Page 1 CL-401 Service Manual Part Number: 7725011 Revision: B1 Issue Date: October 2024...
Page 2 GBC does not warrant or represent that such docu- mentation is complete. GBC does not warrant or represent that it will notify or provide to such customer any future changes to this documentation.
Page 3: Table Of Contents
Cutter Blade ................11 Sensors ..................11 Motors ..................11 Solenoids..................12 Function Tests................12 Files..................... 12 Options 1 ..................13 Options 2 ..................13 Alignment Offsets ................ 13 Printers ..................13 Firmware Update / Save Logs ..........14 CL-401 Service Manual TOC-1...
Page 4 Paper Path Timing Belt ............... 44 Cutter Blade ................45 Cut Stick ..................46 Cartridge Rail ................47 Cartridge Tray ................48 Cartridge Frame ................49 Troubleshooting ............50 Initial Troubleshooting..............52 Advanced Jam Clearing..............53 Roller Wraps................53 CL-401 Service Manual TOC-2...
Page 5 FAULT: TRIM PURGE BLOCKED ..........68 Power Faults ................... 69 No AC Power................69 No DC Power ................71 User Interface is Dark..............73 Paper Jams..................74 Checking for Obstructions ............74 Cutter Jams ..................76 Clutch....................78 CL-401 Service Manual TOC-3...
Page 6 Rear Cover ................108 Undock the Laminator ............... 108 Dock the Laminator ..............109 Cabinet Top Cover ..................110 Front Door..................111 Bottom Hinge Bracket ............... 111 Panel Open Magnet ..............112 Door Latch................. 113 Interlock Switch ................. 114 CL-401 Service Manual TOC-4...
Page 7 Sensors: S1B, S22 and S24............149 Sensors: S2, S3, S4, S5............151 Sensor S28................152 Sensors 6 through 10 ..............153 Sensors 11 through 15 .............. 154 M1-7, M9 Motor Driver (Stepper Board) ........155 M8 Motor Driver (Stepper Board)..........156 CL-401 Service Manual TOC-5...
Page 8 Clamps ..................193 Alignment Sensor Bracket............195 Electronics & Controls Repair Procedures 24V Power Supply ................ 197 AC Filter ..................198 Main Control Board ............... 199 Communication Board ..............200 Chip Reader.................. 200 Bracket ..................201 CL-401 Service Manual TOC-6...
Page 9 Cutter Module ................224 Motor Belt Tension ..............224 Clutch Indexing................225 Pivot ..................226 Connecting Rod Length............. 227 Connecting Rod Spring ............. 229 Lamination Drawer................ 231 Alignment Pin ................231 Drawer Switch ................232 Cut Stick ..................232 CL-401 Service Manual TOC-7...
Page 10 PL 4.1 Cutter ................250 PL 5.1 Laminator ............... 251 PL 6.1 Electronics ..............252 PL6.2 Cable Part Number Index ..........253 PL 7 Kits ..................255 Installation Kit Items ..............255 Cutter..................258 Clutch ..................267 Wiring ................268 CL-401 Service Manual TOC-8...
Page 11: Safety
When you close the front door, the UI displays the “READY” message on the top line of the interface. CAUTION: Certain components in the laminator are susceptible to damage from electrostatic discharge. Observe all ESD procedures to avoid component damage. CL-401 Service Manual...
Page 12: Operational Safety
Do not overload electrical outlets beyond their capacity. To do so may result in fire or electrical shock. Do not open any panels other than those indicated by this manual. Pay particular attention to the WARNINGS and CAUTIONS listed in this and the Operator Manual. CL-401 Service Manual...
Page 13: Introduction
Motors..........11 Solenoids ........... 12 Function Tests ........12 Files ........... 12 Options 1 ........... 13 Options 2 ........... 13 Alignment Offsets ......13 Printers ..........13 Firmware Update / Save Logs ..14 Max Bypass ......... 15 CL-401 Service Manual...
Page 14: Glossary Of Acronyms
Glossary of Acronyms Glossary of Acronyms Acronyms you may encounter in this manual include: Acronym Definition Assy Assembly Cable Motor Driver (Stepper Board) Fuse Ground Connector Motor Nip Roller Plug Power Supply Sensor Solenoid Switch User Interface CL-401 Service Manual...
Page 15: Specifications
A4, A3, SRA4,SRA3, LTR, 9x12, 11x17,12x18 Sheet size tolerance ±0.75mm Serial Number The serial number is located inside the front door on the front frame just below the bypass section. Supplies • Laminator Film Frame Refill • Super Lube • Cut Sticks CL-401 Service Manual...
Page 16: User Interface
The UI displays status messages and fault codes in two rows of text. • The top row displays the status of the Laminator (Ready, Close Door). • The bottom row displays the options selected on the UI. CL-401 Service Manual...
Page 17: Settings
Introduction Settings Settings Click on any blue text to be taken to additional information about the setting. Home Info Settings Language & First Center User Cut Stick Margin Skew Sheet Units Alignment Functions CL-401 Service Manual...
Page 18: User Functions
Small edits to the Gap and Cut values can be made by clicking on the lower two boxes and using the +/- buttons. Skew 1. On the Home screen, tap Settings. 2. Scroll to the third page and tap Enter Service Mode. CL-401 Service Manual...
Page 19: First Sheet
4. Tap the back button again to return to the Home screen. Laminator Cycles Lists the number of lamination cycles completed by the film cartridge that is presently installed in the machine. Firmware Identifies the version of firmware installed. CL-401 Service Manual...
Page 20: Service Menu
This menu allows you to complete service adjustments on the system. This menu is not meant to be accessible by the user. Enter Service Mode Cutter Function Alignment Options Motors Blade Tests Offsets User Options Printers Files Sensors Solenoids Functions CL-401 Service Manual...
Page 21: User Functions
2. Scroll to the third page and tap Enter Service Mode. 3. Type in password 422 and press Enter. 4. You will hear the motors engage. 5. Press the motor button a second time to stop it. 6. Repeat as needed to check the other Stepper Motors. CL-401 Service Manual...
Page 22: Solenoids
The Save Log button will save the latest job information to a USB inserted into the back of the machine. Use this button if directed to by GBC to help troubleshoot issues in the field. Additional information can be found in...
Page 23: Options 1
This panel is used during machine setup at the factory. Do not attempt to use this in the field. Printers Select the correct attachment printer in this section to ensure CL-401 can match the bypass speed of the sheet as it enters the machine.
Page 24: Firmware Update / Save Logs
Information for the last 50 punched sheets will be downloaded to the USB drive. Debug data for last 50 sheets. • Sheet size measured i.e S,M,L,LG or XL • Skew sensors • First deskew steps • Alignment sensor used • Second deskew steps. • Align fail safe stop (if occurred) CL-401 Service Manual...
Page 25: Max Bypass
A high value for max bypass will cause paper jams to be detected more slowly, which could lead to more wasted paper. 6. Press the CHECK MARK button to enter the new value. 7. Click YES to save the value permanently or NO to save only until the next time the machine is turned on. CL-401 Service Manual...
Page 26: Service Call Procedures
Door Latch ........41 Idler Roller and Idler Springs ..... 42 Panel Latch........43 Paper Path Timing Belt...... 44 Cutter Blade........45 Cut Stick ..........46 Cartridge Rail ........47 Cartridge Tray ........48 Cartridge Frame......... 49 CL-401 Service Manual...
Page 27: Tools Needed
2. Enter your service code. 3. View the period for each area of the unit and compare with the schedule. Schedule Customer Maintenance Cutting Stick 1,000 cycles, rotate and replace 4 times = 4,000 cuts Lamination supply Replace when empty CL-401 Service Manual...
Page 28 Minimum Expected Life Idler solenoid module 5M cycles Cutter blade 250,000 cycles Lamination pressure rollers 10,500 metres of film (approx. 160 film refills) (1/year) Anti-static brush 500K cycles Cutter clutch 250K cycles Cartridge frame multiple 3,000 cycles CL-401 Service Manual...
Page 29: Cleaning
3. Clean the rollers with isopropyl alcohol. Base Trims and paper dust fall to the bottom of the laminator. Clean with a vacuum cleaner every service call. Educate the customer on how to do this between technician visits. CL-401 Service Manual...
Page 30: Trim Tray
3. Inspect rollers for wear patterns or grooves. The roller surface should be smooth. 4. Ensure the rollers turn freely on the shaft and that the idler roller shaft “floats” freely in the bushing forks. 5. See Idler Roller on page 136 to install. CL-401 Service Manual...
Page 31: Steering Idler Roller And Springs
3. Confirm that the roller surfaces are free of debris, toner deposits, wear, unevenness, and dents. 4. Inspect the Steering Idler Springs. The springs should be hooked securely and should be wrapped around the bushing. 5. Follow instructions to clean the Drive Rollers on page CL-401 Service Manual...
Page 32: Drive Rollers
3. Go to back of machine and clean rollers on the left and right sides. 4. Return to the front, push lamination drawer in. 5. Lift up and pull down the bypass panel to reach and clean the rollers. Bypass panel in down position to access rollers CL-401 Service Manual...
Page 33: Steering Drive Rollers
1. Open the front door and pull out the lamination drawer. 2. Clean all steering drive rollers N1 – N16 with a clean cloth and isopropyl alcohol. The rollers should be free of toner deposits, wear marks, scuff marks, dents, etc. CL-401 Service Manual...
Page 34: Pressure Roller
5. Inspect the gears on the locking mechanism for discoloration, metal shavings, damaged or missing teeth. If damaged, replace the assembly by referring to Rollers on page 189. 6. Clean the lower pressure roller as you rotate it by hand. CL-401 Service Manual...
Page 35 Service Call Procedures Cleaning NOTE: The lower pressure roller is more easily accessible with the locking mechanism removed. CL-401 Service Manual...
Page 36: Optical Sensor
Use canned air to remove dust/debris from the slot between the 2 LEDs. NOTE: Any group of sensors, for example S6 through S10, will be on one sensor array board while S11 through S15 will be on a different board. CL-401 Service Manual...
Page 37: Exit Panel (Inner)
8. Install the panel by inserting the two tabs into the slots in the rear of the machine. 9. Insert and tighten the (3) screws. 10. Tighten the (3) bypass panel screws. 11. Close the front door and connect the power cord. CL-401 Service Manual...
Page 38: Bypass Paper Path
6. Inspect the path for obstructions and clean as needed. 7. Close the panel and check that it is flat and that paper will pass under it. 8. Ensure the bypass diverter moves freely and returns to the bypass position. CL-401 Service Manual...
Page 39: Lamination Paper Path
9. Inspect the black film for cuts, tears and adhesive build up. 10. If the film is damaged, replace the panel. Clean any adhesive build up using Isopropyl alcohol and a lint-free cloth. 11. Reinstall the panel. CL-401 Service Manual...
Page 40: Solenoid
When the solenoid is fully activated, the idler roller should completely lift off and not be able to drive the drive roller. Fully Activated Not Activated NOTE: Disengaging solenoid modules need to be replaced every 5 million cycles. 3. Clean the solenoid and surrounding area with a vacuum cleaner and canned air. CL-401 Service Manual...
Page 41 4. Make sure the solenoid is clean and dry. 5. Inspect for obstructions, wear or damaged springs. 6. Ensure the solenoid linkage moves freely by pressing linkage down and releasing. IMPORTANT: Do not apply lubricants to the solenoid or linkage. CL-401 Service Manual...
Page 42: Alignment Carriage Rails
3. After the rails are fully cleaned, check the motion of the alignment carriage on the rails. It should move when a force less than 2kgf is applied. If there is binding in the rails, replace the Alignment Carriage Sub-Assy on page 173. CL-401 Service Manual...
Page 43: Cutter Clutch
Rear Cover on page 108. 3. Use a lint-free cloth to wipe the collar of the clutch and remove any oil from the surface. 4. Inspect the collar stop and the metal insert pawl for any wear. CL-401 Service Manual...
Page 44 6. Inspect the tightness of the M6 lock nut and M6 socket head cap screw. 7. Check the Clutch Indexing on page 225. 8. Install the Rear Cover on page 108. 9. Connect the power cord. 10. Run the Function Tests on page CL-401 Service Manual...
Page 45: Cutter Outfield Baffle
8. Feed laminate through the module by using the Jog Film command in the Service Menu > Function Test. Adhesive build up is visible and can be felt. It will not be visible on the sheet output but can cause jams. CL-401 Service Manual...
Page 46: Cutter Blade
If the pad tears or the gathers too much adhesive, use a different part of the pad. 8. Inspect the Cutter Blade on page 45, step 5 bullets and follow the steps in reverse order to replace the parts. 9. Connect the power cord. CL-401 Service Manual...
Page 47: Diverter Solenoid (Sol1) Assembly
7. Open the front door and insert an interlock cheater into the door interlock switch. 8. Press the power switch to the ON position. 9. Activate and deactivate SOL1 by following Solenoids on page The diverter gate should rise and fall when SOL1 is cycled. CL-401 Service Manual...
Page 48: Trim Diverter
11. Insert the washer and E-ring. 12. Connect the solenoid bracket to the shaft with the (2) 7mm screws. 13. Perform the adjustment for the Trim Diverter Solenoid (SOL 8) on page 207. 14. Install the Rear Cover on page 108. CL-401 Service Manual...
Page 49: Trim Diverter Solenoid (Sol8)
7. Open the front door and insert an interlock cheater into the door interlock switch. 8. Press the power switch to the ON position. 9. Activate and deactivate SOL8 by following Solenoids on page The diverter gate should rise and fall when SOL8 is cycled. CL-401 Service Manual...
Page 50: Chip Reader
5. Using a soft, lint-free cloth, gently clean the pins of any debris or dust. 6. Reinsert the film cartridge and power on the machine. 7. Ensure that the film size and film count are correct on the screen. 8. Resume normal operation. CL-401 Service Manual...
Page 51: Inspection
The switch tab should press the switch button just so that it is close to bottom. 1. Ensure latch holds door closed. 2. Confirm the switch is activated when the door is closed. Button 3. Adjust the Door Latch on page 205. CL-401 Service Manual...
Page 52: Idler Roller And Idler Springs
3. Inspect the bearing housing. 4. Press and rotate one roller and confirm that the other one moves in sync. The bearing housing should slide freely in the bearing forks. 5. See Idler Roller on page 20 for cleaning instructions. CL-401 Service Manual...
Page 53: Panel Latch
There should not be any movement in the idler assembly either toward or away from the drive panel. 2. Open and close the idler panel and confirm that the idler springs extend. This ensures proper idler roller pressure. 3. If necessary, follow the procedure to adjust the Idler Panel Magnetic Latches on page 219. CL-401 Service Manual...
Page 54: Paper Path Timing Belt
Belts should be slightly loose with approximately 1/4" deflection. Belts that are too loose will not drive properly and belts that are too tight can wear out prematurely or dam- age their driven components. 3. If replacement is necessary, see Timing Belts on page 142. CL-401 Service Manual...
Page 55: Cutter Blade
5. If any of the above is observed, follow the proce- dure to clean the Cutter Blade on page 6. Follow the steps in reverse order to replace the various parts. 7. Connect the power cord. CL-401 Service Manual...
Page 56: Cut Stick
However, excess material can cause the cut to fail. Removing the excess material may repair the groove and allow additional cutting. 6. Follow the steps in reverse order to return the machine to working order. CL-401 Service Manual...
Page 57: Cartridge Rail
2. Locate the cartridge tray and confirm that the bar is secure. 3. If the bar needs tightening, remove the (4) 7mm screws holding the tray.. 4. Lift the tray up and tighten the (2) bottom screws. 5. Replace the tray and tighten the (4) 7mm screws. CL-401 Service Manual...
Page 58: Cartridge Tray
7. If adjustment was made to the cartridge locking foot, ensure film alignment is correct. Cartridge Locking Foot 8. If the alignment on the film is offset adjust the Cartridge Foot on page 209. 9. When the film alignment is correct resume normal operation. CL-401 Service Manual...
Page 59: Cartridge Frame
• If you notice that the plastic near the foot position has worn enough that the foot does not hold the cartridge firmly in place when installed, it is time to replace the frame. CL-401 Service Manual...
Page 60: Troubleshooting
J3XX Jams ..........82 Film............58 J4XX Jams ..........83 Curl ............59 J408: Pressure Roller Jam....... 83 Cross Path..........59 J422: Film Timeout at Cutter....83 Film Flow ..........59 J423: No Film at Cutter ......84 CL-401 Service Manual...
Page 61 Sensor S29 Trim Tray ....... 98 Solenoid Checks ........... 99 Solenoid SOL1, SOL8 ....... 99 Solenoid SOL6 .......... 99 Solenoids SOL2 - SOL3 ......100 Alternate solenoid inspection method: .. 100 Stepper Motor Checks ........ 102 AC Motor Check ........104 CL-401 Service Manual...
Page 62: Initial Troubleshooting
5. Is the problem one of the faults that does not generate a message on the Operator Interface (Cartridge Will Not Slide Out Easily, Drawer Will Not Pull Out). 6. Go to Advanced Jam Clearing on page CL-401 Service Manual...
Page 63: Advanced Jam Clearing
Pulling the drawer out makes this operation easier but is not required. If the drawer cannot be opened due to the wrap, you can still follow the steps. Once the wrap Is partially resolved you should be able to open the drawer. CL-401 Service Manual...
Page 64: Lamination Quality
• Skew - Paper angle with respect to the lamination film Center Alignment If the center alignment of the laminated sheet is incorrect, there are two methods to adjust it. The first method is to use the Center Alignment Screen inside of Settings on the LCD: CL-401 Service Manual...
Page 65: Margin
Adjustment. Once the margin is consistent between sheets, then 6. Measure the margins on the new sheet and enter the A/B values to proceed to dial in the gap size as detailed in the following procedure. define the margin setting even further. CL-401 Service Manual...
Page 66: Skew
Angled Cuts on page If the cut appears square, proceed with the following skew adjustment steps. 1. Go to the Settings menu and select Skew. 2. Use the +/- buttons to edit the current skew value. CL-401 Service Manual...
Page 67: Film Alignment
If the line is excessively thick, it can be improved by loosening the locking mech- anism springs slightly ~1-2mm. Follow the adjustment procedure for Locking Mechanism Springs on page 233. IMPORTANT: Ensure the springs are set to the same height when the adjustment is completed. CL-401 Service Manual...
Page 68: Wrinkles
24). ment and remove the proof portion in section 4 of the machine between each command. 4. Check that the toggle springs are set correctly by referencing the adjustment procedure for Locking Mechanism Springs on page 233. CL-401 Service Manual...
Page 69: Curl
Make sure there are no obstructions between the not be able to separate from the laminated sheet behind it. A J422-No Trail rollers. Edge Jam error message is another indicator that the machine may not be cutting the sheets completely. CL-401 Service Manual...
Page 70: Angled Cuts
1. If the sheet is skewed all the way across its length, adjust the Skew 2. Clean the sheet metal parts following the procedure for the Lamina- on page tion Paper Path on page CL-401 Service Manual...
Page 71: Dog Ears
Most dog ears are caused in area 3 of the machine. Try these two physical adjustments in the order listed: • Adjust the curved panel height, see Paper Path on page 212. • Adjust the Drawer Switch on page 232. CL-401 Service Manual...
Page 72: Operator Messages
Trim Tray Out - No Message on page TRIM TRAY FULL The trim tray is full and required Open the door, remove and empty emptying. the trim tray, reinstall the tray, and close the door. See Trim Tray Full on page CL-401 Service Manual...
Page 73: Troubleshooting By Lcd Message
5. Switch OFF the machine and unplug the power cord. 6. Remove the (2) M4 nuts that hold the interlock switch bracket and inspect the connections at the interlock switch (see Interlock Switch on page 114 for photos of the connections). CL-401 Service Manual...
Page 74: Check Cartridge
8. If the error message remains, follow instructions to replace the replace the Main Control Board on page 199 (PL 6.1). 9. If all of the above actions have been executed and the message still remains, escalate to next level of support. CL-401 Service Manual...
Page 75: Trim Tray Out - Message
5. Replace Cable 7725565 (see Trim Level Emitter on page 169 Board on page 199. Trim Level Receiver on page 169. This clears the fault. Yes- Return to normal operation; - Replace the Main Control Board on page 199. CL-401 Service Manual...
Page 76: Trim Tray Full
Re-flashing the firmware clears the fault. Yes- Return to normal operation; - Go to step 6 6. Replace the Trim Level Emitter on page 169. This clears the fault Yes- Return to normal operation; - Go to step 7 CL-401 Service Manual...
Page 77: Troubleshooting By Error Code
Cutter Clutch on page 2. Troubleshoot the clutch for damage, see Sensor Checks on page • If damage is present, replace the Clutch on page 162 (PL 4.1). 3. If the problem persists, escalate to the next level of support. CL-401 Service Manual...
Page 78: Fault Codes
If this cannot be cleared, or occurs when nothing is blocking the sensor, 3. Check M8 functions by performing a Trim Film & Eject user function. perform the procedures in Trim Tray Full on page 4. Escalate to the next level of support. CL-401 Service Manual...
Page 79: Power Faults
There is AC power on Cable 7715498 at the AC filter. Cable is connected at the AC filter. Yes- Go step 13; - Replace AC Filter on page 198. Yes- Go to step 7; - Connect the cable. CL-401 Service Manual...
Page 80 7715494 at pin J4 on the control board (BLU & BRN wires). There is AC power on Cable 7715494 at Pin J4 the control board. Yes- Replace the Main Control Board on page 199; - Replace cable 7715494 CL-401 Service Manual...
Page 81: No Dc Power
There is 24 VDC at Connector J1 on the control board. 5. Check the following connections: Yes- Go to step 12; - Replace cable 7715492. • Cable 7715492 at J1 at the main control board. • Cable 7715493 at J3 at the main control board. CL-401 Service Manual...
Page 82 24 VDC power output from the control board to another component. There is 24 VDC power output from the control board to another component. Yes- Return the machine to normal operation; - Replace Main Control Board on page 199. CL-401 Service Manual...
Page 83: User Interface Is Dark
5. Check that LCD cable is connected at connector J36 on the control This resolves the issue board (See Wiring on page 268). Yes- Normal Operation; - Escalate to next level of support Cable 7724421 is connected at connector J36. Yes- Go to step 6; - Connect cable 7724421 CL-401 Service Manual...
Page 84: Paper Jams
S1 to S5, S25 to S27 on page 92). 5. If the sensor is fully functional, ensure panel 3 is properly latched. 6. If panel 3 is not latching correctly, adjust the magnet (see Paper Path on page 212). CL-401 Service Manual...
Page 85 8. Inspect S6-10 (Sensors S6 to S10 on page 95). laminated with the lead 9. Try using a different cartridge and refill. edge undamaged and the next sheet had crashed into its trail edge. Check the fol- lowing: CL-401 Service Manual...
Page 86: Cutter Jams
CAUTION: Use Extreme caution when turning the shaft and grip the wrench tightly. Once the blade is unjammed the wrench will forcefully move forward. 6. If the encoder disc is broken, replace it using the instructions for Cut- ter Encoder on page 166. CL-401 Service Manual...
Page 87 7. Confirm that the belt tension on the motor is as tight as possible. If the belt is loose follow the adjustment procedure Steering Motor Belt on page 218. 8. If jamming issues persists, follow the steps in Clutch Indexing on page 225. CL-401 Service Manual...
Page 88: Clutch
If these are loose, the clutch will not activate properly. Perform the following steps in order to troubleshoot the cutter clutch on CL-401. The machine should be powered off for all of these steps. 1. Check that the clutch is in the proper home position (~2 o'clock) and is not stuck in the “down”...
Page 89: Jam Codes
J505: PAPER IN AREA 5 This jam occurs when a S5 timeout is detected. J514: NO SHEET AT EXIT This jam occurs when the LE of the sheet is not detected at S4 in the expected time. CL-401 Service Manual...
Page 90: J1Xx Jams
- Go to step 6 6. Check the nip force of rollers N1, N11, N12, N13 and N14. This can be done by: • Perform Idler Roller on page 20 to inspect and clean the idler roller springs for these rollers. CL-401 Service Manual...
Page 91: J2Xx Jams
Yes- Return to normal operation; - Go to step 5 5. Check solenoids SOL2 and SOL3 in Solenoids SOL2 - SOL3 on page 100. This clears the fault Yes- Return to normal operation; - Go to step 6 CL-401 Service Manual...
Page 92: J3Xx Jams
Yes- Return to normal operation; - Go to step 6 6. See Checking for Obstructions on page 74 – Area 4 (cutter module). This clears the fault Yes- Return to normal operation; - Go to step 7 CL-401 Service Manual...
Page 93: J4Xx Jams
Drawer on page 231. 9. Escalate to the next level of support. 8. Perform the troubleshooting procedures for J3XX Jams on page 9. If the issue persists, perform the troubleshooting steps for J422: Film Timeout at Cutter on page CL-401 Service Manual...
Page 94: J423: No Film At Cutter
11. Check that the locking mechanism springs are set correctly following the adjustment Locking Mechanism Springs on page 233. 12. Inspect the cartridge for damage following Cartridge Frame on page 13. Escalate to the next level of support. CL-401 Service Manual...
Page 95: J5Xx Jams
S5. This clears the fault Yes- Return to normal operation; - Go to step 3 3. See Sensors S6 to S10 on page This clears the fault Yes- Return to normal operation; - Go to step 4 CL-401 Service Manual...
Page 96: Jam: Cutter Knife Down
207V and 253V for 230V machines. 9. Perform the No AC Power on page 69 procedure. 10. Replace the cutter motor following the procedure Cutter Module on page 161. 11. Escalate to the next level of support. CL-401 Service Manual...
Page 97: Resetting The Film Cartridge
6. Insert the film cartridge back into the machine. After inserting the cartridge back into the machine, it may be necessary to follow the next steps if you are unable to get the film to feed through CL-401 Service Manual...
Page 98 1-6, from the previ- 12. Push the drawer in and close the machine door. ous page, until the film is 13. Test run film through the machine using the user functions menu. reset more smoothly. CL-401 Service Manual...
Page 99: Sensor Checks
6. Perform the procedure to upgrade the firmware found here, Firmware Update / Save Logs on page WARNING: Sensor emits High Intensity narrow angle Infrared beam (940nm). It is invisible to naked eye, avoid looking directly at the sensor when the machine is powered ON. CL-401 Service Manual...
Page 100 This clears the fault Yes- Resume normal operation; - Go to step 7 7. Replace the Main Control Board on page 199. This clears the fault Yes- Resume normal operation; - Escalate to next level of support. CL-401 Service Manual...
Page 101: Sensor Cables
Shares cable with S1, S26 Bypass Sensor 7725551 Shares cable with S1, S26 Align Home Sensor 7725575 Header 7725554 Trim Tray Level Sensor - Emitter/ 7725152 Header 7725583 Receiver (Emitter) 7725583 (Receiver) Cut Sensor 7725583 (Emitter) 7725565 (Receiver) CL-401 Service Manual...
Page 102: Sensors S1 To S5, S25 To S27
Yes- Go to step 6; - Replace the sensor cable. 6. Updgrade the firmware (see Firmware Update / Save Logs on page 14). Re-flashing firmware clears the fault Yes- Resume normal operation; - Go to step 7 CL-401 Service Manual...
Page 103 Replacing the sensor cable corrects the issue Yes- Resume normal operation; - Go to step 8 8. Replace the Main Control Board on page 199. This clears the fault Yes- Resume normal operation; - Escalate to next level of support CL-401 Service Manual...
Page 104: Sensor 1B - Cutter
(2) nuts. Check that the bracket is not bent or bowed in the middle, which could cause the sensors to be mounting position to be incorrect. If this is the case, the bracket will need to be replaced. CL-401 Service Manual...
Page 105: Sensors S6 To S10
Sensors S6 to S10 Sensors S6, S7, S8, S9, S10 To access the sensors do the following: • Open front door. • Remove the cartridge. • Pull out the lamination drawer. Sensors are on the skew sensor board. CL-401 Service Manual...
Page 106: Sensor S11 To S15
Troubleshooting Sensor Checks Sensor S11 to S15 To access the sensors do the following: • Open front door. • Remove the cartridge. • Pull out the lamination drawer. CL-401 Service Manual...
Page 107: Sensor S28 Align Home Sensor
Yes- Resume normal operation; - Go to step 8 See the table Sensor Cables on page 91 for cable numbers. Wiring on page 268 for the location of the connector. CL-401 Service Manual...
Page 108: Sensor S29 Trim Tray
1.3V, which requires a ohm reading from 350-500 ohms. 5. Replace the emitter and receiver. 6. Replace the Main Control Board on page 199. CL-401 Service Manual...
Page 109: Solenoid Checks
(Diverter (SOL1 and SOL8) on page 158), as needed. If the solenoid functions, do the below steps: • Go to Diverter Solenoid (SOL1) on page 206 Trim Diverter Sole- noid (SOL 8) on page 207 to perform an adjustment, if necessary. CL-401 Service Manual...
Page 110: Solenoids Sol2 - Sol3
To check the holding force of the solenoid, go to step 3 actuated using GP 6.2.6 Solenoids Proce- If the solenoid does not actuate, go to step 4 dure, and the corresponding drive roller rotated manually to check this. CL-401 Service Manual...
Page 111 This clears the fault Yes- Return to normal operation; - Go to step 8 8. Replace the Main Control Board on page 199. This clears the fault Yes- Return to normal operation; - Escalate to next level of support CL-401 Service Manual...
Page 112: Stepper Motor Checks
Carriage Sub-Assy on page 173. All timing belts are okay N1, N11, N12, N13, N14 Yes- Go to step 7; - Replace the faulty belt and resume operation 3. Remove the Rear Cover on page 108. CL-401 Service Manual...
Page 113 - Replace the faulty cable and resume normal This clears the fault operation Yes- Resume normal operation; - Escalate to next level of support 11. See Firmware Update / Save Logs on page 14 to upgrade the firmware. CL-401 Service Manual...
Page 114: Ac Motor Check
5. Use a multimeter to check the wire continuity from the AC motor to where it connects to the main control board at J36. • If there is no continuity, identify where the connection is broken and replace that wire. CL-401 Service Manual...
Page 115: Repair Procedures
Sensors: S2, S3, S4, S5 ..........151 Casters ................118 Sensor S28 ..............152 Docking Brackets ..............118 Sensors 6 through 10............ 153 Exhaust Fan ................ 119 Sensors 11 through 15..........154 M1-7, M9 Motor Driver (Stepper Board) ......155 CL-401 Service Manual...
Page 116 Steering Drive Roller Shaft ..........179 Steering Idler Panel Weldment ........... 180 Steering Idler Roller Assembly ..........181 Steering Idler Roller Bearing ..........183 Steering Drive Panel Weldment .......... 184 Laminator Module.......... 185 M8 Motor Driver ..............185 CL-401 Service Manual...
Page 117: Precautions
• This equipment is not intended for use by children. Be sure to have a stable, clean working environment. Dust and dirt can get into the system components and cause a malfunction. Adequate lighting and proper tools can prevent accidentally damaging the internal components. CL-401 Service Manual...
Page 118: Pre-Requisites
3. Grasp the handle and remove the rear cover. Install 1. Place the rear cover in position and tighten the (6) screws. 2. Install the MK 737 boxes. 3. Connect the communication cables. 4. Connect the power cord. CL-401 Service Manual...
Page 119: Dock The Laminator
2. Slide in the upstream and downstream docking mechanisms and install the locking screws. 3. Connect the Communications cable. 4. Connect the power cord. 5. Run a small test job in both Laminator and Bypass mode to ensure the machine is working properly. CL-401 Service Manual...
Page 120: Cabinet
2. Install and tighten the (4) Phillips screws through the tabs. 3. Connect the LCD panel connector and place the LCD cable in the wire saddles 4. Close the Front Door. 5. Install the Rear Cover on page 108. 6. Connect the Power Cord. CL-401 Service Manual...
Page 121: Front Door
1. Insert the upper part of the door on to the pin. 2. Align the holes on the bottom hinge to the bracket and screw into place. 3. Close the door. 4. Run the Door Latch on page 205 adjustment procedure. 5. Connect the power cord. CL-401 Service Manual...
Page 122: Panel Open Magnet
Front Door Panel Open Magnet 1. Open the front door. 2. Remove the (2) screws holding the magnet. Screws 3. Install the new magnet and tighten the (2) screws. 4. Close the door. 5. Connect the power cord. CL-401 Service Manual...
Page 123: Door Latch
1. Open the front door and remove the (2) screws holding the latch. 7. Close the front door. 8. Connect the power cord. 9. Test the door latch operation. 2. Remove (1) screw from the top of the interlock box. Interlock Box CL-401 Service Manual...
Page 124: Interlock Switch
4. Note the location of the (4) wires, then dis- connect them from the interlock switch. Tabs Yellow Orange Position 8 Position 7 Black White Position 4 Position 3 CL-401 Service Manual...
Page 125: Upstream Rear Side Cover
2. Install the Rear Cover on page 108. Dock the Laminator on page 109. Downstream Left Side Cover Install 1. Place the cover in position, insert and tighten the (6) screws. Dock the Laminator on page 109. CL-401 Service Manual...
Page 126: Downstream Rear Side Cover
3. Remove the (8) screws on the cover. 4. Remove the cover. Downstream Rear Side Cover Install 1. Place the cover in position, insert and tighten the (7) screws. 2. Install the Rear Cover on page 108. Dock the Laminator on page 109. CL-401 Service Manual...
Page 127: Lcd Display
4. Disconnect the small ribbon cable from the LCD by gently pulling 3. Connect the large ribbon cable to the adapter board. horizontally on the tabs of the cable connector to release it. 4. Close the front door. 5. Connect the power cord. CL-401 Service Manual...
Page 128: Casters
Install 7. Connect the power cord. 1. Place the docking brackets in position on the upstream devices and tighten the screws. Dock the Laminator on page 109. 3. Connect the communication cable. 4. Connect the power cord. CL-401 Service Manual...
Page 129: Exhaust Fan
4. To remove the exhaust fan from the bracket, disconnect cable (7715267) at connector J20 on the control board (Wiring on page 268). 5. Open the (3) wire saddles towards the bottom of the bracket. 8. Remove the fan. CL-401 Service Manual...
Page 130 4. Place the exhaust fan bracket assembly in position and tighten the screw. 5. Connect cable (7715267) to connector J20 on the control board (Wiring on page 268). 6. Install the Rear Cover on page 108. 7. Connect the power cord. CL-401 Service Manual...
Page 131: Paper Path Lower Entrance Panel
5. Pull the panel out of the machine, sliding it down the shaft. Install 1. Slide the panel up the shaft. 2. Reseat the shaft in the front frame. 3. Install the E-clip at the front end of the shaft. 4. Install the grounding strap. CL-401 Service Manual...
Page 132: Lower Exit Panel
1. Slide the panel up the shaft. 2. Reseat the shaft in the front frame. 3. Install the E-clip at the front end of the shaft. 4. Install the grounding strap. 3. Remove the (1) E-clip from the front of the shaft. CL-401 Service Manual...
Page 133: Inner Entrance Panel
4. Remove the (2) screws from the front frame and the (2) screws from 5. Connect the power cord. the rear frame that are used to mount the inner entrance panel. 5. Remove the Inner Entrance Panel. CL-401 Service Manual...
Page 134: Entrance Idler Panel
7. Remove the E-rings from the top and bottom SOL 2 of the idler panel shaft. SOL 3 Sensor 3 4. Disconnect the connectors for sensors S2 and S3. Remove the screw for the ground strap. Bottom CL-401 Service Manual...
Page 135 Idler Panel Magnetic Latches on page 219. Dock the Laminator on page 109 to the upstream and downstream devices. 10. Close the front door. 10. Grasp and remove the entrance idler panel. 11. Connect the power cord. CL-401 Service Manual...
Page 136: Entrance Drive Panel
Stepper and Mount Assembly on page 147. 6. Install the Entrance Idler Panel on page 124. 7. Adjust the Drive Panel on page 220. 8. Install the Rear Cover on page 108. 9. Connect the power cord. CL-401 Service Manual...
Page 137: Exit Idler Panel
3. Open the cable clamps and release sensor cables S4 and S5 at the sensor. 6. Open the entrance idler panel from the front side. 7. Carefully remove the shaft. 4. Remove the M4 screw for the ground strap. CL-401 Service Manual...
Page 138 7. Close the front door. 8. Connect the power cord. To replace the exit idler panel weldment, do the following procedures to remove and install these components. • Idler Roller on page 136 • Panel Close Magnet on page 135 CL-401 Service Manual...
Page 139: Drive Exit Panel
4. Remove (5) screws from the front frame which mount the exit drive panel. 6. Remove the drive exit panel. Install 1. Place the drive exit panel in position. 2. Install the (5) screws in the front frame and (5) screws in the rear frame. CL-401 Service Manual...
Page 140 220. 4. Install the Exit Idler Panel on page 127. 5. Adjust the Idler Panel Magnetic Latches on page 219. Dock the Laminator on page 109 to the upstream and downstream equipment. 7. Connect the power cord. CL-401 Service Manual...
Page 141: Hinged Exit Panel
Rear Cover on page 108. 4. Install Drive roller cover. Rear Frame Dock the Laminator on page 109 to the upstream and downstream equipment. 6. Connect the power cord. 7. Adjust the Diverter Solenoid (SOL1) on page 206. CL-401 Service Manual...
Page 142: Upper Bypass Panel
6. Remove (2) idler panel magnetic latches from the upper bypass assembly by unscrewing (4) screws. 4. Remove the screw and nut for the ground strap. 7. Remove the (2) screws from the handle assembly. CL-401 Service Manual...
Page 143: Lower Bypass Panel
Rear Cover on page 108. Dock the Laminator on page 109 to the upstream and downstream equipment. 11. Adjust the Idler Panel Magnetic Latches on page 219. Install 12. Connect the power cord. Do the steps in reverse order. CL-401 Service Manual...
Page 144: Bypass Diverter
4. Install the E-clip on the diverter shaft at the front side. 5. Install the Rear Cover on page 108. 6. Connect the power cord. 7. Adjust the Diverter Solenoid (SOL1) on page 206. 4. Remove the E-clip from the diverter shaft on the rear side. CL-401 Service Manual...
Page 145: Panel Close Magnet
Exit Idler Panel on page 127 • Upper Bypass Panel on page 132 1. Remove the (2) screws and (2) nuts. 2. Remove the magnet bracket. 3. Remove the old magnet. 6. Connect the power cord. Magnet Bracket CL-401 Service Manual...
Page 146: Idler Roller
4. Place the (2) extension springs over the (2) bearing housings. 5. Place the hooks on the ends of the springs on the notches at the top of the bushing forks. 6. Connect the power cord. CL-401 Service Manual...
Page 147: Idler Panel Mount Bracket
3. Remove the (2) nuts on the bracket. Install 1. Place the bracket in position and tighten the nuts. 2. Install the Rear Cover on page 108. 3. Connect the power cord. CL-401 Service Manual...
Page 148: Flange Ball Bearing
5. Place the new flange ball bearing in position. Front 6. Install the flat washer. 7. Install the E-ring. 8. Connect the power cord. Rear There are 22 flange ball bearings on the frame - shown in blue color. CL-401 Service Manual...
Page 149: Snap-In Bearing
Exit Idler Panel on page 127 • Lower Exit Panel on page 122 1. Click on the relevant panel link above to remove and access the snap-in bearing. 2. Remove the snap-in bearing. 3. Place the new bearing in position. CL-401 Service Manual...
Page 150: Bearing Housing
Upper Bypass Panel on page 132 1. Remove Idler Roller on page 136. Bearing Flange 4. Install the Idler Roller on page 136. Idler Roller Bearing Housing 2. Remove the (2) bearing housings from the end of the shaft. CL-401 Service Manual...
Page 151: Drive Idler Roller
Drive Roller Assembly on page 145. 6. Install the appropriate timing belt. 7. Connect the power cord. 7. Adjust the relevant timing belt (see Adjustments on page 203). 8. Install the Rear Cover on page 108. 9. Connect the power cord. CL-401 Service Manual...
Page 152: Timing Belts
3. Place the new belt around the pulleys. 162T, 3mm 3GT 162T Timing Belt on 4. Adjust the belt tension, see 132T Timing Belt on page 216. page 144 5. Install the Rear Cover on page 108. 6. Connect the power cord. CL-401 Service Manual...
Page 153: Timing Belt
5. Install the Rear Cover on page 108. 6. Connect the power cord. 4. Adjust the belt tension per 539T Timing Belt on page 214. 5. Install the Rear Cover on page 108. 6. Connect the power cord. CL-401 Service Manual...
Page 154: Timing Belt
5. Install the Rear Cover on page 108. 4. Adjust the belt tension per 197T Timing Belt on page 217. 6. Connect the power cord. 5. Install the Rear Cover on page 108. 6. Connect the power cord. CL-401 Service Manual...
Page 155: Drive Roller Assembly
9. Remove the drive roller. Drive Roller 10. Remove the bearing from the front of the machine. 4. For all drive rollers except N1 and N11, remove the cutter module. 11. Remove the bearing from the rear of the machine. CL-401 Service Manual...
Page 156 Timing Pulley on page 141 on the appropriate drive roller. 6. Install the Timing Belts on page 142 on the appropriate drive roller. 7. Install the Rear Cover on page 108. 8. Close the front door. 9. Connect the power cord. CL-401 Service Manual...
Page 157: Stepper And Mount Assembly
1. Place the stepper and mount assembly in place and tighten the (4) screws. 2. See Timing Belts on page 142 and adjust the relevant belt’s tension. 3. Connect the motor connector. 4. Install the Rear Cover on page 108. 5. Connect the power cord. CL-401 Service Manual...
Page 158: Paper Path Sensors
28 on Align Home page 153 page 152 11 on Alignment 27 on Exit page 154 page 149 12 on Alignment page 154 13 on Alignment page 154 14 on Alignment page 154 15 on Alignment page 154 CL-401 Service Manual...
Page 159: Sensors: S1, S25, S26 And S27
6. Plug the sensor in and install the sensor assembly bracket. the barrel screw. 5. Close the front door. 7. Push the lamination drawer in and close the front door. 6. Connector the power cord. 8. Connect the power cord. CL-401 Service Manual...
Page 160 S22 Sensor 1. Open the front door and pull out the lamination drawer. 2. Use a Phillips screwdriver to remove the screw securing the sensor bracket by going through the hole in the bracket to access the screw. CL-401 Service Manual...
Page 161: Sensors: S2, S3, S4, S5
5. Remove the old sensor and place the new one in position and tighten the barrel screw. 6. Close the front door. Dock the Laminator on page 109 to the upstream and downstream equipment. 8. Connector the power cord. CL-401 Service Manual...
Page 162: Sensor S28
7. Close the front door. Dock the Laminator on page 109 to the upstream and downstream equipment. 9. Connector the power cord. 3. Remove the (2) M3 screws that secure the sensor to the bracket. Bracket Screws CL-401 Service Manual...
Page 163: Sensors 6 Through 10
Sensors on page 11 to confirm the skew board is fully functioning. 12. Resume normal operation. 4. Remove the (4) M4 nuts and (4) washers located beneath the nuts. IMPORTANT: Do NOT remove the washers beneath the board. CL-401 Service Manual...
Page 164: Sensors 11 Through 15
8. Connect the alignment sensor board connector. 9. Push in the laminator drawer. 10. Connect the power cord. 11. Run Sensors on page 11 to ensure the alignment board is fully func- tioning. 12. Resume normal operation. CL-401 Service Manual...
Page 165: M1-7, M9 Motor Driver (Stepper Board)
6. Set the (5) dip switches on the new Dip Switches 8. Connect the (3) connectors. motor driver in accordance with the table to the right. 9. Install the Rear Cover on page 108. 10. Connect the power cord. CL-401 Service Manual...
Page 166: M8 Motor Driver (Stepper Board)
Examples of incorrect functioning are the motor traveling in the wrong direction or at the wrong speed. 4. Install the driver following the install instructions for M8 Motor Driver on page 185. CL-401 Service Manual...
Page 167: Solenoids
Repair Procedures Solenoids Solenoids Replacement Solenoid # Solenoid Type Procedure SOL1, SOL8 Diverter page 158 SOL2 Entrance Idler, Top page 159 SOL3 Entrance Idler, Bottom page 159 SOL6 Cutter Clutch page 162 CL-401 Service Manual...
Page 168: Diverter (Sol1 And Sol8)
Trim Diverter Solenoid (SOL 8) on page 207. 5. Remove the (2) screws from the diverter solenoid sub-assembly. 5. Install the bracket for the Exhaust Fan on page 119. 6. Install the Rear Cover on page 108. 7. Connect the power cord. CL-401 Service Manual...
Page 169: Entrance Idler (Sol2 And Sol3)
6. Place the new solenoid assembly in position and tighten the barrel screws. 7. Connect the solenoid connector. 8. Place the cable into the cable clamps and close the clamps 9. Close the front door. Dock the Laminator on page 109. 11. Connect the power cord. CL-401 Service Manual...
Page 170: Anti-Static Brush
2. Peel off the old anti-static brush. 3. Clean the surface with some isopropyl alcohol. 4. Affix the new brush inside, referencing the cut-outs as shown above. Dock the Laminator on page 109 from the downstream equipment. 6. Connect the power cord. CL-401 Service Manual...
Page 171: Cutter Module
Motor Belt Tension on page 224. on page 224 6. Tighten the (5) bolts. 6. Tighten the bolts. 7. Install the Rear Cover on page 108. 7. Install the Rear Cover on page 108. 8. Connect the power cord. CL-401 Service Manual...
Page 172: Clutch
5. Gently lower the connecting rod while making sure the washer between the rod and crank does not fall into the machine. Remove the set screw securing the shaft to the crank. Set Screw CL-401 Service Manual...
Page 173 (see Cutter Module on page 224). 12. Apply red thread locker to the bolt, provided with the kit, and use to secure the connecting rod to the crank. IMPORTANT: Place the washer between the bearing and crank. CL-401 Service Manual...
Page 174: Blade
9. Confirm the blade assembly is tight and resistant to sideways motion. 10. Push in drawer, connect the power cord, and run some test cuts. 11. Check that double groove from Cut Stick on page 46 inspection is no longer present. CL-401 Service Manual...
Page 175: Cutter Shaft Ball Bearing
4. Remove the ball bearing. 5. Place the new ball bearing in position. 6. Place the nylon washer in position. 7. Place the E-ring in position. 8. Install the Rear Cover on page 108. 9. Connect the power cord. CL-401 Service Manual...
Page 176: Cutter Encoder
Do not fully tighten the screw. 3. Install the sensor bracket using a 5.5mm driver to tighten the (2) screws. 4. Confirm that the encoder is centered in between the sensor veins and tighten the M3 screw the rest of the way. CL-401 Service Manual...
Page 177 Repair Procedures Cutter Encoder 5. Wait 30 minutes for the threadlocker to cure before running the cutter. 6. Install the Rear Cover on page 108. 7. Connect the power cord. CL-401 Service Manual...
Page 178: Trim Tray
6. Connect cable at the trim tray home switch. 7. Put the trim tray in position and push in firmly until it latches. 8. Close the front door. 2. Remove the trim tray. 9. Connect the power cord. CL-401 Service Manual...
Page 179: Trim Level Emitter
8. Put the trim tray in position and push in firmly until it latches. 8. Put the trim tray in position and push in firmly until it latches. 9. Close the front door. 9. Close the front door. 10. Connect the power cord. 10. Connect the power cord. CL-401 Service Manual...
Page 180: Steering Module Alignment Module
7. Locate and disconnect the S28 alignment home sensor and remove 4. Disconnect and unclamp the skew and alignment board cables and it from the wire harnesses. gently move them away from the alignment module. Alignment Skew CL-401 Service Manual...
Page 181 9. Remove the (4) 7mm screws located at the front and the (4) screws 11. Hold the module by the base then pull up and out. at the rear of the laminator drawer. NOTE: Alignment module will drop down when all screws are removed. FRONT REAR CL-401 Service Manual...
Page 182: Laminator Alignment Stepper Motor, Pulley And Bracket
188. 4. Remove the (4) Phillips screws and the timing belt. 5. Replace the alignment stepper mount bracket by removing the (2) screws holding the bracket. 6. Place the new bracket in position and tighten the screws. CL-401 Service Manual...
Page 183: Alignment Carriage Sub-Assy
2. Remove the steering idler and drive panel assemblies by removing the (4) M3 nuts. 5. Remove the align home sensor bracket sub-assembly by removing the (2) screws and its cable. 3. Remove (4) E-clips from steering drive roller shaft. Align Home Sensor Bracket CL-401 Service Manual...
Page 184 6. Remove left and right steering stepper motors, along with their corre- Installation Tip: Look at the images for selecting the proper cable sponding cables, by removing the (8) screws. for the motors: 7715529 Install 1. Install the parts that were removed in the new alignment carriage sub-assembly. CL-401 Service Manual...
Page 185 Repair Procedures Alignment Carriage Sub-Assy 7715528 2. Install the Steering Module on page 170. 3. Push in the laminator drawer. 4. Install the Rear Cover on page 108. 5. Connect the power cord. CL-401 Service Manual...
Page 186: Steering Stepper Motor
170. 4. Remove the (4) M3 Phillips screws. Remove the rear side steering motor, the Steering Module on page 170 needs to be removed. 2. Disconnect the steering motor cable at the motor and at the header. CL-401 Service Manual...
Page 187 4. Install the align home sensor bracket and tighten the (2) M3 screws. 5. Install the Steering Module on page 170. 6. Push in the laminator drawer. 7. Connect the power cord. CL-401 Service Manual...
Page 188: Steering Motor Belt (65 Groove)
2. Install the steering drive roller and the (2) flat washers and the spring on the end of the shaft. 3. Install the E-rings on the steering drive roller shaft. 4. Push in the laminator drawer. 5. Connect the power cord. CL-401 Service Manual...
Page 189: Steering Drive Roller Shaft
5. Install the (2) E-rings, spring, steering drive roller and the (2) flat washers on each end of the shaft. 6. Install the Steering Module on page 170. 7. Push in the laminator drawer. 8. Connect the power cord. CL-401 Service Manual...
Page 190: Steering Idler Panel Weldment
(use semi perfs for placement). 2. Place the steering idler panel sub-assembly in position on the drive panel steering sub-assembly. 3. Install the (4) screws. 4. Push in the laminator drawer. 5. Connect the power cord. CL-401 Service Manual...
Page 191: Steering Idler Roller Assembly
4. Disconnect the skew sensor board connector. 8. Gently move the (2) springs off the ends of the roller. 5. Release the cable clamp and move the cable out of the way. 6. Remove the (2) M4 Nuts. 9. Remove the roller assembly. CL-401 Service Manual...
Page 192 5. Install and tighten the M4 Nuts. 6. Place the skew sensor board cable in the cable clamp and close. 7. Connect the skew sensor board connector. 8. Push in the laminator drawer. 9. Connect the power cord. CL-401 Service Manual...
Page 193: Steering Idler Roller Bearing
2. Remove the (2) steering idler roller bearings from the ends of shaft on the steering idler roller assembly. Roller Bearing 3. Place the new steering idler roller bearings on to the ends of shaft . 4. Replace the Steering Idler Roller Assembly on page 181. CL-401 Service Manual...
Page 194: Steering Drive Panel Weldment
1. Place the steering drive panel weldment in place. 2. Tighten the nuts that hold the weldment. 2. Remove the (2) spacers. 3. Install the spacers. 4. Install the Steering Idler Roller Assembly on page 181. 5. Connect the power cord. CL-401 Service Manual...
Page 195: Laminator Module
5. Unplug all (4) cables from the driver board. 8. Rotate the assembly clockwise 270° to orient it for removal. IMPORTANT: Do not try to rotate it counter clockwise. It will not fit and may cause damage to the machine. CL-401 Service Manual...
Page 196 Once the assembly has cleared the top roller, you can lift the locking mechanism to create more space to remove the driver. 9. Confirm that the locking mechanism is in the down position before lifting out the assembly. CL-401 Service Manual...
Page 197 If the plate does not drop in easily, you will need to press or tap the flange tabs in to get them inside the frame. 6. Rotate the assembly 270° counterclockwise until the resistor is on top. CL-401 Service Manual...
Page 198: Cartridge Rail Plate
4. Use a 7mm driver to remove the (4) screws holding in the cartridge rail plate and then lift the plate out and set it aside. NOTE: After installing the new cartridge rail, adjust the Rail Height on page 211. CL-401 Service Manual...
Page 199: Rollers
8. Remove the pulley from the shaft. 5. Loosen the belt idler pulley on the shaft. 6. Loosen the (2) set screws on the pulley. 9. At the front of the machine, pull out the laminator drawer and remove the (2) 7mm screws. CL-401 Service Manual...
Page 200: Pressure
13. Pull out the toggle clamps, being careful not to lose washers, and replace the roller. 14. Perform the steps in reverse order to install the new rollers. 15. Install the Rear Cover on page 108. 16. Connect the power cord. CL-401 Service Manual...
Page 201: Locking Mechanism
5. Remove the (2) 5.5mm screws holding the S24/receiver bracket, located on the toggle clamp baffle. Install Install the new locking mechanism and follow the steps in reverse order and connect the power cord. CL-401 Service Manual...
Page 202: Handle
2. Use a 2.5mm Allen wrench to remove the (1) socket head cap screw. Handle 3. Install the new handle and tighten down the cap screw. 4. Push the lamination drawer in and close the front door. 5. Connect the power cord. CL-401 Service Manual...
Page 203: Clamps
If below. they have loosened, turn them with a 10mm wrench until they are snug against each other and the top washer. Clamps CL-401 Service Manual...
Page 204 If the mechanism is still not working, it will need to be tance is correct. Make sure the two bottom nuts are snug with each replaced. Follow the previous repair steps, but instead of fixing the other when finished. existing locking mechanism, replace it with new service parts. CL-401 Service Manual...
Page 205: Alignment Sensor Bracket
7. After the new bracket is installed ensure that both paper paths are at the same height and that the sheets will not be obstructed. CL-401 Service Manual...
Page 206 (2) nuts after. 9. Reconnect the power cord and run a single sheet to confirm that the alignment sensor bracket is not causing obstructions in the paper path. 10. If no jam occurs resume normal operation. CL-401 Service Manual...
Page 207: Electronics & Controls Repair Procedures
5. Remove the power supply and the cables through the opening on top by releasing the cable clamps and guiding the connectors through the grommet. 3. Remove the (1) M4 screw and remove the ground cable from the power supply. Screw on Ground Wire CL-401 Service Manual...
Page 208: Ac Filter
4. Connect connectors J1 and J3 to the main control board. 6. Install the Rear Cover on page 108. 5. Install the Rear Cover on page 108. 7. Connect the power cord. 6. Connect the power cord. CL-401 Service Manual...
Page 209: Main Control Board
Wiring on page 268. 5. Replace the PCB cover plate using the (4) M4 Screws. 6. Install the Rear Cover. 7. Connect the power cord. 4. Disconnect the connectors from the main and comm boards and remove the boards. CL-401 Service Manual...
Page 210: Communication Board
3. Replace the PCB cover plate using the M4 screws. board and the chip reader. 4. Install the Rear Cover on page 108. 4. Install the Rear Cover on page 108. 5. Connect the power cord. 5. Connect the power cord. CL-401 Service Manual...
Page 211: Bracket
3. Perform the adjustment for the Cartridge Stop Magnet on page 208. 4. Disconnect the (5) connectors on the breakout board and remove the 4. Install the Rear Cover on page 108. (4) 5.5mm screws. 5. Connect the power cord. CL-401 Service Manual...
Page 212 9. Replace the (1) 7mm screw to secure the fan bracket. 10. Install the Rear Cover on page 108. 5. Replace the board. The Breakout Board replacement should have 3 jumpers. 6. Secure the board using the (4) 5.5mm screws. 7. Reconnect the (5) cables. CL-401 Service Manual...
Page 213: Adjustments
Steering Sub-Assembly....214 539T Timing Belt ......214 166T Timing Belt ......215 132T Timing Belt ......216 197T Timing Belt ......217 162T Timing Belt ......217 Steering Motor Belt......218 Idler Panel Magnetic Latches ... 219 CL-401 Service Manual...
Page 214: Precautions
3. Grasp the handle and remove the rear cover. Installation 1. Place the rear cover in position and tighten the (6) screws. 2. Install the MK 737 boxes. 3. Connect the Communication cables. 4. Connect the power cord. CL-401 Service Manual...
Page 215: Door Latch
• Move the door out by moving the latch away from the front of the door. 4. Tighten the Adjustment Screws (2). 5. Close the Front Door. 6. Connect the Power Cord. 7. Test the Door Latch operation. CL-401 Service Manual...
Page 216: Solenoids
8. Check that the clearance between the diverter and the cutout in the lower entrance panel at both sides has a mini- mum clearance of 1.0mm. 9. Install the Rear Cover on page 204. CL-401 Service Manual...
Page 217: Trim Diverter Solenoid (Sol 8)
9. Install the Rear Cover on page 204. 2. Plug in the power cord, power up the machine and follow the instruc- 10. Connect the power cord. tions for Solenoids on page 12 to power on SOL8. CL-401 Service Manual...
Page 218: Cartridge
4. From the rear of the machine, locate the cartridge magnet bracket 9. Tighten the (2) screws on the bracket. 5. Loosen, but do NOT remove, the (2) screws on the bracket. 10. Connect the power cord and resume normal operation. CL-401 Service Manual...
Page 219: Cartridge Foot
0 +/-0.5mm. The LCD margin adjust- 8. Adjust the tabs to the proper position as shown in the next pictures. ment is not meant to make up for gross film misalignment. 9. Connect the power cord and resume normal operation. CL-401 Service Manual...
Page 220 Adjustments Cartridge 9. Tighten the (4) bolts back in place to fix the cartridge locks into their new position. 10. Push the drawer into the machine. 11. Connect the power cord and power on the machine. CL-401 Service Manual...
Page 221: Rail Height
7. Tighten the (4) screws on the cartridge tray after making the proper adjustments. 8. Insert the film cartridge and ensure the film size and count are being read properly on the screen. 9. Connect the power cord and resume normal operation. CL-401 Service Manual...
Page 222: Paper Path
5. If dog ear issues occur on sheets, ensure the right curved panel in area 3 is properly adjusted. 3. Loosen the (2) screws that hold the magnet. The screws should be tightened while the panel is fully closed. CL-401 Service Manual...
Page 223: Pressure Roller Idler
(2) nuts on the bracket. 5. Ensure the belt is tight. 8. Run a test job to ensure dog eared sheets are gone. 6. Connect the power cord and resume normal operation. 9. Connect the power cord and resume normal operation. CL-401 Service Manual...
Page 224: Timing Belts
5. Install the Rear Cover on page 204. 6. Connect the power cord. 5. Tighten the (4) Phillips screws. 6. Install the cartridge rail. 7. Push in the drawer and close the door. 8. Connect the power cord. CL-401 Service Manual...
Page 225: Timing Belt
Rear Cover on page 204. 2. Loosen the tensioner. 4. Tighten the tensioner. 3. Adjust the belt tension such that there is a deflection of 3~5mm. 5. Install the Rear Cover on page 204. 6. Connect the power cord. CL-401 Service Manual...
Page 226: 132T Timing Belt
Rear Cover on page 204. 2. Loosen the tensioner. 4. Tighten the tensioner. 5. Install the Rear Cover on page 204. 6. Connect the power cord. 3. Adjust the belt tension such that there is a deflection of 4~6mm. CL-401 Service Manual...
Page 227: Timing Belt
3. Adjust the belt tension such that there is a deflection of 3~5mm. 4. Tighten the tensioner. 4. Tighten the tensioner. 5. Install the Rear Cover on page 204. 5. Install the Rear Cover on page 204. 6. Connect the power cord. 6. Connect the power cord. CL-401 Service Manual...
Page 228: Steering Motor Belt
Move the steering carriage to access all screws 5. Tighten the (4) Phillips screws. 6. Push in the drawer. 7. Close the front door. 8. Connect the power cord. 4. Adjust the belt tension such that there is a deflection of 1~2mm. CL-401 Service Manual...
Page 229: Idler Panel Magnetic Latches
With the panel fully closed (the panel will hit limiting tabs and you will Two round spacer studs should contact the drive panels completely. If there hear a sound), tighten the two screws. is movement when the idler assembly is latched, adjust the assembly. CL-401 Service Manual...
Page 230: Drive Panel
This drive panel controls the nip forces of N2, N3, N4 and N5. To adjust the position of the drive panel, loosen (5) screws from the front frame and (5) screws from the rear frame. • Entrance Drive Panel • Exit Drive Panel • Lower Bypass Panel CL-401 Service Manual...
Page 231: Exit Drive Panel
1.5±0.5mm through the drive panel. This drive panel controls the nip forces of N8, N9 and N10. 1. To adjust the position of the drive panel, loosen (6) screws from the front frame and (6) screws from the rear frame. CL-401 Service Manual...
Page 232 3. Use the (6) reference holes in the front and (5) in the rear frames and the sheet metal panel, position the drive panel to ensure the drive rollers protrude 1.5±0.5mm through the drive panel. FRONT Cover Plate REAR CL-401 Service Manual...
Page 233: Lower Bypass Panel
1.5±0.5mm through the drive panel This drive panel controls the nip forces of N12, N13 and N14. To adjust the position of the lower bypass panel, loosen (5) screws from the Front frame and (5) screws from the rear frame. CL-401 Service Manual...
Page 234: Cutter Module
NOTE: Belt tension can be difficult to measure accurately. Loose belts can result in cutter jams. If those occur, the belt can be tightened beyond what seems to be 5mm of deflection. CL-401 Service Manual...
Page 235: Clutch Indexing
If the clutch needs to stop later, rotate the stop collar counter-clockwise. position, check that the set screws on the clutch are secure. f. If the flats are not horizontal, the clutch must be indexed (±5° from horizontal). CL-401 Service Manual...
Page 236: Pivot
11. After the cut cycles, confirm that the shaft flat returned. 12. Install the Rear Cover on page 204. 13. Connect the power cord. WARNING: Moving Parts, keep hands clear of nips and belts when the interlock cheater is inserted. CL-401 Service Manual...
Page 237: Connecting Rod Length
Instead, the connecting rod length or spring length must be adjusted. See Connecting Rod Spring on page 229. 4. Measure and record the distance (D), in millimeters, between the two surfaces shown below. The length should be 32.7mm. CL-401 Service Manual...
Page 238 Do not adjust the threaded rod shorter than the nominal. Doing so may result in cutter jams and reduced component life. To shorten, turn the hex adapter towards the cutter frame. To lengthen, turn the hex adapter towards yourself. CL-401 Service Manual...
Page 239: Connecting Rod Spring
7. To adjust, insert the bent wrench over the locknut and either turn the 4. Locate the connecting rod spring in the exposed rear of the machine. nut towards the frame to loosen the spring or towards you to tighten. CL-401 Service Manual...
Page 240 It is usually best to turn the eye bolt slightly more biased towards the frame, because it tends to rotate downwards during opera- tion if it is set completely parallel to the frame. 11. Replace the side cover and install the Rear Cover on page 204. CL-401 Service Manual...
Page 241: Lamination Drawer
4. While holding it in position, tighten the screw securing the pin. 5. Check the alignment and, if necessary, repeat steps 2-4 until correct. 6. Install the Rear Cover on page 204. 7. Connect the power cord. CL-401 Service Manual...
Page 242: Drawer Switch
When you remove the stick, there must be a groove in position 1. 6. Check if there is a groove in position 2 and if not, rotate the stick so that position 2 is facing the cutter. CL-401 Service Manual...
Page 243: Locking Mechanism Springs
5. Tighten the top jam nut without changing the spring compression. 2. Loosen the top jam nut using a 10mm wrench. 6. Repeat on the other locking mechanism. 7. Push in the drawer and close the door. 8. Connect the power cord. CL-401 Service Manual...
Page 244: Drawer Latch
9. Confirm the drawer screw comes in contact with the switch. 10. If no contact is being made between the switch and screw, adjust the Drawer Switch on page 232. 11. Connect the power cord. CL-401 Service Manual...
Page 245: Sensors
3. Adjust the screw on the potentiometer next to the test points until the correct resistance range is achieved. 4. With the power on and door closed, re-check the voltage acrossTP1B-GND and TP-1B is close to 1.3V. CL-401 Service Manual...
Page 246: Parts List
PL 3.6 Disengaging Roller Solenoid 249 Drawer ........... 250 PL 4.1 Cutter......250 PL 5.1 Laminator ....... 251 PL 6.1 Electronics...... 252 PL6.2 Cable Part Number Index 253 PL 7 Kits ..........255 Installation Kit Items....255 Cutter ......... 258 Clutch......... 267 CL-401 Service Manual...
Page 247: 1.1 Final Assembly
Parts List PL 1.1 Final Assembly PL 1.1 Final Assembly Part Item Description Number 7725001 FINAL ASSEMBLY, OLYMPIA, KM, 115V 7725101 FINAL ASSEMBLY, OLYMPIA, KM, 230V CL-401 Service Manual...
Page 248: Pl 1.2 Covers
COVER ASSY, SIDE, LEFT BACK, OLY Z7725316 POCKET E, ASSY, OLY 7718873 FOAM, KM SPARTA TOP COVER WELDMENT, SPARTA 2.0 OLYMPIA Z7725288 TOP COVER, OLY, KM 7724422 RIBBON CABLE, LCD Z7729801 KIT, SCREWS, OLY 7715828 COVER, USB DRIVE CL-401 Service Manual...
Page 249: Pl 2.1 Frame Assembly
SHAFT, IDLER PANEL HINGE 7715210 SHAFT, IDLR PANEL HINGE,LONG 7715251 BRACKET, IDLER PANEL MOUNT 7725470 PANEL WELDMENT, DRIVE, EXIT, OLY 7725466 PANEL, BYPASS, LOWER, OLY Z7729802 SNAP-IN BEARING, 6MM ID (1821209) 7718619 SHAFT, IDLER PANEL HINGE, OFFSET GROOVE, LONG CL-401 Service Manual...
Page 250: 2.2 Front
BRACKET, MAGNET STANDOFF, ASSY Z7725532 BRACKET, MAGNET Z7725388 TRIM TRAY, WELDMENT, OLYMPIA 7715650 LATCH, BYPASS 7715637 POWER SUPPLY, 24V, MW SP 480 7715789 MAGNET, PANEL, OPEN, WEAK Z7725181 CAP, RUBBER .032x1.00, BLUE 7723799 CASTER, ADJUSTABLE, ASSY, KM CL-401 Service Manual...
Page 251: Pl 2.3 Rear
7712703 7715383 ROLLER, IDLER, DRIVE ASSY 7715813 SOLENOID, BRACKET, DIVERTER, SUB ASSEMBLY, RICOH Z7729803 WIRE SADDLE, MEDIUM, LOCKING TOP, V-0 7715818 Z7729803 WIRE SADDLE, LARGE, LOCKING TOP, V-0 7715819 Z7729803 WIRE SADDLE, SMALL, LOCKING TOP, V-0 7715817 CL-401 Service Manual...
Page 252: 2.4 Drive Rollers
BEARING, BALL, FLANGE 6X13X5, SUJ2 Z7729801 WASHER, FLAT, 6.025 X 8 X 0.75 1822005 Z7729802 E-RING, JE-5 1822202 Z7725455 PULLEY, TIMING, 3MM GT2, 20 GROOVES Z7725456 PULLEY, TIMING, 3MM GT2, 16 GROOVES 7715204 PULLEY,TIMING,2MM 2GT,30T 1825501 RETAINING RING, 6 MM SHAFT CL-401 Service Manual...
Page 253: 2.5 Internal Parts
SCREW, PHILLIPS HX HD W/SEMS M4 X 12 1823915 7711970 EMITTER 7711973 RECEIVER Z7729801 NUT, KEPS M4 1824001 7715131 BYPASS DIVERTER Z7725529 TRIM DIVERTER ASSY 7715186 CHIP TRAY SENSOR MOUNT ASSY 7715637 POWER SUPPLY, 24V, MW SP 480 Z7725392 SPACER, 4X6X9 CL-401 Service Manual...
Page 254: 2.9 Belts
7725335 BLOCK, SPRING, TOGGLE CLAMP 7725336 SPRING PIN, COILED, M3 X 14 7725337 FRAME, TOGGLE CLAMP, ASSY 7725455 PULLEY, TIMING, 3MM GT2, 20 GROOVES 7725456 PULLEY, TIMING, 3MM GT2, 16 GROOVES 7715204 PULLEY,TIMING,2MM 2GT,30T 7715245 TENSIONER ASSEMBLY CL-401 Service Manual...
Page 255: Paper Path
7715291 SENSOR AND BRACKET ASSY Z7725181 CAP, RUBBER .032x1.00, BLUE 7717410 SPRING,TRANSPORT IDLR ROLLER 7715382 BEARING HOUSING Z7725182 HANDLE ASSY, IDLER PANELS, BLUE 7715625 WIRE SADDLE, SHORT Z7725432 PANEL, WELDMENT, IDLER, ENTRANCE, OLY 7714679 GROUND STRAP, M4 CL-401 Service Manual...
Page 256: 3.3 Entrance Corner Panel
Parts List Paper Path PL 3.3 Entrance Corner Panel Item Part No. Description Z7725181 CAP, RUBBER .032x1.00, BLUE Z7725479 PANEL ASSEMBLY, LOWER, EXIT, OLY 7718630 GROUND STRAP, M4 7715893 BRUSH, ANTI STATIC, SUS, LONG CL-401 Service Manual...
Page 257: 3.4 Exit Idler Panel
SENSOR AND BRACKET ASSY 7717410 SPRING,TRANSPORT IDLER ROLLERS Z7725182 HANDLE ASSY, IDLER PANELS, BLUE 7715382 BEARING HOUSING ASSY Z7725476 PANEL WELDMENT, IDLER, EXIT, OLY 7714679 GROUND STRAP, M4 Z7725181 CAP, RUBBER .032x1.00, BLUE Z7729801 SCREW, BARREL, M4, 7MM DEEP 7715629 CL-401 Service Manual...
Page 258: 3.5 Upper Bypass Panel
SENSOR AND BRACKET ASSY,S1 Z7729801 SCREW, BARREL, M4, 7MM DEEP 7715629 Z7725459 PANEL WELDMENT, BYPASS, UPPER, OLY 7714679 GROUND STRAP, M4 Z7725181 CAP, RUBBER .032x1.00, BLUE 7715103 ROLLER ASSY, IDLER 7715291 SENSOR AND BRACKET ASSY, 1824002 1824002 NUT, KEPS, M3 CL-401 Service Manual...
Page 259: 3.6 Disengaging Roller Solenoid
Parts List Paper Path PL 3.6 Disengaging Roller Solenoid Item Part No. Description Qty. 7724134 MODULE, SOLENOID, DISENGAGING ROLLER CL-401 Service Manual...
Page 260: Drawer
CONNECTING ROD ASSY, SPRING, OLY Z7725250 OUTFEED WELDMENT, CUTTER Z7729804 KIT, CLUTCH, OLYMPIA Z7729805 KIT, PULLEY, OLYMPIA Z7725243 CRANK, OLYMPIA Z7725244 BEARING, FLANGED, 30X62X16 Z7725720 BRACKET, SENSOR, S22 Z7725692 MOTOR MOUNT ASSEMBLY, CUTTER, OLY, 115V KIT Z7729814 KIT, CUT STICKS, X5 CL-401 Service Manual...
Page 261: Pl 5.1 Laminator
PULLEY, TIMING, HTD5MM, 32T X 1/2IN BORE 1824001 NUT, KEPS M4 Z7725376 BELT, HTD5MM, 100T X 15W Z7725414 BRACKET, DRAWER SLIDE, RH, ASSY, OLY Z7725415 BRACKET, DRAWER SLIDE, LH, OLY 7718047 DRAWER SLIDE ASSEMBLY, 550MM 1825605 BUTTON-HEAD SOCKET SCREW M4X8 CL-401 Service Manual...
Page 262: Pl 6.1 Electronics
Parts List Drawer PL 6.1 Electronics Item Part No. Description Qty. Z7725636 RFI FILTER Z7729815 BOARD, CONTROL, MAIN 7718799 BOARD, CONTROL, COMM Z7725522 BOARD, BREAKOUT 7715863 FUSE, AC POWER, 250V, 5A CL-401 Service Manual...
Page 263: Pl6.2 Cable Part Number Index
CABLE, CARTRIDGE DETECTION 7725559 CABLE, SOLENOIDS, EXIT, BRD TO HDR OLY 7725510 CABLE, SWITCH, JUMPER, OLYMPIA 7725560 CABLE, STEPPER MOTOR DRIVERS, M1, M2 7725643 CABLE, M8 POWER, BOARD TO ARM 7725561 CABLE, STEPPER MOTOR DRIVER, M3, M4, M5 OLY CL-401 Service Manual...
Page 264 7725653 CABLE, AC STEPPER DRIVER, HDR, TERMI- 7715462 CABLE SENSOR 27 7725178 REGNERATIVE RESISTOR ASSY 7715476 CABLE, PUNCH MOTOR 7725640 STEPPER MOTOR, LAM, ASSY 7725684 CABLE, SOLENOID 6 TO HDR OLY 7718876 CABLE, PASS THROUGH, KM SPARTA CL-401 Service Manual...
Page 265: 7 Kits
SCREW, ROUND TIP, M4 X 8 7610500 CABLE ASSY, INTERFACE (37 PINS) 7723873 DOCKING BRACKET ASSY, REAR, SPARTA, KM 7718832 BRKT SUBASSY, DOCKING, LOWER FRNT, KM 7710227 BRACKET, LOCK, FRONT, LOWER 7718834 BRKT SUBASSY, DOCKING, UPPER FRNT, KM CL-401 Service Manual...
Page 266 Part Number Description Qty. Part Number Z7725704 7725704 HINGE ASSY, LOWER, KM, OLY 1823903 SCREW, PHILLIPS HX HD W/SEMS M4 X 8 Part Number Description Qty. Part Number Z7725450 7725450 EXHAUST FAN, BRACKET, ASSY, OLY 1822202 E-RING, JE-5 CL-401 Service Manual...
Page 267 WASHER, FLAT, 4.1X8X1.5 7715629 SCREW, BARREL, M4, 7MM DEEP 1822117 WASHER, 3.2ID, 8OD, 0.75MM THICK Part Number Description Qty. Part Number Z7729802 KIT, DRIVE HARDWARE, OLY 1821209 SNAP-IN BEARING, 6MM ID 1822202 E-RING, JE-5 1825501 RETAINING RING, 6MM SHAFT CL-401 Service Manual...
Page 268: Cutter
7715819 WIRE SADDLE, LARGE, LOCKING TOP, V-0 7715817 WIRE SADDLE, SMALL, LOCKING TOP, V-0 Cutter Part Number Description Qty. Part Number Z7725215 BLADE KIT 7725215 BLADE 7725707 M6X20 FLAT HEX HEAD SCREW 7729811 BLADE REMOVAL TOOL, OLY CL-401 Service Manual...
Page 269 M8X1.25 - HIGH PRECISION THREADED SHOULDER BOLT 7725249 SHIM, 16X10X0.5 7725711 10MM EXTERNAL RETAINING RING 7729813 SERVICE, THREADLOCKER, RED 271 Part Number Description Qty. Part Number Z7725250 CUTTER OUTFEED 7725250 OUTFEED WELDMENT, CUTTER 7725254 SCREW, KNURLED-HEAD, M4X.07X8 CL-401 Service Manual...
Page 270 Description Qty. Part Number Z7725266 DISC SENSOR KIT 7725266 DISK, SENSOR 1821611 SCREW, PHILLIPS HD HD W/SEMS, M3X10 7729812 SERVICE, THREADLOCKER, BLUE 243 7715340 SENSOR, VEIN, SHARP 7725260 BRACKET, HOME SENSOR 1823901 SCREW, PHILLIPS, HEX HD M3X6 CL-401 Service Manual...
Page 271 Part Number Description Qty. Part Number Z7725692 MOTOR MOUNT ASSEMBLY, CUTTER, OLY, 115V KIT 7725692 MOTOR MOUNT ASSEMBLY, CUTTER, OLY, 115V 1824703 SCREW, HEX CAP, M8, 16MM LONG 1823909 SCREW, PHILLIPS HX HD W/SEMS M4 X 6 CL-401 Service Manual...
Page 272 SCREW, SHCS, M4X20 7725326 TOGGLE CLAMP, ASM, FRONT 1824902 LOCK WASHER, M4 Part Number Description Qty. Part Number Z7729807 KIT, TOGGLE CLAMP SET 7725716 TOGGLE CLAMP, ASM, REAR 7725326 TOGGLE CLAMP, ASM, FRONT Replace with Bearing + plates CL-401 Service Manual...
Page 273 Z7725368 KIT, CLAMP, CARTRIDGE, LAMINATOR 7725368 CLAMP, CARTRIDGE, LAMINATOR kit 7725513 M6 BOLT, 16MM LENGTH 1823715 NUT, HEX, M6 7715379 SPRING, STEERING IDLER ROLLERS 1823906 SCREW, PHILLIPS HX HD W/SEMS M5 X 10 7725180 BRACKET, CARTRIDGE STOP CL-401 Service Manual...
Page 274 STEERING MODULE SUB ASSY, OLY 1823903 SCREW, PHILLIPS, HX HEAD W/SEMS M4X8 Part Number Description Qty. Part Number Z7725638 KIT, SENSOR, VEIN, BRACKET, SUB ASSEMBLY, OLY 7725638 SENSOR, VEIN, BRACKET, SUB ASSEMBLY, OLY 1823901 SCREW, PHILLIPS, HX HEAD W/SEMS M3X6 CL-401 Service Manual...
Page 275 PULLEY, TIMING, HTD5MM, 32T X 12MM BORE 1823603 SET SCREW, NYLON PATCH, M5X6 7725374 PULLEY, TIMING, HTD5MM, 32T X 1/2IN BORE 7725703 TENSIONER ASM, OLYMPIA 1824001 NUT, KEPS M4 7725376 BELT, HTD5MM, 100T X 15W 7729813 SERVICE, THREADLOCKER, RED CL-401 Service Manual...
Page 276 KNURLED THUMB SCREW, M4X0. Part Number Description Qty. Part Number Z7725417 LATCH, SOUTHCO, VIB RSISTANT, 10LBS 7725417 LATCH, SOUTHCO, VIB RSISTANT, 10LBS 1823901 SCREW, PHILLIPS, HX HEAD W/SEMS M3X6 1823903 SCREW, PHILLIPS, HX HEAD W/SEMS M4X8 7725518 M4X8, ULTRA-LOW PROFILE CL-401 Service Manual...
Page 277: Clutch
SCREW, PHILLIPS, HX HD W/SEMS, M5X1 1823901 SCREW, PHILLIPS HX HD W/SEMS, M3 X 1823906 SCREW, PHILLIPS HX HD W/SEMS, M5 X1 1823909 SCREW, PHILLIPS HX HD W/SEMS, M4 X 1822204 E-RINGS, JE-9 7725257 CLUTCH BRACKET, ASM 7725241 SHAFT, CLUTCH, OLYMPIA CL-401 Service Manual...
Page 278: Wiring
Wiring CL-401 Service Manual...

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