Introduction

For the workaround you need only a staple, bent straight -- or a straight pin. For the repair with a paperclip you will need two very small flathead screwdrivers for prying and one normal Philips head screwdriver and a pair of pliers or two. You will be removing the outer shells of the two main body pieces, removing a small shaft and bending a paperclip around the shaft to make it fit tightly in place again.

THE PROBLEM: In the front section that you pull up on the gray lever to allow to swivel out about 30 degrees --it's the section that says Epson on the front and has the lights-- a piece went bad in there. Here's the gist-- in order to pull just one sheet at a time, the rollers in the front panel must not move until the last sheet; they provide friction as the scanner pulls the sheets underneath out. What's happened is that one piece that's supposed to hold the roller from moving has failed and the roller now rolls and therefore the whole stack comes through. A small plastic shaft has tabs that have become splayed on one end and won't hold the rollers in place.

It should be easily replaceable -- almost without disassembly, but the Epson parts diagrams don't show this piece separately so I haven't found a place to buy a new one.

This first few step are a WORKAROUND, the repair guide starts at step FOUR. Use this if you're desperate and absolutely need it to scan hundreds of pages RIGHT NOW. Open the front panel by pulling the gray lever as indicated.
  • This first few step are a WORKAROUND, the repair guide starts at step FOUR. Use this if you're desperate and absolutely need it to scan hundreds of pages RIGHT NOW. Open the front panel by pulling the gray lever as indicated.

  • NOTE: One person posted that this worked for them without it jamming and is therefore their permanent fix so try this first.

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Inside, on the back of the panel you just opened, you will see two identical foam rollers. Stick a straightened staple or straight pin through the foam so they won't be able to roll anymore once the pin hits the bar between them. NOTE: One person posted that this worked for them without it jamming, so try this first.
  • Inside, on the back of the panel you just opened, you will see two identical foam rollers. Stick a straightened staple or straight pin through the foam so they won't be able to roll anymore once the pin hits the bar between them. NOTE: One person posted that this worked for them without it jamming, so try this first.

Hi, ur help is awesome. Just one clip didnt worked for me, jammed every 6 pages, then i used 1 paperclip in each foam and it works amazing. )) thank u very much.

Andreas Wessel - Reply

  • When you go to scan this way, you'll have to put an extra sheet at the end of your stack that will then "jam" once it tries to scan, since the rollers won't let go of it, but you'll at least get the rest of the papers scanned.

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THE REPAIR: There are 4 screws on the front panel's cover that we need to remove, but they're not accessible until you remove that whole panel from the main body of the scanner. The screws nearest where it hinges are the ones that are tough to remove.
  • THE REPAIR: There are 4 screws on the front panel's cover that we need to remove, but they're not accessible until you remove that whole panel from the main body of the scanner. The screws nearest where it hinges are the ones that are tough to remove.

  • If you have a very low-profile ratchet you may be able to get to all four without having to remove the front panel. If so, skip straight to step 7.

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find and remove the three screws on the bottom of the main body-- you will need to extend the tray all the way out to access one of them. Then there are three more screws up above, on the main face of the scanner, where you place the sheets to be scanned. One is beneath the replaceable roller, two are behind the gray paper width sliders find and remove the three screws on the bottom of the main body-- you will need to extend the tray all the way out to access one of them. Then there are three more screws up above, on the main face of the scanner, where you place the sheets to be scanned. One is beneath the replaceable roller, two are behind the gray paper width sliders
  • find and remove the three screws on the bottom of the main body-- you will need to extend the tray all the way out to access one of them. Then there are three more screws up above, on the main face of the scanner, where you place the sheets to be scanned. One is beneath the replaceable roller, two are behind the gray paper width sliders

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Black Friday
Broken doesn't stand a chance.
Once that's accomplished you pull the main body of the scanner OUT of its wraparound shell (back, bottom and sides), using a small pry tool to help pop the shell loose around the edges. It's tough plastic so you probably won't break anything, and it's mostly hollow too so don't worry about where the screwdriver goes inside of it while you're prying
  • Once that's accomplished you pull the main body of the scanner OUT of its wraparound shell (back, bottom and sides), using a small pry tool to help pop the shell loose around the edges. It's tough plastic so you probably won't break anything, and it's mostly hollow too so don't worry about where the screwdriver goes inside of it while you're prying

  • Seen here is the shell once the "guts" are out of it.

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you will need to remove a screw from each side for the hinges for the front panel and they both have little covers to take off too. you will need to remove a screw from each side for the hinges for the front panel and they both have little covers to take off too.
  • you will need to remove a screw from each side for the hinges for the front panel and they both have little covers to take off too.

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THEN you can remove the front panel from the hinges if you start from the RIGHT SIDE (as you face the unit). This takes some finagling. Now except for the cabling, the panel is free of the main and you can expose the screws.
  • THEN you can remove the front panel from the hinges if you start from the RIGHT SIDE (as you face the unit). This takes some finagling. Now except for the cabling, the panel is free of the main and you can expose the screws.

I found by taking off the panel to the right side, has two screws holding it in place, that it was much easier to finagle the front board off of the hinge points. Again thanks for your help in doing this repair

Eric Hargis - Reply

Agree with Eric. Removing that side bezel make taking the panel off a breeze. should be added to the full instructions.

Bill Stathakos - Reply

Remove the four screws and use a small flat tool to pop/pry the cover off of the panel. The gray bar that runs inside, that has on it the lever to open the panel-- because of its springs you should keep it attached to the panel and NOT the cover. You can pop it out of its groove in the cover you're removing and thus not need to take the spring off. Remove the four screws and use a small flat tool to pop/pry the cover off of the panel. The gray bar that runs inside, that has on it the lever to open the panel-- because of its springs you should keep it attached to the panel and NOT the cover. You can pop it out of its groove in the cover you're removing and thus not need to take the spring off.
  • Remove the four screws and use a small flat tool to pop/pry the cover off of the panel. The gray bar that runs inside, that has on it the lever to open the panel-- because of its springs you should keep it attached to the panel and NOT the cover. You can pop it out of its groove in the cover you're removing and thus not need to take the spring off.

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Remove the rollers from the inboard side of the panel (the ones that are covered in foam, they touch the paper once the panel is closed) and wedge a small flathead screwdriver behind the end of the bad shaft that you can see from that side. Remove the rollers from the inboard side of the panel (the ones that are covered in foam, they touch the paper once the panel is closed) and wedge a small flathead screwdriver behind the end of the bad shaft that you can see from that side. Remove the rollers from the inboard side of the panel (the ones that are covered in foam, they touch the paper once the panel is closed) and wedge a small flathead screwdriver behind the end of the bad shaft that you can see from that side.
  • Remove the rollers from the inboard side of the panel (the ones that are covered in foam, they touch the paper once the panel is closed) and wedge a small flathead screwdriver behind the end of the bad shaft that you can see from that side.

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Keep the screwdriver in place as you simultaneously depress the carrier that the rollers were in. That will pop the bad shaft out of its groove. You can only do this while the shaft is turned one particular way, however; otherwise it has tabs that make it too wide to come out of the groove, so you may need to turn it by hand which is not difficult. Keep the screwdriver in place as you simultaneously depress the carrier that the rollers were in. That will pop the bad shaft out of its groove. You can only do this while the shaft is turned one particular way, however; otherwise it has tabs that make it too wide to come out of the groove, so you may need to turn it by hand which is not difficult.
  • Keep the screwdriver in place as you simultaneously depress the carrier that the rollers were in. That will pop the bad shaft out of its groove. You can only do this while the shaft is turned one particular way, however; otherwise it has tabs that make it too wide to come out of the groove, so you may need to turn it by hand which is not difficult.

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Using the pliers, tightly wrap a paperclip around the shaft you have removed. Wrap it near the end that is NOT splayed out, then pull it up to the end which IS bad, as you move it up, it will squeeze the splayed ends back in place. Using the pliers, tightly wrap a paperclip around the shaft you have removed. Wrap it near the end that is NOT splayed out, then pull it up to the end which IS bad, as you move it up, it will squeeze the splayed ends back in place.
  • Using the pliers, tightly wrap a paperclip around the shaft you have removed. Wrap it near the end that is NOT splayed out, then pull it up to the end which IS bad, as you move it up, it will squeeze the splayed ends back in place.

I have always saved things for future projects. One thing was a container of springs. I had just the right size spring that worked great. Thanks for the spring idea. It went over both parts with the needed flexibility to allow the part to flex. Thanks again for this page to help fix a problem. I too had mine break right after it went out of warranty.

Eric Hargis - Reply

I myself used electrical tape. Not sure how long it will last but it gives it enough fallibility if needed. Works like new.

Bill Stathakos - Reply

I used silicon caps (for 5 mm diameter shelf pins) such as the one shown here. Cut the closed end to obtain ~ 0.75 cm length cap and inserted them over the plastic parts at the two joints. It was a snug and secure fit. Inserted the long plastic components from the side shown in the second image and secured in its slot first on the other side before pushing it out with a flat screw driver and inserting it into its slot on this side shown in the image.  It ran smoothly after the fix. It remains to be seen how long it will last.
  • I used silicon caps (for 5 mm diameter shelf pins) such as the one shown here. Cut the closed end to obtain ~ 0.75 cm length cap and inserted them over the plastic parts at the two joints. It was a snug and secure fit.

  • Inserted the long plastic components from the side shown in the second image and secured in its slot first on the other side before pushing it out with a flat screw driver and inserting it into its slot on this side shown in the image. It ran smoothly after the fix. It remains to be seen how long it will last.

  • Another user, Eric Hargis, recommends as another alternative putting an old spring over it

  • Yet another user, lszablya recommended a different twist: "I used double wall heat shrink tubing. Looks like it sucked in around the prongs just fine."

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  • The original poster on Amazon who inspired me to try this fix (and if I could find his name I'd give him credit) recommended tightening up the defective piece with some string tightly wound around it and then caulking it to keep the string from getting caught up in things, but I'm doubtful about it holding up long-term.

lszablya recommended a different twist: "I used double wall heat shrink tubing. Looks like it sucked in around the prongs just fine."

steve - Reply

  • If you're like me, you may wonder why not just glue it to the next shaft in line. Well it actually needs to meet that next shaft at a constantly changing angle, so that will not work.

Thank you for taking the time to post these instructions. I struggled a bit with some of the steps but in the end my scanner was working again. Just seemed like an awful lot of work to put the same flawed part back in. Sure would have been great to replace both shafts for peace of mind, but like the author I too could not find any info on ordering new parts. Thanks again!

Domenic Aquino - Reply

Gracias me ha sido de una gran ayuda. he utilizado el metodo del alambre utilizando para ello un clip, he tenido que levantar la plaquita del sensor para tener un mejor acceso,

Un saludo

juanfragarciaaguilera - Reply

Thank you so much for this fix. It took a while but it worked. I was a bit confused as there were two white shafts. I put paperclips on both for good measure. Hope it will be fine.

Suzanne Priddle-Luck - Reply

Conclusion

To reassemble your device, follow these instructions in reverse order.

15 other people completed this guide.

steve

Member since: 08/01/2016

529 Reputation

1 Guide authored

48 Comments

I'm surprised no one else commented on this. Awesome article - worked perfectly. It's a bit tricky and I wouldn't recommend this for a rookie with tools, but it saved me. I couldn't find the part for this thing nor could I find a repair shop to work on it. It's funny how it started clicking 3 weeks out of warranty! THANKS FOR THE POST! and the effort. awesome!

wowonwheels - Reply

thank you very much for posting this. was scratching my head for an hour, after reading your post, took 5 minutes to fix and get it going. what a relief. technical phone support was useless, troubleshooting was useless. scanner would have probably ended up in the trash if not for you. thank you!!!

debbie many - Reply

Excellent advice - the safety pin worked a treat and doesn't even get stuck on the last page now- thank you so much! Strange how the first three comments on this are within a week apart - Our machine is just over two years - limited life span - but lives to scan another day now!

Catherine - Reply

Excellent post! Thank you so much for great instructions. I was able to fix 2 scanners in about an hour. Saved me hundreds of dollars because otherwise I would have had to replace the scanners, now they are as good as new.

Sledder - Reply

This comment is for the next guy that Googles DS-560 disassembly. Thanks for the article!

gregvaughan - Reply

Got mine disassembled, and looking at the part pretty wimpy design. when this breaks again I guess it time to buy FUJITSU. Sorry Epson, you failed.

baichler -

Ok, I didn't like the paper clip idea, so I went to the hardware store and bought a package of springs, labeled as extension springs, size 9/32" x 2-1/4" x 0.026". I cut one spring to 1/4" in length and it slips over the shaft perfectly with some tension to hold it together.

baichler -

I knew it was this little part that needed repair and have been trying to find something to confirm and tell me how to fix it. Between my work and fixing this it took longer than it probably should have but I am satisfied with the results. I can actually use the machine again and didn't have to pay someone else to fix it. Thank you for posting this solution. It saved me a lot of money and irritation!

reneamueller - Reply

Great tutorial. Thanks for taking the time to post it. Would you happen to know the part number and if the average Joe can purchase it?

stvly - Reply

Sorry, from the intro: "It should be easily replaceable -- almost without disassembly, but the Epson parts diagrams don't show this piece separately so I haven't found a place to buy a new one."

steve -

can i buy the replacement shafts...looks like mine are cracking and would love to be able to just replace them...

Elizabeth Vigneux - Reply

You and me both! As above though, "It should be easily replaceable -- almost without disassembly, but the Epson parts diagrams don't show this piece separately so I haven't found a place to buy a new one."

steve -

Thank you! Tried getting Epson Canada to repair this on my DS-560 but they claim that it's not a common problem :-( They offered a 15% discount on a new product (I'm out of warranty), but it's hard to justify buying another one though since it'll probably have the same defect :-(

In any case thank you for this--hopefully it'll give me a couple more years with this scanner.

rusty - Reply

I'm so glad this was worth the time it took to document it!

It looks like there are a number of similar models that this repair would be good for:

The GT-S50 isn't outwardly identical like the rest, but the DS-510 and the DS-760 and DS-860 at least look outwardly similar.

steve - Reply

Great job diagnosing and documenting. I found that the fix could be done without disassembling any of the covers. Go directly to the rollers and remove, then follow removal of the stub shaft for your repair. Assembly required that the DS-510 be put on its side looking down into the access hole and ensure that the interior shaft is there to engage and complete assembly and reinstall rollers. Thanks Steve, now if we only can find replacement parts, this scanner could be superior. May have to fab one out of metal.

Saul

Saul Rosenthal - Reply

Nice, Saul. I thought it might be possible that way. That would save a lot of time

steve -

Any one have any tips on how to get the part with the paperclip to snap back into the piece where the rollers go? i have been trying for an hour to put it back together.....

pstdon - Reply

IIRC, the piece with the clip on it has a tab so it will only go back into the roller area if it's turned a particular way. Either turn it or the rollers and it will work. See step 11 for what I mean.

steve -

Great documentation. My problem was the next shaft after the one you had highlighted as the broken one. Nevertheless, your documentation helped me to understand and fix my specific problem. If anyone finds a place to purchase replacement parts, please post here. I'll do the same if I find a source.

allen - Reply

Does anyone have a suggestion for when rather than being splayed, one of the ends snaps off? Thanks.

Jeff - Reply

Terrific post, BUT. Boy, is that last screw hard to get out. I took an extra phillips bit, and ground it down. Then grabbed it with a needle nose pliers. The fun is getting the drive back in. I lightly pried away the roller holder.

It's fun fixing things, but this took about two and a half hours. Very simple in concept.

lennypop - Reply

Great fix, but shame on Epson for not selling replacement part. I'll never buy Epson again. Shouldn't have to buy a new $350.00 scanner when .50 cent part is why it doesn't work. I did this fix about two months ago and now I'm spending 1/2 an hour re-doing it. Of course, a piece of wire isn't going to stay put forever. I suspect eventually it will fail again.

JZZZ - Reply

Good tip: If you raise the grey switch on the front panel that has the booklet and stacked paper icons to up/booklet, you'll release the gear which controls the shaft you're repairing. This will make it much easier to line up when you're making the final re-insertion as per step 11 revisited.

JZZZ - Reply

I've done this fix a couple of times and it didn't last. Rather than use wire, I'm using some strong nylon string. You can get it much tighter than the wire. Go on Youtube and find a basic fly fishing knot tying video and you'll be set.

JZZZ - Reply

This is absolutely brilliant! Thank you so much for documenting. Nice job!

My office has dozens of these DS-510's, and we've been just replacing them when this happens because it seemed like it was a broken internal gear or something. Today the one on my desk started pulling the same trick. Only has 30k on the odometer. Shame on Epson for making such a weak part that's so hard to access, while also failing to offer a replacement. Seems they could make it easier to replace, since it's right there with the replaceable rollers.

Indeed, as mentioned in an earlier post...might be time to seek a better product brand.

Singh Duhd - Reply

After very little work in terms of number of sheets, mine got the now familiar "clicking" sound when I tried multiple sheet scanning via the manual switch on the lid, and failed to do the multiple sheet task. It continued to work as a single sheet scanner. The software worked fine. I paid $450 AUD for this DS 510 by Epson, but only got 12 months warranty, so a quote to replace the whole lid was $100. But why spend the money on something designed to fail? No, it must be said Epson make an excellent single sheet scanner, which thinks it is a multi-sheet scanner. The name "workhorse" is used to describe this failed device, so it seems a cynical attempt to rope in people who have quite a lot sheets in their project, knowing full well they will have to buy something else. My new scanner will be a brand other than Epson, and I will not focus too much on scanning speed, but rather reliability.

phillip colquitt - Reply

Hi Jeff

I also had one end completely broken off and was not able to find any glue to hold it in place (before doing the above steps). I ended up bending (slightly) the paperclip so that it technically replaced the bit of plastic that had broken off and it is now working like a charm.

If Epson doesn't want to sell the small components, I am sure someone out there has a 3D scanner and a 3D printer, we could make our own :).

Great article, saved me time and money.

D Train - Reply

Thanks so much for taking the time to share this; worked like a charm! Don't know that I'd say the difficulty level was "Easy"; getting the shafts back in place was very difficult for me, but finally succeeded. Don't attempt to do this DIY project if you're already frustrated or in a bad mode:)

kyle - Reply

Thanks for this! Fixed one this morning using this guide! Took roughly 30 minutes.

erickpz1984 - Reply

Thanks for this solution.. I have one to try to repair.. Wish we could buy the part!

George Starr - Reply

Thanks for the tip. I found it remarkably easy to do this fix. Popped right out and right back in without taking the machine apart. I think the 3-D printer idea is the way to go but I am sure Epson would sue anyone selling the part for patent infringement. Hopefully this will last a while.

edpapa - Reply

Thanks again for the making the time to post the detail repair and photos. Using your instructions along with an Amazon review that used a straw to sleeve over the splayed shaft. However, instead of using a disposable straw and metal tape reinforcement as the Amazon reviewer did, I found a thicker walled hard plastic washable straw with the same ID. I used this for the ends of both shafts that connect to that roller. I think this may hold up as well or better than the paper clip, and was (to me) much easier to slice off a half inch off a hard walled straw than to wrap a clip tightly around the shaft. Would not have tried to tackle without your detailed instructions, kudos.

Bill Beddow - Reply

I am working for an IT department and one of our business users Epson DS-510 scanner had the clicking, skipping on the second-page issue. I took a leap of faith in this guide and got working on it. After a lot of finagling and carefully pulling things around I have completed the guide. It works like a charm now and I totally support the steps. It is technical and a little bit of bravery is required.

Turker Ayar - Reply

Thanks! Worked perfectly. The hardest part was getting the shaft back in place.

Cameron - Reply

awesome thanks man!!

Will Reed - Reply

Sure enough the straightened staple through one of the foam rollers worked. I don't need to add and extra sheet at the end either. Thank you!

kelly.phil - Reply

I bought three of these scanners maybe 10 months ago. The first one showed the problem after about 4 months. Thanks to this walkthru, I was able to get it working again and it's been feeding/scanning as it should ever since. Today, however, a second one started showing the issue. I found this walkthu much quicker this time! I followed the steps verbatim, but could not, for the life of me, get the problem piece back into its place! I tried JZZZ's suggestion about the front panel grey switch to free the gear, but still nope. Does the similar (non-splayed) piece go into place first, and then the "fixed" piece go in last? The only way I can fit the "fixed" piece in (step11) is if I slide it in from the side, which obviously doesn't leave enough room in the line for the first piece. Much thanks to the original creator of this walkthru. Anyone with specific advice on getting the "fixed" piece back in?

thatguy888 - Reply

I just couldn't leave it alone and had to try again... I can't let Epson beat me!!!

This time, I used aluminium duct tape to wrap the prongs several times, as the paper clip was too frustrating and painful to wrap tight enough. Most importantly, I found that the grey roller cover and white tray underneath it (1st pics in Step 10 and 11, respectively) can be [carefully] pried out, which makes putting the two plastic pieces back in SooooOoooOoooo much easier!!

I'm proud to say I was able to get this scanner back to 'normal' functionality. Kudos to this walk-thru and all the helpful comments. Regardless, I'm never buying this scanner again.

thatguy888 - Reply

Alright! Way to go. Thank you for posting your resolution, too.

steve -

Wow, coolest fix ever! Took me almost 35 minutes (went the paperclip route and super glued it so it will stay in place) to complete and is working great again. Can't believe Epson wont send a replacement part for that little plastic piece. What garbage they make these days. Otherwise, I've had this unit for two years and scan almost every day and this scanner is otherwise quite remarkable. Thanks for the steps OP!

David Skowronek - Reply

Excellent Article, Thanks.

I did a little twist. We will see how it works out.

I used double wall heat shrink tubing. Looks like it sucked in around the prongs just fine.

I have only used the DS-510 a few times but so far so good. If I have any problems I will give an update.

lszablya - Reply

I downloaded your page and with my scanner in full view, threatened it with your remedy and it began to scan correctly. We will see how long it lasts.

sasems - Reply

Looks like Epson has addressed this issue and has reinforced the rod in new generations of this scanner.

I've got the problem described in this repair, but when I stripped it apart I found that the end of the rod in question is thicker and seems to be less prone to splaying.

This rod connects directly to the Mode Selection switch (allowing you to toggle between sheet and booklet scanning.) When I engage the toggle switch for standard sheet scanning and try to force the rollers to move, I found the clicking happens at the cog connecting the rollers to what appears to be another cog designed not to move in order to stop the rollers. It seems these cogs are slipping while rolling instead of holding in place.

The only way I've found to stop this is to press down on the toggle switch to engage the gears more tightly. Not sure if there is a way to do it otherwise.

Chris Krahn - Reply

So it looks like the DS-560 uses slightly different shafts. They have a bulge in the area where these shafts normally splay whereas the “bad” ones do not.

erickpz1984 -

Brilliant fix! Thorough step-by-step instructions. I might up the difficulty rating a bit, but the 45 minute time seemed about right.

Stanley Majka - Reply

worked great, I used paper clip.

Got it nice and tight then slid it over end. 45 min to 1 hr time.

make sure you set it to single page to uninstall and install repaired part…

Thanks for the knowledge.

Matt

Matt Harding - Reply

Great solution, took some time to get it apart, but the instructions were right on. Problem I had after reassembly the yellow light was flashing…disassembled again and found the torque on the cover getting the hinges on and off pulled on the wires which pulled the plug on one of the circuit boards…it took 3 dis-assemblies to get it to stay plugged in, and finally the yellow light wasnt flashing. Mine isnt clicking anymore, but apparently there is another problem with it…as I can only scan one doc at a time. I load 2 and it jambs (no clicking)…and gives me an error…UGH.

Wile E - Reply

I have an the DS-560 that has seen relatively light use. About a month ago I got the dreadful “clicking” and paper jam situation.

My approach to fix it is more or less the same. Instead of using a paper clip or silicone caps I opted to use 1/4” copper pipe. The challenge is getting the copper pipe to fit over the shafts. What I did is “stretch” out the copper pipe using the back end of a drill bit. Rotating the copper pipe using a drill and holding progressively larger drill bits in the other hand enabled me to stretch the copper pipe snug around the shafts. My DS-560 is working perfectly now!

Nathan Smardenka - Reply

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