 Y
52 E4-0074-A 9110066B WASHER 4.06x7.24x0.81 4 Y
53 F4-0293-A 9109978K GEAR 40T 1M IDLER 7 Y
54 F4-0295-A 9109980M GEAR 48T 1M IDLER 1 Y
55 F4-0299-A 9109983Q GEAR 25T 1M 10ID 3 Y
56 F4-0302-A 9109986T GEAR 25/48T 1M 1 Y
57 F4-0307-A 9110067C GEAR 30T 1M IDLER 1 Y
58 G0167A 91056000Z EC30 CLUTCH PIN 5 Y
59 G4051A BEARING HOUSING 12mm MOD 1 N
60 G4092A BRIDGE CLAMP 18 N
61 G6-0220-A 9109561A GUIDE TAPE UPPER 2 Y
62 G6-0221-A 9109576R GUIDE TAPE LOWER 2 Y
63 G6-0223-A 9109562B FLAP GUIDE SHIM 2 Y
64 P2001A GUIDE SPIGOT 2 N
65 B3-1247-A RESTRICTOR ARM 1 N (See Spares Assy 6)
66 D0051A SEPARATOR PAD 45-55 1 N (See Spares Assy 6)
67 E0448A 3M VHB TAPE 9469 x 14mm A/R N (See Spares Assy 6)
68 C5-1051-A CHASSIS TIE-BAR 1 N
69 C3-0758-A IDLER POST SOLO LONG 3 N

Fixings
SEE FIXING KIT FOR THIS ASSEMBLY
80 E2-0839-A SCREW M3 x 6 TORX PAN HD 2 A0-0546-A (9110043C)
81 E2826A SCREW M4 x 8 TORX PAN HD 8 NOTE: FIXINGS ARE NOT AVAILABLE
82 E2834A SCREW M4 x 10 TORX CSK HD 2 INDIVIDUALLY.
83 E2827A SCREW M4 x 12 TORX PAN HD 8 Spares Assemblies
84 E4009A M3 WASHER 6 SA1 ENV P/UP STUB BRG ASSY A2-1303-A
85 E4011A M4 WASHER 8 (9110070F) QTY. A/R
86 E3557A M3 NYLOC NUT 4 SA2 ENV FEED I/P SHAFT ASSY A2-1307-A
87 E3505A M4 NYLOC NUT 4
(9110071G) QTY. A/R
88 E3502A M4 FULL NUT 4
SA3 ENV OPENER I/P SHAFT ASSY A2-1308-A
89 E5126A 3 DIA x 8 GROOVED PIN 6
(9110072H) QTY. A/R
90 E5103A 3 DIA x 10 DOWEL PIN 6
91 E5086A 3 DIA x 16 DOWEL PIN 6 SA4 ENV OPENER O/P SHAFT ASSY A2-1309-A
92 E5081A 4.5mm ‘E’ CLIP 4 (9110073J) QTY. A/R
93 E5092A 12mm ‘E’CLIP 4 SA5 ENV FEED O/P SHAFT ASSY A2-1310-A
94 169-126 PLASTIC RIVET 3.5 DIA 1.2 - 2.1mm GRIP 4 (9110074K) QTY. A/R
95 E2-0836-A SCREW M4 x 6 TORX PAN HD 2 SA6 RESTRICTOR ARM ASSY A2-1380-A
96 E5073A 9.5mm ‘E’ CLIP 4 (9110322T) QTY. A/R

4.6 - C4 Envelope Feeder Assy. - A2-1064-A (9110075L) Page 4-18


Maximailer HD Service Manual Exploded Views Issue 3 Oct 2011

NOTE
BRIDGE CLAMPS G4092A (ITEM 19) WITH M4 x 12 TORX HD
SCREWS E2830A ( ITEM 34) ARE FITTED IN ALL LOCATIONS MARKED

4.7 - C4 Envelope Separator Assy. - A2-1065-A (9109900D) Page 4-19


Maximailer HD Service Manual Exploded Views Issue 2 Mar 2011

Item Part No. Description Qty. Spares

1 181-0850 9108955U WIRED MTR 179-802 2W SM 1 Y


2 B2-1465-A SEPARATOR SIDE PLATE 2 N
3 B2-1466-A SEPARATOR MOUNT BRACKET 1 N
4 B2-1792-A SEPARATOR BRIDGE 1 N
5 B3-1362-A SHIELD PROTECTOR PLATE 1 N
6 B4-0444-A 9109905J SEPARATOR ACTUATOR ASSY 1 Y
7 C2755A 9102934X DRIVE ECCENTRIC 1 Y
8 C2887A CLUTCH HOLDER 2 N
9 C3-0711-E SEPARATOR ADJUSTOR KNOB 1 N
10 C3420A INNER TIE BAR 1 N
11 C4269A SEPARATOR SHAFT 1 N
12 C5-1120-A SEPARATOR ADJUSTOR SHAFT 1 N
13 C6-0427-A SEPARATOR ADJUSTOR BLOCK 1 N
14 C8135A 9103513A SEPARATOR ROLLER 2 Y
15 E1068A 9103828D ROLLER CLUTCH 6x10x12mm 3 Y
16 E0062A 9103705A STEEL BALL 4mm DIA 1 Y
17 G1-0280-A 9109560Z SEPARATOR SHIELD 1 Y
18 G1046A 9104636V SPRING INDEX 1 Y
19 G4092A BRIDGE CLAMP 4 N
20 G6150A 9104817N WASHER 2 Y

Fixings

30 E2774A SCREW M2 x 6 POZI CSK HD 2


31 E2-0839-A SCREW M3 x 6 TORX PAN HD 2
32 E2505A SCREW M4 x 6 SKT SET 2
33 E2826A SCREW M4 x 8 TORX PAN HD 4
SEE FIXING KIT FOR THIS ASSEMBLY
34 E2830A SCREW M4 x 12 TORX PAN HD 2
A0-0550-A 9110047G
35 E2-0838-A SCREW M4 x 12 TORX CSK HD 2
NOTE: FIXINGS ARE NOT AVAILABLE
36 E2517A SCREW M5 x 10 SKT SET 1
INDIVIDUALLY.
37 E2-0874-A SCREW M5 x 10 TORX C’SK HD 2
38 E5079A 6mm ‘E’ CLIP 1
39 E5092A 12mm ‘E’ CLIP 1

Spares Assemblies

SA1 A0-0548-A 9110045E CLUTCH LOCATOR OP ASSY A/R


SA2 A0-0549-A 91100446 CLUTCH LOCATOR DR ASSY A/R
SA3 A0-0547-A 9110044D SEP ACTUATOR ASSY A/R

4.7 - C4 Envelope Separator Assy. - A2-1065-A (9109900D) Page 4-20


Maximailer HD Service Manual Exploded Views Issue 2 Mar 2010

SENSOR
Item Description Ref.
S1 Envelope Conveyor (Flag) 5.12

4.8 - C4 Envelope Tractor Assy. - A2-1067-A (9110059U) Page 4-21


Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

Item Part No. Description Qty. Spares


1 180-776 9100753 PCB SENSOR FLAG 1 Y
2 181-0810 9110054P MOTOR WIRED 179-802 0.2M SM 1 Y
3 B2-1473-A TRACTOR MOUNT BRACKET 1 N
4 B2-1548-A TRACTOR OVERGUIDE 1 N
5 B3-1241-A TRACTOR MOUNT PLATE 1 N
6 C2-1136-A 9110055Q TRACTOR PIVOT POST 1 Y
7 C3-0720-A TRACTOR MOTOR STAND-OFF 3 N
8 C4-0565-A TRACTOR BEARING SHAFT 1 N
9 C5-1070-A TRACTOR FEED SHAFT 1 N
10 C5-1146-A TRACTOR PIVOT SHAFT 1 N
11 C8194A 9103545J SLOTTED FEED WHEEL 2 Y
12 D1076A 9105521S T BEARING 6mm 10SQ 2 Y
13 E0367A 9103789N WASHER WAVED 23mm ID 2 Y
14 E1030A ROLLER CLUTCH 8x12x12mm 1 N (See Spares Assy 1)
15 E1061A 9103826B BEARING BALL 8x16x5mm 4 Y
16 E1078A 9103835L BEARING FL 8x22x7mm 2 Y
17 F4-0311-A 9110056R 16T TRACTOR DRIVE GEAR 1 Y
18 F4-0312-A 32T GEAR x 12mm BORE 1 N (See Spares Assy 1)
19 G1029A 9110058T SPRING D.D. 1 Y

Fixings

30 169-145 RIVET 3.5mm 2.0-3.0 GRIP 2


31 E2760A SCREW M2 x 5 POZI CSK HD 2
32 E2-0848-A SCREW M3 x 6 TORX CSK HD 2
33 E2518A SCREW M4 x 4 SKT SET 1
34 E2826A SCREW M4 x 8 TORX PAN HD 2 SEE FIXING KIT FOR THIS ASSEMBLY
35 E2-0857-A SCREW M4 x 25 TORX PAN HD 2 A0-0552-A 9110094J
36 E3502A M4 FULL NUT 2 NOTE: FIXINGS ARE NOT AVAILABLE
37 E3505A M4 NYLOC NUT 1 INDIVIDUALLY.
38 E5003A 7mm ‘E’ CLIP 2
39 E5073A 9.5mm ‘E’ CLIP 4
40 E5071A PIN DOWEL 3 DIA x 14 1

Spares Assemblies

SA1 A0-0551-A 9110048H 32T GEAR/ROLLER CLUTCH ASSY A/R

4.8 - C4 Envelope Tractor Assy. - A2-1067-A (9110059U)


Page 4-22
Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

4.9 - C4 Envelope Feed Shaft Assy. - A2-1068-A (9110060V) Page 4-23


Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

Item Part No. Description Qty. Spares


1 C2653A 9102919G ENVELOPE FEED BEARING 1 Y
2 C2655A 9102920H BEARING NYLON 2 Y
3 C5-1058-A ENVELOPE FEED SHAFT 1 N
4 C8-0209-A ENV FEED ROLLER 10mm DIA 8 N
5 E5078A PIN GROOVED S8 2.5x14 1 N
6 E5079A 9104139C CIRCLIP ‘E’ TYPE 6mm 1 Y
7 E5086A PIN DOWEL 3 DIA x 16(m6) SS 8 N
8 E5092A CIRCLIP ‘E’ TYPE 12mm 8 N
9 G1139A 9104698K SPRING RELEASE 1 Y

4.9 - C4 Envelope Feed Shaft Assy. - A2-1068-A (9110060V)


Page 4-24
Maximailer HD Service Manual Exploded Views Issue 4 Mar 2011

48

C
C 48
45
16
12
C
C
6
47
D
D
45
45

D
D K

47

7
11
45
J
K
H
H 16 54
20
54
26
4 47
J 36
50 35
3 54

(2) ENV. CONVEYOR BACKSTOP 50


A2-1200-A (SEE SECTION 4.11)
50 26
24 34
E 3
53 28
50
E 35
54 C
14 E 38 B
46 C
F

E
* 54
26
13 48 53 47
F F
5 15 23 D
54
E 26 10 D
C
54 C 49
E 49 18
27
J
F * 46
28 A
21
47
* F
D
26
51
10 D 37
B
F
8 49
J 50 18
H 50 23
H 54

36
22 * A
NOTE
49
1
BRIDGE CLAMPS G4092A WITH M4 x 12 TORX HD
SCREWS E2827A ARE FITTED IN ALL LOCATIONS MARKED* 21
25 G
17 26
55 51
19 37
57 30 32 54
G 27 46
25 47
47 29
17
56 33 52 47
32 9
55 31

4.10 - C4 Envelope Conveyor Assy. - A2-1066-A (9110088Z) Page 4-25


Maximailer HD Service Manual Exploded Views Issue 2 May 2010

Item Part No. Description Qty. Spares


1 181-0870 9109558X MTR W/D 179-056 2WSM (H1)J13 1 Y
2 A2-1200-A 9110080R ENV CONVEYOR BACKSTOP 1 Y
3 B2-1209-A BELT TENSIONER BRACKET 2 N
4 B2-1212-A ENV CONVEYOR CHASSIS 1 N
5 B2-1220-A CONVEYOR BRIDGE 1 N
6 B2-1221-A SIDE GUIDE OPERATOR 1 N
7 B2-1222-A SIDE GUIDE DRIVES 1 N
8 B2-1469-A CONV STRENGTHENING BKT 1 N
9 B2-1470-A GEAR SUPPORT PLATE 1 N
10 B2-1682-A SIDE GUIDE LOCATOR BRACKET 4 N
11 B3-1236-S CONVEYOR UNDER COVER 1 N
12 B3-1238-S CONVEYOR END CAP 1 N
13 B3-1322-S CONVEYOR INFILL PLATE OP 1 N
14 B3-1323-S CONVEYOR INFILL PLATE DR 1 N
15 C2-1053-V 9110081S SIDE GUIDE ADJUSTOR KNOB 1 Y
16 C3-0689-A 9110082T SEALER LATCH POST 2 Y
17 C3-0710-A 9110083U CONVEYOR GEAR POST 2 Y
18 C3-0741-A SCROLL SCREW 4 N
19 C4-0534-A 9110084V ENV CONV DRIVE ROLLER 2 Y
20 C4-0535-A 9110085W ENV CONV IDLER ROLLER 2 Y
21 C4-0563-A SIDE GUIDE SLIDER 4 N
22 C5-1053-A CONVEYOR DRIVE SHAFT 1 N
23 C5-1055-A SIDE GUIDE ADJUST SHAFT 2 N
24 C5-1056-A CONVEYOR TENSIONER SHAFT 2 N
25 D0007A 9103591G TYRE JOGGLER 4 Y
26 D1040A 9103641J T BEARING 8mm 12SQ 8 Y
27 E1102A 9103841S BEARING FL 8x19x6mm F698ZZ 2 Y
28 F1-0445-A 9109822X PULLEY 12 XL x 8mm 2 Y
29 F4-0306-A 9110086X GEAR 12 TOOTH CONVEYOR 1 Y
30 F4150A 9104398X GEAR 40Tx8mm 1.0M 1 Y
31 F4151A 9104399Y GEAR 48Tx8mm 1.0M 1 Y
32 F4152A 9104400Z GEAR 25Tx8mm 1.0M 2 Y
33 F4278A 9106542F GEAR 20T 1M x 6mm 1 Y
34 F5007A 9104435L BELT 200XL 037 1 Y
35 G1117A 9104686X SPRING HEAVY PRESSURE 4 Y
36 G5074A 9107152W BELT CONVEYOR(HAT-5E) 1165x60 1 Y
37 G6002A WASHER 4 N
38 P2520A M4 LOCK CAP 1 N

4.10 - C4 Envelope Conveyor Assy. - A2-1066-A (9110088Z) Page 4-26


Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

Item Part No. Description Qty. Spares

Fixings

45 E2-0838-A SCREW M4X12MM TORX CSK TAPTITE 2


46 E2505A SCREW M4 SOCKET SETx6 KCP 1
47 E2826A SCREW M4x8 TORX PAN HD 6
48 E2834A SCREW M4x10 TORX CSUNK HD 3
49 E3501A NUT M5 FULL BZP 2
50 E3505A NUT M4 NYLOC DIN 985 BZP 4 SEE FIXING KIT FOR THIS ASSEMBLY
51 E4033A WASHER WAVED 8.89ID12.5OD0.18THICK 2 A0-0558-A (9110087Y)
52 E5003A CIRCLIP 7mm 1 NOTE: FIXINGS ARE NOT AVAILABLE
53 E5071A PIN DOWEL 3 DIA x 14(m6) 1 INDIVIDUALLY
54 E5073A CIRCLIP 9.5mm ‘E’ TYPE 3
55 E5074A PIN DOWEL 3 DIA x 8(m6) 2
56 E5123A PIN DOWEL 2.5 DIA x 10 m6 1
57 E5111A PIN DOWEL 3 DIA x 30 m6 1

4.10 - C4 Envelope Conveyor Assy. - A2-1066-A (9110088Z)


Page 4-27
Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

10
7
18

8
20 21
9 1 17 19
12
15

20

A
A 16
9
3
16
4 11 B
6 B
17
5

4.11 - C4 Envelope Conveyor Backstop. - A2-1200-A (9110080R)


Page 4-28
Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

Item Part No. Description Qty. Spares


1 B0145A 9105556D SPRING GUIDE DAMPER 2 Y
2 B3-1281-A 9110077N ENVELOPE BACKSTOP 1 Y
3 B3-1317-A BACKSTOP SUPPORT BRACKET 1 N
4 B3-1318-S ENVELOPE BACK REST (OP) 1 N
5 B3-1319-S ENVELOPE BACK REST (DR) 1 N
6 C2-1155-A 9110078P BACKSTOP SLIDER SPIGOT 4 Y
7 C5-1052-A BACKSTOP SHAFT 1 N
8 C8098A 9103501N ROLLER ENVELOPE FEED 2 Y
9 E0330A 9105861W HANDWHEEL M5 MALE 2 Y
10 G1166A 9105852M RETAINING SPRING 2 Y
11 G6176A 9105814X SIDE GUIDE TAPE 4 Y
12 R2392C 9105896H SPACER PLATE 2 Y

Fixings

15 E2-0839-A SCREW M3x6MM TORX PAN HD 1


16 E2826A SCREW M4x8 TORX PAN HD 2
17 E3502A NUT M4 FULL BZP 2 SEE FIXING KIT FOR THIS ASSEMBLY
18 E5071A PIN DOWEL 3 DIA x 14(m6) 1 A0-0557-A (9110079Q)
19 E5073A CIRCLIP 9.5mm ‘E’ TYPE 2 NOTE: FIXINGS ARE NOT AVAILABLE
20 E4012A M5 WASHER 2 INDIVIDUALLY.
21 E4011A M4 WASHER 2

4.11 - C4 Envelope Conveyor Backstop. - A2-1200-A (9110080R)


Page 4-29
Maximailer HD Service Manual Exploded Views Issue 2 Mar 2010

SENSORS
Item Description Ref.
S1 Collate Pocket RX 5.12
S2 Envelope Deskew TX 5.12
S3 Collate Pocket Load TX 5.12

NOTE
BRIDGE CLAMPS G4092A (ITEM 60) WITH M4 x 12 TORX HD
SCREWS E2830A (ITEM 53) ARE FITTED IN ALL LOCATIONS MARKED*

4.12 - C4 Collate Pocket Clam Assy. - A2-1069-A (9110098K) Page 4-30


Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

Item Part No. Description Qty. Spares


1 169-128 9108602B RIVET 4mm 3.5-4.5mm GRIP 2 Y
2 181-1630 9109557W WIRED 24V BLOWER SM 1 Y
3 A2-1311-A 9110091C INPUT SHAFT ASSY CLAM 1 Y
4 A2-1312-A 9110092D OPENER I/P SHAFT ASSY CL 1 Y
5 A2-1313-A 9110093E OPENER O/P SHAFT ASSY CL 1 Y
6 B0-0206-A 9110094F COLLATE OVERGUIDE SPRING 2 Y
7 B1-0936-A COLLATE CLAM ROOF ASSY 1 N
8 B1-0982-A 9110095G OPENER (ASSEMBLY) C4 1 Y
9 B2-1205-A COLLATE CLAM SIDE PL OP 1 N
10 B2-1206-A COLLATE CLAM SIDE PL DR 1 N
11 B2-1215-A COLLATE CLAM BRIDGE UPR 1 N
12 B2-1472-A LATCH PLATE 2 N
13 B3-1093-F COLLATE CLAM COVER 1 N
14 B3-1100-A COLLATE SENSOR BRACKET 1 N
15 B3-1103-A 9110096H COLLATE CENTRAL OVERGUIDE 1 Y
16 B3-1329-A GUIDE LATCH BRACKET 1 N
17 B3-1330-A BLOWER MOUNT BRACKET 1 N
18 C2-1028-A 9109991Y T BEARING HOUSING 6 Y
19 C4-0527-A OVERGUIDE PIVOT SHAFT 1 N
20 C4-0568-A OPENER PIVOT OPERATOR C4 1 N
21 C4-0569-A OPENER PIVOT DRIVES C4 1 N
22 C5-1046-V COLLATE CLAM HANDLE 1 N
23 C5-1060-A COLLATE LATCH SHAFT 1 N
24 D0054A 9105522T CAP RECT VINYL 23x13x1.5 1 Y
25 E0227A 9103755C M3 STUD CAP 2 Y
26 E0375A 9105804M BUSH SNAP 12.7IDx6.4L 1 Y
27 E1107A 9105507C BEARING BALL 6x13x5 12 Y
28 E1108A 9105506B BEARING FLANGED 6x13x5 2 Y
29 G1025A 9104625J SPRING PRESSURE 6 Y
30 G1186A 9106068F CONVEYOR LATCH SPRING 1 Y
31 G1189A 9106087G LATCH SPRING LH 1 Y
32 G6028A 9104879Y SHIM BRAKE 4 Y
33 G6200A 9105820D GUIDE SHIM 1 Y
34 P2001A GUIDE SPIGOT 2 N
35 P2057A 9105696Z LATCH CLAMP SPIGOT 2 Y

4.12 - C4 Collate Pocket Clam Assy. - A2-1069-A (9110098K)


Page 4-31
Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

Item Part No. Description Qty. Spares

Fixings

50 E2826A SCREW M4x8 TORX PAN HD 8


51 E2-0848-A SCREW M3x6 TORX CSK HD 2
52 E2827A SCREW M4x12 TORX PAN HD 2
53 E2830A SCREW M4x12 TORX PAN HD T/T 4
54 E2834A SCREW M4x10 TORX CSK HD 1 SEE FIXING KIT FOR THIS ASSEMBLY
55 E3505A NUT M4 NYLOC 4 A0-0559-A (9110097J)
56 E3507A NUT M4 HALF 2 NOTE: FIXINGS ARE NOT AVAILABLE
57 E5003A CIRCLIP 7mm ‘E’ TYPE 4 INDIVIDUALLY.
58 E5073A CIRCLIP 9.5mm ‘E’ TYPE 2
59 E5081A CIRCLIP 4.5 ‘E’ TYPE 2
60 G4092A BRIDGE CLAMP A/R

4.12 - C4 Collate Pocket Clam Assy. - A2-1069-A (9110098K)


Page 4-32
Maximailer HD Service Manual Exploded Views Issue 7 Mar 2012

35 SEE NOTE 2
59
45
SENSORS 36
Item Description Ref. 55
28
S1 Collate Pocket Input TX 5.12
27
37
44 55

36
39
56 56
24
24

S1 36 3
15
56 58 33
26 24 29
20 10
52 29
55 33
34 24
19 56
28
1 55 55
52 22 28 44
11
19 25
53 28
55 55
28 39 24
11 56
54 25
14 28
SA1 50 55
4 24
56 7 56
41
38 16
51
SA2 C2-1034-A (x6)
50
F1-0461-A (x6) BELT BOBBIN
PULLEY 25T XL (ITEM 10)
17 2
(ITEM 34)

57 42
30 C2-1036-A (x6)
9 52
30 CONVEYOR
32 40 F5119A (x1.5) WHEEL
53 18 56 BELT SET (ITEM 11)
56 14 140XL O37
8 5 53 (ITEM 36)
56
31
56

21 38 NOTES C2-1036-A (x6)


1) BRIDGE CLAMPS G4092A (ITEM 43) WITH M4 x 12 TORX HD CONVEYOR
23
SCREWS E2827A ARE FITTED IN ALL LOCATIONS MARKED WHEEL
32
30 (ITEM 11)
9
2) ITEMS 35 & 59 MUST BE ORDERED TOGETHER
30
57

4.13 - C4 Head Input Conveyor Upper A2-1054-A (9110107U) Page 4-33


Maximailer HD Service Manual Exploded Views Issue 4 Feb 2012

Item Part No. Description Qty. Spares


1 B2-1151-A CONVEYOR SIDE PLATE DR 1 N
2 B2-1152-A CONVEYOR SIDE PLATE OP 1 N
3 B2-1154-A BOBBIN BRACKET 6 N
4 B2-1156-A LATCH CONVEYOR DRIVE 1 N
5 B2-1157-A LATCH CONVEYOR OP 1 N
6 N/R
7 B2-1161-A CONVEYOR BRIDGE 1 N
8 B9313A CENTRAL OVERGUIDE 4 N (See Spares Assy 2)
9 C2-1028-A T BEARING HOUSING 2 N (See Spares Assy 1)
10 C2-1034-A 9110099L BELT BOBBIN 6 Y
11 C2-1036-A 9110100M CONVEYOR WHEEL 12 Y
12 N/R
13 N/R
14 C2751A WASHER ‘D’ SHAFT 2 N
15 C3-0685-A 9110101N IDLER PIN 6 Y
16 C5-1038-V LATCH HANDLE 1 N
17 C5-1042-A CONVEYOR LATCH SHAFT 1 N
18 C5-1043-A OVERGUIDE PIVOT SHAFT 1 N
19 C5-1045-A IDLER PULLEY SHAFT 2 N
20 C5-1312-A UPPER CONV. DRIVE SHAFT 10mm 1 N
21 C5-1048-A CONV. P. WHEEL SHAFT 1 N
22 C9278A SENSOR POST 106mm 1 N
23 D0-0063-A SOFT RUBBER WHEEL 40 DIA 4 N (See Spares Assy 1)
24 D1040A 9103641J T BEARING 8mm 12SQ 16 Y
25 E0367A 9103789N WASHER WAVED 23mm 12 Y
26 E0375A 9105805M BUSH SNAP 12.7I/D x 6.4L 1 Y
27 E0475A 9103795U WAVED WASHER EPL5 1 Y
28 E1-0138-A 9109987U BEARING BALL FL 10 x 22 x 6 26 Y
29 E1078A 9103835L BEARING FL 8 x 22 x 7mm 12 Y
30 E1107A BEARING BALL 6 x 13 x 5 4 N (See Spares Assy 1)
31 E1114A BEARING BALL 8 x 22 x 7 5 N (See Spares Assy 2)
32 E4-0073-A 9110108V WAVY WASHER 6.73 I/D 0.76 H 9.32 O/D 2 Y
33 E4033A 9104072H WASHER WAVED 8.89 I/D,12.5 O/D 12 Y
34 F1-0461-A 9112106B PULLEY 25T XL x 10 DIA 6 Y
35 F4-0319-A 9112445E GEAR 40T 1M 10 I/D 1 Y
36 F5119A 9104497A BELT 140XL 037 POLYURETHANE 1.5 Y
37 G1-0254-A 9110102P BELT TENSION SPRING 0.51 DIA 12 Y
38 G1-0258-A SEALER SPRING 2 N (See Spares Assy 1)
39 G1182A 9104715C SPRING CONVEYOR 2 Y
40 G1184A 9105602B SPRING LATCH RH 1 Y

4.13 - C4 Head Input Conveyor Upper - A2-1054-A (9110107U) Page 4-34


Maximailer HD Service Manual Exploded Views Issue 5 Feb 2012

Item Part No. Description Qty. Spares


41 G1185A 9105590P SPRING LATCH LH 1 Y
42 G1206A OVERGUIDE SPRING 4 N (See Spares Assy 2)
43 G4092A BRIDGE CLAMP 6 N
44 G1-0289-A 9111631G SPRING CONV. INPUT 2 Y
45 E0425A 9110007Q WASHER 10.2 x 17 x 2 1 Y

Fixings

50 E2826A M4 x 8mm TORX PAN HD SCREW 2


51 E2832A M4 x 10mm TORX PAN HD SCREW 1
52 E2830A M4 x 12mm TORX PAN HD SCREW T/T 6
53 E2-0858-A M4 x 16mm TORX PAN HD SCREW 2
54 E3505A M4 NYLOC NUT 2 SEE FIXING KIT FOR THIS ASSEMBLY
55 E5092A 12mm ‘E’ TYPE CIRCLIP 2 A0-0562-A (9110106T)
56 E5073A 9.5mm ‘E’ TYPE CIRCLIP 6 NOTE: FIXINGS ARE NOT AVAILABLE
57 E5076A 7mm ‘E’ TYPE CIRCLIP 2 INDIVIDUALLY.
58 E5086A PIN DOWEL 3 DIA x 16mm 6
59 E5105A PIN DOWEL 3 DIA x 24mm 1

Spares assemblies

SA1 A0-0560-A 9110104R CONV. P. WHEEL SHAFT ASSY A/R


SA2 A0-0561-A 9110105S CENTRAL OVERGUIDE ASSY A/R

4.13 - C4 Head Input Conveyor Upper - A2-1054-A (9110107U) Page 4-35


Maximailer HD Service Manual Exploded Views Issue 4 Mar 2012

5 14
21
10
9 A
2
B

14

5
12
11
3
8 11
22
12
BELT FITTING DIAGRAM
15
7

1
8
15 6
21 20 22
F1-0461-A (x6) C2-1036-A (x6)
PULLEY 25T XL F5120A (x1.5) CONVEYOR 13
(ITEM 13) WHEEL 23
BELT SET
130XL O37 (ITEM 3) 10
(ITEM 14) 21

4.14 - C4 Head Input Conv. Lower - A2-1055-A (9110116D) Page 4-36


Maximailer HD Service Manual Exploded Views Issue 2 Jul 2011

Item Part No. Description Qty. Spares


1 B2-1153-A PULLEY IDLER BRACKET 6 N
2 B2-1164-A LOWER CONVEYOR BODY 1 N
3 C2-1036-A CONVEYOR WHEEL 6 N
4 N/R
5 C3-0678-A BEARING POST 2 N
6 C3-0685-A 9110101N IDLER PIN 6 Y
7 C5-1036-A LOWER CONV. DR. SHAFT 1 N
8 D1040A 9103641J T BEARING 8mm 12 SQ. 12 Y
9 E0367A 9103789N WASHER WAVED 23mm ID 1 Y
10 E1-0138-A 9109987U BEARING BALL FL 10x22x6 2 Y
11 E1078A 9103835L BEARING FL 8x22x7mm 12 Y
12 E4033A 9104072H WASHER WAVED 8.89ID, 12.5OD 12 Y
13 F1-0461-A 9112106B PULLEY 25T XL x 10 BORE 6 Y
14 F5120A 9104499C BELT 130XL 037 POLYURETHENE 1.5 Y
15 G1111A 9104681S SPRING LIGHT PRESSURE 12 Y

Fixings

20 E3505A M4 NYLOC NUT 1


21 E5092A 12mm ‘E’ TYPE CIRCLIP 4 SEE FIXING KIT FOR THIS ASSEMBLY
22 E5073A 9.5mm ‘E’ TYPE CIRCLIP 4 A0-0564-A 9110115C
23 E5086A PIN DOWEL 3 DIA x 16mm 2 NOTE: FIXINGS ARE NOT AVAILABLE
24 N/R INDIVIDUALLY

4.14 - C4 Head Input Conv. Lower - A2-1055-A (9110116D)


Page 4-37
Maximailer HD Service Manual Exploded Views Issue 3 Jan 2011

S1

SENSORS
Item Description Ref.
S1 AC Motor Disc 5.12

Note: Belt F5112A (Item 13) is also shown on


Chassis Drive Side (Rear). see (Section 4.2)

4.15 - Motor Assy. - A2-1056-A (9110111Y): 115V or A2-1057-A (9110112Z): 230V


Page 4-38
Maximailer HD Service Manual Exploded Views Issue 2 Jan 2011

Item Part No. Description Qty. Spares


MOTOR ASSEMBLY 115V: A2-1056-A (9110111Y)

1 181-569 9100831G MOTOR W/D 179-073 1 Y


2 180-776 9110109W PCB WIDEBODY DISK SENSOR 1 Y
3 B2-1149-A TENSION BRACKET 1 N
4 B2-1150-A MOTOR BRACKET 1 N
5 B3-1053-A SINGLE SLOT DISC 1 N
6 C3-0678-A BEARING POST 1 N
7 E0181A 9103738K FAN 2 5/8” DIA CCW 1 Y
8 E1061A 9103826B BEARING BALL 8x16x5mm 2 Y
9 E4033A 9104072H WASHER WAVED 8.89ID,12.5 OD 1 Y
10 F1373A 9104297S PULLEY 15T S2M MOTOR 1 Y
11 G1006A 9104609S SPRING TRACTOR 1 Y
12 P2448A 9105669W BELT IDLER 1 Y
13 F5112A 9104493W BELT 100-S2M-280 1 Y

Fixings

15 E2-0840-A SCREW M5 x 10mm TORX PAN HD. 1


16 E2505A SCREW M4 x 6mm SOCKET SET 2 SEE FIXING KIT FOR THIS ASSEMBLY
17 E2502A SCREW M3 x 8mm CSK HD. 2 A0-0563-A (9110110X)
18 E3505A M4 LOCKNUT 2 NOTE: FIXINGS ARE NOT AVAILABLE
19 E5073A 9.5mm ‘E’ CLIP 2 INDIVIDUALLY.

See following page for 230V Motor Assy.

4.15 - Motor Assy. - A2-1056-A (9110111Y): 115V


Page 4-39
Maximailer HD Service Manual Exploded Views Issue 2 Jan 2011

Item Part No. Description Qty. Spares


MOTOR ASSEMBLY 230V: A2-1056-A (9110112Z)

1 181-069 9105274K MOTOR W/D 179-072 1 Y


2 180-776 9110109W PCB WIDEBODY DISK SENSOR 1 Y
3 B2-1149-A TENSION BRACKET 1 N
4 B2-1150-A MOTOR BRACKET 1 N
5 B3-1053-A SINGLE SLOT DISC 1 N
6 C3-0678-A BEARING POST 1 N
7 E0181A 9103738K FAN 2 5/8” DIA CCW 1 Y
8 E1061A 9103826B BEARING BALL 8x16x5mm 2 Y
9 E4033A 9104072H WASHER WAVED 8.89ID,12.5 OD 1 Y
10 F1372A 9105627C PULLEY 15T S2M MOTOR 1 Y
11 G1006A 9104609S SPRING TRACTOR 1 Y
12 P2448A 9105669W BELT IDLER 1 Y
13 F5112A 9104493W BELT 100-S2M-280 1 Y

Fixings

15 E2-0840-A SCREW M5 x 10mm TORX PAN HD. 1


16 E2505A SCREW M4 x 6mm SOCKET SET 2 SEE FIXING KIT FOR THIS ASSEMBLY
17 E2502A SCREW M3 x 8mm CSK HD. 2 A0-0563-A (9110110X)
18 E3505A M4 LOCKNUT 2 NOTE: FIXINGS ARE NOT AVAILABLE
19 E5073A 9.5mm ‘E’ CLIP 2 INDIVIDUALLY.

See previous page for 115V Motor Assy.

4.15 - Motor Assy. - A2-1057-A (9110112Z): 230V


Page 4-40
Maximailer HD Service Manual Exploded Views Issue 4 Sep 2012

K
H
H
K

L J
L
H
J
H

B M

E
B J
E J
A
G
A G
F D
C

NOTE
D BRIDGE CLAMPS G4092A (ITEM 27) WITH M4 x 12 TORX HD
SCREWS E2827A (ITEM 37) ARE FITTED IN ALL LOCATIONS MARKED
4.16 - Sealer Assembly - A2-1058-A Page 4-41
Maximailer HD Service Manual Exploded Views Issue 2 Sep 2012

Item Part No. Description Qty. Spares


1 131-824 9100302F SWITCH MAGNET SMALL 1 Y
2 B1-0933-A SEALER ROLLER BKT ASSY 1 N
3 B1-0934-S SEALER COVER ASSY 1 N
4 B2-1177-F LATCH BRACKET 1 N
5 B2-1179-A SEALER ASSY BRIDGE 1 N
6 B2-1180-A SEALER LATCH ARM DR. 1 N
7 B2-1181-A SEALER LATCH ARM OP. 1 N
8 B2-1182-S SEALER SIDE ARM DR. 1 N
9 B2-1183-S SEALER SIDE ARM OP. 1 N
10 B3-1079-S SEALER LATCH COVER 1 N
11 B3-1345-A GUIDE PLATE 1 N
12 C2-1028-A 9109991Y T BEARING HOUSING 4 Y
13 C2-1029-A 9109975G GEAR SPACER 1 Y
14 C2-1046-A 9110117E SEALER ASSY PIVOT 2 Y
15 C3-0681-A 9109970B IDLER POST 1 Y
16 C5-1049-A SEALER LATCH PIVOT 1 N
17 C8-0208-A 9109563C UPPER SEAL ROLLER 48 DIA 2 Y
18 E0367A 9103789N WASHER WAVED 23mm I/D 1 Y
19 E0475A 9103795U WAVED WASHER EPL5 1 Y
20 E1-0138-A 9109987U BEARING BALL FL 10x22x6 4 Y
21 E1107A 9105507C BEARING BALL 6x13x5 8 Y
22 E4-0073-A 9110108V WAVY WASHER 6.73 I/D 0.76H 4 Y
23 F4-0295-A 9109980M GEAR 48T 1M IDLER 1 Y
24 F4182A 9105633J GEAR 35Tx8mm 1.0M 2 Y
25 G1-0258-A 9109992Z SEALER SPRING 2 Y
26 G1091A 9104665A SPRING SEPARATOR 2 Y
27 G4092A 9104827U BRIDGE CLAMP 6 Y
28 G1-0285-A 9110118F CLOSER SPRING 1.2 N/mm 2 Y
29 B0-0229-A 9113670F GUIDE SPRING 1 Y
30 181-A0005751 EARTH BRAID 0.75M 1 Y

4.16 - Sealer Assembly - A2-1058-A (9110121J)


Page 4-42
Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

Item Part No. Description Qty. Spares


Fixings

35 E2-0840-A M5 x 10 TORX PAN HD SCREW 1


36 E2826A M4 x 8 TORX PAN HD SCREW 4
37 E2834A M4 x 10 TORX CSK HD SCREW 4
38 E2-0838-A M4 x 12 TORX CSK HD SCREW 4
39 E2-0842-A M3 x 8 TORX CSK HD SCREW 2
40 E2559A M3 x 10 PAN HD SCREW 2 SEE FIXING KIT FOR THIS ASSEMBLY
41 E3505A M4 NYLOC NUT 2 A0-0566-A (9110119G)
42 E3557A M3 NYLOC NUT 2 NOTE: FIXINGS ARE NOT AVAILABLE
43 E5071A PIN DOWEL 3 DIA x 14 2 INDIVIDUALLY
44 E5092A CIRCLIP 12mm ‘E’ TYPE 2
45 E5073A CIRCLIP 9.5mm ‘E’ TYPE 2
46 E5003A CIRCLIP 7.0mm ‘E’ TYPE 4
47 G6028A BRAKE SHIM A/R

4.16 - Sealer Assembly - A2-1058-A (9110121J)


Page 4-43
Maximailer HD Service Manual Exploded Views Issue 2 Mar 2010

SENSORS
Item Description Ref.
S1 Collate Pocket Load RX 5.12

S1

4.17 - Split Shaft Sub-Assemblies A2-1059/1060/1061-A (911012M/9110125N/9110126P)


Page 4-44
Maximailer HD Service Manual Exploded Views Issue 2 June 2010

Item Part No. Description Qty. Spares


A2-1061-A 9110126P SPLIT SHAFT OPERATOR 1 Y

1 C4319A SPLIT SHAFT HOUSING 1 N
2 C5-1035-A SPLIT SHAFT SHORT 1 N
3 D0045A ROLLER TRANSPORT NOTCHED 1 N
4 E0367A WASHER WAVED 23mm I/D 1 N
5 E1-0138-A BEARING BALL FL 10 x 22 x 6 2 N
6 P2048A SPIGOT 2 N
7 B3-1123-A SPLIT SHAFT COVER 1 N

A2-1059-A 9110124M SPLIT SHAFT CENTRE 1 Y



10 C3-0679-A SPLIT SHAFT HOUSING 1 N
11 C4-0514-A SPLIT SHAFT CENTRE 1 N
12 D0045A ROLLER TRANSPORT NOTCHED 2 N
13 E1102A BEARING FL 8x19x6mm 2 N
14 E4033A WASHER WAVED 1 N
15 F4152A GEAR 25Tx8mm 1.0M 1 N
16 G6028A SHIM BRAKE 1 N
17 B3-1121-A COLLATE SENSOR BRACKET 1 N
18 C4-0528-A COLLATE PANEL PIVOT 1 N
19 G1016A 9104618B SPRING 1 Y

A2-1060-A 9110125N SPLIT SHAFT DRIVES 1 Y

25 C4319A SPLIT SHAFT HOUSING 1 N


26 C5-1034-A SPLIT SHAFT LONG 1 N
27 D0045A ROLLER TRANSPORT NOTCHED 1 N
28 E0367A WASHER WAVED 23mm I/D 1 N
29 E1-0138-A BEARING BALL FL 10 x 22 x 6 2 N
30 P2048A SPIGOT 2 N
31 B3-1123-A SPLIT SHAFT COVER 1 N

Fixings
SEE FIXING KIT FOR THIS ASSEMBLY
40 E2826A SCREW M4 x 8mm TORX PAN HD. 4 A0-0568-A (9110127Q). ORDER THIS
41 E5071A PIN DOWEL 3 DIA x 14mm 1 KIT FOR ANY ONE ASSY, OR ALL 3.
42 E5092A 12mm ‘E’ TYPE CIRCLIP 2 NOTE: FIXINGS ARE NOT AVAILABLE
43 E5073A 9.5mm ‘E’ TYPE CIRCLIP 2 INDIVIDUALLY

4.17 - Split Shaft Sub-Assemblies A2-1059/1060/1061-A (911012M/9110125N/9110126P)


Page 4-45
Maximailer HD Service Manual Exploded Views Issue 3 Oct 2010

NOTE
BRIDGE CLAMPS G4092A (ITEM 48) WITH M4 x 12 TORX HD
SCREWS E2830A ( ITEM 63) ARE FITTED IN ALL LOCATIONS MARKED

SENSORS
Item Description Ref.
S1 Finger Datum (flag) 5.12
S2 Finger Disc 5.12

S1
S2

4.18 - Finger Assembly - A2-1062-A (9110143G) Page 4-46


Maximailer HD Service Manual Exploded Views Issue 3 Apr 2010

Item Part No. Description Qty. Spares


1 169-145 9104649E RIVET 3.5mm 2.0-3.0 GRIP 4 Y
2 181-070 9100788M WIRED MOTOR 1 Y
3 181-1610 9109568H SOLENOID W/D 179-3550 (MIDDLE) 1 Y
3a 181-1610 9109568H SOLENOID W/D 179-3550 (DR) 1 Y
4 180-760 9100745S PCB SPLITTER 3 SEN 4 SOL H/D (No. 7) 1 Y
5 B2-1244-A FINGER CHASSIS 1 N
6 B2-1246-A FINGER STOP BRACKET DR 1 N
7 B2-1251-A FINGER SOLENOID BRACKET 1 N
8 B2-1492-A INNER SOLENOID BRACKET 1 N
9 B2-1493-A SOLENOID SUPPORT BRACKET 1 N
10 B3-1108-Z 9110128R FINGER OUTER DRIVES C4 1 Y
11 B3-1109-Z 9110129S FINGER OUTER OPERATOR C4 1 Y
12 B3-1110-A 9110130T FINGER MIDDLE DRIVES C4 1 Y
13 B3-1111-A 9110131U FINGER MIDDLE OP C4 1 Y
14 B3-1112-A FINGER SENSOR FLAG 1 N
15 B3-1113-A FINGER DISK SENSOR BKT 1 N
16 B3-1114-A 9110132V INSERTION FINGER SUPPORT 2 Y
17 B3-1249-A INNER FINGER DRIVE BKT 1 N
18 B3-1251-A FINGER PIVOT BRACKET DR 1 N
19 B3-1325-A 9110133W FINGER S/GUIDE OPERATOR 1 Y
20 B3-1326-A 9110134X FINGER S/GUIDE DRIVES 1 Y
21 B4330A DISC ASSEMBLY 1 N
22 B7433A SENSOR BRACKET 1 N
23 C2-1062-A 9110135Y FINGER PIN C4 8 Y
24 C2-1116-A 9110136Z FINGER SPACER 4 Y
25 C2-1191-A FINGER BUSH 2 N
26 C3-0714-A FINGER PIVOT 1 N
27 C3-0715-A 9110137A SOLENOID PIN 1 Y
28 C3-0739-A FINGER NUT OPERATOR 1 N
29 C3-0740-A FINGER NUT DRIVES 1 N
30 C4-0548-A 9110138B INNER FINGER DRIVE SHAFT 1 Y
31 C4-0564-A INNER FINGER PIVOT 1 N
32 C5-1062-A ADJUSTMENT SHAFT 1 N
33 C5-1127-A FINGER ROD 1 N
34 C6-0432-A INNER FINGER BODY 2 N
35 D1040A 9103641J T BEARING 8mm 12 SQ. 4 Y
36 D1076A 9105521S T BEARING 6mm 10 SQ. 2 Y
37 D1080A MOULDED FINGER BODY 2 N
38 E0204A 9103744R VINYL PROTN CAP 3.5x12.7 1 Y
39 E0291A 9105793A FOOT PUSH-IN 5 Y

4.18 - Finger Assembly - A2-1062-A (9110143G) Page 4-47


Maximailer HD Service Manual Exploded Views Issue 3 Apr 2010

Item Part No. Description Qty. Spares


40 E0375A BUSH SNAP 12.7 I/D x 6.4L 1 N
41 F4175A 9104405E GEAR 45Tx6mm 0.7M 1 Y
42 F4176A 9104406F GEAR 35Tx6mm 0.7M 1 Y
43 G0079A 9104579L CLUTCH PIN 1 Y
44 G1-0256-A 9109575Q SPRING LINK 1 Y
45 G1-0257-A 9110139C FINGER SPRING C4 4 Y
46 G1-0277-A 9110140D INNER FINGER SPRING 1 Y
47 G1152A 9104699L SPRING SOLENOID 1 Y
48 G4092A BRIDGE CLAMP 6 N
49 P2031A SHAFT ADAPTOR 1 N
50 180-776 9100753A SENSOR PCB FINGER DATUM (FLAG) 1 Y
50a 180-776 9100753A SENSOR PCB FINGER DISC 1 Y

Fixings

60 E2-0857-A M4 x 25mm TORX PAN HD SCREW 1
61 E2571A M3 x 5mm SOCKET SET SCREW 1
62 E2826A M4 x 8mm TORX PAN HD SCREW 6
63 E2830A M4 x 12mm TORX PAN HD SCREW 2
64 E3557A M3 NYLOC NUT 4 SEE FIXING KIT FOR THIS ASSEMBLY
65 E4072A M20 WASHER INT SH/PROOF 2 A0-0569-A (9110142F)
66 E5073A CIRCLIP 9.5mm E TYPE 3 NOTE: FIXINGS ARE NOT AVAILABLE
67 E5076A CIRCLIP 7mm E TYPE 2 INDIVIDUALLY
68 E5082A PIN GROOVED 2.5 x 12 1
69 E2774A M2 x 6mm POZI CSK HD SCREW 1

4.18 - Finger Assembly - A2-1062-A (9110143G)


Page 4-48
Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

4.19 - Finger Bkt. Op Assembly - A2-1073-A (9110171L)


Page 4-49
Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

Item Part No. Description Qty. Spares


1 181-1610 9109568H SOLENOID W/D 179-3550 XH 1 Y
2 B2-1250-A FINGER BRACKET OPERATOR 1 N
3 B2-1251-A FINGER SOLENOID BRACKET 1 N
4 B2-1254-A FINGER STOP BKT OPERATOR 1 N
5 B3-1250-A FINGER PIVOT BRACKET OP 1 N
6 C3-0714-A FINGER PIVOT 1 N
7 D1040A 9103641J T BEARING 8mm 12SQ 2 Y
8 E0204A VINYL PROTN CAP 3.5x12.7 1 N
9 G0079A 9104579L CLUTCH PIN 1 Y
10 G1-0256-A 9109575Q SPRING LINK 1 Y
11 G1152A 9104699L SPRING SOLENOID 1 Y

Fixings

20 E2826A SCREW M4 x 8mm TORX PAN HD 2
21 E2-0857-A SCREW M4 x 25mm TORX PAN HD 1
22 E4072A WASHER M20 INT SH/PROOF 1 SEE FIXING KIT FOR THIS ASSEMBLY
23 E4011A M4 WASHER 2 A0-0572-A (9110170K)
24 E3502A M4 FULL NUT 2 NOTE: FIXINGS ARE NOT AVAILABLE
25 E5073A CIRCLIP 9.5mm ‘E’ TYPE 2 INDIVIDUALLY

4.19 - Finger Bkt. Op Assembly - A2-1073-A (9110171L)


Page 4-50
Maximailer HD Service Manual Exploded Views Issue 3 Dec 2010

S2

S1
SENSORS
Item Description Ref.
S1 Side Guide Disc 5.12
S2 Side Guide Datum (flag) 5.12

4.20 - Side Guide Adjust Assembly - A2-1063-A (9110146K) Page 4-51


Maximailer HD Service Manual Exploded Views Issue 2 Dec 2010

Item Part No. Description Qty. Spares


1 169-145 9100469E RIVET 3.5mm 2.0-3.0 GRIP 4 Y
2 181-070 9100788M WIRED MOTOR 1 Y
3 180-776 9110109W PCB WIDEBODY DISC SENSOR 2 Y
4 B4330A DISC ASSEMBLY 1 N
5 B7478A SIDEGUIDE MOTOR BRACKET 1 N
6 B7498A GUIDE CARRIER 2 N
7 C3476A FINGER NUT RH 1 N
8 C3477A FINGER NUT LH 1 N
9 C5-1062-A ADJUSTMENT SHAFT 1 N
10 C6340A GUIDE CARRIER 2 N
11 D1076A 9105521S T BEARING 6mm 10SQ 1 Y
12 E0-0618-A 9110144H O RING 6.1I/D x 9.3O/D 4 Y
13 F4175A 9104405E GEAR 45Tx6mm 0.7M 1 Y
14 F4176A 9104406F GEAR 35Tx6mm 0.7M 1 Y
15 P2031A SHAFT ADAPTOR 1 N

20 E2826A SCREW M4 x 8mm TORX PAN HD 2


21 E2571A SCREW M3 x 5mm SOCKET SET 2 SEE FIXING KIT FOR THIS ASSEMBLY
22 E2774A SCREW M2 x 6mm POZI CSK HD 2 A0-0570-A (9110145J)
23 E5082A PIN GROOVED 2.5 DIA x 12mm 2 NOTE: FIXINGS ARE NOT AVAILABLE
24 E5076A CIRCLIP 7mm ‘E’ TYPE 4 INDIVIDUALLY

Spares Assemblies
SA1 A0-0597-A 9110630P GUIDE CARRIER ASSY RH A/R
SA2 A0-0598-A 9110631Q GUIDE CARRIER ASSY LH A/R

4.20 - Side Guide Adjust Assembly - A2-1063-A (9110146K)


Page 4-52
Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

4.21 - Pawl Tension Bracket Assy - A2-1072-A (9110173N)


Page 4-53
Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010

Item Part No. Description Qty. Spares

1 B2-1245-A PAWL TENSION BRACKET 1 N


2 C4-0526-A GEAR IDLER SHAFT 2 N
3 C5-1065-A UPPER SPROCKET IDLE SHAFT 1 N
4 D1040A 9103641J T BEARING 8mm 12 SQ 6 Y
5 E1102A 9103841S BEARING FL 8x19x6mm 4 Y
6 F3-0046-C 9110090B IDLE SPROCKET 15T 2 Y
7 F4156A 9104402B GEAR 30Tx8mm 1.0M 2 Y
8 G1117A 9104686X SPRING HEAVY PRESSURE 2 Y
9 G6028A 9104879Y SHIM BRAKE 2 Y

15 E3505A M4 NYLOC NUT 1 SEE FIXING KIT FOR THIS ASSEMBLY
16 E5071A DOWEL PIN 3 DIA x 14mm 1 A0-0573-A (9110172M)
17 E5073A CIRCLIP 9.5mm ‘E’ TYPE 2 NOTE: FIXINGS ARE NOT AVAILABLE
INDIVIDUALLY

4.21 - Pawl Tension Bracket Assy - A2-1072-A (9110173N)


Page 4-54
Maximailer HD Service Manual Exploded Views Issue 3 Apr 2011

SENSORS
Item Description Ref.
S1 Wetter Down (flag) 5.12

4.22 - Wetter Lever Assy - A2-1352-A (9110421W)


Page 4-55
Maximailer HD Service Manual Exploded Views Issue 2 Apr 2011

Item Part No. Description Qty. Spares


1 169-145 9100469E PLASTIC RIVET 3.5mm 2.0-3.0 GRIP 2 Y
2 181-1610 9109568H SOLENOID W/D 179-3550 XH SDT2652L628 1 Y
3 B2-1942-A PIVOT ARM 1 N
4 B2-1943-A WETTER SOLENOID BKT 1 N
5 B2-1944-A WETTER LEVER 1 N
6 B3-1401-A BEAM ADJ PLATE 1 N
7 C2-1164-A BEARING SPIGOT 1 N
8 C2-1213-A LEVER BEARING HOLDER 1 N
9 C2-1214-A PIVOT BEARING HOLDER 1 N
10 C2-1215-A BEARING SPIGOT 2 N
11 C3-0759-A ACTUATOR ROD 1 N
12 E1-0140-A 9110065A BEARING NEEDLE 4 IDx8x8 1 Y
13 E1-0146-A 9110385J BEARING 5IDx7ODx10LONG 1 Y
14 E1088A 9103839Q BEARING BALL 4x12x4 SHLD 604ZZ 4 Y
15 G1-0255-A 9110574P SPRING SOLENOID 1 Y
16 180-776 9100753A PCB WIDEBODY DISK SENSOR 1 Y

Fixings

20 E2-0836-A SCREW M4x6MM TORX PAN HD ST/STL 2


21 E2-0837-A SCREW M4x16MM TORX CSK HD 2 SEE FIXING KIT FOR THIS ASSEMBLY
22 E2-0841-A SCREW M3x8 TORX PAN HD 4 A0-0612-A (9110736Z)
23 E4011A WASHER M4 FORM A BZP 2 NOTE: FIXINGS ARE NOT AVAILABLE
24 E5099A GROOVED PIN S80 3x18LG 1 INDIVIDUALLY

4.22 - Wetter Lever Assy - A2-1352-A (9110421W)


Page 4-56
Maximailer HD Service Manual Exploded Views Issue 1 Apr 2010

DETAIL SHOWN IS PART OF


WETTER ACTUATOR ASSEMBLY
(A2-1286-A) SEE EXPLODED VIEW
SECTION 4.22

4.23 - Wetter Beam Assembly


Page 4-57
Maximailer HD Service Manual Exploded Views Issue 1 Apr 2010

Item Part No. Description Qty. Spares


1 B3-1320-A WETTER BEAM 1 N
2 C2-1158-A 9110308D BEAM PIVOT BASE 2 Y
3 E1077A 9103834K FLANGED BEARING 4mm BORE 2 Y
4 E2-0836-A 9110004M M4 x 6mm TORX PAN HD. SCREW 2 Y
5 E2826A 9108961A M4 x 8mm TORX PAN HD. SCREW 2 Y

4.23 - Wetter Beam Assembly


Page 4-58
Maximailer HD Service Manual Exploded Views Issue 2 Apr 2010

4.24 - Wetter Tank Assy - A2-1070-A (9110168H)


Page 4-59
Maximailer HD Service Manual Exploded Views Issue 3 May 2010

Item Part No. Description Qty. Spares

A2-1070-A 9110168H WETTER TANK ASSY 1 Y


1 A2-1304-A FELT ON FELT BRIDGE 1 N
2 B3-1105-A WETTER TANK 1 N
3 C3482A OVERFLOW PIPE 1 N
4 D0054A CAP RECT. VINYL 23x13x1.5 1 N
5 E0235A O RING (12.1 x 1.6) 1 N
6 P2375A NUT M12 5mm 1 N

A2-1304-A 9110169J FELT ON FELT BRIDGE 1 Y
10 169-115 RIVET 5mm 2.5-3.5mm GRIP 1 N
11 B4-0448-A FELT BRIDGE ASSEMBLY 1 N
12 G0-0181-A WETTER FELT C4 1 N

B4-0448-A FELT BRIDGE ASSY
15 B3-1334-A FELT BRIDGE 2 1 N
16 B3-1335-A FELT BRIDGE 1 1 N
17 C2-1167-A SPACER RIVET 7 N

4.24 - Wetter Tank Assy - A2-1070-A (9110168H)


Page 4-60
Maximailer HD Service Manual Exploded Views Issue 1 Apr 2010

4.25 - No Seal Assembly - A2-1214-A (9110309E)


Page 4-61
Maximailer HD Service Manual Exploded Views Issue 1 Apr 2010

Item Part No. Description Qty. Spares


1 181-1610 9109568H SOLENOID W/D 179-3550 XH 1 Y
2 B2-1185-A NO SEAL SOLENOID BKT 1 N
3 B2-1518-A NO SEAL BRACKET 1 N
4 B3-1256-A NO SEAL COMB 1 N
5 E0204A VINYL PROTN CAP 3.5 x 12.7 2 N
6 E0253A INSERT FOOT 049-1000 3 N
7 E1077A 9103834K FLANGED BEARING 4mm BORE 2 Y
8 G0167A 9105600Z EC30 CLUTCH PIN 1 Y
9 G1-0256-A 9109575Q SPRING LINK 1 Y
10 G1152A 9104699L SPRING SOLENOID 2 Y

Fixings

15 E2827A SCREW M4 x 12mm TORX PAN HD 2 SEE FIXING KIT FOR THIS ASSEMBLY
16 E2826A SCREW M4 x 8mm TORX PAN HD 2 A0-0580-A (9110307C)
17 E4072A WASHER M20 INTERNAL SH/PROOF 1 NOTE: FIXINGS ARE NOT AVAILABLE
18 E4011A WASHER M4 4 INDIVIDUALLY

4.25 - No Seal Assembly - A2-1214-A (9110309E)


Page 4-62
Maximailer HD Service Manual Exploded Views Issue 2 Apr 2010

4.26 - Head Ribbon Bkt. Assy. - 184-2260 (9110179U)


Page 4-63
Maximailer HD Service Manual Exploded Views Issue 3 May 2010

Item Part No. Description Qty. Spares


1 182-8330 9109555U LOOM C4 HEAD RIBBON SET 1 Y
2 B3-1130-A RIBBON PLATE 1 N
3 B3-1131-A RIBBON BRIDGE 1 N

4 E3505A 9104039Y M4 NYLOC NUT 2 Y
5 E4011A 9104059U M4 WASHER 2 Y

4.26 - Head Ribbon Bkt. Assy. - 184-2260 (9110179U)


Page 4-64
Maximailer HD Service Manual Exploded Views Issue 2 Apr 2010

4.27 - C4 Universal Head PSU - 184-2150 (9109570K)


Page 4-65
Maximailer HD Service Manual Exploded Views Issue 2 Apr 2010

4.28 - C4 Mains Input Hardwired - 184-2250 (9110180V)


Page 4-66
Maximailer HD Service Manual Exploded Views Issue 2 Apr 2010

4.29 - C4 Head Covers


Page 4-67
Maximailer HD Service Manual Exploded Views Issue 2 Apr 2010

Item Part No. Description Qty. Spares


1 B1-0934-S 9110147L SEALER COVER ASSY 1 Y
2 B1-0939-S 9110148M TRACTOR INFEED COVER ASSY 1 Y
3 B1-0940-T 9110149N HEAD SIDE COVER DRIVES 1 Y
4 B1-0942-T 9110150P MAIN COVER LOWER ASSY 1 Y
5 B1-0943-T 9110151Q HEAD SIDE COVER OP ASSY 1 Y
6 B1-0981-A 9110152R UPPER COVER ASSY 1 Y
7 B2-1290-T C4-A4 CONV PLATE 1 N
8 B2-1291-A 9110153S COVER PIVOT BKT LH 1 Y
9 B2-1299-T 9110154T SIDE COVER LATCH 1 Y
10 B2-1313-A 9110155U COVER PIVOT BKT RH 1 Y
11 B3-1136-T 9110156V HEAD COVER SKIRT OP 1 Y
12 B3-1139-S 9110157W HEAD OUTPUT COVER 1 Y
13 B3-1142-T 9110158X DRIVES SKIRT 1 Y
14 B3-1231-F 9110159Y INTERNAL COVER 2 1 Y
15 B3-1233-F 9110160Z INTERNAL COVER 1 1 Y
16 B3-1236-S 9110161A CONVEYOR UNDER COVER 1 Y
17 B3-1238-S 9110162B CONVEYOR END CAP 1 Y
18 C2436A 9102840Z PIVOT BUSH 1 Y
19 C4366A 9106257J HINGE PIN 2 Y
20 C5-1116-A 9110163C LATCH PIVOT 1 Y
21 C6358E 9106403L HINGE 1 Y
22 G1006A 9104609S TRACTOR SPRING 2 Y
23 G3068A 9105609J WARNING PLATE 1 Y
24 G3410A 9105917E WARNING LABEL 1 Y
25 G3463A 9110164D MAXI DATACARD NAME PLATE 1 Y
26 G7-0179-A 9110165E VIEWING PANEL 1 Y
27 G7154A 9108948M HEAD SIDE COVER DRIVES 1 Y
28 G7155A 9105676D HEAD SIDE COVER OP 1 Y
29 P2230A 9110166F TRAY SPIGOT 2 Y
30 R2211T 9105121A CATCH TRAY 1 Y
31 R2229F TOP COVER HANDLE 1 N
32 131-824 9100302F SWITCH MAGNET SMALL 2 Y

4.29 - C4 Head Covers Page 4-68


Maximailer HD Service Manual Exploded Views Issue 2 Apr 2010

Item Part No. Description Qty. Spares

Fixings

40 E2565A SCREW M5 x 12mm TORX CSK. HD 2
41 E2-0838-A SCREW M4 x 12mm TORX CSK. HD T/T 2
42 E2827A SCREW M4 x 12mm TORX PAN HD 1
43 E2834A SCREW M4 x 10mm TORX CSK. HD 1
44 E2829A SCREW M4 x 8mm TORX PAN HD T/T 2
SEE FIXING KIT FOR THIS ASSEMBLY
45 E2826A SCREW M4 x 8mm TORX PAN HD 8
A0-0571-A (9110167G)
46 E2559A SCREW M3 x 10mm PAN HD 2
NOTE: FIXINGS ARE NOT AVAILABLE
47 E2-0842-A SCREW M3 x 8mm TORX CSK. HD 2
INDIVIDUALLY
48 E3505A NUT M4 NYLOC 4
49 E3502A NUT M4 FULL 4
50 E3557A NUT M3 NYLOC 2
51 E4048A WASHER M4 FORM C 8
52 E5003A CIRCLIP 7mm ‘E’ TYPE 2

4.29 - C4 Head Covers


Page 4-69
Maximailer HD Service Manual Exploded Views Issue 1 Apr 2010

4.30 - C4 External Float Switch - A3-0421-A (9110289J) Page 4-70


Maximailer HD Service Manual Exploded Views Issue 1 Apr 2010

Item Part No. Description Qty. Spares


1 125-432 TUBE CLEAR FOR PERI/PMP 0.4 M N
2 169-107 CABLE TIE 200 x 2.6 4 N
3 184-2300 FLOAT SWITCH WAND ASSY 1 N
4 E0-0631-A PIPE CONNECTOR 5mm I/D 1 N

NOTE: FOR REPLACEMENT, ONLY THE COMPLETE ASSY. 9110289J CAN BE ORDERED.

4.30 - C4 External Float Switch - A3-0421-A (9110289J)


Page 4-71
Maximailer HD Service Manual Exploded Views Issue 2 Dec 2011

4.31 - Lift Beam Assembly - A2-1520-A Page 4-72


Maximailer HD Service Manual Exploded Views Issue 2 Dec 2011

1 B2-2355-H LIFTING BEAM 1 N


2 B2-2428-G LIFT BEAM HANDLE 4 N
3 B4-0472-H LIFTING BKT. ASSY. LH 1 N
4 B4-0473-H LIFTING BKT. ASSY. RH 1 N
5 E0-0654-A LOBE KNOB BLACK M8 x 16 1 N
6 E0342A WING HANDWHEEL 2 N

Fixings

8 E2582A SCREW M8 SKT CAP HD x 20 2


9 E2698A SCREW M8 SKT CAP HD x 12 1
10 E2834A SCREW M4 x 10 TORX CSK HD 8
11 E3525A M8 NYLOC NUT 2
12 E4044A M8 WASHER FORM D 6
13 E4026A M6 WASHER 2

4.31 - Lift Beam Assembly - A2-1520-A Page 4-73


Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 3 Dec 2010

Section 5
Electrical
and
Circuit/Wiring Diagrams

Sect. Page
5.1 Sensors.........................................................................................5-2 Wiring Diagrams
5.1.1 Sensors List..................................................................................5-2 Sect. Page
5.1.2 Sensors Diagram, Operator Side..................................................5-4 5.11 Inserter Head Wiring Diagram...................................................... 5-24
5.1.3 Sensors Diagram, Drive Side........................................................5-5 5.12 Inserter Head Splitter PCB’s Wiring Diagram............................... 5-25
5.2 Electrical Components..................................................................5-6 5.13 Ins. Head PSU & Interlock Wiring Diagram.................................. 5-26
5.2.1 Physical Locations of Components...............................................5-8

Circuit Diagrams
Sect. Page
5.3 Control PCB Circuit Diagram........................................................5-14
5.4 Processor PCB Circuit Diagram....................................................5-17
5.5 Comms PCB Circuit Diagram.......................................................5-18
5.6 Wetter PCB Circuit Diagram.........................................................5-19
5.7 Expansion PCB Circuit Diagram...................................................5-20
5.8 Interlock PCB Circuit Diagram......................................................5-21
5.9 Stepper Motor PCB Circuit Diagram.............................................5-22
5.10 R/Splitter & Disk PCBs Circuit Diagrams......................................5-23

Page 5-1
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 2 Mar 2010

SECTION 5.1 SENSORS


5.1.1 Sensor List
There are three sensor types fitted to the machine:
Thro’ beam (Emitter/Receiver pair)
Reflective (1 part)
Encoder (for slotted disks & flags)
All are supplied as part of a sensor & lead assembly with the attached con-
nector. Replacement is a matter of ascertaining the sensor’s PCB connector
and fitting the new item in its place. In most cases, sensors connect to a
ribbon splitter PCB which in turn connects to a Module or Control PCB. Wir-
ing diagrams showing the connections can be identified below and found at
the end of this section.
Physical locations of the sensors are shown on the relevant exploded view
section number whose reference is shown below. The list in the exploded
view will also reference to this page. The relevant wiring diagram section
number is also referenced below. The part number of the cable/sensor assy.
is shown, and the Splitter, Module or Stepper PCB/Connector that it con-
nects to.

Insert Head

Sensor P/No. (PFE) P/No. (SAP) Drawing Ref Wiring

Envelope feed RX 182-444 9101014X 4.6 (S3) 5.12


Envelope feed TX 182-443 9101013W 4.6 (S2) 5.12
Envelope deskew RX 182-445 9101015Y 4.6 (S4) 5.12
Envelope deskew TX 182-337 9100975G 4.12 (S2) 5.12
Envelope flap RX 182-439 9101009S 4.4 (S1) 5.12
Envelope flap TX 182-443 9101013W 4.6 (S1) 5.12
Envelope in hopper (reflective) 182-8310 9109571L 4.6 (S5) 5.12
Envelope conveyor (flag) 180-776 9110109W 4.8 (S1) 5.12
Collate pocket input RX 182-342 9100980M 4.4 (S2) 5.12
Collate pocket input TX 182-340 9100978K 4.13 (S1) 5.12
cont.

Page 5-2
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 2 Mar 2010

Sensor P/No. (PFE) P/No. (SAP) Drawing Ref Wiring

Collate pocket load RX 182-339# 9100977J 4.4 (S3) 5.12


Collate pocket load RX 182-339# 9100977J 4.17 (S1) 5.12
Collate pocket load TX 182-337 9100975G 4.12 (S3) 5.12
Collate pocket RX 182-339 9100977J 4.12 (S1) 5.12
Collate pocket TX 182-337 9100975G 4.4 (S4) 5.12
Top pawl RX 182-442 9101012V 4.4 (S5) 5.12
Top pawl TX 182-443 9101013W 4.4 (S6) 5.12
Lower pawl RX 182-339 9100977J 4.4 (S7) 5.12
Lower pawl TX 182-337 9100975G 4.4 (S8) 5.12
Finger disc 180-776* 9110109W 4.18 (S2) 5.12
Finger datum (flag) 180-776* 9110109W 4.18 (S1) 5.12
Side guide disc 180-776* 9110109W 4.20 (S1) 5.12
Side guide datum (flag) 180-776* 9110109W 4.20 (S2) 5.12
Envelope seal RX 182-441 9101011V 4.4 (S9) 5.12
Envelope seal TX 182-440 9101010T 4.4 (S10) 5.12
Wetter output RX 182-345 9100983Q 4.4 (S11) 5.12
Wetter output TX 182-443 9101013W 4.4 (S12) 5.12
Wetter down (flag) 180-776* 9110109W 4.22 (S1) 5.12
Closer output (reflective) 182-693 9101087Y 4.4 (S13) 5.12
AC motor disc 180-776* 9110109W 4.15 (S1) 5.12
Hybrid motor disc 180-746* 9100741N 4.1 (S1) 5.12

* Sensor PCB only, detachable from cable.


# Sensor shown in both drawings

For diagrams of sensor locations, see following page.

Page 5-3
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 2 Mar 2010

5.1.2 Sensor diagram - operator side

For drive side, see following page


Page 5-4
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 2 Mar 2010

5.1.3 Sensor diagram - drive side

For operator side, see previous page


Page 5-5
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 2 Mar 2010

SECTION 5.2 ELECTRICAL COMPONENTS


Electrical components on the 200/300 include PCBs, motors, clutches,
brakes, solenoids etc. The relevant exploded view and wiring diagram for
each component is indicated in the list below.
See also section 5.2 for pictorial illustration of the physical locations of key
components on the drive and operator chassis sides.
Insert Head

Component P/N (PFE) P/N (SAP) Drawing Wiring


Motors
Main drive motor assy. (230V) A2-1057-A 9110112Z 4.15 5.13
Main drive motor assy. (115V) A2-1056-A 9110111Y 4.15 5.13
Motor W/D 179-093 Hybrid 181-050 9100779C 4.1 5.11
Motor W/D Pump 24V 181-0890 9110257A 4.3 5.12
Motor W/D 179-802 Fingers 181-070 9100788M 4.18 5.12
Motor W/D 179-802 Side Guide 181-070 9100788M 4.20 5.12
Motor W/D 179-802 SM Env. Sep. 181-0850 9108955U 4.7 5.12
Motor W/D 179-056 Env. Conv. 181-0870 9109558X 4.10 5.12
Motor W/D 179-802 Env. Tract. 181-0810 9110054P 4.8 5.12
Motor W/D 24V Blower SM 181-1630 9109557W 4.12 5.12

Solenoids
Solenoid W/D 179-3450 Short 181-1600 9109569J 4.2 5.12
Solenoid W/D 179-3450 Long 181-1600 9109569J 4.2 5.12
Solenoid W/D 179-3450 Ex. Long 181-1600 9109569J 4.3 5.11
Solenoid W/D 179-3550 Finger Op 181-1610 9109568H 4.19 5.11
Solenoid W/D 179-3550 Finger Dr 181-1610 9109568H 4.18 5.12
Solenoid W/D 179-3550 Finger Mid 181-1610 9109568H 4.18 5.12
Solenoid W/D 179-3550 Wetter 181-1610 9109568H 4.22 5.12
cont.

Page 5-6
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 2 Mar 2010

Component P/N (PFE) P/N (SAP) Drawing Wiring

Clutches & Brakes


Closer reverse drive clutch 181-128 9100807G 4.3 5.12
Closer reverse drive brake 181-129 9100808H 4.1 5.12
Closer forward drive clutch 181-128 9100807G 4.1 5.12
Insert pawl track drive clutch 181-128 9100807G 4.1 5.12
Insert pawl track drive brake 181-129 9100808H 4.3 5.12
Collate pocket entry slow clutch 181-128 9100807G 4.2 5.12
Collate entry fast clutch 179-110 9108383Y 4.3 5.11
Collate entry brake 179-109 9108382X 4.2 5.12
Input conveyor clutch 179-109 9108382X 4.3 5.11
Input conveyor brake 179-109 9108382X 4.2 5.12
Envelope pick-up clutch 179-109 9108382X 4.6 5.12
Envelope upper drive clutch 179-109 9108382X 4.6 5.12
Envelope upper drive brake 179-109 9108382X 4.6 5.12
Envelope lower drive clutch 179-110 9108383Y 4.6 5.12
Envelope lower drive brake 179-109 9108382X 4.6 5.12
Wetter output drive clutch 179-110 9108383Y 4.1 5.12

PCBs
PCB Assy C4 Control 180-8360 9109914T 4.3 5.11
PCB Assy C4 Processor 180-720 9100723U 4.3 5.11
PCB Assy C4 Expansion 180-8300 9108643U 4.3 5.11
PCB Assy Brainless Dongle 180-8320 9109590F 4.3 5.11
PCB Assy Env. Wetter 180-702 9100715L 4.3 5.12
cont.

Page 5-7
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 2 Mar 2010

Component P/N (PFE) P/N (SAP) Drawing Wiring

PCB Splitter 1 180-759 9100744R 4.3 5.12


PCB Splitter 2 180-759 9100744R 4.2 5.12
PCB Splitter 3 180-759 9100744R 4.2 5.12
PCB Splitter 4 180-760 9100745S 4.4 5.12
PCB Splitter 5 180-759 9100744R 4.6 5.12
PCB Splitter 6 180-759 9100744R 4.1 5.12
PCB Splitter 7 180-760 9100745S 4.18 5.12
PCB Splitter E4 180-759 9100744R 4.6 5.12

Switches
Top cover reed switch 182-417 9105287Y 4.3 5.11
Side cover reed switch 182-418 9105294F 4.3 5.11
Closer cover reed switch 182-494 9101032R 4.1 5.12

Power Supply Unit


C4 Universal Head PSU 184-2150 9109570K 4.25 5.11
C4 Mains Input Hardwired 184-2250 9110180V 4.26 5.11

SECTION 5.2.1 ELECTRICAL COMPONENTS PHYSICAL


LOCATIONS
The following pages show clutches, brakes, solenoids, PCBs, ribbon cables
etc. that are external to the chassis sides, both drive and operator.

Note that other components are internal and can be found from the refer-
ences in the previous section.

Page 5-8
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

179-109 EC30LL
179-110 EC30LL Drive Side Key Components
(BLU) Envelope
pickup clutch (see also part 2)

182-8330F
Ribbon Cable
179-109 EC30LL
179-110 EC30LL
Envelope upper
179-109 EC30LL
drive clutch 182-759 Splitter
(YLW) Envelope
lower drive PCB (No6)
clutch

180-746 Hybrid
motor disk sensor 181-129 Lenze
Closer reverse
drive brake

181-128 Lenze
Insert pawl drive
clutch

181-128 Lenze
179-110 EC30LL Closer forward
Wetter Drive drive clutch
Clutch
181-050 Hybrid DC
motor

IPSS Group
Page 5-9
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

Drive Side Key Components (see also part 1)


180-759 Splitter 182-8330B
179-109 EC30LL PCB (No2) Ribbon Cable
Input Conveyor
Brake
180-759 Splitter
PCB (No3)

179-109
EC30LL
Collate Entry
Brake

181-128 Lenze
Collate pocket
A2-1057-A
entry clutch -
(230V) or A2- Slow
1056-A (115V)
AC motor assy

182-8330C
Ribbon Cable
181-128 Lenze
Insert pawl drive
clutch

180-776 AC 181-1600 181-1600


motor disk Collate Pocket Collate Pocket
sensor backstop - backstop - long
short

184-2150 Head
Power Supply

IPSS Group Page 5-10


Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

Operator Side Key


Components (see also
181-128 Lenze
parts 2 & 3)
Closer Reverse Drive
Brake

181-129 Lenze Insert


Pawl Drive Brake

182-8320
Wetter fluid probe link

182-8330A
Ribbon Cable

180-702 Envelope
Wetter PCB

180-759
Splitter PCB (No1)

IPSS Group
Page 5-11
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

Operator Side Key Components (see also parts 1 & 3)

179-109 EC30LL
179-110 EC30LL Input Conveyor
Collate Entry FAST Brake
Clutch

180-720
PCB Assy AM4
Processor

181-1600
Collate Pocket
backstop –
Extra Long

181-1610
Solenoid W/D
Fingers

182-8330(x) 180-8360
Ribbon Cable PCB Assy AM4
Control

IPSS Group
Page 5-12
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

Operator Side Key Components 180-759 Splitter


(see also parts 1 & 2) PCB (NoE4)

179-109 EC30LL 182-8330H Ribbon


Envelope Upper Drive Cable
Brake

180-759 Splitter
Eccentric fitted –
PCB
shaft turns in one
(No5)
direction
182-8330E Ribbon
Cable

179-109 EC30LL
Envelope Lower Drive
Brake

IPSS Group
Page 5-13
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

This circuit is in three parts


- see also following page.

Section 5.3 - Control PCB Circuit Diagram (part 1) Page 5-14


Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

This circuit is in three parts -


see also following page. This circuit is in
three parts - see also
following & previous page.

Section 5.3 - Control PCB Circuit Diagram (part 2) Page 5-15


Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

This circuit is in three parts -


see also previous page.

Section 5.3 - Control (Comms) PCB Circuit Diagram (part 3) Page 5-16
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

Section 5.4 -Processor PCB Circuit Diagram Page 5-17


Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

Section 5.5 - Comms PCB Circuit Diagram Page 5-18


Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

Section 5.6 - C4 Envelope Wetter PCB Circuit Diagram Page 5-19


Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

Section 5.7 -Expansion PCB Circuit Diagram Page 5-20


Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

Section 5.8 -Interlock PCB Circuit Diagram Page 5-21


Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

Page 5-22

Section 5.9 -Stepper Motor PCB Circuit Diagram


Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

Section 5.10 -Ribbon Splitters/Motor Disk PCB Circuit Diagrams Page 5-23
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

Section 5.11 - Inserter Head Wiring Diagram


Page 5-24
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

5.12 - Inserter Head Splitter PCBs Wiring Diagram Page 5-25


Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010

NOTE: Items shown (except for motor components,


dashed) are part of Power Supply Unit 184-2150

5.13 - Inserter Head PSU, Motor & Interlock Wiring Diagram Page 5-26

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