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GBC AdvancedPunch Pro, Service Manual

Introducing the GBC AdvancedPunch Pro - a powerful and efficient document binding solution. Unlock the full potential of this exceptional device with our comprehensive Service Manual. Download it for free from manualshive.com to access step-by-step instructions and tips, maximizing your productivity and ensuring the utmost performance of your investment.

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GBC AdvancedPunch Pro 

09-11-2018 

Parts List 

5-37 

1823913

B

 

026N00818

B

  SCREW, HX, W/SEMS, M3 X 8 

5.6 

1821611

B

 

026N00819

B

  SCREW, PHILLIPS HD W/SEMS, M3X10 

5.7 

1822005

C

 

028N00375

C

  WASHER, FLAT, 6.025 X 8 X 0.75 

5.7 

1823910

B

 

026N00821

B

 

SCREW, PHILLIPS HX HD W/SEMS M4 X 
14 

5.8 
5.7 

1825501

A

 

028N00383

A

  RETAINING RING, 6MM SHAFT 

5.7 

1902863

B

 

026N00833

B

  SCREW, PAN #4-40X15/32 PHILLIPS 

5.7 

1925044

C

 

028N00382

C

  WSHR, .192 ID X .625 OD X .060 T 

5.7 

1952208 

014N00483 

SPACER, TIMING BELT IDLERS,  
BRONZE 

5.7 

1954011 

016N00313 

GROMMET, 3/8 I.D X 1/2 O.D 

5.7 

1954032 

016N00312 

GROMMET, 1 1/4 I.D. X 1 1/2 O.D. 

5.7 

7712703 

072N00035 

WIRE HEADER CONNECTOR, 2 POS 

5.7 

7715185 

074N00075 

BRACKET, PUNCH MODULE MOUNT 

5.7 

7715383 

022N02809 

ROLLER, IDLER, DRIVE ASSY,  

5.7 

7715390

E

 

072N00032

E

  WIRE CLAMP, EDGE 

5.7 

7715445

E

 

072N00033

E

  WIRE CLAMP, EDGE, SMALL 

5.7 

7715595 

121N01245 

SOLENOID,BRACKET,DIVERTER,SUB 
ASSY 

5.7 

5.12 

7715818

E

 

072N00037

E

  WIRE SADDLE, MEDIUM, LOCKING TOP 

5.7 

5.20 
5.31 

7715819

E

 

072N00036

E

  WIRE SADDLE, LARGE, LOCKING TOP 

5.7 

5.31 

7715817

E

 

072N00040

E

  WIRE SADDLE, SMALL, LOCKING TOP 

5.7 

5.16 
5.31 

7715093 

022N02805 

ROLLER ASSY, DRIVE (USED FOR ALL 
ROLLERS EXCEPT N2) 

5.8 

7715097 

002N02808 

ROLLER ASSY, ONE WAY DRIVE (USED 
IN N2 POSITION ONLY) 

5.8 

1821116

D

 

013N13948

D

  BEARING, BALL, FLANGE 6X13X5, SUJ2 

5.8 

7706532 

013N13946 

BEARING BALL FLANGE 

5.8 

1925222

C

 

028N00372

C

  WASHER FLAT, 1/4X3/8X/1/32 

5.8 

7715862 

005N01168 

ONE WAY CLUTCH SUB ASSEMBLY 

5.8 

1822108

C

 

028N00374

C

  WASHER, FLAT, 4.1X8X1.5 

5.9 

1823911

B

 

026N00820

B

 

SCREW, PHILLIPS HX HD W/SEMS M4 X 
10 
 

5.14 

5.9 

7711970 

107N00458 

CHIP LEVEL SENSOR - EMITTER 

5.9 

5.11 
5.15 

7711973 

050N00665 

CHIP LEVEL SENSOR - RECEIVER 

5.9 

5.11 
5.14 

7715418 

050N00664 

BYPASS DIVERTER 

5.9 

7715186 

130N01761 

CHIP TRAY SENSOR MOUNT ASSY 

5.9 

5.12 

7715213 

006N01356 

SHAFT, ACCEL IDLER LATCH 

5.9 

7715216 

003N01105 

LATCH,ASSY, FRONT, ACCEL IDLER 
PANEL 

5.9 

7715222 

003N01104 

LATCH,ASSY, REAR, ACCEL IDLER 
PANEL 

5.9 

7715159 

127N07845 

ENTRANCE MOTOR STEPPER AND 
MOUNT ASSY 

5.10 

ACCEL MOTOR STEPPER AND MOUNT 
ASSY 

5.10 

EXIT MOTOR STEPPER AND MOUNT 
ASSY 

5.10 

DECEL MOTOR STEPPER AND MOUNT 
ASSY 

5.10 

BYPASS MOTOR STEPPER AND MOUNT 
ASSY 

5.10 

 

 
 

 

A 

7715973  600N03432  KIT, HARDWARE, RINGS 

B 

7715974  600N03433  KIT, HARDWARE, FASTENERS 

C 

7715975  600N03434  KIT, HARDWARE, WASHERS 

D 

7715976  600N03435  KIT, HARDWARE, BEARINGS 

E 

7715977  600N03436  KIT, HARDWARE, WIRE CLAMPS 

F 

7715978  600N03437  KIT, HARDWARE, SPRINGS 

Summary of Contents for AdvancedPunch Pro

Page 1: ...mber 7718590 Revision Number A1 Issue Date November 2018 GBC AdvancedPunch Pro Service Manual CAUTION Certain components in the GBC AdvancedPunch Pro are susceptible to damage from electrostatic discharge Observe all ESD procedures to avoid component damage ...

Page 2: ...rvice Changes are periodically made to this document Changes technical inaccuracies and typographic errors will be corrected in subsequent editions Please contact Xerox Digital Content and Language Services with any comments or suggestions regarding the content within this document Copyright Notice GBC ACCO Brands Inc Four Corporate Drive Lake Zurich IL 60047 USA Copyright 2014 by ACCO Brands Inc ...

Page 3: ...s ii Introduction iii Organization iv How to Use This Documentation iv Safety Messages in other Languages vi Other Information xvi The Use of Caution Warning and Note statements xvi Safety Devices xvi Door Interlock xvi Operational Safety xvii Warnings and Cautions xvii Acronyms xviii Reference Symbology xviii ...

Page 4: ...nostic activities in this section may direct the Service Representative to perform additional service activities found elsewhere in the documentation such as RAPs Removal and Replacement Procedures and Adjustment Procedures Section 2 Status Indicator RAPs Section 2 of this documentation contains the Repair Analysis Procedures RAPs necessary to repair all faults other than the image quality faults ...

Page 5: ...ed in conjunction with other diagnostic or maintenance procedures that are contained in other sections of the service documentation Block Schematic Diagrams BSD s Block Schematic Diagrams BSDs are used as an aid to troubleshoot electrical problems Wirenet Diagrams This section contains wirenet diagrams used to troubleshoot AC power DC power AC neutral and DC return distributions and are sometimes ...

Page 6: ...ella macchina hanno tensioni elettriche pericolose che possono provocare scosse elettriche ed eventuali lesioni serie D WARNUNG Keine Reparaturarbeiten durchführen wenn die Maschine eingeschaltet oder an die Stromversorgung angeschlossen ist Einige Maschinenkomponenten führen gefährliche elektrische Spannungen die zu einem Stromschlag und möglicherweise schweren Verletzungen führen können NL WAARS...

Page 7: ... fonte de energia Se as instruções deste aviso não forem seguidas poderão ocorrer mortes ou ferimentos graves RU ВНИМАНИЕ Перед началом работ по очистке необходимо убедиться в том что устройство отключено от источника питания Несоблюдение данного предупреждения может привести к получению серьезной травмы или летальному исходу CHI 警告 确保清洁之前把AdvancedPunch Pro与其电源断开 未 能遵守这一点可导致严重伤亡事故 GB WARNING Movin...

Page 8: ...a est branché Les composants de la machine contiennent des tensions électriques dangereuses qui peuvent provoquer une électrocution ou des blessures graves E ADVERTENCIA No toque los terminales de la fuente de alimentación o de cualquier otro conector cuando el cable de alimentación de CA esté conectado Los componentes de la máquina contienen tensiones eléctricas peligrosas que pueden provocar una...

Page 9: ...ctamente el sensor cuando la máquina esté encendida I CAUTELA Il sensore emette un raggio a infrarossi ad angolo stretto e ad alta intensità 940 nm È invisibile a occhio nudo evitare quindi di guardare direttamente il sensore quando la macchina è accesa D VORSICHT Der Sensor gibt einen schmalen Infrarotstrahl hoher Intensität ab 940 nm Er ist mit bloßem Auge nicht sichtbar Bei eingeschalteter Masc...

Page 10: ...ecaución Advertencia o Nota Estos avisos se encuentran a través de toda la documentación de servicio Los avisos de Precaución Advertencia y Nota aparecen antes de los pasos a los que se aplican Estos avisos se deben leer antes de continuar con el siguiente paso en el procedimiento Precaución Un aviso de Precaución indica un procedimiento operativo o de mantenimiento una práctica o una condición qu...

Page 11: ...es são encontradas em toda a documentação dos serviços As declarações de advertências alerta e declarações aparecem antes dos passos a que elas se aplicam Antes de continuar para a próxima etapa de um procedimento leia estas declarações Advertência Uma declaração de advertência indica que uma operação ou procedimento de manutenção prática ou uma condição que se não for rigorosamente respeitada pod...

Page 12: ...uvrez la porte avant un dispositif de verrouillage de sécurité désactive automatiquement les moteurs d entraînement jusqu à ce que la porte soit refermée Lorsque la porte avant est ouverte le panneau de l opérateur affiche le message FERMER LA PORTE sur la ligne du haut de l interface Lorsque vous refermez la porte avant le panneau de l opérateur affiche le message PRÊT sur la ligne du haut de l i...

Page 13: ...occo di sicurezza disabilita I motori di alimentazione finché non si richiude lo Sportello frontale Quando lo Sportello anteriore è aperto il Pannello operatore mostra il messaggio CHIUDERE LO SPORTELLO sulla linea superiore dell interfaccia Quando si chiude lo Sportello frontale il Pannello operatore mostra il messaggio PRONTO sulla linea superiore dell interfaccia Sicurezza operativa Non far fun...

Page 14: ...schijnt het bericht CLOSE DOOR SLUIT DEUR op de bovenste regel van de interface Als u het deurtje vooraan sluit dan verschijnt het bericht READY KLAAR op de bovenste regel van de interface Veiligheidsvoorschriften Bedien de GBC AdvancedPunch Pro niet als de vergrendelingen uitgeschakeld zijn Wees voorzichtig wanneer een procedure uit deze Handleiding aangeeft dat u een cheater stukje om vergrendel...

Page 15: ...ыта передняя дверца При открытой передней дверце на верхней строчке интерфейса панели управления высвечивается сообщение ЗАКРЫТЬ ДВЕРЦУ При закрытии передней дверце на верхней строчке интерфейса панели управления высвечивается сообщение ГОТОВО Техника безопасности Не допускается использовать перфоратор GBC AdvancedPunch Pro при неработающих блокировочных устройствах Соблюдать осторожность если с ц...

Page 16: ...an operating or maintenance procedure practice or condition that if not strictly observed could result in damage to or destruction of equipment Warning A Warning statement indicates an operating or maintenance procedure practice or condition that if not strictly observed could result in personal injury or loss of life Note A Note statement indicates an operating or maintenance problem practice or ...

Page 17: ...lock Cheater is inserted Do not open any panels other than those indicated by this Manual Pay particular attention to the WARNINGS and CAUTIONS listed in the Operator Manual Warnings and Cautions Pinch Points WARNING Moving Parts keep hands clear of the belts when the Rear Cover Assembly is removed The Punch Module Motor Belt PL 3 1 is a potential pinch point Shock Hazard WARNING Electrical Shock ...

Page 18: ...lature Reference Symbology Notes adjustments and parts lists support the checklists and the RAP information The symbols that refer to this supportive data are shown below Adjustment ADJ 3 2 The mechanical adjustment symbol indicates the component is adjustable and the number identifies the adjustment procedure location in the Repair and Adjustments section of this manual Note This symbol is used t...

Page 19: ...tents Service Call Procedures Title Page CALL FLOW 1 2 INITIAL ACTION 1 3 SYSTEM CHECKS 1 3 EVERY CALL ACTIVITIES 1 4 SCHEDULED MAINTENANCE 1 4 PREVENTATIVE MAINTENANCE 1 4 AdvancedPunch Pro Maintenance Schedule 1 5 Customer Maintenance 1 5 Periodic Maintenance 1 5 Periodic Replacement 1 6 HFSI 1 7 FINAL ACTION 1 7 ...

Page 20: ...ggest a direction for using the information obtained during Initial Action You can then repair and verify the repair of the problem This step may also provide information to assist in the identification of new problems and suggest actions to take to repair resolve them FINAL ACTIONS This step is used to ensure that the punch quality the punch performance and the punch appearance are satisfactory I...

Page 21: ... 5 if needed 8 Vacuum all paper path punch dust box area of scrap debris SYSTEM CHECKS Purpose Direct repair activity for problems found in Initial Action PROCEDURE 1 Select the appropriate condition from the list below and perform the directed service actions Replace any obviously broken parts If there is a Punch Quality problem go to 3 2 Defect Entry RAP in Section 3 If there is a Fault Code go ...

Page 22: ...ptical Sensor Cleaning SCHEDULED MAINTENANCE Purpose Check the supply of customer consumables See Section 5 for customer consumable part numbers PROCEDURE 1 Do GP 6 1 10 DIE CYCLES Procedure to check the cycle life on the Die Set installed in the Advance Punch Pro 2 See the AdvancedPunch Pro Maintenance Schedule on page 1 5 PREVENTATIVE MAINTENANCE Purpose If operating properly the Advanced Punch ...

Page 23: ... Inspect and clean Alcohol and Cloth Punch Clutch Cleaning 1 000K cycles GP 6 24 Clean Cloth Sensors S1 to S28 500K cycles GP 6 17 Clean Air Drive and Idler Rollers 1 000K cycles GP 6 14 GP 6 15 Inspect and clean Alcohol cloth Solenoid Module 1 000K cycles GP 6 22 Inspect Idler Panel Closing Magnet Latches 1 000K cycles GP 6 16 Inspect Acceleration Panel Latch 1 000K cycles GP 6 16 Inspect Paper P...

Page 24: ...Periodic Replacement Area Unit Part Number Qty per machine Rough Standard Remarks Die Set See PL 6 1 750K Cycles Replacement Punch Module 180N00019 115V PL 5 1 180N00020 230V PL 5 1 1 15M Cycles Replacement Solenoid module 133N23254 PL 4 6 6 5M Cycles Replacement ...

Page 25: ...inted test sheets through the punch mode and examine the output for clean hole quality and even hole alignment 4 Use the customer s primary Die Set pattern to run 200 duplex printed test sheets through the punch mode and examine the output for clean hole quality and even hole alignment 5 Use any of the customer s secondary Die Set pattern to run 100 simplex printed test sheets through the punch mo...

Page 26: ...Service Call Procedures 08 20 2015 GBC AdvancedPunch Pro 1 8 Notes ...

Page 27: ...nter Keys Do Not Respond 2 20 2 PAPER JAMS 2 20 RAP 2 1 Jam Type A 2 20 RAP 2 2 Jam Type B 2 21 RAP 2 3 Jam Type C 2 22 RAP 2 4 Jam Type D 2 24 RAP 2 5 Jam Type E 2 25 RAP 2 6 Jam Type F 2 26 RAP 2 7 Multiple Sheets Jammed Die Pins Partially Through the Sheets 2 27 RAP 2 8 Checking Obstruction in Paper Path 2 28 RAP 2 9 PAPER JAM J431 2 31 RAP 2 10 PAPER JAM J432 2 31 RAP 2 11 PAPER JAM J433 2 32 ...

Page 28: ...GBC AdvancedPunch Pro 11 07 2018 RAPS 2 2 ...

Page 29: ...air Analysis Procedure may apply to several Fault Codes In those cases subsequent Fault Codes include a cross reference to the pertinent RAP To help you locate each component the Repair Analysis Procedures include part locators PL x y that refer to the pertinent page in Section 5 Part List Symbology Caution Potential damage to the machine could result unless the specified procedures are followed S...

Page 30: ...of Contents for Section 2 and locate the RAP for that fault code 5 Check the top row of text on the Operator Interface to determine if there is there a Fault Code There is a Fault Code on line 1 Y N Go to Step 6 Go to the Table of Contents for Section 2 and locate the RAP for that fault code 6 Is there a Power Fault No AC Power No DC Power No power to Control Board Operator Panel Does Not Illumina...

Page 31: ...he Front Door READY The system is ready Use the Punch to punch paper or bypass the Punch Bottom Row of Text Message Description Action CHECK DIE Check the Die Set Check the Die Set BYPASS The Punch is in Bypass Mode Use the Punch in Bypass Mode SINGLE PUNCH The Punch is in Single Punch Mode Use the Punch in Single Punch Mode DOUBLE PUNCH Available for DFA configuration only The Punch is in Double ...

Page 32: ...operation 5 Clean the Dieset Recognition Board in the Die and the Die set Recognition Reader Board in the machine This clears the fault code Y N Go to step 6 Normal operation 6 Check if the Dieset Recognition Reader Board Spring Clips contact the Dieset Recognition Board in the Dieset If Spring Clips look like they are broken replace Dieset Recognition Reader Board If the springs clips do not cont...

Page 33: ...N Go to step 9 Normal operation 9 Do REP 5 3 to replace the Dieset Recognition Reader Board Assembly PL 5 1 This clears the fault code Y N Go to step 10 Normal operation 10 Do REP 5 1 Main Control Board Replacement to replace the Main Control Board PL 7 1 This clears the fault code Y N Escalate to second level Normal operation ...

Page 34: ... and return to normal operation 5 Switch OFF the machine and unplug the Power Cord 6 Remove the M4 Nuts 2 that hold the Interlock Switch Bracket PL 2 2 and inspect the connections at the Interlock Switch see REP 1 13 Interlock switch replacement for photos of the connections Interlock cable is connected at the Interlock switch Y N Make the connection and return to Normal operation Go to step 7 7 I...

Page 35: ...ard Replacement to replace the Main Control Board PL 7 1 Return to normal operation Chip Tray Out message is not displayed when the Chip tray is out This message is displayed when the Chip Tray Out message is not displayed when the Chip tray is out 1 Make sure the 2 spade connectors to the Chip tray home switch PL 3 5 SW2 is securely inserted see REP 2 30 for details Connectors are securely connec...

Page 36: ...avity in the lower portion of the front frame See REP 2 31 and REP 2 32 for more details See the Sensor Cables table on page 2 35 for cable numbers The connections are good Y N Make the connection and return to normal operation 4 Do REP 1 6 to remove the Rear Cover 5 Check if Cable 023N01327 see Section 7 Wiring is connected to J27 at the Main Control Board PL 7 1 The connection is good Y N Make t...

Page 37: ... should be downloaded again ERROR E451 DIE ENCRYPTION ERROR This means that the die is not a GBC certified die 1 Open the Front Door PL 2 1 2 Remove the Die Set see AdvancedPunch Pro User Manual 3 Check that the Die Set is the correct Die Set for the Punch The Die Set is the correct die Set for the Punch Y N Replace the Die Set PL 6 Escalate to second level ERROR E452 INCOMPATIBLE DIE This means t...

Page 38: ...ith the letter J followed by a 3 digit code Fault Code Areas When you open the Front Door the front panel of the Punch is labelled to identify the location of the six 6 areas of the machine These numbers match the numbers in the bottom row of text Bottom Row of Text Area General Location Clear 1 Area 1 Bypass Section Clear 2 Area 2 Entrance Idler Section Clear 3 Area 3 Acceleration Roller Section ...

Page 39: ...of the first jammed sheet is stopped past nip N1 but before nip N5 Do RAP 2 2 Jam Type B Jam Type C The lead of the first jammed sheet is stopped past nip N5 but before Steering Rollers N6 and N7 Do RAP 2 3 Jam Type C Jam Type D The lead edge of the first jammed sheet is past N6 and N7 but its trail edge is before or just past N6 N7 Do RAP 2 4 Jam Type D Jam Type E The trail edge of the first jamm...

Page 40: ...ected to the ground and to the AC Filter Ground Wire 023N01320 is connected Y N Connect Ground Wire 023N01320 Go to step 8 8 Check that Cable 023N01336 see Section 7 Wiring is connected at the AC Filter For DFA configurations cable is 023N01335 Cable 023N01336 023N01335 for DFA is connected at AC Filter Y N Connect Cable 023N01336 023N01335 for DFA 9 For DFA configuration only Check that Cable 023...

Page 41: ...36 023N01335 for DFA at the AC Filter Y N Replace AC FILTER PL 7 1 17 Check for input voltage 110 VAC 60 Hz or 240 VAC 50 Hz on Cable 023N01336 see Section 7 Wiring at the Pin J14 on the Communications Board BRN BLU wires For DFA configurations cable is 023N01335 There is AC power on Cable 023N01336 023N01335 for DFA at Pin J14 on the Communications Board Y N Replace Cable 023N01336 023N01335 for ...

Page 42: ...e make the connections at J1 and J3 and the ground cable WARNING Do not touch the open terminals of the power supply or any other connector with the AC power cord connected The machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury See Section 0 page viii for other languages 8 Check if the LED in the power supply is lit LED is lit Y...

Page 43: ...GBC AdvancedPunch Pro 11 07 2018 RAPS 2 17 RAP 1 3 No Power to Control Board Use this RAP when there is no power to the Control Board 1 Do RAP 1 2 No DC Power to check DC power ...

Page 44: ... With the front door closed there will be 4 LEDs that will be lit With the front door open there will be 3 LEDs that will be lit The LEDs are lit Y N Do RAP 1 2 No DC Power 7 Check that LCD Cable 023M01337 is connected at Connector J36 on the Control Board see Section 7 Wiring Cable 023M01337 is connected at Connector J36 Y N Connect Cable 023M01337 see Section 7 Wiring Go to step 8 8 Check that L...

Page 45: ...Connector J36 Y N Connect Cable 7715523 4 Check that LCD Cable 7715523 is connected at the LCD Panel on the rear of the User Interface See Section 7 Wiring and PL 2 2 Cable 023M01337 is connected at the LCD Panel Y N Connect Cable 023M01337 5 Upload firmware Do GP 6 1 16 The Operator Interface shows text Y N Go to step 6 Normal operation 6 Check the condition of LCD Cable 023M01337 see Section 7 W...

Page 46: ... following if the lead edge stopped by nip N1 1 Check to see if there is any obstruction to paper flow at the entrance of the machine PL 3 1 PL 3 2 Do RAP 2 8 Checking Obstruction in Paper Path Area 1 Entrance This clears the fault Yes Return to normal operation No Go to Step 2 2 Do RAP 3 1 to check Sensors S21 and S25 This clears the fault Yes Return to normal operation No Go to Step 3 3 Do RAP 5...

Page 47: ...al operation No Go to Step 4 4 Do RAP 4 3 Check Solenoids SOL 3 to SOL 8 to 8 to check solenoids SOL3 and SOL 4 This clears the fault Yes Return to normal operation No Go to Step 5 5 Check the diverter mechanism PL 3 3 PL 3 8 Do RAP 4 1 Check Solenoid SOL 1 This clears the fault Yes Return to normal operation No Go to Step 6 6 Check the nip force of rollers N2 N3 N4 PL 3 4 This can be done by Do G...

Page 48: ...and M2 This clears the fault Yes Return to normal operation No Go to Step 5 5 Remove the Die Set and inspect the die throat Make sure there is nothing restricting the flow of paper This clears the fault Yes Return to normal operation No Go to Step 6 6 Do RAP 2 8 Checking Obstruction in Paper Path Area 4 Punch Module This clears the fault Yes Return to normal operation No Go to Step 7 7 If the shee...

Page 49: ...ult Yes Return to normal operation No Go to Step 10 10 Check the nip force of roller N5 PL 3 4 Do GP 6 16 Panel Latch Inspection to inspect the Acceleration Idler Panel Latch PL 3 5 If the Acceleration Idler Panel is not closed firmly there will be insufficient nip force at N5 Do GP 6 14 Idler Roller Inspection and Cleaning to inspect the idler roller springs for these rollers Inspect Idler Roller...

Page 50: ...ection and Cleaning to Inspect and Clean Steering Drive Rollers This clears the fault Yes Return to normal operation No Go to Step 9 9 Do GP 6 14 2 Steering Idler Roller and Springs Inspection and Cleaning This clears the fault Yes Return to normal operation No Go to Step 10 10 Inspect Punch Clutch Anti Rotation Screw M6 socket head screw of the Punch clutch If it is loose tighten it See REP 3 4 f...

Page 51: ... normal operation No Go to Step 5 5 Do RAP 4 3 to check Solenoids SOL3 to SOL8 This clears the fault Yes Return to normal operation No Go to Step 6 6 Do RAP 5 1 to check Motors M6 M7 and M8 This clears the fault Yes Return to normal operation No Go to Step 7 7 Check the nip forces of roller N8 N9 and N10 This can be done by same as Jam type B Do GP 6 14 Idler Roller Inspection and Cleaning to insp...

Page 52: ...rmal operation No Go to Step 4 4 Check the Diverter mechanism PL 3 3 L 3 8 do RAP 5 1 This clears the fault Yes Return to normal operation No Go to Step 5 5 Check the nip force of rollers N1 N11 N12 N13 N14 PL 3 1 PL 3 4 This can be done by Do GP 6 14 Idler Roller Inspection and Cleaning to inspect the idler roller springs for these rollers PL 4 5 Do GP 6 15 Drive Roller Inspection and Cleaning to...

Page 53: ... sheets 3 If it is too difficult to crank the punch shaft Remove rear cover Disconnect the clutch wires at the Clutch Solenoid PL 5 1 PL 5 6 Remove two screws that hold the Clutch Stud bracket Rotate the Clutch along with the shaft in the opposite direction clockwise direction when viewed from the back until the pins exit the sheet Remove the jammed sheets Return the Clutch Bracket and the Clutch ...

Page 54: ...r objects like loose fasteners along the paper path A few key areas to inspect are shown below Area 1 Entrance 1 Open the Front Door 2 Open the Bypass Panel 3 Inspect the gap between the Drive Roller and the sheet metal panel for any objects Area 2 Entrance Idler Panel Assembly 1 At the top of Area 2 Entrance Idler Panel Assembly check if there is a 2 to 3mm gap for sheet flow 2 If the Lower entra...

Page 55: ...d between the roller and sheet metal window Area 4 Punch Module 1 Remove the Die Set and inspect at the following locations 2 Check the Guide Brackets immediately upstream and downstream of the Die Set 3 Remove the M4 Nuts 3 and the cover for Area 5 4 Inspect the paper path for any obstructions closely Cont ...

Page 56: ...rive panel and the Idler Panel of the Steering module subassembly PL 5 4 and PL 5 5 are centered to the guide brackets as shown If one of the below panels is bent replace Steering idler panel weldment PL 5 4 REP 3 10 Steering drive panel weldment PL 5 5 REP 3 12 ...

Page 57: ...his condition do the following 1 For DFA configurations only Check if the line speed is set correctly GP 6 2 2 For all OEM configurations go to Step 2 Line speed is set correctly Yes Go to Step 2 No correct it and resume normal operation 2 Do RAP 3 1 Check Sensors S1 S2 S3 S4 S5 S22 S23 S24 S25 S26 to check Sensor S1 S11 S12 S13 S14 and S15 This clear the fault Yes Resume normal operation No Go to...

Page 58: ...the following 1 Inspect the docking pins in the upstream side Section 8 8 8 Machine is properly docked Yes Go to Step 2 No Correct the docking and resume normal operation 2 Do RAP 3 2 to check Sensors S6 to 10 This clears the fault Yes Resume normal operation No Go to Step 3 3 Do RAP 3 3 to check Sensor S28 This clears the fault Yes Resume normal operation No Go to Step 4 4 Check correct skew from...

Page 59: ... sensors should show 0 on the LCD when uncovered and 1 when covered If any sensor shows 1 when uncovered clean that sensor Also check is there us any obstacle in the sensor window Sensors S1 S25 and S26 are on the Upper Bypass Panel PL 4 5 Sensors S2 S3 and S4 are on the Entrance Idler Panel PL 4 2 Sensor S5 is on the Acceleration Roller Idler PL 4 3 Sensor S22 23 and 24 are on the Exit Idler pane...

Page 60: ...acing the sensor corrects the issue Yes Use the new sensor and return to normal operation No Go to Step 4 4 Do GP 6 3 to Undock the AdvancedPunch Pro and visually inspect the Cable from the sensor all the way to the Control Board PL 7 1 If the Cable is damaged replace the Cable See the Sensor Cables table in Section 7 Wiring Sensor cable looks okay Yes Go to Step 5 No Go to Step 6 5 Do GP 6 2 16 F...

Page 61: ...r Board 023N01325 Header 023N01344 J24 S15 Alignment Sensor Board 023N01325 Header 023N01344 J24 S16 Trail Edge BG Sensor Board 023N01326 Header 023N01345 J25 Shares cable with S28 S17 Trail Edge BG Sensor Board 023N01326 Header 023N01345 J25 Shares cable with S28 S18 Large Mid Punch Sensor Bd 023N01348 J26 Shares cable with S20 S21 S19 Large Mid Punch Sensor Bd 023N01348 J26 Shares cable with S20...

Page 62: ...nsors S6 S7 S8 S9 S10 To Access Sensors S6 S7 S8 S9 S10 Undock AdvancedPunch Pro This step is optional if possible reach in through the jam access opening without undocking the punch Open Front Door Open Lower Exit Panel Assembly Note Sensors S6 7 8 9 and 10 are on the Skew Sensor Board S6 S7 S8 S9 S10 S6 S7 S8 S9 S10 ...

Page 63: ...ccess Sensors S11 S12 S13 S14 and S15 Undock AdvancedPunch Pro This step is optional if possible reach in through the jam access opening without undocking the punch Locate the Alignment Sensor Board Sensors S11 12 13 14 and 15 are on the Alignment Sensor Board S15 S14 S13 S12 S11 ...

Page 64: ...ancedPunch Pro 11 07 2018 RAPS 2 38 Sensors S16 and S17 To Access Sensors S16 and S17 Open the Front Door Unlatch and open the Acceleration Idler Panel Sensors S16 and S17 are on Backgage Sensor Board S16 S17 ...

Page 65: ...nd S21 To Access Sensors S18 S19 S20 and S21 Open the Front Door Unlatch and open the Entrance Idler Panel Sensors S18 and S19 are on Mid Punch Large Backgage Sensor Board Sensors S20 and S21 are on Mid Punch XL Backgage Sensor Board S18 S19 S20 S21 S18 S19 S20 S21 ...

Page 66: ...he sensor when the machine is powered ON See Section 0 page ix for other languages a If there is no light from any sensor on that particular board S6 S10 S11 S15 S16 17 S18 19 S20 21 Replace cable Replace the Cable from the Sensor Board to the Punch Frame first If that does not solve the issue replace cable from frame to Main Control Board See the Sensor Cables table in Section 7 Wiring Replace th...

Page 67: ... sensor and 0 when the Alignment carriage flag unblocks the sensor LCD shows 0 when unblocked and 1 when blocked Yes Return to the RAP that directed you here No Go to Step 2 2 Make sure the sensor wire is connected securely at the header in the punch module frame and the main control board See the Sensor Cables table in Section 7 Wiring See REP 3 1 for the location of the Connector Connection is s...

Page 68: ... Go to Step 6 6 Do GP 6 2 16 FIRMWARE UPGRADE Procedure to Re flash the firmware for the AdvancedPunch Pro This clears the fault Yes Resume normal operation No Go to Step 7 7 Replace the Sensor Cable from Align Home Sensor to header PL 7 3 see Section 7 Wiring This clears the fault Yes Resume normal operation No Go to Step 8 8 Replace the cable from header to Main control board PL 7 3 see Section ...

Page 69: ...6 to remove the Rear Cover Check the cable from the solenoid to the in line header This cable is part of the solenoid body Check the cable 023N01351 see Section 7 Wiring that connects the in line header to the Main Control Board Replace the SOL1 REP 2 28 1 or 023N01351 PL 7 3 as needed If SOL1 functions do the below steps Go to ADJ 1 2 and perform adjustment if necessary This clears the fault Yes ...

Page 70: ...and in turn drive the drive roller not activated fully activated When the solenoid is fully activated the idler roller should completely lift off and not be able to drive the drive roller NOTE Disengaging solenoid modules need to be replaced every 5 million cycles To check the holding force of the solenoid go to Step 3 If the solenoid does not actuate go to Step 4 Alternate solenoid inspection met...

Page 71: ...to control board PL 4 2 PL 4 3 and PL 4 4 The solenoid cables look okay Yes Go to Step 5 No Replace the faulty solenoid module REP 2 28 5 Do REP 2 28 Solenoid Replacement to replace the faulty Solenoid PL 4 6 This clears the fault Yes Return to normal operation No Go to Step 6 6 Do GP 6 2 16 FIRMWARE UPGRADE Procedure to Re flash the firmware for the AdvancedPunch Pro This clears the fault Yes Ret...

Page 72: ...motor M5 All the connectors are securely connected Yes Go to Step 5 No Make the connection and resume operation 5 For the motor in question make sure three connectors at the Stepper Driver board J1 J2 and J3 and two connectors at the Main Control Board are inserted firmly see Section 7 Wiring J17 and J16 for M3 M4 and M5 J17 and J15 for M6 M7 and M8 J17 and J14 for M1 and M2 All the connectors are...

Page 73: ...ADE Procedure to Re flash the firmware for the AdvancedPunch Pro This clears the fault Yes Resume normal operation No Go to Step 11 12 Replace the driver board for the faulty motor with DIP switch set correctly for the position you are replacing REP 2 26 This clears the fault Yes Resume normal operation No Go to Step 12 13 Replace the faulty stepper motor REP 2 23 for M1 M2 M6 M7 and M8 REP 3 8 fo...

Page 74: ...st The Exhaust Fan operates Y N Go to step 2 To prevent excessive heat build up the maximum recommended monthly punch volume should not exceed 400 000 In addition no more than 2 sheets of 300gsm per 5 sheets of 75 gsm This clears the fault Y N Go to step 2 Normal operation 2 Check for obstructions at the vents in the Rear Cover This clears the fault Y N Go to step 3 To prevent excessive heat build...

Page 75: ...fication 2 Check the operation of Diverter solenoid do RAP 4 1 This clears the fault Yes Return to normal operation No Go to Step 3 3 Check and clear and obstructions in the paper path This clears the fault Yes Return to normal operation No Go to Step 4 4 Inspect the sheet guides stainless steel guides in the die throat They should be firmly affixed to the plates of the die and should be parallel ...

Page 76: ...vered for too long C Jam Types J316 S16 covered for too long C Jam Types J317 S17 covered for too long C Jam Types J411 S11 covered for too long C Jam Types J412 S12 covered for too long C Jam Types J413 S13 covered for too long C Jam Types J414 S14 covered for too long C Jam Types J415 S15 covered for too long C Jam Types Jam code Description Jam Type Reference J431 Sheet cannot be double punched...

Page 77: ...ly cut 4 3 3 3 Oil on Paper 4 3 4 Alignment Offset 4 3 5 Backgage Offset 5 3 6 Skewed Punch 6 3 7 Punching Accuracy Inconsistent 6 3 8 Sheet Without Punched Holes 8 3 9 Punched holes look elongated towards the trail edge of the sheet 9 3 10 Sheet Damaged at the Lead Edge of the Sheet 10 3 11 Scuff Marks on Paper 10 3 12 Wrinkle in the sheet 10 3 13 Clear Cover media hole position 10 3 14 Punch Spe...

Page 78: ...Punch Quality 11 07 2018 GBC AdvancedPunch Pro 3 2 This page intentionally left blank ...

Page 79: ...1 10 DIE CYCLES Procedure to check the cycle life on the Die Set installed in the AdvancedPunchPro 2 If any of the Die Set life cycles have exceeded 750 000 sheets cycles go to Section 3 and check the Punch Quality DIE CYCLES 750 129 If the Punch Quality is acceptable monitor the Punch Quality frequently to ensure that the Punch Quality is okay If the Hole Quality is not acceptable replace the Die...

Page 80: ...d until oil marks cease to appear 3 4 Alignment Offset Alignment Offset refers to alignment in the fast scan or creoss0 process direction Use this procedure if the Alignment of all the punched sheets is consistently off If the Alignment is not consistent go to Section 3 7 Punching Accuracy Inconsistent 1 Is the die configured for the correct sheet size See Section 8 of AdvancedPunch Pro User Manua...

Page 81: ...l subsequent sheets go to Step 4 If the punched hole positions are not consistent for all sheets go to section 3 7 Punching Accuracy Inconsistent 1 Do GP 6 1 1 Backgage Offset This clears the fault Yes Return to normal operation No Go to Step 2 2 If the backgage depth is too shallow holes towards the trail edge of the sheet do RAP 4 3 to check Solenoids SOL 6 SOL 7 and SOL 8 This clears the fault ...

Page 82: ...ing will be inaccurate if Solenoid SOL 6 SOL 7 or SOL 8 PL 4 4 is not disengaging the roller completely when actuated punched holes will be shifted towards the trail edge of the sheet in this case Do the following to check whether SOL6 7 or 8 is causing the punch accuracy inconsistency 1 Leave the front door open and insert an interlock cheater 2 Leave the jam access panel of area 5 open 3 Run a 2...

Page 83: ...e any play in the mechanism The set screws are secured tightly Yes Go to Step 7 No Tighten set screw s and return to normal operation 7 There are three more pulleys involved in the Aligner drive PL 5 3 Driven pulley of the Alignment Stepper motor Pulley adjacent to the driven pulley Pulley on the other shaft of the Aligner drive Make sure all the set screws in these three pulleys are tightened sec...

Page 84: ...r to Control board 023N01340 see Section 7 Wiring If a cable is damaged replace it PL 7 3 Do GP 6 2 16 FIRMWARE UPGRADE Procedure to Re flash the firmware for the AdvancedPunch Pro With the Rear Cover removed do GP 6 2 12 Function tests Cycle Punch Check the relay towards the bottom left of the main control board You should be able to see the relay make contact when the punch motor starts If this ...

Page 85: ...ongated towards the trail edge of the sheet This failure usually occurs when the Punch cycle is slowed 1 Lubricate die set Do GP 6 7 3 This clears the fault Yes Return to normal operation No Go to Step 2 2 Check if correct pulley is used depending on 115V or 230V machine 115V machine should use 38T pulley and 230V machine should use 34T pulley PL 5 6 The correct pulley is used Yes Go to Step 3 No ...

Page 86: ...s the fault Yes Return to normal operation No Go to Step 2 2 Do RAP 4 3 to inspect Solenoids SOL 3 SOL 4 SOL 5 SOL 6 SOL 7 and SOL 8 This clears the fault Yes Return to normal operation No Go to Step 3 3 Do RAP 3 1 to inspect Sensors S3 S4 S5 S22 S23 and S24 This clears the fault Yes Return to normal operation No Escalate to 2nd level 3 12 Wrinkle in the sheet 1 If the wrinkling is at the trail ed...

Page 87: ...ct the issue Yes Continue normal operation No Escalate to next level 3 14 Punch Specifications Speed Up to 157 sheets per minute Punch Sheet Size and Edge LEF Long Edge Fed SEF Short Edge Fed US Sizes LTR LEF LTR SEF Statement LEF Legal SEF Ledger SEF 9 x 12 SEF 9 x 12 LEF 12 x 18 SEF DFA Configurations offer Double Punching below sizes LTR SEF Ledger SEF 9x12 SEF 12x18 SEF ISO sizes A4 LEF A4 SEF...

Page 88: ... 2 Skew variance at pick up 25mrads Alignment variance at exit 2 0mm from Center justified Skew variance at exit 5mrads for Punch job incremental to skew at entrance for bypass job Speed variance at exit 1 compared to speed variance at pick up Duty Cycles Maximum recommended monthly volume 400 000 Punch cycles Maximum Punch duty cycle In addition to above no more than 2 sheets of 300gsm per 5 shee...

Page 89: ...placement 4 37 REP 2 8 Lower Exit Panel Replacement 4 39 REP 2 9 Upper Bypass Panel Replacement 4 40 REP 2 10 Lower Bypass panel replacement 4 42 REP 2 11 Panel Close Magnet Replacement 4 43 REP 2 12 Idler Roller Replacement 4 44 REP 2 13 Flange Ball Bearing Replacement 4 46 REP 2 14 Snap in Bearing Replacement 4 47 REP 2 15 Bearing Housing Replacement 4 48 REP 2 16 Accel Idler Latch Handle Replac...

Page 90: ...95 REP 3 7 Alignment Carriage Sub Assembly Replacement 4 98 REP 3 8 Steering Stepper Motor Replacement 4 100 REP 3 9 Steering Motor Belt 65 Groove Replacement 4 102 REP 3 10 Steering Idler Panel Weldment Replacement 4 104 REP 3 11 Steering Idler Roller Assembly Replacement 4 105 REP 3 11 1 Steering Idler Roller Bearing Replacement 4 107 REP 3 12 Steering Drive Panel Weldment Replacement 4 108 REP ...

Page 91: ...the Rear Cover 5 Do REP 1 11 to remove the Upper Downstream Side Frame Cover 6 Remove the Phillips Head Screws 4 from the Top Cover Tabs Caution Top Cover will drop upon removal of fasteners Stabilize the Top Cover with your free hand to insure the Top Cover does not fall unexpectedly 7 Disconnect the LCD Panel Connector and release the LCD Cable from wire saddles 8 Remove the Top Cover Installati...

Page 92: ...our free hand to prevent movement 6 Lift the Door up off the pin on the Front Door Bottom Hinge Bracket 7 Remove the Front Door 8 Remove the Interlock Switch actuator and latch receptacle PL 2 2 from the old Door and install it on the new Door 9 Remove the Magnet Strike Plate from the old Door and install it on the new Door 10 Transfer the wrench and the mounting bracket to the new door 11 Transfe...

Page 93: ...ighten the Screws 2 7 Do REP 1 2 Front Door Replacement to install the Front Door 8 Connect the Power Cord 9 Power ON the entire printing system REP 1 4 Front Door Top Hinge Bracket Replacement PARTS LIST ON PL 2 2 Use this procedure to remove and install the Front Door Top Hinge Bracket 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 2 Front Door Replacement to...

Page 94: ...install a Panel Open Magnet 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Open the Front Door 4 Remove the Screws 2 and the Panel Open Magnet 5 Place the Panel Open Bracket in position and tighten the Screws 2 6 Close the Front Door 7 Connect the Power Cord 8 Power ON the entire printing system Screw 2 Panel Open Magnet ...

Page 95: ...ossible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 DFA Configurations Disconnect the Upstream and Downstream DFA Cables 4 Hold the Rear Cover in place so it doesn t fall as you remove the M4 Screws 6 from the Rear Cover 5 Grasp the Rear Cover by the handle and remove the Rear Cover Installation Procedure 1 Pla...

Page 96: ...nting system 2 Disconnect the Power Cord 3 Do GP 6 4 to undock the Punch from the upstream and downstream equipment 4 Do REP 1 6 to remove the Rear Cover 5 Remove the Screw from the right side of the Exhaust Fan Bracket Assembly 6 Remove the Screws 6 holding the Upstream Rear Side Cover 7 Remove the Upstream Rear Side Cover Installation Procedure 1 Place the Upstream Rear Side Cover in position 2 ...

Page 97: ...t can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do GP 6 4 to undock the Punch from the upstream and downstream equipment 4 Remove the Screws 4 on the entrance side 5 Remove the Upstream Side Frame Cover Installation Procedure 1 Place the Upstream Side Frame Cover in pos...

Page 98: ...ges that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do GP 6 4 to undock the Punch from the upstream and downstream equipment 4 Remove the Screws 4 5 Remove the Downstream Front Side Cover Installation Procedure 1 Place the Downstream Front Side Cover in position 2 Ti...

Page 99: ...e Punch from the upstream and downstream equipment 4 Do REP 1 6 to remove the Rear Cover 5 Release the wire saddles and cables 6 Remove the Screw from the left side of the Exhaust Fan Bracket Assembly 7 Remove the Screws 6 holding the Downstream Rear Side Cover 8 Remove the Downstream Rear Side Cover Installation Procedure 1 Place the Downstream Rear Side Cover in position 2 Tighten the Screws 6 h...

Page 100: ...guages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do GP 6 4 to undock the Punch from the upstream and downstream equipment 4 Remove the 2 screws and Docking plate off the Side cover you are uninstalling 5 To remove the Upper downstream side frame cover remove 4 screws shown in blue 6 To remove the Lower downstream side frame cover remove 6 screws shown in green 7 Re...

Page 101: ...wing to ensure the door latch holds the door closed and that the activating bracket tab depresses the door switch The tab should press the switch button just so that it is close to bottoming out 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Open the Front Door 4 Remove the two screws on the Door Latch 5 Remove Screws 2 from the Interlock Box Installation Procedure 1 Re...

Page 102: ... the M4 Nuts 2 5 Remove the Interlock Switch Bracket Do not knock the Nuts 2 into the machine 6 Press in the Tabs 2 on the sides of the Switch and remove the Interlock Switch from the Interlock Switch Bracket 7 Note the location of the Wires 4 then disconnect the Wires from the Interlock Switch PL 2 2 From right to left Yellow wire Position 8 Black wire Position 4 White wire Position 3 Orange wire...

Page 103: ...s that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Press the Power switch to OFF position 2 Disconnect the Power Cord 3 Open the Front Door 4 Remove the Screws 2 and the Switch Bracket 5 Note the connections on the back of the Switch 6 Press the Tabs and remove the Switch Installation Procedure 1 Install the Switch in the Bracket 2 Insert ...

Page 104: ...r OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 11 to remove the Upper Downstream Side Frame Cover 4 Open the Front Door 5 Disconnect the Cables from the LCD Display 6 From the bottom side of the Top Cover remove the Screws 3 holding the LCD Display to the Top Cover 7 Remove the LCD Display Installation Procedure 1 Place the new LCD Display Panel in position 2 Tighten the Sc...

Page 105: ... and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Open the Front Door 4 Disconnect the LCD Membrane Switch Connector from the LCD Display 5 Remove the M4 nut that secures the strap to the Top cover 6 Peel off the old LCD Membrane Switch Installation Procedure 1 Install the new Membrane within the indent...

Page 106: ...mponents contain dangerous electrical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Carefully lift the corner of the Punch by the Caster 4 Loosen the Jam Nut 5 Unsccrew the Caster to remove it 6 Place the new Caster in position and screw it in 7 Tighten th...

Page 107: ...upplied to the machine Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do GP 6 4 Undock the Punch to separate the Punch from the upstream and downstream devices Cont 4 Remove 2x M3 screws to remove the Doc...

Page 108: ...tighten the 2x screws at the rear side of the Docking Bracket 2 Tighten the 1x screw at front side of the Docking Bracket 3 Place the Docking latch bracket and tighten 2x screws 4 Do GP 6 3 Dock the Punch to connect the Punch to the upstream and downstream devices 5 Connect the Power Cord 6 Power ON the entire printing system ...

Page 109: ...t the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Remove the Screws 2 and the Exhaust Fan Bracket 5 Do the following to remove the Exhaust Fan from the Exhaust Fan Bracket Disconnect Cable 7715267 at Connector J20 on the Control Board PL 7 1 and PL 7 4 Open the Wires Saddles Remove the Screws 4 from the front and the Nuts 4 from the rear of the Bracket Remove the Exhaust Fan Installation Pr...

Page 110: ...4 from the front and tighten the Nuts 4 from the rear of the Bracket Place Cable 7715267 into the Wires Saddles 2 Place the Exhaust Fan Bracket Assembly in position and tighten the Screws 2 3 Connect Cable 7715267 at Connector J20 on the Control Board 7 1 4 Do REP 1 6 to install the Rear Cover 5 Connect the Power Cord 6 Power ON the entire printing system ...

Page 111: ...chine Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 For Entrance side Remove 2 screws from the front frame and 2 screws from the rear frame 5 For exit side Remove 2 ...

Page 112: ... injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do GP 6 4 to undock the Punch from the upstream and downstream equipment 4 Do REP 1 6 Rear Cover Replacement to remove the Rear Cover 5 Do REP 1 20 to remove the Entrance side Drive roller cover 6 Open the Upper Bypass Assembly 7 Remove the Screws 2 from the Front Frame used...

Page 113: ...nt the Lower Entrance Panel 3 Intall the Timing belt pulley shield with 1 screw and 1 nut 4 Close the Upper Bypass Assembly 5 Do REP 1 6 Rear Cover Replacement to install the Rear Cover 6 Do GP 6 3 to dock the Punch to the upstream and downstream equipment 7 Connect the Power Cord 8 Power ON the entire printing system 9 Do ADJ 1 2 Diverter Solenoid Adjustment ...

Page 114: ...ge vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Open the Front Door 4 Do GP 6 4 Undock the Punch to separate the Punch from the upstream and downstream devices 5 Do REP 1 8 to remove the Upstream Side Cover 6 Do REP 1 18 to remove the Docking Bracket 7 Open the Cable Clamps to release all the sensor cables and disconnect S2 S3 S4 and S1b 8 Remov...

Page 115: ...re 1 Place the Entrance Idler Panel in position 2 Insert the Shaft through the holes 2 at the left side of the Entrance Idler Panel 3 Install the E Rings 2 at the top and bottom of the Shaft 4 Connect the Connectors for Solenoids SOL3 SOL4 to the header 5 Connect the Connectors for Sensors S2 S3 S4 and S1b 6 Place the sensor cables into the Cable Clamps and close the Clamps 7 Install the Ground st...

Page 116: ...h to separate the Punch from the upstream and downstream devices 4 Open the Front Door 5 Do REP 1 8 to remove the Upstream Side frame Cover 6 Grasp the Handle and open the Acceleration Idler Roller Panel 7 Open the Cable Clamps to release the Sensor Cable 8 Disconnect the Accel Sensor S5 Connector 9 Disconnect the Acceleration Idler Roller Solenoid SOL5 Connector at the sensor on the Acceleration ...

Page 117: ... position 2 Slide the Accel Idler Latch Shaft through the holes in the frame and the holes at each end of the Acceleration Idler Roller Assembly 3 Install the E Ring 2 at each end of the Accel Idler Latch Shaft 4 Connect the Acceleration Idler Roller Solenoid SOL5 Connector at the header 5 Connect the Acccel Sensor S5 Connector 6 Place the Cable in the cable Clamps and close the cable Clamps 7 Gra...

Page 118: ...contain dangerous electrical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 to remove the Punch Module 5 Do GP 6 4 Undock the Punch to separate the Punch from the upstream and downstream devices 6 Do REP 1 8 ...

Page 119: ...ngs 2 11 Unhook the Springs 2 from the Idler panel side 12 Do REP 2 22 1 to remove the Drive Roller for Roller N5 13 Open the Cable Clamps and release the Sensor Cables 14 Disconnect the Sensor Board Connectors 2 and the Clear Cover Sensor Cont Acceleration Roller Idler Assembly Acceleration Panel Latch Springs Drive Roller Cable Clamps Sensor Board Connectors ...

Page 120: ... 08 20 2015 GBC AdvancedPunch Pro 4 32 15 Remove the Screws 5 that hold the Entrance Drive Panel to the front Frame 16 Remove the Screws 5 that hold the Entrance Drive Panel to the Rear Frame Screws 5 Entrance Drive Panel ...

Page 121: ...o the rear Frame 4 Install the Screws 5 that hold the Entrance Drive Panel to the front Frame 5 Connect the Sensor Board Connectors 2 6 Place the Sensor Cables in the Cable Clamps and close the Cable Clamps 7 Do REP 2 22 1 to install the Drive Roller for Roller N5 8 Hook the Acceleration Panel Latch Springs 2 to the Idler Panel side 9 Do REP 2 3 to install the Acceleration Idler Roller Panel 10 Do...

Page 122: ... serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 11 to remove Lower downstream Side frame cover 4 Remove the screw for Ground strap 5 Open the Front Door 6 Remove the E clips 2 from the Shaft 7 Remove the M4 screw for the ground strap 8 Slide the Shaft out of place 9 Remove the Lower Exit Panel Installatio...

Page 123: ...ry See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Open the Front Door 4 Do GP 6 4 Undock the Punch to separate the Punch from the downstream devices 5 Do REP 1 11 to remove the Lower Downstream Side Frame Cover 6 Open the Cable Clamps to release all the sensor cables 7 Disconnect the Connectors for Sensors S22 S23 S24 8 Disconne...

Page 124: ...ent REP 2 11 Panel Close Magnet Replacement Installation Procedure 1 Place the Exit Idler Panel in position 2 Insert the Shaft through the holes 2 at the left side of the Exit Idler Panel 3 Install the E Rings 2 at the top and bottom of the Shaft 4 Connect the Connectors for Solenoids SOL5 SOL6 SOL7 to the header 5 Connect the Connectors for Sensors S22 S23 S24 6 Install the Ground strap 7 Place t...

Page 125: ...s 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do GP 6 4 to undock the Punch from the upstream and downstream equipment 4 Do REP 1 11 Downstream Side Frame Cover Replacement remove the Downstream Side Frame Cover 5 Do REP 2 5 to remove the Punch Lower Exit Panel 6 Do REP 2 6 to remove the Exit Idler Panel 7 Remove 3 M4 nuts to remove the Bracket in Area 5 of the machi...

Page 126: ...6 in position and tighten the 2 nuts 5 Do REP 2 23 to install Motor M7 6 Place the Bracket in position in Area 5 of the machine and tighten the 3 M4 nuts 7 Do REP 2 6 to install the Exit Idler Panel 8 Do REP 2 5 to install the Punch Lower Exit Panel 9 Do ADJ 1 7 Idler Panel Magnetic Latches Adjustment 10 Do REP 1 11 Downstream Side Frame Cover Replacement install the Downstream Side Frame Cover 11...

Page 127: ...move the upper and lower Downstream Side Frame Cover 6 Remove the Screws 2 from the Front Frame and the Screws 2 from the Rear Frame used to mount the Lower Exit Panel 7 Open the Upper Bypass Assembly 8 Remove the Lower Exit Panel Installation Procedure 1 Place the Lower Exit Panel in position 2 Tighten the Screws 4 used to mount the Inner Entrance Panel 3 Do REP 1 11 Downstream Side Frame Cover R...

Page 128: ...ction 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do GP 6 4 to undock the Punch from the upstream and downstream equipment 4 Do REP 1 6 Rear Cover Replacement to remove the Rear Cover 5 Unplug the Sensors from the Upper Bypass Panel and release the sensor cables from the cable clamps 6 Remove 2 E clips from the hinge shaft and remove the...

Page 129: ...anel magnetic latches 5 Install the Idler Panel Mount Brackets 2 on the rear frame 6 Place the Shaft in position and install the 2 E clips 7 Connect the Sensors from the Upper Bypass Panel and place the sensor cables in the cable clamps 8 Do REP 1 6 Rear Cover Replacement to install the Rear Cover 9 Do GP 6 3 to dock the Punch to the upstream and downstream equipment 10 Connect the Power Cord 11 P...

Page 130: ... that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 2 9 Upper bypass removal 4 Remove 4 M4 screws from Front frame 5 Remove 4 M4 screws from Rear frame 6 Remove the Lower Bypass panel Installation Procedure 1 Place the new Lower Bypass panel in position 2 Install...

Page 131: ...he machine Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Remove the Screws 2 and Nuts 2 4 Remove the Magnet Bracket 5 Remove the old Magnet Installation Procedure 1 Place the Magnet Bracket in position a...

Page 132: ... Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do the following to access the Idler Rollers For the Idler Rollers in the Entrance Idler Panel do REP 1 8 to remove the Upstream Side Frame Cover For the Idler Rollers in the Acceleration Roller Idler Assembly do do REP 1 8 to remove the Upstream Side Frame Cover For the Idler Rollers in the Exit Idler Panel do REP 1 11 to r...

Page 133: ...he fork 6 Place the Extension Spring 2 over the Bearing Housings 2 7 Place the hooks on the ends of the Extension Springs 2 on the notches at the top of the Bushing Forks 2 8 Do the following to install the covers For the Idler Rollers in the Exit Idler Panel do do REP 1 8 to remove the Upstream Side Frame Cover For the Idler Rollers in the Acceleration Roller Idler Assembly do REP 1 8 to remove t...

Page 134: ...d 3 Locate the Flange Ball Bearing There are 22 Flange Ball Bearings Pt 013N13948 on the Frame PL 3 4 There are 2 Flange Ball Bearings Pt 013N13946 on the Frame PL 3 4 4 Remove the E Ring 5 Remove the Flat Washer 6 Remove the Flange Ball Bearing NOTE To replace a Bearing from the rear side do REP 2 20 to remove the Pulley 7 Place the new Flange Ball Bearing in position 8 Install the Flat Washer 9 ...

Page 135: ...ee Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do one of the following to remove the panel so you can access the Snap in Bearing REP 2 2 Entrance Idler Panel Replacement REP 2 3 Acceleration Roller Idler Assembly Replacement REP 2 9 Upper Bypass Panel Replacement REP 2 6 Exit Idler Panel Replacement REP 2 5 Punch Lower Exit Panel...

Page 136: ...dler Panel Acceleration Roller Idler Assy Exit Idler Panel Bypass Panel 1 Do REP 2 12 to remove the Idler Roller with the Bearing Housings 2 from the Bushing Forks 2 Remove the old Bearing Housings 2 from the ends of the Shaft 3 Place the new Bearing Housings 2 on the ends of the Shaft with the flange of the Bearing facing in toward the Idler Roller 4 Do REP 2 12 to install the Idler Roller Idler ...

Page 137: ...trical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Open the Front Door 4 Remove 2 screws from the Accel Idler Latch Handle 5 Remove the Rubber Cap and transfer it to the new part if re using the rubber cap If a new Rubber cap has been ordered use the new...

Page 138: ...Idler Panel Rear Latch Assembly Accel Idler Panel Front Latch Assembly Removal Procedure 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 1 to remove the Punch Module 5 Unhook the Extension Springs from the Accel Idler Panel Front and Rear Latches 6 Remove the M3 screws 2 from the Accel Idler Panel Front and Rear Latches 7 ...

Page 139: ...from the Accel Idler Shaft on the front side 10 For the Accel Idler Panel Rear Latch Assembly slide the shaft towards the front side to remove 11 For the Accel Idler Panel Front Latch Assembly slide the shaft towards the rear side to remove 12 Remove Accel Panel Rear and Front Latch assemblies to remove the Accel Idler Latch shaft ...

Page 140: ...y slide the shaft towards the rear side to install 4 Install the E clip on the Accel Idler Shaft from the front side 5 Do REP 2 16 to install the Accel Idler Latch Handle 6 Install the E clip on the Accel Idler Shaft from the rear side 7 Install the M3 screws 2 in the Accel Idler Panel Front and Rear Latches 8 Hook the Extension Springs to the Accel Idler Panel Front and Rear Latches 9 Do REP 3 1 ...

Page 141: ...sembly on to the Shaft 7 Install the Washer and the E Clip 8 Connect the Power Cord 9 Power ON the entire printing system REP 2 19 Drive Idler Roller Assembly Replacement PARTS LIST ON PL 3 3 Use this procedure to remove and install a one way Drive Idler Roller Assembly Removal Procedure WARNING Do not perform repair activities with the power on or electrical power supplied to the machine Some mac...

Page 142: ...ossible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 2 21 to remove the appropriate Timing Belt from the Pulley 5 Remove the retaining ring from the roller shaft 6 Remove the Timing Pulley by sliding it out Installation Procedure 1 Place the Timing Pulley in position ...

Page 143: ...e the belts REP 2 21 1 534T Belt Replacement PARTS LIST ON PL 3 9 Use this procedure to remove and install the 534T Belt for the Bypass Motor M8 WARNING Do not perform repair activities with the power on or electrical power supplied to the machine Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for ...

Page 144: ...ar Cover 8 Connect the Power Cord 9 Power ON the entire printing system REP 2 21 3 150T Belt Replacement PARTS LIST ON PL 3 9 Use this procedure to remove and install the 150T Belt connecting rollers N1 and N2 N2 and N3 N8 and N9 Removal Procedure WARNING Do not perform repair activities with the power on or electrical power supplied to the machine Some machine components contain dangerous electri...

Page 145: ...ine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Loosen the Tensioner and remove the old Belt 5 Place the new Belt in position around the Pulleys 6 Adjust the Belt Tension ADJ 1...

Page 146: ...ing system 2 Do REP 1 6 to remove the Rear Cover 3 Open the Front Door 4 Locate the appropriate Drive Roller 5 For all Drive Rollers except N1 and N11 do REP 3 1 to remove the Punch Module 6 Do REP 2 21 to remove the Belt from the appropriate Drive Roller Shaft 7 Do REP 2 20 to remove the Pulley from the appropriate Drive Roller Shaft 8 Remove the E Ring and the Washer from the end of the Drive Ro...

Page 147: ...n position the end of the Drive Roller Shaft at the front of the machine 5 Place the Washer and the E Ring in position the end of the Drive Roller Shaft at the rear of the machine 6 Do REP 2 20 to install the Pulley on the appropriate Drive Roller Shaft 7 Do REP 2 21 to install the Belt on the appropriate Drive Roller 8 Adjust the Belt Tension ADJ 1 4 9 For all Drive Rollers except N1 and N11 do R...

Page 148: ...oval Procedure 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 to remove the Punch Module 5 Loosen the nuts 2 on the Tensioner of the M2 motor belt 6 Remove the retaining ring from the shaft of roller N5 7 Remove the Belt from the Motor Pulley 8 Slide the Pulley off the Roller Shaft Tensioner Nuts 2 ...

Page 149: ...nd the Washer from the rear side of the Shaft 10 Remove the E Ring at the front side of the Shaft 11 Remove the Washer and Ball Bearing from the front side 12 Remove the Ball Bearing from the rear side of the Shaft Cont E Ring and Washer E Ring Washer and Ball Bearing Ball Bearing ...

Page 150: ...ide of the Shaft 5 Install the Washer and the E Ring at the rear side of the Shaft 6 Slide the Pulley on to the Roller Shaft 7 Place the Belt over the Pulley 8 Install the retaining ring on the Drive Roller N5 9 Move the Tensioner of the M2 motor belt into position and tighten the Screws 2 10 Adjust the Belt Tension ADJ 1 7 4 11 Do REP 3 1 to install the Punch Module 12 Do REP 1 6 to install the R...

Page 151: ...itch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Locate the affected Motor see PL 3 6 5 Disconnect the Motor Connector from the corresponding Motor Drrver PL 3 6 6 Remove the Screws 4 and the Stepper and Mount Assembly from the Rear Panel Installation Procedure 1 Place the Stepper and Mount Assembly in position and tighten the Screws 4 Se...

Page 152: ...he Power Cord 3 Do GP 6 4 to undock the Punch from the upstream and downstream equipment 4 Do REP 1 11 Downstream side frame cover to remove the upper cover 5 Do REP 1 6 to remove the Rear Cover 6 Disconnect the Sensor Connector at the Sensor 7 Remove the Screw and Nut that secure the Sensor to the sheet metal part Installation Procedure 1 Place the Sensor in position then install and tighten the ...

Page 153: ...25 2 S8 REP 2 25 6 S23 REP 2 25 2 S9 REP 2 25 6 S24 REP 2 25 2 S10 REP 2 25 6 S25 REP 2 25 1 S11 REP 2 25 7 S26 REP 2 25 1 S12 REP 2 25 7 S27 REP 2 24 S13 REP 2 25 7 S28 REP 2 25 4 S14 REP 2 25 7 S1b REP 2 25 2 S15 REP 2 25 7 REP 2 25 1 Entrance Sensor S1 Exit Sensor S25 and Bypass Middle Sensor S26 Replacement PARTS LIST ON PL 4 5 Use this procedure to remove and install the Sensor and Bracket As...

Page 154: ...sor S2 S3 S4 and Exit Sensor S22 S23 S24 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Remove the side panels as needed to access the Sensor see REP 1 8 or REP 1 11 4 Disconnect the sensor wire and the Sensor 5 Remove the Barrel Screw and Lock Washer that secure the Sensor to the sheet metal part 6 Remove the old Sensor 7 Place the new Sensor in position then install L...

Page 155: ... Power Cord 3 Do REP 1 8 to remove the Upstream Side Frame Cover 4 Open the Wire Saddles and release the Sensor Cable 5 Disconnect the sensor connector at the Sensor 6 Remove the Barrel Screw and Lock Washer that secure the Sensor to the sheet metal part 7 Remove the old Sensor 8 Place the new Sensor in position then install Lockwasher and Barrell Screw 9 Place Sensor Cable in the Wire Saddles 10 ...

Page 156: ...e the Lower Downstream Side Frame Cover 4 Disconnect the Sensor Wire Connector from the Sensor 5 Remove the M3 Screws 2 that secure the Sensor to the Bracket 6 Remove the Sensor Sub assembly 7 Place the new Sensor in position 8 Tighten the M3 Screws 2 that secure the Sensor to the Bracket 9 Connect the Sensor Connector to the Sensor 10 Do REP 1 11 to install the Downstream Side Frame Cover 11 Conn...

Page 157: ...ges 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 to remove the Punch Module 5 Locate the Drive Entrance Panel The upper board is the Backage Sensor Board S20 S21 The lower board is the Backage Sensor Board S18 S19 6 Disconnect the Sensor Board Connectors 2 7 Remove the Nuts 3 and Washers 3 8 Remove the old Backage Senso...

Page 158: ... Module 5 Disconnect the Skew Sensor Board Connector 6 Remove the Nuts 4 Washers 4 and the Skew Sensor Board do not remove the washers under the sensor board 7 Place the new Skew Sensor Board in position 8 Install the Washers 4 and tighten the Nuts 4 Make sure there are 4 washers below the sensor board 9 Connect the Sensor Board Connector 10 Do REP 3 1 to install the Punch Module 11 Do REP 1 6 to ...

Page 159: ...ct the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 to remove the Punch Module 5 Disconnect the Skew Sensor Board Connector 6 Release the Cable Clamp and move the Cable out of the way 7 Remove the M4 Nuts 2 8 Remove the Roller Cover 9 Disconnect the Alignment Sensor Board Connector 10 Release the Cable Clamp and move the Cable out of the way 11 Remove the M4 Nuts 2 and Washers 2 1...

Page 160: ... location 3 Place the Alignment Sensor Board Cable into the Cable Clamps and close the Cable Clamps 4 Connect the Alignment Sensor Board Connector 5 Place the Roller Cover in position 6 Place the Skew Sensor Board Cable into the Cable Clamps and close the Cable Clamps 7 Connect the Skew Sensor Board Connector 8 Do REP 3 1 to install the Punch Module 9 Do REP 1 6 to install the Rear Cover 10 Connec...

Page 161: ... To replace the Lower Backage Sensor Bracket or the Bracket Weldment Open the Wire Saddles and remove the Sensor Cable Remove the M3 Nuts 2 Remove the Bracket Remove the Bracket Weldment Place the new Bracket Weldment in position on the Studs 2 Place the new Bracket in position in position on the Studs 2 Tighten the M3 Nuts 2 Place the Sensor Cable in the Wire Saddles then close the wire Saddles 8...

Page 162: ...rinting system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Locate the appropriate Motor Driver see PL 3 6 5 Disconnect the Connectors 3 6 Remove the M4 Screws 2 and the Driver and Bracket Assembly 7 Disconnect the Cables from the Motor Driver Board 8 Set the Dip switches 6 on the new Motor Driver in accordance with the table below M1 Motor Driver M2 Motor Driver M3 Motor Dr...

Page 163: ...ustments 4 75 Installation Procedure 1 Place the Driver and Bracket Assembly in position and tighten the M4 Screws 2 2 Connect the Connectors 3 3 Do REP 1 6 to install the Rear Cover 4 Connect the Power Cord 5 Power ON the entire printing system ...

Page 164: ...emoval Procedure 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Remove the E clip from the Diverter Shaft on the front side 5 Remove the M4 screws 2 from the Diverter Shaft on the rear side 6 Remove the E clip from the Diverter Shaft on the rear side 7 Slide the Diverter Assembly to the back side and remove the part Cont ...

Page 165: ...T ON PL 3 8 Use this procedure to remove and install the Solenoids in these assemblies Solenoid Solenoid REP Diverter Subassembly SOL 1 REP 2 28 1 Punch Clutch SOL 2 REP 3 4 Entrance Idler Solenoid Middle SOL 3 REP 2 28 2 Entrance Idler Solenoid Bottom SOL 4 REP 2 28 2 Acceleration Roller Idler Solenoid SOL 5 REP 2 28 3 Exit Idler Solenoid Bottom SOL 6 REP 2 28 4 Exit Idler Solenoid Middle SOL 7 R...

Page 166: ...ove the Rear Cover 4 If necessary Do REP 1 19 to remove the Exhaust Fan Bracket along with the fan Do not remove the fan from the bracket 5 Remove the M4 2 screws from the Diverter Shaft 6 Disconnect the inline Connector for the Diverter Solenoid sub assembly 7 Remove Screws 2 from the diverter solenoid sub assembly 8 Remove the Diverter Solenoid Sub assembly Installation Procedure 1 Place the new...

Page 167: ... Cable Clamps 12 Close the Front Door 13 Do GP 6 3 Dock the Punch 14 Connect the Power Cord 15 Power ON the entire printing system REP 2 28 3 Acceleration Roller Idler Solenoid Replacement PARTS LIST ON PL 4 3 Use this procedure to remove and install the Acceleration Roller Idler Solenoid SOL 5 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do GP 6 4 Undock the Punch 4 ...

Page 168: ...o REP 1 11 to remove the Lower Downstream Side Frame Cover 5 Open the Front Door 6 Disconnect the Solenoid Connector 7 Open the Cable Clamps and remove the Cable 8 Remove the M4 Barrel Screws 3 and the Solenoid 9 Place the new Solenoid in position and tighten the Screws 3 10 Connect the Solenoid Connector 11 Place the the Cable into the Cable Clamps and close the Cable Clamps 12 Close the Front Do...

Page 169: ...tion 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do GP 6 4 to undock the Punch from the downstream equipment 4 Peel off the old Anti Static Brush 5 Clean the surface with some rubbing alcohol 6 Affix the new brush inside referencing the cut outs as shown above 7 Do GP 6 4 to dock the Punch from the downstream equipment 8 Connect the Powe...

Page 170: ...witch Bracket 5 Place the new Chip Tray Home Switch Bracket in position and tighten the Screws 2 6 Connect Cable 023N01327 at the Chip Tray Home Switch 7 Put the Chip Tray in position and push the Chip Tray Assembly in firmly until it latches 8 Close the Front Door 9 Connect the Power Cord 10 Power ON the entire printing system Chip Tray Home Switch Cable Screws 2 ...

Page 171: ... Door 12 Connect the Power Cord 13 Power ON the entire printing system REP 2 32 Chip Level Receiver Replacement PARTS LIST ON PL 3 5 Use this procedure to remove and install the Chip Level Receiver Assembly WARNING Do not perform repair activities with the power on or electrical power supplied to the machine Some machine components contain dangerous electrical voltages that can result in electrica...

Page 172: ...See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Open the Front Door 5 Use the handle to unlock the Die Set Remove the Die set and insert it into one of the Die storage racks 6 Use the levers blue to open the Acceleration Roller Idler Panel and the Accel Idler Panel compartments 7 Remove the M...

Page 173: ...5 11 Disconnect the Connector for Sensor S28 12 Disconnect the Connector for Solenoid SOL2 13 Disconnect the Connector for the M5 Motor Driver 14 Disconnect the Connectors 2 for the M3 Header and the M4 Header 15 Disconnect the Die Set Recognition Connector ...

Page 174: ... 18 Do the following to remove the Punch Module Mount Bracket Lock Plates Use a Phillips Head Screwdriver to loosen the Captive Screw from the left Punch Module Mount Bracket Remove the left Punch Module Mount Bracket Use a Phillips Head Screwdriver to loosen the Captive Screw from the right Punch Module Mount Bracket Remove the right Punch Module Mount Bracket ...

Page 175: ...to the slot 2 Do the following to install the Lock Plates green Place the Lock Plates 2 in position Use a Phillips Head Screwdriver to tighten the Screws 2 through the Lock Plates 2 3 Connect all electrical Connectors 11 Connector for Punch Motor M10 Connector for Sensors S16 and S17 Die Set Recognition Connector Connectors 2 for the M3 Header and the M4 Header Connector for the M5 Motor Driver Co...

Page 176: ...r Cover 4 Do REP 3 1 to remove the Punch Module 5 Do REP 3 3 Punch Motor Belt Replacement Timing Belt to remove the Punch Motor Belt 6 Remove the M8 Hex Cap Screws 4 the M8 Split Lock Washers 4 and the Flat Washers 4 7 Remove the old Punch Motor Installation Procedure 1 Using the position marks on the Bracket place the new Punch Motor in position 2 Place the Flat Washers 4 and the M8 Split Lock Wa...

Page 177: ...ges that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 There is no need to uninstall the punch module however for ease of operation it is recommended to uninstall it using REP 3 1 5 Remove the E Ring nylon washer and ball bearing 6 ...

Page 178: ...s 2 11 Place the Ball Bearing in position 12 Place the Nylon Washer in position 13 Place the E Ring in position NOTE The tension on the Belt is set using the reference marks on the punch motor bracket see REP 3 2 14 Do REP 1 6 to install the Rear Cover 15 Connect the Power Cord 16 Power ON the entire printing system Mark ...

Page 179: ...ical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 1 Punch Module Removal 5 Remove the E Ring nylon washer and ball bearing 6 Remove the Screws 2 and the Bearing Bracket 7 Remove the Timing belt 8 To remove ...

Page 180: ...ith the notches on the Shaft The Cone point set screw should be properly seated in the notch of the Punch shaft 4 Put a drop of Loctite on each Set Screw 5 Tighten the Set Screws 2 6 Place the long M56Screw and the Lock Nuts 2 in position 7 Use a shim of thickness between 3 and 5mm to set the gap between the head of the Screw and the Clutch Bracket 8 Use a 10 mm wrench and a 6mm Allen Wrench to ti...

Page 181: ...ock Washers 3 12 Place the Punch Shaft Bearing Bracket in position and tighten the Screws 2 13 Do REP 3 3 to install the Punch Motor Belt 14 Do Error Reference source not found Ball Bearing Replacement o install the Ball Bearing 15 Do REP 3 1 2 Punch Module Installation 16 Do REP 1 6 to install the Rear Cover 17 Connect the Power Cord 18 Power ON the entire printing system ...

Page 182: ...serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 to remove the Punch Module 5 Remove the Phillips Screws 4 6 Remove the Steering Belt from the Pulley 7 Remove the Punch Alignment Stepper Motor and Pulley Installation Procedure 1 Place the Steering Belt around the Pull...

Page 183: ...result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 to remove the Punch Module 5 Disconnect the Skew Sensor Board Connector 6 Do the following to take the Alignment motor Belt off the Pulley Remove the Phillips Screws 2 from Alignm...

Page 184: ...top side Then press the bottom tab to release the connector fully Similarly disconnect the Align Home sensor connector 9 Release the Cable Clamp for Steering Stepper wires 10 Remove the Phillips Screws 8 11 Remove the Steering Module from the Punch Module by tilting the Steering Module as shown 12 Remove the Steering Module from the Punch Module by tilting the Steering Module as shown This is to e...

Page 185: ...reference holes for positioning the part A 3mm pin can be inserted to hold the part in position while the screws are tightened 4 Connect the Alignm Home Sensor and the Left Right Steering Motor Connectors 5 Place the Alignment Stepper motor Belt around the Pulley 6 Tighten the Phillips Screws 2 7 Do REP 3 1 to install the Punch Module 8 Close the Front Door 9 Do REP 1 6 to install the Rear Cover 1...

Page 186: ...that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 1 to remove the Punch Module 5 Remove the Steering Idler and Drive Panel assemblies by removing the M3 Nuts 4 6 Remove E clip from steering drive roller shaft 7 Remove th...

Page 187: ... Install the parts that were removed in the new Alignment Carriage Sub assembly Installation tip The cable of the motor closer to the ground strap has a 7 pin connector the other cable has a 6 pin connector 2 Do ADJ 1 4 5 and ADJ 1 4 1 to adjust the tension on the timing belts installed 3 Do REP 3 1 2 to install the Punch Module 4 Do REP 1 6 to install the Rear Cover 5 Connect the Power Cord 6 Clo...

Page 188: ...rous electrical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 to remove the Punch Module 5 Do REP 3 6 to remove the Steering Module 6 Disconnect the Steering Motor Cable at the Motor and at the Header 7 Remo...

Page 189: ...he Steering Motor Cable at the Motor and at the Header 4 Install the Screws 4 and tighten with the Belt in place 5 Install the Align Home Sensor Bracket and tighten the M3 Screws 2 6 Do REP 3 6 to install the Steering Module 7 Do REP 3 1 to install the Punch Module 8 Do REP 1 6 to install the Rear Cover 9 Close the Front Door 10 Connect the Power Cord 11 Power ON the entire printing system ...

Page 190: ...hat can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 to remove the Punch Module 5 Remove the E Ring from the Steering Drive Roller shaft from the side that needs the part to be replaced 6 Slide the Shaft in the opposite dire...

Page 191: ...pring Intallation Procedure 1 Place the belt around the Timing Pulley 2 Do ADJ 1 4 5 to set the belt tension 3 Install the Steering Drive Roller and the Flat Washers 2 and the Spring on the end of the Shaft 4 Install the E Ring on the Steering Drive Roller Shaft 5 Do REP 3 1 to install the Punch Module 6 Do REP 1 6 to install the Rear Cover 7 Connect the Power Cord 8 Power ON the entire printing s...

Page 192: ... the Skew Senor and release the Cable Clamp 6 Remove the Screws 4 that hold the Steering Idler Panel Sub Assembly to the Drive Panel Steering Sub Assembly 7 Remove the Steering Idler Panel Sub Assembly 8 Transfer the Skew Sensor Steering Islder Roller Idler roller Cover and all fasteners to the new Weldment Installation Procedure 1 Make sure the Spacers 2 are in position on the Steering Drive Pane...

Page 193: ...ts contain dangerous electrical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 to remove the Punch Module 5 Disconnect the Skew Sensor Board Connector 6 Release the Cable Clamp and move the Cable out of the w...

Page 194: ...rings 2 are over the white Roller Bushings 2 4 Place the Roller Cover in position 5 Install and tighten the M4 Nuts 2 6 Place the Skew Sensor Board Cable in the Cable Clamp and close the Cable Clamp 7 Connect the Skew Sensor Board Connector 8 Do REP 3 1 to install the Punch Module 9 Do REP 1 6 to install the Rear Cover 10 Connect the Power Cord 11 Power ON the entire printing system Spring Steerin...

Page 195: ...lectrical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Do REP 3 11 Steering Idler Roller Replacement to remove the Steering Idler Roller 2 Remove the Steering Idler Roller Bearing 2 from the ends of Shaft on the Steering Idler Roller Assembly 3 Place the new Steering Idler Roller Bearing 2 on to the ends of Shaft on the Steeri...

Page 196: ...ure 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 10 through step 6 to remove the Steering Idler Panel Sub Assembly 5 Remove the Spacers 2 6 Remove the Nuts 4 holding the Steering Drive Panel Weldment 7 Replace with new part Installation Procedure 1 Place the Steering Drive Panel Weldment in place 2 Tighten the Nuts 4 that...

Page 197: ...s injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 to remove the Punch Module 5 Remove the left or right Die Lock Bracket Screws 2 6 Note the orientation of the Stripper Pad 7 To replace the components in the Die Lock Plunger and Stripper Remove the E Clip Pull the Die Lock P...

Page 198: ...vi for other languages 1 Remove the Die Set see Operator Manual 2 Switch power OFF to entire printing system 3 Disconnect the Power Cord 4 Do REP 1 6 to remove the Rear Cover 5 Remove the Phillips Screw and the Die Stop Handle 6 Do REP 3 1 to remove the Punch Module 7 Remove the Shoulder Screw from the hole in the Shaft at the rear of the Punch Module 8 Remove the Socket Head Cap Screw and Split L...

Page 199: ...aft at the rear of the Punch Module 6 Insert the Socket Head Cap Screw and Split Lock Washer into the Cam and the Shaft at the front of the Punch Module 7 Insert the Phillips Screw into the Cam and the Shaft at the rear of the Punch Module 8 Insert the Shoulder Screw the hole in the Shaft at the rear of the Punch Module Make sure it is in the correct phase Shoulder Screw facing down as well as Cam...

Page 200: ...ult in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Remove the Die Set see Operator Manual 3 Disconnect the Power Cord 4 Do REP 1 6 to remove the Rear Cover 5 Do REP 3 1 to remove the Punch Module 6 Unplug Back Gage Sensor Board and release the wires from cable clamps 7 Unplug Alignment Sensor Board and releas...

Page 201: ...s If replacing only the Die rail springs remove only the brackets from the Alignment sensor side 12 Unscrew the M2 Screws 4 and M2 Lock Washers 4 to remove the Springs NOTE If you are replacing only the Springs skip the next two steps 13 Remove Nuts 3 and the Chip Chute 14 Remove the old Die Rail ...

Page 202: ...that Die Rail Assembly When installing 4 screws that hold the die rail use 3mm reference holes for positioning the part A 3mm pin can be inserted to hold the part in position while the screws are tightened 7 Tighten the Screws 2 that hold the Dieset Recognition Bracket 8 Connect the Alignment Sensor Board and place the wires in the Cable Clamps 9 Connect the Back Gage Sensor Board and place the wi...

Page 203: ...FF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Do REP 3 1 to remove the Punch Module 5 Remove the M3 Nuts 2 that hold both the Brackets 6 If replacing only the lower bracket replace the Bracket then go to the installation procedure 7 Unplug the Backgage Sensor and release the wires from the Cable Clamps 8 Transfer the Backgage Sensor and all fasten...

Page 204: ... vi for other languages 1 Disconnect the Power Cord 2 Do REP 1 6 to remove the Rear Cover 3 Do GP 6 4 Undock the Punch to separate the Punch from the upstream and downstream devices 4 Dsiconnect Connectors J1 and J3 from the Main Control Board 5 Remove the M4 Screw 1 and remove the Ground Cable from the Power Supply 6 Release the cable clamps for the cables of J1 J3 and ground wire of Power supply...

Page 205: ...de die rack 11 For DFA configurarations Tilt the Power Supply and remove it through the Chip Tray opening The die rack loosened in the above step has to bend up slightly to give room for the Power supply to be removed 12 Transfer all wires to the new Power Supply Installation Procedure 1 Reverse Steps for Installation ...

Page 206: ...oltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Remove the Phillips head Screws 2 and the AC Filter USB Mount Bracket 5 Note the location of the wires 3 6 Remove the Wires 3 and the AC Filter 7 Place the AC Filter in posi...

Page 207: ...lectrical power supplied to the machine Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Remove the M3 Screws 4 from the Main Control Board and the Comm Board 5 Use pli...

Page 208: ...7715473 023N01334 J15 7715453 023N01346 J22 7715495 023N01331 J9 7715468 023N01333 J14 7715457 023N01345 J25 7715456 023N01344 J24 7715476 023N01340 J2 7715493 023N01322 J3 7715494 023N01321 J4 7715487 023N01332 J8 7715492 023N01329 J1 Cable Wire Xerox Cable Wire Connector 7715459 023N01347 J28 7715458 023N01348 J26 7715267 127N07842 J20 7715470 023N01323 J16 7715538 023N01328 J37 7715490 023N0135...

Page 209: ...6 to remove the Rear Cover 4 Disconnect the Connectors 3 Connector J2 Connector J14 Connector J15 For DFA configurations there will be 4 connectors Connector J1 Connector J6 Connector J14 Connector J15 5 Remove the Screws 3 and the old Comm Board Installation Procedure 1 Place the new Comm Board in position and tighten the Screws 4 2 Connect the Connectors 3 Cable Wire Xerox Cable Wire Connector 7...

Page 210: ...ction 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Do REP 1 6 to remove the Rear Cover 4 Disconnect the Connector at the Dieset Recognition Reader Board 5 Remove the M3 nuts 2 and the Dieset Recognition Reader Board Installation Procedure 1 Place the Dieset Recognition Reader Board in position and tighten the nuts 2 2 Connect the Connecto...

Page 211: ... Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Switch power OFF to entire printing system 2 Disconnect the Power Cord 3 Open the Front Door 4 Loosen the Adjustment Screws 2 on the door latch 5 Do one of the following To move the door in move the latch towards the front of the...

Page 212: ...rious injury See Section 0 page vi for other languages 1 Open the Front Door 2 Do REP 1 6 to remove the Rear Cover 3 With the Interlock cheater inserted do GP 6 2 5 to actuate SOL1 L1 Diverter Solenoid This will switch the diverter gate to punch mode The Diverter gate will rise and hit the upper bypass panel 4 When the solenoid in not actuated it needs to rest on the Diverter limiter bracket To pr...

Page 213: ...the Diverter Link and tighten theScrews 2 NOTE Raising the Limiter Bracket too high will position the diverter gate higher which will obstruct the paper flow and cause jams 5 Check the clearance between the Diverter and the cutout in the Lower Entrance Panel at both sides The clearance should be minimum 1 0 mm ...

Page 214: ... voltages that can result in electrical shock and possible serious injury See Section 0 page vi for other languages 1 Open the Front Door 2 Remove the Die Set see Operator Manual 3 Loosen the Nut and Lock Screw 4 Rotate the Die Set Magnet to adjust the position of the Die Set Stop Rotate the Die Set Magnet clockwise to move the hole toward the rear of the Punch Rotate the Die Set Magnet counterclo...

Page 215: ...lectrical shock and possible serious injury See Section 0 page vi for other languages ADJ 1 4 1 Alignment Stepper M5 Belt Adjustment PARTS LIST ON PL 5 3 Use this procedure to adjust the Alignment Stepper Belt tension 1 Disconnect the Power Cord 2 Do REP 1 6 to remove the Rear Cover 3 Do REP 3 1 to remove the Punch Module 4 Loosen the Phillips Screws 4 5 Adjust the belt tension such that there is ...

Page 216: ...Use this procedure to adjust the Belt tension of 534T timing belt 1 Disconnect the Power Cord 2 Do REP 1 6 to remove the Rear Cover 3 Loosen the the tensioner 4 Adjust the belt tension such that there is a deflection of 6 8mm 5 Tighten the tensioner 6 Do REP 1 6 to install the Rear Cover 7 Connect the Power Cord ...

Page 217: ...Use this procedure to adjust the Belt tension of 134T timing belt 1 Disconnect the Power Cord 2 Do REP 1 6 to remove the Rear Cover 3 Loosen the the tensioner 4 Adjust the belt tension such that there is a deflection of 3 5mm 5 Tighten the tensioner 6 Do REP 1 6 to install the Rear Cover 7 Connect the Power cord ...

Page 218: ...Use this procedure to adjust the Belt tension of 134T timing belt 1 Disconnect the Power Cord 2 Do REP 1 6 to remove the Rear Cover 3 Loosen the the tensioner 4 Adjust the belt tension such that there is a deflection of 4 6mm 5 Tighten the tensioner 6 Do REP 1 6 to install the Rear Cover 7 Connect the Power cord ...

Page 219: ...ion 1 Disconnect the Power Cord 2 Do REP 1 6 to remove the Rear Cover 3 Do REP 3 1 to remove the Punch Module 4 Loosen the Phillips Screws 4 from the Steering stepper motor 5 Adjust the belt tension such that there is a deflection of 1 2mm 6 Tighten the Phillips Screws 4 7 Do REP 3 1 to install the Punch Module 8 Do REP 1 6 to install the Rear Cover 9 Connect the Power Cord ...

Page 220: ...ages Note Some designs in the images may be slightly different from those on the machine you are working on but this does not affect the setting procedure 1 Verify that the punch cam needs to be indexed After a punch cycle the flats on the punch shaft have to be horizontal 5 from horizontal is acceptable See below for an image of a properly indexed punch shaft 2 If the flats are not horizontal 5 f...

Page 221: ...s deviated from the horizontal position In the example below the cam has rotated past the home position by 20 6 To index the shaft to the correct position remove the spring clip from the its groove in the Punch clutch 7 Continue to move the spring clip towards the pulley 8 Move the control collar towards the pulley By doing this the toothed hub will be exposed ...

Page 222: ...e Stop Collar Counter clockwise when viewed from the rear side In this instance the cam needs to stop earlier therefore rotate the Stop Collar Clockwise when viewed from the rear side This is done by manually lowering the pawl and freeing the Stop collar to rotate 10 Release the Pawl and slide the Stop collar back to its position 11 Manually rotate the pulley in the counter clockwise direction vie...

Page 223: ...gh torque and the setting will be incorrect Therefore use a wrench to turn the shaft 13 Return the spring clip to its groove Installation Procedure 1 Do REP 3 1 to remove the Punch Module 2 Do REP 1 6 to install the Rear Cover 3 Connect the Power Cord 4 Power ON the entire printing system 5 Run one sheet of paper though the Punch Alternately Cycle Punch Function Test from Service mode can be perfo...

Page 224: ...eader Board 4 Raise Lower the bracket so that the top most point of the spring clips of Reader Board is approximately at the middle of the dieset recognition chip 1 5mm from the lower surface of the chip Note Set the reader board so that there is 1 5 mm interference when the dieset is fully inserted Excessive interference will lead to premature failure of the dieset recognition board and or the sp...

Page 225: ...e Idler Panel PL 4 2 Exit Idler Panel PL 4 4 Upper Bypass Panel PL 4 5 1 Loosen the two screws that hold the magnet With the panel closed firmly pull away the magnet away from the drive panel to eliminate the play in the magnet and tighten both screws The screws should be tightened while the panel is closed firmly and the magnet pulled away as shown ADJ 1 7 2 Lower Exit panel latch Adjustment proc...

Page 226: ...Inspect and adjust the Drive panel positions The drive panels control how far the drive rollers protrude into the paper path which in turn control the roller nip forces All drive rollers should be protruding 1 5 0 5mm through the paper path This procedure applies to Entrance Drive Panel PL 3 1 Exit Drive Panel PL 3 1 Lower Bypass Panel PL 3 1 ...

Page 227: ... N3 N4 and N5 1 To adjust the position of the drive panel loosen 5 screws from the Front frame and 5 screws from the rear frame 2 Using the Reference holes in the front rear frame 5 holes in the front frame and 5 holes in the rear frame and the sheet metal panel position the drive panel to ensure the drive rollers protrude 1 5 0 5mm through the drive panel ...

Page 228: ...N9 and N10 1 To adjust the position of the drive panel loosen 4 screws from the Front frame and 4 screws from the rear frame 2 Using the Reference holes in the front rear frame 4 holes in the front frame and 4 holes in the rear frame and the sheet metal panel position the drive panel to ensure the drive rollers protrude 1 5 0 5mm through the drive panel ...

Page 229: ... N13 and N14 1 To adjust the position of the drive panel loosen 4 screws from the Front frame and 4 screws from the rear frame 2 Using the Reference holes in the front rear frame 4 holes in the front frame and 4 holes in the rear frame and the sheet metal panel position the drive panel to ensure the drive rollers protrude 1 5 0 5mm through the drive panel ...

Page 230: ...Repairs Adjustments 08 20 2015 GBC AdvancedPunch Pro 4 142 Notes ...

Page 231: ... 16 PL 4 4 Paper Path Exit Idler Panel 17 PL 4 5 Paper Path Upper Bypass Panel 18 PL 4 6 Paper Path Disengaging Roller Solenoid 19 5 Punch Module 20 PL 5 1 Punch Module 20 PL 5 1 Punch Module continued 21 PL 5 2 Punch Module Motors Sensors 22 PL 5 3 Punch Module Steering Module 23 PL 5 4 Punch Module Steering Module Steering Idler Panel Sub Assembly 24 PL 5 5 Punch Module Steering Module Drive Pan...

Page 232: ...the piece parts The Change Tag Index tells you which kit or piece parts you need Whenever you install a Tag kit or all the piece parts that make up a Tag mark the appropriate number on the Tag matrix The Tag matrix is located inside the Front Right Door PL 2 2 Symbology Tag Description A Tag number within a circle pointing to an item number shows that the part has been changed by the tag number wi...

Page 233: ...ancedPunch Pro 09 11 2018 Parts List 5 3 2 Main Assembly PL 2 1 Final Assembly ITEM GBC Part Xerox Part DESCRIPTION 1 7715400 X5K 097N02204 ADVANCEDPUNCH PRO 115V 7715500 X6K 097N02205 ADVANCEDPUNCH PRO 230V 1 ...

Page 234: ...5564 002N03227 UPSTREAM REAR SIDE COVER 1 14 7715572 002N03228 COVER SIDE DOWNSTREAM FRONT 1 15 7715843 002N03216 COVER POWER CORD 1 16 7715576 002N03229 DOWNSTREAM REAR SIDE CVR 1 17 7715844 026N00838 CAPTIVE SCREW M4X0 7 5MM 1 18 7715632B 026N00829B SCREW ROUND TIP M4 X 8 22 19 7715682 002N03205 PANEL LCD MEMBRANE 1 20 7715686 002N03230 COVER SIDE FRAME UPSTREAM 1 21 7715687 002N03231 COVER SIDE...

Page 235: ... 002N03202 PANEL ENTRANCE LOWER 1 2 7715690 002N03204 PANEL EXIT LOWER 1 3 7715424 002N03191 PANEL ASSEMBLY LOWER EXIT 1 4 7715209 006N01358 SHAFT IDLER PANEL HINGE 2 5 7715210 006N01359 SHAFT IDLR PANEL HINGE LONG 3 6 7715150 002N03195 PANEL WELDMENT DRIVE EXIT 1 7 7715128 002N03192 PANEL WELDMNT BYPASS LOWER 1 8 1821209D 013N13951D SNAP IN BEARING 6MM ID QTY 2 USED ON ALL IDLER PANELS A B D E AN...

Page 236: ...5195 121N01243 MAGNET PANEL OPEN STRONG 1 9 7715215 003N01110 HANDLE ACCEL IDLER LATCH 1 10 7715385 121N01240 MAGNET BRACKET ASSY 1 11 7715427 005N00686 CHIP TRAY ASSEMBLY 1 12 7715650 003N01106 LATCH BYPASS 1 13 7715637 105N02293 POWER SUPPLY 24V MW SP 480 1 14 7715789 121N01244 MAGNET PANEL OPEN WEAK 3 15 7708163 021N02267 CAP RUBBER RAIN BLUE 2 16 7715630 017N00300 CASTER ADJUSTABLE 4 17 182391...

Page 237: ...T 3 8 I D X 1 2 O D 11 12 1954032 016N00312 GROMMET 1 1 4 I D X 1 1 2 O D 1 13 7712703 072N00035 WIRE HEADER CONNECTOR 2 POS 6 14 7715185 074N00075 BRACKET PUNCH MODULE MOUNT 2 15 7715383 022N02809 ROLLER IDLER DRIVE ASSY 4 16 7715390E 072N00032E WIRE CLAMP EDGE 1 17 7715445E 072N00033E WIRE CLAMP EDGE SMALL 2 18 7715595 121N01245 SOLENOID BRACKET DIVERTER SUB ASSY 1 19 7715818E 072N00037E WIRE SA...

Page 238: ...821116D 013N13948D BEARING BALL FLANGE 6X13X5 SUJ2 22 4 1822005C 028N00375C WASHER FLAT 6 025 X 8 X 0 75 22 5 1822202A 028N00369A E RING JE 5 26 6 7706532 013N13946 BEARING BALL FLANGE 2 7 1925222C 028N00372C WASHER FLAT 1 4X3 8X 1 32 2 8 7715862 005N01168 ONE WAY CLUTCH SUB ASSEMBLY 1 Parts identified above with superscripts are part of Hardware kits A 7715973 600N03432 KIT HARDWARE RINGS C 77159...

Page 239: ...73 050N00665 RECEIVER 1 5 7715418 050N00664 BYPASS DIVERTER 1 6 7715186 130N01761 CHIP TRAY SENSOR MOUNT ASSY 1 7 7715213 006N01356 SHAFT ACCEL IDLER LATCH 1 8 7715216 003N01105 LATCH ASSY FRONT ACCEL IDLER PANEL 1 9 7715222 003N01104 LATCH ASSY REAR ACCEL IDLER PANEL 1 10 7715637 105N02293 POWER SUPPLY 24V MW SP 480 1 Parts identified above with superscripts are part of Hardware kits B 7715974 60...

Page 240: ...RIVER AND BRACKET ASSY TWO PHASE 1 7 7715275 030N00807 DRV M2 M2 STEPPER DRIVER DRIVER AND BRACKET ASSY TWO PHASE 1 8 7715275 030N00807 DRV M6 M6 STEPPER DRIVER DRIVER AND BRACKET ASSY TWO PHASE 1 9 7715275 030N00807 DRV M7 M7 STEPPER DRIVER DRIVER AND BRACKET ASSY TWO PHASE 1 10 7715275 030N00807 DRV M8 M8 STEPPER DRIVER DRIVER AND BRACKET ASSY TWO PHASE 1 11 7715275 030N00807 DRV M3 M3 STEPPER D...

Page 241: ...ENSOR BOARD ASSY 1 9 7715696 130N01767 S18 S19 MID PUNCH LARGE SENSOR BACKAGE SENSOR BOARD ASSY 1 10 7715696 130N01767 S20 S21 MID PUNCH X LARGE SENSOR BACKAGE SENSOR BOARD ASSY 1 11 7715291 130N01762 S22 EXIT SENSOR BOTTOM 1 12 7715291 130N01762 S23 EXIT SENSOR MIDDLE 1 13 7715291 130N01762 S24 EXIT SENSOR TOP 1 14 7715291 130N01762 S25 EXIT SENSOR 1 15 7715291 130N01762 S26 BYPASS SENSOR MIDDLE ...

Page 242: ...N23254 SOL 3 ENTRANCE IDLER SOLENOID MIDDLE 1 4 7715223 133N23254 SOL 4 ENTRANCE IDLER SOLENOID BOTTOM 1 5 7715223 133N23254 SOL 5 ACCELERATION ROLLER SOLENOID 1 6 7715223 133N23254 SOL 6 EXIT IDLER SOLENOID BOTTOM 1 7 7715223 133N23254 SOL 7 EXIT IDLER SOLENOID MIDDLE 1 8 7715223 133N23254 SOL 8 EXIT IDLER SOLENOID TOP 1 9 7610501 110N01437 SW1 FRONT DOOR INTERLOCK SWITCH 1 10 7715186 130N01761 S...

Page 243: ...art Xerox Part DESCRIPTION QTY 1 7715202 023N01316 BELT 534T 2MM 2GT 1 2 7715204 020N00937 PULLEY TIMING 2MM 2GT 30T 14 3 7715206 023N01315 BELT 179T 2MM 2GT 1 4 7715243 023N01314 BELT 150 T 2MM 2GT 3 5 7715245 030N00806 TENSIONER ASSEMBLY 5 6 7715246 023E01313 BELT 134T 2MM 2GT 3 2 1 6 6 4 4 3 6 4 5 ...

Page 244: ...Y BACKGAGE SENSOR 1 7715696 130N01767 S20 S21 MID PUNCH X LARGE SENSOR BOARD BOARD ASSY BACKGAGE SENSOR 1 4 7715851 002N03194 PANEL WELDMENT DRIVE ENTRANCE 1 5 1822108C 028N00374C WASHER FLAT 4 1X 8X1 5 4 6 1822117C 028N00373C WASHER 3 2ID 8OD 0 75MM THICK 12 7 1823903B 026N00823B SCREW PHILLIPS HX HD M4X8 2 Parts identified above with superscripts are part of Hardware kits B 7715974 600N03433 KIT...

Page 245: ...PORT IDLR ROLLER 6 6 7715382 013N13947 BEARING HOUSING 6 7 7715384 003N01111 HANDLE ASSY IDLER PANELS 1 8 7715625E 072N00038E WIRE SADDLE SHORT 2 9 7715629B 026N00813B SCREW BARREL M4 7MM DEEP 13 10 7715639E 072N00041E WIRE SADDLE SMALL SIDE OPEN 11 11 7715853 002N03198 PANEL WLDMT IDLER ENTRY 1 12 7708163 021N02267 CAP RUBBER 1 Parts identified above with superscripts are part of Hardware kits B ...

Page 246: ...N01762 S5 SENSOR AND BRACKET ASSY 1 5 7715380F 009N01702F SPRING TRANSPORT IDLR ROLLER 2 6 7715382 013N13947 BEARING HOUSING ASSY 2 7 7715817E 072N00040E WIRE SADDLE SMALL 5 8 7715629B 026N00813B SCREW BARREL M4 7MM DEEP 4 9 7715855 002N03197 PANEL WLDMNT IDLER ACCEL 1 Parts identified above with superscripts are part of Hardware kits B 7715974 600N03433 KIT HARDWARE FASTENERS E 7715977 600N03436 ...

Page 247: ...LLERS 6 5 7715384 003N01111 HANDLE ASSY IDLER PANEL 1 6 7715382 013N13947 BEARING HOUSING ASSY 6 7 7715625E 072N00038E WIRE SADDLE SHORT 3 8 7715629B 026N00813B SCREW BARREL M4 12 9 7715639E 072N00041E WIRE SADDLE SIDE OPEN 8 10 7715854 002N03199 PANEL WLDMNT IDLER EXIT 1 11 7708163 021N02267 CAP RUBBER 1 Parts identified above with superscripts are part of Hardware kits B 7715974 600N03433 KIT HA...

Page 248: ...ORT IDLER ROLLER 10 5 7715382 013N13947 BEARING HOUSING ASSY 10 6 7715384 003N01111 HANDLE ASSY IDLER PANELS 1 7 7715627 130N01763 S1 SENSOR AND BRACKET ASSY S1 1 8 7715629B 026N00813B SCREW BARREL M4 7MM DEEP 3 9 7715852 002N03193 PANEL WELDMENT BYPASS UPPER 1 10 7708163 021N02267 CAP RUBBER 1 Parts identified above with superscripts are part of Hardware kits B 7715974 600N03433 KIT HARDWARE FAST...

Page 249: ...unch Pro 09 11 2018 Parts List 5 19 PL 4 6 Paper Path Disengaging Roller Solenoid ITEM GBC Part Xerox Part Description QTY 1 7715223 133N23254 SOL 3 SOL 4 SOL 5 SOL 6 SOL 7 SOL 8 MODULE SOLENOID DISENGAGING ROLLER 6 ...

Page 250: ...X 12 2 3 1823911B 026N00820B SCREW PHILLIPS W SEMS M4X10 1 4 7715430 002N03219 STEERING MODULE SUB ASSY 1 5 7715368 003N01111 HANDLE DIE LOCK 1 6 7715818E 072N00037E WIRE SADDLE MEDIUM LOCK TOP 1 7 7715856 180N00018 PUNCH MODULE SHELL SERVICE 1 8 7715859 127K07846 M5 STEPPER MOTOR AND PULLEY ALIGNMENT 1 Parts identified above with superscripts are part of Hardware kits B 7715974 600N03433 KIT HARD...

Page 251: ...TD 1 7715372 023N01318 230V BELT TIMING 80 GROOVE 5MM HTD 1 4 7715238 030N00808 BRACKET BEARING ASSY DIE LOCK 2 5 7715239 010N01188 PLUNGER STRIPPER DIE LOCK 2 6 7715374F 009N01697F SPRING DIE LOCK RETURN 2 7 1824001B 027N00262B NUT KEPS M4 2 8 7715347 130N01769 BOARD DIESET RECOGNITION READER 1 9 PL 5 6 PUNCH CLUTCH PULLEY 1 Parts identified above with superscripts are part of Hardware kits B 771...

Page 252: ...57 127N07847 LEFT FRONT STEERING MOTOR AND PULLEY 1 M4 7715857 127N07847 RIGHT REAR STEERING MOTOR AND PULLEY 1 M5 7715859 127K07846 ALIGNMENT STEPPER MOTOR AND PULLEY 1 S6 S7 S8 S9 S10 7715692 130N01768 SKEW SENSOR BOARD 1 S11 S12 S13 S14 S15 7715694 130N01766 ALIGNMENT SENSOR BOARD 1 S16 S17 7715696 130N01767 BACKAGE SENSOR BOARD 1 ...

Page 253: ...Module Steering Module ITEM GBC Part Xerox Part DESCRIPTION QTY 1 7715597 130N01764 S28 SENSOR VEIN BRACKET SUB ASSLY 1 2 7715858 041N00843 ALIGNMENT CARRIAGE SUB ASSY SERVICE 1 3 PL 5 4 STEERING IDLER PANEL SUB ASSEMBLY 4 PL 5 5 STEERING DRIVE PANEL SUB ASSEMBLY ...

Page 254: ... 4 7715062 002N03200 PANEL WLDMENT IDLER STEERING 1 5 7715379F 009N01701F SPRING STEERING IDLER ROLLER 2 6 7715648E 072N00034E WIRE CLAMP LOCKING 3 7 7715692 130N01768 S6 S7 S8 S9 S10 BOARD ASSY SKEW SENSOR 1 8 7715816 022N02807 ROLLER ASSY IDLER STEERING 1 Parts identified above with superscripts are part of Hardware kits B 7715974 600N03433 KIT HARDWARE FASTENERS C 7715975 600N03434 KIT HARDWARE...

Page 255: ...7 BELT STEERING 65 GROOVES 2MM 2GT 2 7 7715053 002N03196 PANEL WELDMENT DRIVE STEERING 1 8 7715377F 009N01700F SPRING STEERING DRIVE ROLLER 2 9 7715648E 072N00034E WIRE CLAMP LOCKING 2 10 7715857 127N07847 M3 STEPPER MOTOR AND PULLEY STEERING SERVICE 1 7715857 127N07847 M4 STEPPER MOTOR AND PULLEY STEERING SERVICE 1 Parts identified above with superscripts are part of Hardware kits A 7715973 600N0...

Page 256: ...SHCS M5X18 3 2 1821801C 028N00380C WASHER SPLIT LOCK M5 3 3 7715020 005N01167 CLUTCH WRAP SPRING 1 4 7715231 020N00936 115V PULLEY FLANGE 5MM HTD 38T 1 7715371 020N00935 230V PULLEY FLANGE 5MM HTD 34T 1 Parts identified above with superscripts are part of Hardware kits B 7715974 600N03433 KIT HARDWARE FASTENERS C 7715975 600N03434 KIT HARDWARE WASHERS ...

Page 257: ...LDMNT BACKGAGE SENSOR 1 7 7715640E 072N00039E WIRE SADDLE ALIGN SENSOR WIRES 9 8 7715694 130N01766 S11 S12 S13 S14 S15 BOARD ASSY ALIGNMENT SENSOR 1 9 7715696 130N01767 S16 S17 BOARD ASSY BACKGAGE SENSOR 1 10 7715787 009N01698 SPRING DIE RAIL POSITION 1 1 11 7715799 009N01699 SPRING DIE RAIL POSITION 2 1 12 7715938 032N00521 GUIDE ALIGNMENT SENSOR BOTTOM 1 13 7715941 074N00065 BRACKET WELDMENT ALI...

Page 258: ...1823602B 026N00834B SET SCREW NYLON PATCH M4X6 1 4 1824703B 026N00814B SCREW HEX CAP M8 16MM LONG 4 5 7715860 127N07843 115V MOTOR AND PULLEY PUNCH 115V SERVICE INCLUDES CAPACITOR 1 7715861 127N07844 230V MOTOR AND PULLEY PUNCH 230V SERVICE INCLUDES CAPACITOR 1 Parts identified above with superscripts are part of Hardware kits B 7715974 600N03433 KIT HARDWARE FASTENERS C 7715975 600N03434 KIT HARD...

Page 259: ... Wire 2 1 Rnd 7 008R13179 Die Xerox Coil Rnd 8 008R13240 Die Xerox Coil Rnd HD 9 008R13194 Die Xerox Coil Oval 10 008R13187 Die Xerox Velobind 11 Holes Ltr 11 008R13188 Die Xerox Velobind 12 Holes A4 12 008R13182 Die Xerox 3 Hole 8mm 13 008R13241 Die Xerox 3 Hole 8mm HD 14 008R13183 Die Xerox 3 5 7 Hole 8mm 15 008R13184 Die Xerox 4 Hole 8mm 16 008R13185 Die Xerox 4 Hole 6 5mm 17 008R13186 Die Xero...

Page 260: ...142N00168 RFI POWER FILTER 1 2 7718677 140N63872 BOARD CONTROL MAIN 1 3 7718684 140N63875 BOARD CONTROL COMM 1 3 DFA 7715583 140N63703 BOARD CONTROL COMM DFA 1 4 7715863 108N00579 FUSE AC POWER 250V 5A 1 5 7715548 030N00802 COMMUNICATION CABLE ASSY 1 6 DFA 7704376 110N01438 ROCKER SWITCH MP 2500IX 1 DFA Configuration 2 3 1 4 5 3 DFA 5 DFA 4 6 DFA ...

Page 261: ... SCREW PHILLIPS HX HD W SEMS M3X6 1 2 7715817E 072N00040E WIRE SADDLE SMALL LOCKING TOP 4 3 7715818E 072N00037E WIRE SADDLE MEDIUM LOCKING TOP 13 4 7715819E 072N00036E WIRE SADDLE LARGE LOCKING TOP 9 Parts identified above with superscripts are part of Hardware kits B 7715974 600N03433 KIT HARDWARE FASTENERS E 7715977 600N03436 KIT HARDWARE WIRE CLAMPS ...

Page 262: ...H MOTOR 7715477 023N01339 CABLE POWER STEPPER DRIVERS 7715485 023N01327 CABLE CHIP TRAY 7715487 023N01332 CABLE DOOR INTERLOCK 7715490 023N01356 CABLE USB 7715492 023N01329 CABLE DC POWER 7715493 023N01322 CABLE AC TO PSU 7715494 023N01321 CABLE AC TO BOARD 7715495 023N01331 CABLE DIE SET RECOGNITION 7715498 023N01336 CABLE AC FILTER TO AC REMOTE OEM ONLY 7715535 023N01335 CABLE INLET FILTER TO AC...

Page 263: ...GBC AdvancedPunch Pro 09 11 2018 Parts List 5 33 PL 6 4 Wiring Drawing OEM Configurations ...

Page 264: ...Parts List 09 11 2018 GBC AdvancedPunch Pro 5 34 PL 6 5 Wiring Drawing DFA Configurations ...

Page 265: ...ional Kits ITEM GBC Part Xerox Part DESCRIPTION 1 7715864 001N00555 KIT CDI RACEWAY 2 7715865 497N04065 KIT OEM TO DFA CONVERSION 3 7715957 030N00803 BRACKET EXIT GUIDE ANGLED ITEM GBC Part Xerox Part DESCRIPTION QTY 1 7714331 117N01973 115V POWER CORD US 115V RIGHT ANGLED 1 2 7714332 117N01974 230V POWER CORD CONTINENTAL EUROPE RIGHT ANGLED 1 3 7714333 117N01975 230V POWER CORD UK RIGHT ANGLED 1 ...

Page 266: ...R BOTTOM HINGE 5 4 7715684 007N01788 DRIVE USB STICK FLASH DRIVE 5 4 7715828 002N03218 USB DRIVE COVER 5 4 7715101 002N03202 PANEL ENTRANCE LOWER 5 5 7715690 002N03204 PANEL EXIT LOWER 5 5 7715424 002N03191 PANEL ASSEMBLY LOWER EXIT 5 5 Part XEROX PART DESCRIPTION PL 7715209 006N01358 SHAFT IDLER PANEL HINGE 5 5 7715210 006N01359 SHAFT IDLR PANEL HINGE LONG 5 5 7715150 002N03195 PANEL WELDMENT DRI...

Page 267: ...5 ROLLER ASSY DRIVE USED FOR ALL ROLLERS EXCEPT N2 5 8 7715097 002N02808 ROLLER ASSY ONE WAY DRIVE USED IN N2 POSITION ONLY 5 8 1821116D 013N13948D BEARING BALL FLANGE 6X13X5 SUJ2 5 8 7706532 013N13946 BEARING BALL FLANGE 5 8 1925222C 028N00372C WASHER FLAT 1 4X3 8X 1 32 5 8 7715862 005N01168 ONE WAY CLUTCH SUB ASSEMBLY 5 8 1822108C 028N00374C WASHER FLAT 4 1X8X1 5 5 9 1823911B 026N00820B SCREW PH...

Page 268: ...IGNMENT SENSOR 5 11 5 22 5 27 7715696 130N01767 BACKAGE SENSOR BOARD ASSY 5 11 5 22 5 27 MID PUNCH LARGE SENSOR BACKAGE SENSOR BOARD ASSY 5 11 5 14 MID PUNCH X LARGE SENSOR BACKAGE SENSOR BOARD ASSY 5 11 5 14 7715340 130N01765 BYPASS OPEN SENSOR 5 11 7715597 130N01764 SENSOR VEIN BRACKET SUB ASSLY 5 11 5 23 7715774 107N00459 CLEAR COVER SENSOR EMITTER 5 11 7715020 005N01167 CLUTCH WRAP SPRING 5 12...

Page 269: ... M6 35MM LONG 5 21 1821655B 026N00827B SCREW PHILLIPS PAN HD M4X25 5 21 7715232 023N01319 BELT TIMING 82 GROOVE 5MM HTD 5 21 7715372 023N01318 BELT TIMING 80 GROOVE 5MM HTD 5 21 7715238 030N00808 BRACKET BEARING ASSY DIE LOCK 5 21 7715239 010N01188 PLUNGER STRIPPER DIE LOCK 5 21 7715374F 009N01697F SPRING DIE LOCK RETURN 5 21 7715347 130N01769 BOARD DIESET RECOGNITION READER 5 21 7715857 127N07847...

Page 270: ...ULLEY PUNCH 115V SERVICE INCLUDES CAPACITOR 5 28 7715861 127N07844 MOTOR AND PULLEY PUNCH 230V SERVICE INCLUDES CAPACITOR 5 28 008R13190 Die Xerox Comb Bind 5 29 008R13192 Die Xerox Wire 3 1 Sq 5 29 008R13191 Die Xerox Wire 2 1 Sq 5 29 008R13181 Die Xerox Wire 3 1 Rnd 5 29 008R13180 Die Xerox Wire 2 1 Rnd 5 29 008R13179 Die Xerox Coil Rnd 5 29 008R13187 Die Xerox Velobind 11 Holes Ltr 5 29 008R131...

Page 271: ...ORS Procedure 6 36 GP 6 2 8 I O SIGNALS Procedure 6 38 GP 6 2 9 DFA STATUS Procedure DFA Configurations only 6 39 GP 6 2 10 SOLENOIDS Procedure 6 40 GP 6 2 11 MOTORS Procedure 6 41 GP 6 2 12 FUNCTION TESTS Procedure Cycle Punch Aligner Test Fan Test 6 42 GP 6 2 13 SKEW OFFSETS Procedure 6 44 GP 6 2 14 ALIGN OFFSETS Procedure 6 48 GP 6 2 15 LOG 6 50 GP 6 2 16 FIRMWARE UPGRADE Procedure 6 51 GP 6 3 ...

Page 272: ...ecognition Board Clips Inspection 6 77 GP 6 27 Die Lock Mechanism and Die Rail Springs Inspection 6 78 General Information 6 79 Principle of Operation 6 79 Punch Path 6 79 Single Punch 6 79 Double Punch Mid punch trail edge punch DFA configurations only 6 80 Bypass Path 6 80 Glossary of Terms 6 82 Die Sets 6 83 Die Sets List 6 84 Die Sets List cont d 6 85 Tools 6 86 Standard Tools metric 6 86 Othe...

Page 273: ...s selected on the User Interface Single Punch To change the settings on the User Interface 1 From the top level screen press either the up arrow button or the down arrow button then press the ENTER button to display the SETTINGS INFORMATION screen SETTINGS INFORMATION The up arrow indicates that there is a menu option above the option displayed The down arrow indicates that there is a menu option ...

Page 274: ...ge for the user interface The language options are English Francais Espanol Deutsch and Italiano Units The Units feature allows you to select the units displayed on the user interface Select MM for millimeters of IN for inches Paper Size This is used the set the machine for running US ANSI paper sizes or ISO paper sizes Information The User Interface allows you to view information about Die Type D...

Page 275: ...GBC AdvancedPunch Pro 09 11 2018 General Procedures and Information 6 5 User Interface Screen Map ...

Page 276: ...General Procedures and Information 09 11 2018 GBC AdvancedPunch Pro 6 6 DFA configuration only User Interface Screen Map ...

Page 277: ...n the return symbol is next to SETTINGS to display the BACKGAGE ALIGNMENT screen Press the ENTER button when the return symbol is next to the word BACKGAGE to display TRAIL MID screen BACKGAGE ALIGNMENT 2 Press the ENTER button when the return symbol is next to the word Backgage to display the TRAIL MID screen TRAIL MID TRAIL refers to the trail edge punch Single Punch and MID refers to the punch ...

Page 278: ...ove the return symbol Then press the ENTER button This displays the top level screen READY SINGLE PUNCH NOTE The BACKGAGE feature has the option to save as it defines the backgage for that particular die type This means that for any die of that type inserted into that machine the saved backgage will apply If the user does not save the new backgage the next time a die of this type is inserted the m...

Page 279: ...the SAVE VALUES screen SAVE VALUE YES NO To select YES press the ENTER button To select NO press the down arrow button to move the bent arrow Then press the ENTER button 17 This displays the BACKGAUGE ALIGNMENT screen BACKGAGE ALIGNMENT NOTE The BACKGAGE feature has the option to save as it defines the backgauge for that particular die type This means that for any die of that type inserted into th...

Page 280: ...he word SETTINGS To display the display the PUNCH MODE BACKGAUGE screen PUNCH MODE BACKGAGE 3 Press the ENTER button to display the Punch Mode menu PUNCH MODE SINGLE PUNCH Note SINGLE PUNCH is the default 4 To Select Single Punch mode If necessary press the up or down arrow button to display SINGLE PUNCH PUNCH MODE SINGLE PUNCH When the return symbol is next to the word Single Punch press the ENTE...

Page 281: ...ext to the word OFF PUNCH MODE OFF 7 Press the ENTER button to select OFF This will enable Bypass mode PUNCH MODE BACKGAGE 8 Press the up arrow button to display the PREVIOUS MENU option PREVIOUS MENU PUNCH MODE 9 Press the up arrow button to display the EXIT option EXIT PREVIOUS MENU 10 Press the ENTER button to return to the top level screen READY DOUBLE PUNCH ...

Page 282: ...To display the display the BACKGAGE ALIGNMENT screen BACKGAGE ALIGNMENT 3 Press the down arrow button once so the return symbol is next to the word ALIGNMENT BACKGAGE ALIGNMENT 4 Press the ENTER button when the return symbol is next to the word Alignment to display the ALIGNMENT OFFSET screen ALIGNMENT OFFSET 0 0 mm 5 Press the up arrow button or the down arrow button to change the offset by 0 1mm...

Page 283: ...he ENTER button to input the new Alignment value and display the ALIGNMENT TAB COVER MODE screen ALIGNMENT TAB COVER MODE 7 Press the up arrow button four times to display the EXIT option EXIT PREVIOUS MENU 8 Press the ENTER button to return to the top level screen READY SINGLE PUNCH ...

Page 284: ...utton when the return symbol is next to the word TAB COVER to display the TAB COVER screen If PAPER SIZE selected is ISO 225mm WIDE TAB COVER MODE If PAPER SIZE selected is ANSI 9 WIDE TAB COVER MODE The options are TAB COVER SRA4 if PAPER SIZE is ISO 9x12 if PAPER SIZE is ANSI 5 Press either the up arrow button or the down arrow button to change Tab Cover setting If PAPER SIZE is set to ISO If th...

Page 285: ...the ENTER button to input the new Tab Cover setting and display the TAB COVER MODE CLEAR OFFSETS screen TAB COVER MODE TAB COVER MODE 7 Press the up arrow button to display the EXIT option EXIT PREVIOUS MENU Press the ENTER button to return to the top level screen READY SINGLE PUNCH ...

Page 286: ...E CLEAR COVER 3 Press the ENTER button when the return symbol is next to the word CLEAR OFFSET to display the CLEAR OFFSET screen CC BACKGAGE CC ALIGNMENT For CC BACKGAUGE go to step 4 For CC ALIGNMENT go to step 7 See page 6 17 4 To adjust the BACKGAGE values press the ENTER button when the return symbol is next to the words CC BACKGAUGE CC BACKGAGE CC ALIGNMENT This displays the CC BACKGAUGE scr...

Page 287: ...NT This displays the CC ALIGNMENT screen CC ALIGNMENT 0 000 in You can adjust the Alignment position of the Clear Cover media using the up down arrow buttons See GP 6 1 2 ALIGNMENT PROCEDURE for more details 9 Press the ENTER button to display the CC ALIGNMENT PREVIOUS MENU screen CC ALIGNMENT PREVIOUS MENU 10 Press the ENTER button to display the CLEAR COVER LANGUAGE screen CLEAR COVER LANGUAGE 1...

Page 288: ...own arrow button so the return symbol is next to the word Language CLEAR COVER LANGUAGE 3 Press the ENTER button when the return symbol is next to the word Language to display the LANGUAGE screen LANGUAGE ENGLISH 4 Press either the up arrow button or the down arrow button to change language LANGUAGE ESPANOL English Espanol Francais Italiano Deutsch 5 Press the ENTER button to input the new languag...

Page 289: ... 3 Press the ENTER button when the return symbol is next to the word Units to display the UNITS screen UNITS MILIMETERS 4 Press either the up arrow button or the down arrow button to change units displayed UNITS INCHES Millimeters Inches 5 Press the ENTER button to input the value and display the Units Previous Menu screen UNITS PREVIOUS MENU 6 Press the down arrow button once to move the return s...

Page 290: ...ress the ENTER button when the return symbol is next to the word Paper Size to display the Paper Size screen PAPER SIZE ANSI 4 Press the down arrow to scroll through the speed options ANSI ISO PAPER SIZE ISO If you are running LTR 11x17 STMT sizes set the Paper Size setting to ANSI If you are running one of the ISO sizes A3 A4 A5 set the Paper Size setting to ISO 5 When the return symbol is next t...

Page 291: ... arrow button to move the return symbol down until it is next to the word INFORMATION SETTINGS INFORMATION 4 Press the ENTER button to display the DIE TYPE DIE CYCLES screen DIE TYPE DIE CYCLES 5 Press the ENTER button when the return symbol down is next to the words DIE TYPE This displays the DIE TYPE screen DIE TYPE WIRE 3 1 SQUARE 6 Press the ENTER button to return to the DIE TYPE DIE CYCLES sc...

Page 292: ...n DIE TYPE DIE CYCLES 5 Press the down arrow button so the return symbol is next to the words DIE CYCLES DIE TYPE DIE CYCLES 6 Press the ENTER button when the return symbol is next to the words Die Cycles to display the DIE CYCLES screen DIE CYCLES 17 129 7 If any of the Die Set life cycles have exceeded 750 000 sheets cycles go to Section 3 and check the Hole Quality If the Hole Quality is accept...

Page 293: ...next to the word Information SETTINGS INFORMATION 4 Press the ENTER button to display the DIE TYPE DIE CYCLES screen DIE TYPE DIE CYCLES 5 Press the down arrow button until the return symbol is next to the words the PUNCH CYCLES DIE CYCLES PUNCH CYCLES 6 Press the ENTER button when the return symbol is next to the words PUNCH CYCLES to display the PUNCH CYCLES screen PUNCH CYCLES 23 495 7 Press th...

Page 294: ...t is next to the word INFORMATION SETTINGS INFORMATION 4 Press the ENTER button to display the DIE TYPE DIE CYCLES screen DIE TYPE DIE CYCLES 5 Press the down arrow button three times so the return symbol is next to the word FIRMWARE PUNCH CYCLES FIRMWARE 6 Press the ENTER button when the return symbol is next to the word Firmware to display the FIRMWARE screen FIRMWARE 0B 48 B1 20 7 Press the ENT...

Page 295: ...esired paper size ANSI ISO Max Bypass The Max Bypass feature allows you to set the maximum sheet length that will be bypassed through AdvancedPunch Pro Run Mode The Run Mode feature allows you to select the desired run mode AUTO RUN AUTO CYCLE Die cycles The Die cycles menu displays the number of punched cycles on the die currently installed Sensors The Sensors feature allows you to view the state...

Page 296: ... waits for 2 seconds the triggers the Punch at 1 punch per second for 5 cycles The Aligner Test moves the home Aligner CW 10mm back to home CCW 10mm then back to home It repeats this cycle 5 times The Fan Test starts the Exhaust Fan at the rear of the Punch Skew Offsets The Skew Offsets feature allows you to setup the skew offsets to straighten and offset punch depth The options are BG LEFT BG RIG...

Page 297: ...GBC AdvancedPunch Pro 09 11 2018 General Procedures and Information 6 27 Service Interface Screen Map ...

Page 298: ...General Procedures and Information 09 11 2018 GBC AdvancedPunch Pro 6 28 DFA Configurations only Service Interface Screen Map ...

Page 299: ...he Service User Interface 1 Press and hold both the Up Arrow button and the Down Arrow button for 5 seconds Then while still holding down the Up Arrow button and the Down Arrow button press the Enter button The Service User Interface screen will appear Use the procedures in the following pages to use Service User Interface ...

Page 300: ...en while still holding down both the Up Arrow button and the Down Arrow button press the Enter button The Service User Interface screen will appear SPEED ADJUST PAPER SIZE 2 Press the ENTER button when the return symbol is next to the word SPEED ADJUST To display the display the SPEED ADJUST screen SPEED ADJUST ADJUST 1000 3 Press the down arrow to scroll through the speed options until the return...

Page 301: ... Arrow button press the Enter button The Service User Interface screen will appear SPEED DFA MAX BYPASS 2 Press the ENTER button when the return symbol is next to the word SPEED DFA To display the display the SPEED DFA screen SPEED DFA 1090 MM S 3 Press the down arrow to scroll through the speed options until the return is next to the desired option 1090 MM S 1020 MM S 1280 157MAX 1280 144MAX 1130...

Page 302: ...on when the return symbol is next to the word Paper Size to display the Paper Size screen PAPER SIZE ANSI 3 Press the down arrow to scroll through the speed options ANSI ISO PAPER SIZE ISO If you are running LTR 11x17 STMT sizes set the Paper Size setting to ANSI If you are running one of the ISO sizes A3 A4 A5 set the Paper Size setting to ISO 4 When the return symbol is next to the desired paper...

Page 303: ...n and the Down Arrow button press the Enter button The Service User Interface screen will appear SPEED ADJUST PAPER SIZE 2 Press the down arrow button to move the return symbol next to MAX BYPASS Press OK to enter the Max Bypass setting PAPER SIZE MAX BYPASS 3 The below screen will appear MAX BYPASS 488mm 4 762mm is the Max Bypass setting To reduce the Max Bypass setting press the down arrow to th...

Page 304: ...p Arrow button and the Down Arrow button press the Enter button The Service User Interface screen will appear SPEED ADJUST PAPER SIZE 2 Press the down arrow so the return symbol is next to the words RUN MODE Then press OK to enter the RUN MODE setting MAX BYPASS RUN MODE 3 Press the down arrow to scroll through the speed options AUTO RUN This feature is used for manufacturing set up only AUTO CYCL...

Page 305: ...old the both Up Arrow button and the Down Arrow button for 5 seconds Then while still holding down the Up Arrow button and the Down Arrow button press the Enter button The Service User Interface screen will appear SPEED ADJUST PAPER SIZE 2 Press the down arrow so the return symbol is next to DIE CYCLES and then press OK RUN MODE DIE CYCLES DIE CYCLES 501 175 3 Press OK to return to the service men...

Page 306: ...state of each of the 29 sensors to the AdvancedPunch Pro Cover each sensor to check if the sensor status changes from 0 to 1 0 means the sensor is open 1 means the sensor is covered Do the following to check the sensors 1 At the top level screen READY SINGLE PUNCH Press and hold both the Up Arrow button and the Down Arrow button for 5 seconds Then while still holding down the Up Arrow button and t...

Page 307: ...u scroll down from the S26 S27 S28 screen the system displays the Previous Menu EXIT screen PREVIOUS MENU EXIT You can Press the up arrow to return to the last sensor screen Press the down arrow to move the return symbol is next to the word EXIT Then press the ENTER button to return to the top level screen READY SINGLE PUNCH 6 If you use the up arrow to scroll up from the S1 S2 S3 S S5 screen S1 0...

Page 308: ...w so the return symbol is next to the words DFA STATUS SENSORS I O SIGNALS 3 Press the ENTER button when the return symbol is next to the word DFA STATUS to display the display the first DFA STATUS screen C0 0 C1 0 C2 0 C3 0 C4 0 C5 0 4 Press the down arrow to scroll through the DFA STATUS options C6 0 C7 0 S0 0 S1 0 S2 0 S3 0 S4 0 S5 0 S6 0 S7 0 5 If you use the down arrow to scroll through the c...

Page 309: ...he down arrow so the return symbol is next to the words DFA STATUS SENSORS DFA STATUS 3 Press the ENTER button when the return symbol is next to the word DFA STATUS to display the display the first DFA STATUS screen C0 0 C1 0 C2 0 C3 0 C4 0 C5 0 4 Press the down arrow to scroll through the DFA STATUS options C6 0 C7 0 S0 0 S1 0 S2 0 S3 0 S4 0 S5 0 S6 0 S7 0 5 If you use the down arrow to scroll th...

Page 310: ...ss the ENTER button when the return symbol is next to the word SOLENOIDS to display the display the SOLENOIDS screen L1 L2 L3 L4 L5 L6 L7 L8 BACK 4 To check the Solenoids NOTE Door needs to be closed or Interlock Cheater inserted to do this Press the down arrow to scroll through the solenoid options The selected solenoid will flash on and off Press the Enter button to turn the selected solenoid on...

Page 311: ...ress the ENTER button when the return symbol is next to the word Motors to display the display the first MOTORS screen M1 M2 M3 M4 M6 M7 M8 BACK 4 To check the Stepper Motors NOTE Door needs to be closed to do this Press the down arrow to scroll through the motor options The selected motor will flash on and off Press the Enter button to turn the selected motor on You should hear the motor running ...

Page 312: ...un the CYCLE PUNCH test Press the Enter button when the return symbol is next to the words CYCLE PUNCH The CYCLE PUNCH Test starts the Punch Motor waits for 2 seconds the triggers the Punch at 1 punch per second for 5 cycles After the test is complete it stops automatically you may scroll down to Previous Menu or Exit 5 To run the ALIGNER TEST Press the down arrow to move the return symbol next to...

Page 313: ... display the EXIT PREVIOUS MENU screen From the ALIGNER TEST press the up arrow three times to display the EXIT PREVIOUS MENU screen From the FAN TEST press the up arrow four times to display the EXIT PREVIOUS MENU screen EXIT PREVIOUS MENU 8 When the return symbol is next to the word EXIT press the ENTER button to return to the top level screen READY SINGLE PUNCH ...

Page 314: ...W OFFSETS to display the SKEW OFFSETS screen BG LEFT BG RIGHT 4 Press the down arrow to scroll through the Skew Offset options BG LEFT BG RIGHT BG DP L LEFT DFA Configurations only for LTR Short Edge and A4 Short edge Double punch BG DP L RIGHT DFA Configurations only for LTR Short Edge and A4 Short edge Double punch BG DP XL LEFT DFA Configurations only for 11 x 17 Short Edge and A3 Short Edge Do...

Page 315: ...set screen you can scroll up or down through the entire list of Skew Offset options BG DP L RIGHT BG DP XL LEFT 7 If you use the down arrow to scroll through the complete list of skew offset options the system displays the following screens BG DP XL RIGHT PREVIOUS MENU PREVIOUS MENU EXIT You may return to the main Service mode menu or Exit to the Top level screen Cont Holes parallel to the edge To...

Page 316: ...Backgage depth but the bottom hole is too far from the edge of the paper BG LEFT Select 1 1 2 3 etc until the holes are parallel to the edge The bottom hole is in the correct position but the top hole is too close to the edge of the paper BG RIGHT Select 1 1 2 3 etc until the holes are parallel to the edge The top hole is in the correct position but the bottom hole is too close to the edge of the ...

Page 317: ...formation 6 47 DFA Configurations only For Double punch skew offsets the same principle applies Examples shown below BG DP L RIGHT Select 1 2 3 etc until the holes are parallel to the edge BG DP L LEFT Select 1 2 3 etc until the holes are parallel to the edge ...

Page 318: ...LEF SRA4 SEF S15 1 2LTR LEF 1 2LTR tab LTR SEF Legal SEF A5 LEF A5 tab A4 SEF 1 At the top level screen READY SINGLE PUNCH Press and hold both the Up Arrow button and the Down Arrow button for 5 seconds Then while still holding down the Up Arrow button and the Down Arrow button press the Enter button The Service User Interface screen will appear SPEED ADJUST PAPER SIZE 2 Press the down arrow butto...

Page 319: ...p or down through the entire list of Align Offset options S14 S15 7 If you use the down arrow to scroll through the complete list of align offset options the system displays the S15 PREVIOUS MENU screen S15 PREVIOUS MENU From this screen you can Select S15 Press the up arrow to return to the previous Align Offsets screen Press the down arrow to move the return symbol is next to the word PREVIOUS M...

Page 320: ...nd the USB Debug E wire port cover 2 Insert a USB flash drive 3 At the top level screen READY SINGLE PUNCH Press and hold both the Up Arrow button and the Down Arrow button for 5 seconds Then while still holding down the Up Arrow button and the Down Arrow button press the Enter button The Service User Interface screen will appear SPEED ADJUST PAPER SIZE 4 Press the down arrow so the return symbol ...

Page 321: ...wn Arrow button press the Enter button The Service User Interface screen will appear SPEED ADJUST PAPER SIZE 5 Insert the USB Flash drive with the firmware file you want to upload Note this step can be done at any time before you press the Enter button for Main or Comm firmware upload in Step 8 6 Press the down arrow button so the return symbol is next to the words FIRMWARE UPGRADE LOG FIRMWARE UP...

Page 322: ...n arrow to scroll through the Firmware Upgrade options until the return symbol is next to the Word EXIT FIRMWARE UPGRADE EXIT 12 Press the ENTER button when the return symbol is next to the word EXIT to return to the top level screen READY SINGLE PUNCH 13 Remove the USB flash drive with the firmware file you uploaded 14 Install the Cover for USB port and tighten the Screws 2 15 Switch off the mach...

Page 323: ... Undock the downstream device and move it at least 6 inches 150mm away 2 Open the Front door of AdvancedPunch Pro 3 Remove the M3 lock screw 4 Pull the docking lever 5 While having the docking lever pulled move the machine to the right DFA configurations 1 Remove the ground straps from the rear cover of AdvancedPunch Pro 2 Remove the 2 screws 3 Slide the AdvancedPunch Pro to Service position ...

Page 324: ... position Note If the AdvancedPunch Pro does not easily slide to Operating and Service positions level the AdvancedPunch Pro using the adjustable casters 2 Latch the docking bracket and install the M3 screw 3 For DFA configurations Install the 2 screws 4 For DFA configurations Install the ground straps to the Rear cover of AdvancedPunch Pro 5 Run a small test job in both Punch and Bypass mode to e...

Page 325: ...es smoothly and produces the desired holes in the customer s paper 2 Refer to section 3 14 Punch Specifications GP 6 6 Internal Inspection Do the following whenever the cover has been removed for corrective maintenance 1 Visually inspect for defects and problems such as damaged components loose screws or nuts abraded wire insulation loose terminals etc 2 Correct any problems before returning the m...

Page 326: ...pectancy The AdvancedPunch Pro Die Sets have a minimum life expectancy of 750K cycles sheets of paper punched when punching 75 gsm paper With periodic lubrication and optimum paper types life can exceed this number Use the Die Cycles feature on the User Interface to view the number of cycles on the Die Set Variables that affect life expectancy Failure to follow the lubrication schedule or using th...

Page 327: ...lt pads 1 Depress the Die Set so that the pins protrude from the bottom plate 2 Apply a drop of high quality machine oil to the end of each pin 3 Wipe clean leaving a light coat of oil on them 4 Oil from the die may blemish the first few punched sheets after oil has been applied Run test punched copies until clean copies can be made To lubricate Die Set pins that have felt pads 1 Lubricate with a ...

Page 328: ...heets of the customer s paper through the punch Inspect the holes Holes should be clean and even with no tearing or frayed edges Holes should be punched completely leaving no chip attached Holes should be straight no skew and evenly spaced from the edge of the paper and aligned See GP 6 2 13 SKEW OFFSETS Procedure GP 6 7 4 Die Set Shoulder Bolts Do the following to inspect and lubricate the Die Se...

Page 329: ...vii for other languages GP 6 9 Internal Cleaning Do the following to clean the interior of the AdvancedPunch Pro 1 Occasionally remove the covers and remove paper dust and chips Paper dust can accumulate throughout the punch including around the motor and other electrical components Use a vacuum cleaner if possible A small paintbrush can also be used but extreme care should be used around electric...

Page 330: ...e call 1 Clean with a vacuum cleaner each time the machine is serviced 2 The customer can also do this between the technician s visits GP 6 11 Chip Bin Cleaning Do the following on every service call to clean the Chip Tray 1 Remove the Chip Bin and empty it 2 Vacuum out paper chips and dust from the Chip Bin tray especially at the holes on the sides of the Chip Tray ...

Page 331: ...vacuum cleaner GP 6 13 Door Latch Inspection Inspect the Door Latch every 1000K cycles The door latch must hold the door closed and ensure that the switch activation tab is depressing the door switch 1 The switch tab 2 should press the switch button just so that it is close to bottom 1 Ensure latch holds door closed 2 Ensure switch is activated when the door is closed 3 To adjust the door latch se...

Page 332: ...le Inspect and clean every 1000K cycles Procedure 1 For the Idler Rollers in the following nips inspect the rollers for wear debris toner marks unevenness and dents N1 N9 N2 N10 N3 N11 N4 N12 N5 N13 N8 N14 2 Inspect Springs 2 for each Idler Roller and make sure they are correctly hooked 3 Inspect the Bearing Housing The Bearing Housing should slide freely in the Bearing Forks Retaining Spring Idle...

Page 333: ...ct and clean every 1000K cycles Procedure 1 Do REP 2 12 Idler Roller Replacement to remove the Idler Roller 2 Clean the Idler Rollers with a soft cloth and alcohol 3 Inspect rollers for wear patterns or groves 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 Do REP 2 12 Idler Roller Replacement to...

Page 334: ... Schedule Inspect and clean every 1000K cycles Procedure To clean non removable idler rollers 1 Do REP 3 1 1 Punch Module Removal 2 Clean the Steering Idler Rollers with a soft cloth and alcohol 3 The roller surfaces should be 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...

Page 335: ... are removed Where practical make sure the rollers are clean Clean with a soft cloth and alcohol See also GP 6 14 1 Idler Roller Cleaning on page 6 63 It is recommended to clean the Drive Rollers with the Punch Module removed because with the Punch Module removed it is easy to access all Drive Rollers 1 Do REP 3 1 1 Punch Module Removal 2 Clean all Drive Rollers N1 N16 with a clean cloth and alcoh...

Page 336: ...ler Panel Latch Exit Idler Panel Latch Upper Bypass Panel Latch Inspection To inspect these three latches follow the procedure below Entrance Idler Panel Latch Exit Idler Panel Latch Upper Bypass Panel Latch 1 Open the Front door 2 When the idler panel is latched the idler panel spacers 2 spacers for each Idler assembly should contact the drive panels completely There should not be any movement in...

Page 337: ...s in the Idler panel should contact the drive panel Inspect this for the latches in the front side and rear side 4 Do REP 3 1 1 Punch Module Removal to remove the Punch Module 5 Inspect the Acceleration Idler Panel latch assembly front and rear side There should be two springs between the latch mechanism and the Entrance Drive panel 6 If the Springs are damaged do REP 2 17 Accel Idler Panel Rear L...

Page 338: ...dPunch Pro 6 68 7 When the idler panel is opened and closed you should be able to see the Idler springs extend which will ensure proper idler roller pressure 8 To adjust the Acceleration Idler Panel Latch do ADJ 1 8 1 Entrance Drive Panel Position Adjustment ...

Page 339: ...ction sensors S6 S21 use an anti static pre moistened lens cleaning wipe non alcohol based for cleaning the LED see parts list and canned air for the sensor slot Cleaning For paper path sensors use canned air or a clean cloth with alcohol to remove the debris off each sensor eye For edge detection sensors use the folder corner of the wipe to clean the lens of the LED s as shown Wipe the LED lenses...

Page 340: ...ves The surface should be rough and even Make sure the rollers are clean Clean rollers with a soft cloth and alcohol See also GP 6 14 Idler Roller and Idler Springs Inspection page 6 62 and GP 6 15 Drive Roller and Steering Drive Roller Inspection and Cleaning on page 6 65 3 Raise the panel and ensure the magnet holds it in open 4 Inspect the path for obstructions Clean as needed 4 Close the panel...

Page 341: ...ructions 2 Inspect the rollers for wear patterns or groves 3 Open the Entrance Idler Panel Acceleration Roller Idler and Exit Idler Panel and make sure there are no obstructions 4 Confirm that the Entrance Idler Panel Latch Acceleration Roller Idler Latch and Exit Idler Panel Latch hold the panels tightly in place If the latch is bent or damaged replace the Entrance Idler Panel REP 2 2 Acceleratio...

Page 342: ...ry 5000K cycles with Teflon grease Procedure 1 Do REP 1 6 Rear Cover Replacement to remove the Rear Cover 2 Do REP 3 1 Punch Module Replacement to remove the Punch Module 3 Clean the old grease from the cams and then apply a light coat of high quality grease not oil 4 Do REP 3 1 Punch Module Replacement to install the Punch Module 5 Do REP 1 6 Rear Cover Replacement to install the Rear Cover ...

Page 343: ...It is these five belts that should be checked Maintenance Schedule Inspect the Timing Belt every 1000K cycles Procedure Do the following to inspect the Timing Belts 1 Inspect all timing belts for wear missing teeth frayed edges and cracks 2 For replacement see REP 2 21 Timing Belt Replacement 3 Check for proper deflection of belts The belts should be slightly loose with approximately 1 4 deflectio...

Page 344: ...d solenoid When the solenoid is not activated the idler roller should be able to rotate freely and in turn will drive the drive roller not activated fully activated When the solenoid is fully activated the idler roller should completely lift off and not be able to drive the drive roller NOTE Disengaging solenoid modules need to be replaced every 5 million cycles 3 Clean the solenoid and surroundin...

Page 345: ...d air to remove dust from the alignment carriage rails The carriage can be moved back and forth on the rails to clean the entire surface Alternately a soft cloth and alcohol can be used Important Note DO NOT use any lubricant on the rail 3 Once the rails are cleaned check the motion of Alignment carriage PL 5 3 on the rails It should move when a force less than 2kgf is applied If there is binding ...

Page 346: ...lutch and remove any oil from the surface 5 Inspect the collar stop and the metal insert pawl for any wear 6 Check the tightness of 2 cone point set screws in the clutch 7 Inspect the tightness of the M6 lock nut and M6 socket head cap screw 8 Check the indexing of the Punch cam ADJ 1 5 Punch Cam Indexing 9 If necessary do REP 3 1 2 Punch Module Installation 10 Do REP 1 6 to install the Rear Cover...

Page 347: ...2 2 8 Press the Power Switch to the on position Warning Moving Parts keep hands clear of nips and the belts when the Interlock is cheater is inserted See Section 0 page vii for other languages 9 Do GP 6 2 10 Solenoids Procedure to activate and deactivate Solenoid SOL1 The diverter gate should rise and fall when SOL1 is cycled GP 6 26 Die Set Recognition Board Clips Inspection Use this procedure to...

Page 348: ...d The load is quite heavy and the plunger may not move up This is normal and can be verified again during Step 10 6 Inspect 4 plastic bushings in the Die lock brackets 2 in the front and 2 in the back 7 Inspect the surface of the cam and cam follower pad if there is any debris clear it 8 Inspect the 2 external compression springs 9 Inspect the Die rail springs The tip of the springs should be in c...

Page 349: ... lead edge of the sheet reaches Sensor S5 plus a delay to ensure the sheet is in roller N5 the sheet is accelerated to system speed of 1300mm s The sheet enters the steering rollers N6 N7 and the angle of the sheet is measured by Sensors S6 S10 and is then de skewed by rollers N6 N7 After deskew the front edge of the sheet is moved to alignment sensor S11 S15 The sheet is transported by N6 N7 unti...

Page 350: ... sheet is mid punched Once the punch cycle is complete the sheet is accelerated by N6 N7 to the system line speed The front edge of the sheet is moved to Alignment Sensors S11 S15 When the trail edge is close to the Backgauge Sensors S16 S17 the sheet is slowed and moves until the trail edge is detected at S16 S17 at which point it moves a further set number of steps backgauge and stops The sheet ...

Page 351: ...sor S16 Circuit Board Backgage Sensor Sensor S17 Circuit Board Backgage Sensor Sensor S18 Circuit Board Large Mid Punch Backgage Sensor Sensor S19 Circuit Board Large Mid Punch Backgage Sensor Sensor S20 Circuit Board XL Mid Punch Backgage Sensor Sensor S21 Circuit Board XL Mid Punch Backgage Sensor Sensor S22 Optical Exit Idler Panel Sensor Sensor S23 Optical Exit Idler Panel Sensor Sensor S24 Op...

Page 352: ...rom the punch output orientation Backgauge A predetermine distance from the trail edge of the sheet of paper to the punched hole s For double punch a predetermined distance from the center of the sheet of paper to the mid punched hole s Deskew The term used to describe the process of aligning the sheet of paper until it is parallel to the paper path Skew The term used to describe the fact that the...

Page 353: ...te die set for the AdvancedPunch Pro The AdvancedPunch Pro can hold up to four Die Sets in its cabinet one in the operating slot and three in the storage area Die Sets will decrease in performance over time based on the types of stocks and weights that are being punched The expected life of a die set is 750K punches when punching 20 lb bond 75 gsm paper Die Sets should be regarded as a long term s...

Page 354: ...s and Information 09 11 2018 GBC AdvancedPunch Pro 6 84 Die Sets List By selecting the appropriate die set you can use your AdvancedPunch Pro to punch documents in any of the binding styles indicated in the tables below ...

Page 355: ... 09 11 2018 General Procedures and Information 6 85 Die Sets List cont d By selecting the appropriate die set you can use your AdvancedPunch Pro to punch documents in any of the binding styles indicated in the tables below ...

Page 356: ...en End Wrench Needle Nose Pliers Phillips Screwdriver Flathead Screwdriver Wire Cutters Metric Allen Key Set 1 5mm 2mm 2 5mm 3mm 4mm 5mm Other Recommended Tools and Supplies 0 25mm 1mm and 3mm Shim Gauges 0 to 2 kgf Force gage Loctite 10mm Open End wrench 6mm Allen Key 150mm Metric ruler Lubrication For General lubrication please see the following sections GP 6 7 3 Die Set Lubrication GP 6 20 Punc...

Page 357: ...Cleaning GP 6 9 Internal Cleaning Use a soft cloth and alcohol to clean the following GP 6 14 Idler Roller Inspection and Cleaning GP 6 15 Drive Roller Inspection and Cleaning Use canned air or soft cloth to clean the following GP 6 17 Optical Sensor Cleaning GP 6 26 Alignment Carriage Rails Use canned air or vacuum cleaner to clean the following GP 6 22 Solenoid Cleaning and Inspection ...

Page 358: ...the ACCO AdvancedPunch Pro up to the publication time of this service manual revision The Tag matrix is located inside the Front Door PL 2 2 TAG 001 None Serial Numbers The GBC AdvancedPunch Pro Serial Number is located inside the Front Door on the front frame just below the Bypass Section The first three digits of this number is the Xerox Product Code ...

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Page 360: ...General Procedures and Information 09 11 2018 GBC AdvancedPunch Pro 6 90 Notes ...

Page 361: ... 08 20 2015 Wiring Data 7 1 Section Contents 7 Wiring Data Section Contents Wiring Data Title Page System Wiring 7 3 System Wiring DFA Configurations 7 4 Plug Jack Connectors 7 5 Plug Jack connectors DFA Configurations 7 6 ...

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Page 363: ...GBC AdvancedPunch Pro 08 20 2015 Wiring Data 7 3 System Wiring ...

Page 364: ...Wiring Data 08 20 2015 GBC AdvancedPunch Pro 7 4 System Wiring DFA Configurations ...

Page 365: ...GBC AdvancedPunch Pro 08 20 2015 Wiring Data 7 5 Plug Jack Connectors ...

Page 366: ...Wiring Data 08 20 2015 GBC AdvancedPunch Pro 7 6 Plug Jack Connectors DFA Configurations ...

Page 367: ...GBC AdvancedPunch Pro 08 20 2015 Wiring Data 7 7 Notes ...

Page 368: ...GBC AdvancedPunch Pro 08 20 2015 Installation Instructions 8 1 8 Installation Instructions ...

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Page 382: ...rackets 8 9 8 7 1 Install the Upstream Docking Bracket 8 9 8 7 2 Install the Downstream Docking Bracket 8 9 8 8 Level the Punch 8 10 8 9 Dock the AdvancePunch Pro to the Upstream Device 8 11 8 10 Install the CNC DFA Circuit Board and Cables 8 11 8 11 Connect the Punch Cables 8 12 8 12 Install the Lift Kit Cover 8 13 8 13 Dock the AdvancedPunch Pro to a Downstream Device 8 13 8 14 Install the Die S...

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Page 384: ...e Packing List The AdvancedPunch Pro shipping material should contain 4 boxes Pallet with AdvancedPunch Pro Cardboard box containing the Lift Kit Pt 497K14060 Cardboard box containing the OEM to DFA Conversion Kit Pt 497N04065 Cardboard box containing the Communications Adaptor Kit Pt 497K14700 Cardboard box containing the Long Train Cable Kit Pt 497K15210 8 2 Space Requirements Dimensions Before ...

Page 385: ...cedPunch Pro 1 Clear the space needed for the AdvancedPunch Pro 2 Move the Shipping Container into position near where you will install the AdvancedPunch Pro 3 Remove the metal straps from the Shipping Container 4 Remove the top outer cover of the Shipping Container 5 Remove the packing material from inside the Shipping Container and discard it Shipping Container ...

Page 386: ...e pallet 7 Remove the outer corner supports 4 from the pallet 8 Cut the corners of the cardboard packaging under the AdvancedPunch Pro 9 Fold down the corners of the cardboard packaging 10 Remove the tape from the inner packaging 11 Pull the plastic bag off the Coasters at the bottom of the AdvancedPunch Pro ...

Page 387: ...let until there is enough room to attach the Lift Kit 1 Unpack the Lift Kit 2 Remove the following items from the Lift Kit Assembly see Drawing 049K33580 Locking Bracket Caster Wrench Lift Cover M 4X10 Screw 2 M 6X16 Screw 2 DFA Cable 18 Ft Install Instructions 3 Place the Lift Kit Assembly and the Locking Bracket in place against the bottom of the AdvancedPunch Pro Locking Bracket Lift Kit Assemb...

Page 388: ...aster Wrench to level the AdvancedPunch Pro and the Lift Kit Assembly 8 3 2 Rotate the AdvancedPunch Pro to the upright Position 1 Have two 2 people shift and rotate the AdvancedPunch Pro until two 2 of the Casters touch the floor 2 Have two 2 people shift and rotate the AdvancedPunch Pro stand it upright on the Casters 4 3 Make sure the AdvancedPunch Pro stands firmly upright on the Casters 4 Scr...

Page 389: ... the cardboard packaging 5 Remove the plastic bag from the AdvancedPunch Pro 6 Remove the tape from the front of the AdvancedPunch Pro 7 Open the Front Door and remove the tape from the inside of the AdvancedPunch Pro 8 Check the entire AdvancedPunch Pro and remove any other Tape or packing material Tape ...

Page 390: ...tches the power requirements of the AdvancedPunch Pro 8 6 DFA Conversion Use the OEM to DFA Conversion Kit 497N04065 Instructions to do the conversion to install the DFA specific parts 8 7 Prepare the Docking Brackets Do the following to install the items shipped in the Accessories Box Use the Nuvera Interface Kit 49714700 Instructions to do an installation on a Nuvera 8 7 1 Install the Upstream D...

Page 391: ... with the upstream device SEM Module 1 Open the front door of the SEM Module 2 Remove the 7mm screws 2 and the Trim Strip from the SEM Module 3 Move the AdvancedPunch Pro into position against the upstream device SEM Module 4 Check the level of the AdvancedPunch Pro front to rear 5 Check the level of the AdvancedPunch Pro left to right ...

Page 392: ... until it is level with the SEM Module front rear 7 Check that the tabs on the upstream device SEM Module align with the slots in the Mounting Pins on the Upstream Docking Bracket See the 497K14700 Nuvera Interface Kit 8 9 Dock the AdvancePunch Pro to the Upstream Device See the 497K14700 Nuvera Interface Kit 8 10 Install the CNC DFA Circuit Board and Cables See the 497K14700 Nuvera Interface Kit ...

Page 393: ...the Punch Cables Do the following to connect the cables to the AdvancedPunch Pro 1 Connect the Power Cord to the AC Filter on the rear of the AdvancedPunch Pro 2 Connect the Upstream DFA Cable to the AdvancedPunch Pro 3 Connect the Power Cord to AC power outlet DFA Cable Power Cord ...

Page 394: ...cludes a downstream DFA device 1 Move the downstream device into position against the AdvancePunch Pro 2 Level in accordance with the instructions in the installation manual for the DFA device 3 Connect the required cables 8 14 Install the Die Set Do the following to install the Die Set 1 Locate the box for the Die Set 1 Remove the Die Set from the box 2 Remove the Pins as needed to set the correc...

Page 395: ... the Front Door 2 Press the Power Switch to the On I position 3 Close the Front Door 4 Wait until the User Interface indicates that the Punch is READY READY SINGLE PUNCH NOTE After you turn on the Power Switch the User Interface will read CLOSE DOOR momentarily after you close the door Power Switch ...

Page 396: ...e version e g 1 02 2 Do GP 6 1 12 to check the firmware version installed in the AdvancedPunch Pro FIRMWARE 1 00 1 00 3 If the firmware version is out of date perform GP 6 2 16 FIRMWARE UPGRADE Procedure to update the firmware LOG FIRMWARE UPGRADE When you install a GBC you also install the 2 2 xx FW on the PSK and set the PSK NVM 9099 from 1 to 3 If you ever install different printer software and...

Page 397: ...he ENTER button when the bent arrow is next to the words PUNCH MODE to display the Punch Mode menu PUNCH MODE SINGLE PUNCH 6 Press the Up Arrow Button until the bent arrow is next to the word OFF PUNCH MODE OFF 7 Press the ENTER button to select OFF This will enable Bypass mode 8 Press the Up Arrow Button to display the PREVIOUS MENU option PREVIOUS MENU PUNCH MODE 9 Press the Up Arrow Button agai...

Page 398: ...t to the words PUNCH MODE to display the Punch Mode menu PUNCH MODE OFF 6 Press the Up Arrow Button until the bent arrow is next to the words SINGLE PUNCH PUNCH MODE SINGLE PUNCH 7 Press the ENTER button to select OFF This will enable Single Punch mode 8 Press the Up Arrow Button to display the PREVIOUS MENU option PREVIOUS MENU PUNCH MODE 9 Press the Up Arrow Button again to display the EXIT opti...

Page 399: ...Start the Punch 2 Run a test sheet through the Punch 3 Check that the holes in the paper are aligned from an end to end as shown in the Figure below Check the position of the punched holes from the trail edge of the sheet Check the position of the punched holes in the onboard outboard position If not go to Section 6 General Procedures and follow the adjustment procedures explained in GP 6 1 1 BACK...

Page 400: ...g Matrix on the inside of the Right Front Door Update as needed 8 22 Operator Manual Make sure the customer has the Operation Instructions Manual 8 23 Tools Check that the Castor Wrench remains with the AdvancedPunch Pro 1 Store the Castor Wrench in the Lift Kit Slot behind the Front Door Tag Matrix ...

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