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GBC FusionPunch II Service Manual

System Checks

12/2003

1-14

Stacker 1 Cover Open
Stacker 1 Door Open
Stacker 2 Cover Open
Stacker 2 Door Open

Stacker 2 Cover Open
Stacker 2 Door Open

Failure of +24VDC to Stacker 1

Failure of +24VDC to Stacker 2

Call for Service

Go to RAP 1.5 Stacker
+24VDC Power

Stacker Upper Switch??

The Stacker Upper Switch did not release
during an emptying operation.

Go to RAPs 1.2 AC Power to
the Stacker, and RAP 5.2
Stacker Tray Direction.

Table 1-3 FusionPunch II Control Panel Messages (Continued)

FusionPunch II Message

Meaning

Operator Action

Technician Action

Summary of Contents for FusionPunch II

Page 1: ...GBC FusionPunch II With Stacker and Bypass Service Manual Revision 4 0 December 17th 2003 Part Number 1722683 ...

Page 2: ...ll notify or provide to such customer any future changes to this documentation Service by the customer of equipment or modules components or parts of such equipment may void any otherwise applicable GBC warranties If Customer services such equipment modules components or parts thereof Customer releases GBC from any and all liability for actions by the Customer and Customer agrees to indemnify defe...

Page 3: ...breviations ii 1 Service Call Procedures 1 1 Section Contents 1 1 2 Status Indicator RAPs 2 1 Section Contents 2 1 3 Quality RAPs 3 1 Section Contents 3 1 4 Repair Adjustment 4 1 Section Contents 4 1 5 Parts Lists 5 1 Section Contents 5 1 6 General Procedures 6 1 Section Contents 6 1 7 Wiring Data 7 1 Section Contents 7 1 8 Installation Instructions 8 1 Section Contents 8 1 9 FusionPunch II User G...

Page 4: ...on information This section also contains Host Enablement procedures and Personality Profiles for Host Printer to Finisher Section 7 Wiring Data This section contains illustrations and lists of the signals and connectors The illustrations show the power ground and the control signal distribution The lists show the signals and pin assignments for all connectors Section 8 Installation Instructions T...

Page 5: ...edures in this chapter in the order given By ignoring the sequence of procedures you may diagnose a symptom incorrectly and cause the customer undue frustration and expense Initial Actions are used to gather information regarding the performance of the machine and to prepare the product for servicing System Checks are used to verify the normal operation of the machine In the Y N steps of the syste...

Page 6: ...er to confirm travel arrangements d Customer s address phone number and contact 3 The GBC National Technical Specialist makes decision to go out on site Next Flight Out NFO or sends the following a A well trained experienced GBC local technician if available b GBC National Technical Specialist goes himself NFO if available c If not available asks another GBC National Technical Specialists to go on...

Page 7: ...stimated Time of Arrival ETA 5 The GBC Material Handler contacts the shipper and sends out the Emergency Parts Order Next Flight Out NFO GENERAL BINDING CORPORATION Emergency Parts Order Form Xerox Fax To 1 630 259 1724 Date ___________________________ Work Order No _________________________________ Customer P O ___________________________ DSS Initials _________________________________ Dealer Numb...

Page 8: ... and Estimated Time of Arrival ETA 5 The GBC Material Handler contacts the shipper and sends out the replenishment parts order UPS Ground GENERAL BINDING CORPORATION Parts Replenishment Order Form Xerox Fax To 1 630 259 1718 Date ___________________________ Work Order No _________________________________ Customer P O ___________________________ DSS Initials _________________________________ Dealer...

Page 9: ...GBC requires thirty 30 days prior notice to schedule training classes 2 GBC National Technical Support will arrange training schedule 3 GBC National Technical Support calls back Xerox with training dates and accommodations 4 Class size is limited to maximum of Six 6 CSE s minimum of two 2 and is two 2 days in length 5 GBC National Technical Support will maintain training records and send to Xerox ...

Page 10: ...GBC FusionPunch II Service Manual GBC Training Process 12 2003 1 6 Notes ...

Page 11: ...E through the call Procedure 1 Ask the customer to describe or demonstrate the problem that causes the service call and the job being finished when the problem occurred 2 Inspect any rejected work for evidence of defects 3 Note and record any errors displayed on the LCD 4 Examine any customer maintenance records for previous problems or activities that may be related to this service call 5 Go to S...

Page 12: ...o to Step 3 2A Remove the rear covers of the Punch and the Stacker s Refer to the information in Table 1 1 to evaluate the Punch and Stacker LEDs for normal operation The LEDs are operating normally Y N Refer to Table 1 2 for instructions Go to RAP 2 1 Control Panel RAP 3 Evaluate error messages on the FusionPunch II Control Panel Compare any messages displayed to Table 1 3 and follow table instru...

Page 13: ...rs Bypass the Interlock Switches b Press the Diagnostics button until the following message is displayed FOR SERVICE MENU Enter Keycode c Enter the Diagnostics keycode 1 Left Arrow 2 Right Arrow 3 Down Arrow 4 Up Arrow d Press Stop Reset e Press the Online Offline button until the following message is displayed FUSION TEST MODE Full Stop When you press START in the following step the Punch and Sta...

Page 14: ...ansport Sensor 2 and the Reflector Go to RAP 4 1 Document Transport JAMs Jam At Punch Sensor A sheet of paper blocks the Jam at Punch Sensor The Jam at Punch Sensor is dirty or is not working correctly Remove any paper from the Punch Sensor and press Reset Use a dry cloth a Q tip or a can of air to clean the Punch Sensor and the Reflector Go to RAP 4 1 Document Transport JAMs Jam PunchExit Sensor ...

Page 15: ...Sensor has failed Call for service Check the downstream device for failure indications If there are no indications of failure go to RAP 5 5 Stacker Exit Sensors Punch Covers Open The Covers did not actuate one or both of the IS4 and IS5 Cover Interlock Switches Close the Punch Covers Go to RAP 3 1 Punch Interlock Switches Punch Mid Door Open The Middle Door did not actuate the IS2 Mid Door Interlo...

Page 16: ...sed and see the related error information below in this table The Stacker Door did not actuate the Stacker Door Interlock Switch Close the Stacker Door Remove the rear cover of the Stacker and observe LED LOB1 LOB3 and LOB4 on the Stacker I O PWB If they are flashing dimly go to RAP 1 5 Stacker 24 VDC Power If the LEDs are normal flashing brightly go to RAP 3 2 Stacker Interlock Switches Stacker 1...

Page 17: ...tch Close the Stacker 2 Door Go to RAP 3 2 Stacker Interlock Switches Stacker2 Cover Open Note This dialog may appear with other interlock related dialogs If may occur with Stacker 1 Cover Open Stacker 1 Door Open and Stacker 2 Door Open It may also occur with Stacker 2 Door Open If either of these situations occurs ensure all covers and doors are closed and see the related error information below...

Page 18: ...e of 24VDC to Stacker 1 or Failure of 24VDC to Stacker 2 Call for Service Go to RAP 1 5 Stacker 24VDC Power Stacker Upper Switch The Stacker Upper Switch did not release during an emptying operation Go to RAPs 1 2 AC Power to the Stacker and RAP 5 2 Stacker Tray Direction Table 1 3 FusionPunch II Control Panel Messages Continued FusionPunch II Message Meaning Operator Action Technician Action ...

Page 19: ...rectly set If the failure continues to occur go to RAP 5 5 Stacker Bypass Exit Sensors Docutech 135 displays Clear External Finisher to run jobs to the Bypass Transport External Finisher Not Ready The current job is faulted and requires a reset The FusionPunch II is not on line Click on the Printer Icon Select reset if the reset option is available Press Stop Reset then press Online Offline to ens...

Page 20: ...o to Quality RAP 5 7 Table 1 6 Jam Locations Jam Location Technician Action Punch Document Transport Go to RAP 4 1 Document Transport Jams Stacker not in the Bypass If there is no Bypass installed go to RAP 5 3 Stacker Jams If there is a Bypass installed and the jam is in Stacker 2 that backs up into the Stacker 1 Bypass check the LEDs on the Stacker 1 Exit Sensor Normal conditions are Green LED a...

Page 21: ...ach second Go to Quality RAP 5 6 and ADJ 4 4 4 5 Stacker Tappers The Stacker Tappers actuate three times each second Go to Quality RAP 5 5 Offset Solenoids The Offset Solenoids actuate alternately each second Go to Quality RAP 5 3 Stacker Tray Motor If the Stacker Tray is in the maximum vertical position the Tray Motor lowers the Tray one position a second when the Upper Switch is deactivated Go t...

Page 22: ...completed during each service call 1 Clean all Sensors and Reflectors 2 Use alcohol to clean all Rollers Belts and O rings Subsystem Maintenance The following maintenance should be completed when servicing a subsystem 1 Remove the Covers and inspect all Belts Bearings and Shafts for excessive wear 2 Remove the Deck Covers Use a vacuum to clean the inside of the machine 3 Clean the Punch Motor and ...

Page 23: ...Service Manual 12 2003 1 19 Final Actions 1 Use a lint free cloth and water or Formula A to clean the exterior of the FusionPunch II and Stacker 2 Ensure that the Punch main power has been turned off and on to exit the Diagnostics Mode ...

Page 24: ...GBC FusionPunch II Service Manual Final Actions 12 2003 1 20 Notes ...

Page 25: ...P 1 5 Stacker 24VDC Power 2 13 RAP 2 1 Control Panel 2 17 RAP 3 1 Punch Interlock Switches 2 19 RAP 3 2 Stacker Interlock Switches 2 22 RAP 4 1 Document Transport Jams 2 27 RAP 4 2 Punch Jam Sensors 2 30 RAP 5 1 Stacker Full Almost Full and Upper Switch 2 33 RAP 5 2 Stacker Tray Direction 2 36 RAP 5 3 Stacker Jams 2 39 RAP 5 4 Stacker Bypass Jams 2 44 RAP 5 5 Stacker Bypass Exit Sensors 2 50 RAP 6...

Page 26: ...stribution PWB and CN1 on the 24 VDC Power Supply PWB PL 6 1B Go to Step 5 5 Measure the AC input voltages at P J 3 on the AC DC Distribution PWB across the brown and blue wires The voltages are within 108 VAC to 120 VAC tolerance Y N Replace the Punch AC DC Distribution PWB PL 3 1 Check the input voltage at CN 1 on the 5 VDC Power Supply PWB The voltage is within 108 VAC to 120 VAC tolerance Y N ...

Page 27: ...DC DISTRIBUTION PWB P2 P1 3 4 LINE NEU P1 J1 BRN GRN BLU 24 VDC POWER SUPPLY PWB NEU LINE BRN BLU LINE NEU CN1 PL3 1 PL1 1I PL3 1 P2 J2 AC RECEPTICLE LINE FILTER PL1 1I AC LINE AC NEUTRAL MAIN POWER SWITCH CIRCUIT BREAKER 5 VDC POWER SUPPLY PWB NEU LINE BRN BLU LINE CN1 PL3 1 P3 J3 NEU ...

Page 28: ...he Stacker Bypass Motor in the problem stacker NOTE The Stacker Dir output is used to change the direction of the Stacker Tray so that it can be moved up and down Toggle this output to change the direction of the tray The Stacker Tray Motor Stacker O Ring Motor and Stacker Bypass Motor if installed in the problem stacker all operate when the outputs are active Y N The Stacker Tray Motor Stacker O ...

Page 29: ...DC Distribution PWB check 24 VDC to Stacker 1 by placing the meter leads across P J 14 24V and P J14 0V There is 24 VDC at this point Y N Go to RAP 1 5 Stacker 24 VDC Power Replace the Stacker 1 AC DC Distribution PWB PL 3 2 7 On the problem Stacker AC DC Distribution PWB disconnect P J 7 to the Stacker Tray Motor Activate the Stacker Tray Motor using the information in the table below If installe...

Page 30: ...ass Motor using the information in the table below Only on Stackers with Bypass installed With the output active check for 108 VAC to 120 VAC between J10 NUI and J10 RMTR There is 108 VAC to 120 VAC between these points Y N Replace the Stacker AC DC Distribution PWB PL 3 2 in the problem Stacker Check continuity between P10 and the Stacker O Ring Motor If the harness is OK replace the Stacker Bypa...

Page 31: ... MOT P8 STACKER 1 BYPASS MOTOR PL 1 3A NUI RMTR J10 MOT P10 STACKER 2 AC DC DISTRIBUTION PWB PL3 2 24V 0V P13 J13 STACKER 2 TRAY MOTOR PL 1 2B NUI FWD J7 MOT P7 REV STACKER 2 O RING MOTOR PL 1 2B NUI RMT2 J8 MOT P8 STACKER 2 BYPASS MOTOR PL 1 3A NUI RMTR J10 MOT P10 PUNCH AC DC DISTRIBUTION PWB PL3 1 P14 J14 24V 0V P2 P1 3 4 BRN GRN BLU PL1 2A AC RECEPTICLE LINE FILTER PL1 2A AC LINE AC NEUTRAL MA...

Page 32: ...a digital multimeter place the common lead on CN2 Pin 3 or 4 black wire and the positive lead on Pin 1 or 2 red wire on the 5VDC Power Supply PWB The 5 VDC voltage is within tolerance Y N Replace the 5 VDC Power Supply PL 3 1 Go to Step 9 9 Switch off the Main Power Switch Circuit Breaker Reconnect the CN2 Connector and disconnect P J12 from the AC DC Distribution PWB Then switch on the Main Power...

Page 33: ...nual 12 2003 2 9 PUNCH I O PWB PUNCH AC DC DISTRIBUTION PWB PL3 1 5V 0V 5 VDC POWER SUPPLY PWB NEU LINE BRN BLU LINE CN1 CN2 5V 0V PL3 1 P3 J3 RED BLK NEU PUNCH AC DC DISTRIBUTION PWB 5V 0V PL3 1 5V 0V 5V 0V RED BLK 5V 0V PL3 1 P5 J5 J12 J12 P28 J28 ...

Page 34: ... to the Punch Replace the harness between J2 on the AC DC Distribution PWB and the 24 VDC Power Supply PWB PL 6 1B Place the common lead on CN2 Pin 5 6 7 and 8 black wires and the positive lead on Pin 1 2 3 and 4 orange wires on the 24VDC Power Supply PWB The voltage is 23 5 VDC to 25 5 VDC Y N Replace the Punch 24 VDC Power Supply PWB PL 3 1 On the Punch AC DC Distribution PWB check for 24 VDC be...

Page 35: ... the Punch AC DC Distribution PWB PL 3 1 On the Stacker AC DC Distribution PWB check for 24 VDC between P J 14 24V and P J 14 0V The voltage is 23 5 VDC to 25 5 VDC Y N Replace the harness between the Punch AC DC Distribution PWB P J 14 and the Stacker AC DC Distribution PWB P J 14 PL 6 1B The 24 VDC Power Circuit are OK ...

Page 36: ...B 24V 5V 0V 24VI STACKER AC DC DISTRIBUTION PWB 24V 5V P28 J28 J14 P14 P14 J14 0V P26 J26 24V 24V 0V LITTLE STAR CONTROLLER PWB ORN ORN BLK ORN RED BLK BLK RED ORN J1 P1 DC IN K GND PL 3 1 PL3 1 PL3 1 PL 3 2 PUNCH INTERLOCK CIRCUITS RIGHT DOOR MIDDLE DOOR LEFT DOOR TOP COVER 1 TOP COVER 2 24 VDC P6 J6 ORN 1 24V PUNCH AC DC DISTRIBUTION PWB 24 VDC POWER SUPPLY PWB NEU LINE BRN BLU LINE NEU CN1 CN2 ...

Page 37: ...AC DC Distribution PWB disconnect P J 16B Check continuity between P 16B 24VI and P 16B 24V across the orange and yellow wires There is continuity through the closed Stacker 1 Top Cover Interlock Y N Reconnect P J 16 and go to RAP 3 2 Stacker Interlock Switches Reconnect P J 16 and go to Step 4 4 Switch on the Main Power There are areas of high voltage in the Stacker Use caution when working in th...

Page 38: ...the harness between P J 13 on the Stacker 1 AC DC Distribution PWB and P J 13 on the Stacker 2 AC DC Distribution PWB PL 6 2B Go to Step 8 8 On the Stacker 2 AC DC Distribution PWB check for 24 VDC between P J 12 24V and P J 12 0V The voltage is 23 5 VDC to 25 5 VDC Y N Replace the Stacker 2 AC DC Distribution PWB PL 3 2 On the Stacker 2 I O PWB check for 24 VDC between P J 28 24V and P J 28 0V Th...

Page 39: ...A ORN 24V STACKER INTERLOCK CIRCUITS FRONT DOOR YEL 24V INTERRUPTED 24VI P16A 24 VDC ORN 24V STACKER INTERLOCK CIRCUITS TOP COVER J16A P16A J16A Notes Single Stacker Configuration or Stacker 1 of 2 Dual Stacker Configuration Stacker 2 only Not installed for Single Stacker Configuration STACKER 1 AC DC DISTRIBUTION PWB 0V 24V ORN BLK PL3 3 P13 J13 24V 0V P13 J13 PUNCH AC DC DISTRIBUTION PWB 0V 24V ...

Page 40: ...RN 24V STACKER INTERLOCK CIRCUITS FRONT DOOR YEL 24V INTERRUPTED 24VI P16B 24 VDC ORN 24V STACKER INTERLOCK CIRCUITS TOP COVER J16B P16B J16B Stacker configured with Bypass STACKER 1 AC DC DISTRIBUTION PWB 0V 24V ORN BLK PL3 3 P13 J13 24V 0V P13 J13 PUNCH AC DC DISTRIBUTION PWB 0V 24V ORN BLK PL3 1 P14 J14 24V 0V P14 J14 Notes Dual Stacker Configuration Stacker 1 of 2 only Dual Stacker Configurati...

Page 41: ... The LCD Panel Backlight is lit and messages are displayed Y N The backlight is not lit On the Daughter PWB check for 5 VDC across J1 red wire and J1 black wire There is 5 VDC at this point Y N Go to RAP 1 3 5 VDC Power Go to Step 3 Go to Step 4 3 Open the Control Panel Assembly Check continuity on the ribbon cable between P J 3 on the Punch Daughter PWB and the connector to the LCD Panel Assembly...

Page 42: ...YEL GRN PLATE 7610299 BLU WHT BLK DISTRIBUTION BRN RED ORN YEL GRN BLK BLU WHT RED BRN 7610452 J22 ORN YEL GRN BLK BLU WHT J23 BRN RED ORN YEL GRN J25 J24 J1 J5 1 BLACK RED ORANGE 1 BLU WHT J2 J3 EXPANSION I O BUS 7610458 7610495 1 7610459 LCD ASS Y 1 NOT CONNECTED WHITE NOTE WHITE WIRE PIN BROWN 7610496 LITTLE STAR CONTROLLER PWB 1 H1 PL3 1 ...

Page 43: ...ing table check the continuity of the cable between the P25 pin corresponding to the Interlock and the corresponding pin on P3 The continuity is OK Y N Replace the cable between the Punch I O PWB and the Little Star Controller PWB PL 6 1A Replace the Little Star Controller PWB PL 3 1 4 Using the information in the following table disconnect P J 19 on the Punch I O PWB Check the corresponding I O P...

Page 44: ...e the circuit across the interlock by disconnecting the two NO3 connectors Check continuity across the contacts while activating the interlock When the interlock is closed there is continuity across the NO3 contacts Y N Replace the Interlock Switch PL 1 1A Reconnect the NO3 connectors and go to Step 9 10 With all other interlocks closed check continuity in the 24 VDC harness between P J 6 24V on t...

Page 45: ...ERLOCK SW2 LEFT DOOR INTERLOCK SW3 TOP COVER 1 INTERLOCK SW4 TOP COVER 2 INTERLOCK SW5 1 1 3 1 1 3 3 1 1 3 3 1 1 3 1 3 3 24V INTERRUPTED YEL P19 J19 INB1 INB1 INB2 INB2 INB3 INB3 INA6 INA6 RIGHT DOOR TOP COVERS LEFT DOOR MIDDLE DOOR LITTLE STAR CONTROLLER PWB P25 J25 J3 P3 13 14 15 16 0V 0V 0V 3 PL 1 1A PL 1 1A PL 1 1A PL 1 1A PL 1 1A PL 3 1 PL 3 1 P24A J24A PUNCH AC DC DISTRIBUTION PWB 24VI J6 P6...

Page 46: ... 4 4 The table below contains information for Stacker 1 and Stacker 2 Depending on your configuration use the information in the table to enter the Diagnostics mode and select the desired input with the left right keys Sequentially activate and deactivate the interlock and observe the Control Panel for a change in state 0 to 1 or 1 to 0 There is a change in state when the interlock is activated an...

Page 47: ...corresponds If two Stackers are installed this connector will be P24B The continuity is OK Y N Replace the faulty harness PL 6 2A Depending on the problem Stacker replace Daughter PWB 1 or Daughter PWB 2 PL 3 1 9 The table below contains information for Stacker 1 and Stacker 2 Using the information in the table place a jumper between the signal input on J19 and the 0 VDC pin on J19 on Stacker 1 or...

Page 48: ...on PWB check continuity between P J 6A 24V and P J 6A 24VI Front Door Interlock The continuity check is good Y N Replace the harness PL 6 2A Go to Step 16 15 With all interlocks closed on the Stacker AC DC Distribution PWB check continuity between P J 16A 24V and P J 16A 24VI Top Cover Interlock The continuity check is good Y N Replace the harness PL 6 2A Go to Step 16 16 Ensure all other interloc...

Page 49: ... check is good Y N Replace the harness PL 6 2A Go to Step 19 19 Ensure all other interlocks are closed Using the information in the table below check the harness between P J 20 and P J 19 on the Stacker I O PWB The continuity check is good Y N Replace the harness PL 6 2A Replace the Daughter PWB PL 3 1 If the problem is still present replace the Stacker I O PWB PL 3 2 Interlock P J 20 Pin P J 19 P...

Page 50: ...WB PL 3 1 P24A J24A 6 1 BLK 0V BLK J25 P25 24 VDC 24V P6A J6A ORN FRONT DOOR INTERLOCK SW1 PL 1 1A 1 3 3 24V P16A J16A 1 P24 J24 P25 J25 STACKER AC DC DISTRIBUTION PWB PL 3 2 PL 1 2A 1 P16A J16A P6A J6A STACKER AC DC DISTRIBUTION PWB PL 3 2 24VI 24VI ORN YEL YEL 24 VDC 24 VDC INTERRUPTED 24 VDC INTERRUPTED Notes In Stackers with a Bypass installed the interlocks are connected to P J16B Top Cover a...

Page 51: ...2 If it is off when the output is on go to Step 3 Check the condition of the Document Transport Main Drive Timing Belt The belt is loose or faulty Y N When the motor activates the infeed belts in the Interface Assembly drive smoothly Y N Grasp the Document Transport Main Drive Timing Belt and pull it in a counterclockwise direction to test its motion and the motion of the infeed belts in the subsy...

Page 52: ... enabled by a ground on P11 MT2 When the output is activated there should be 0VDC at this point When it is deactivated there should be 24 VDC at this point Activate and then deactivate the output and check for 0 VDC and then 24 VDC between P J11 MT2 and P J 12 0V on the Punch AC DC Distribution PWB There is 0 VDC when the output is activated and 24VDC when the output is deactivated Y N Replace the...

Page 53: ...tion of the infeed belts in the subsystem in which the jam is occurring If the belts in any area binding loose or are not rotating smoothly check the belts pulleys idlers and shafts to ensure proper operation Repair replace as required PL 4 3A 4 3N Check the Punch Assembly for obstructions burrs bent or missing components Repair replace as required PL 4 3A 4 3N Output Diagnostic Document Transport...

Page 54: ...sor Sequentially block and unblock the sensor and observe the LED for a change in state Blocked Off Unblocked On There is a change in state when the sensor is blocked and unblocked Y N Go to Step 4 Go to step 3 3 Using the information in the following table check the continuity of the cable between the P25 pin corresponding to the sensor and the corresponding pin on P3 The continuity is OK Y N Rep...

Page 55: ...ould extinguish With the jumper in place the corresponding Punch I O PWB LED extinguishes Y N Replace the Punch I O PWB PL 3 1 Leave the connector disconnected and go to Step 7 7 Check for 24 VDC between the 0 VDC pin and the 24 VDC pin on the disconnected jack There is 24 VDC at this point Y N Replace the Punch I O PWB PL 3 1 Check the harness between the sensor and its plug on the Punch I O PWB ...

Page 56: ...2 SENSOR PUNCH SENSOR EXIT SENSOR P10 J10 24V 0V P9 J9 24V 0V P1 J1 24V 0V P2 J2 24V 0V PL 4 2A PL 4 2A PL 4 3A PL 4 3D P11 J11 INB4 P10 J10 INB5 P9 J9 INB6 P2 J2 INB7 P1 J1 INB8 P25 J25 INB4 INB5 INB6 INB7 INB8 LITTLE STAR CONTROLLER PWB 13 J3 12 11 10 9 EXIT PUNCH ENTRANCE SENSOR DOC XPORT 2 SENSOR DOC XPORT 1 SENSOR SIGNAL SIGNAL SIGNAL SIGNAL SIGNAL RED BLK BLK RED RED BLK RED BLK WHT WHT WHT ...

Page 57: ...y need to disconnect J10 on the Stacker I O PWB to isolate the circuit There is continuity across the switch Y N Go to Step 3 Replace the Stacker Full Switch PL 5 1A 3 Examine the cable from P10 on the Stacker I O PWB to the Stacker Full Sensor Check for shorts to ground or opens in this harness The harness is shorted to ground or open Y N Go to Step 4 Replace the harness PL 6 2A 4 For Stacker 1 o...

Page 58: ...ut Select the table for Stacker 1 or Stacker 2 below Enter the Diagnostics mode and use the left right keys to select the desired input Stacker 1 Stacker 2 Manually activate the Stacker Upper switch and observe the Control Panel for a change in state The display indicates a change in state Y N Go to Step 10 The Stacker Upper Switch and related circuits are good 10 Disconnect the Stacker Upper Swit...

Page 59: ...0 J9 J10 J11 J9 STACKER I O PWB PL 3 2 0V UPPER SWITCH PL 5 1A FULL SWITCH PL 5 1A ALMOST FULL SWITCH PL 5 1A 0V 0V STACKER I O PWB PL 3 2 INB6 INB5 INB4 SIGNAL SIGNAL SIGNAL INB6 INB5 INB4 DAUGHTER PWB PL 3 1 6 5 4 UPPER SWITCH FULL SWITCH ALMOST FULL SWITCH WHT WHT WHT BLK BLK BLK BLK GRN YEL 5 VDC 5 VDC 5 VDC ...

Page 60: ...r the Stacker Tray The error message returns after the Stacker Tray is lowered and raised Y N Problem resolved Go to Step 3 3 Check the wiring harness connecting P30 on the Stacker I O PWB to P11 on the Stacker AC DC Distribution PWB Check for continuity between P30 OUTA C7 and J11 DIR There is continuity between P30 OUTA C7 and P11 DIR Y N Repair or replace the harness PL 6 2A Go to Step 4 4 Chec...

Page 61: ...WB The cable designation is the same for single stacker or dual configurations however depending on the problem stacker be sure to check the cable between the Stacker 1 I O and its Punch I O Daughter PWB or the Stacker 2 I O PWB and its Punch I O PWB There is continuity between P24A INA8 and P 8 Y N Repair or replace the harness PL 6 2A Replace the Punch I O Daughter PWB PL 3 1 ...

Page 62: ...C DC DISTRIBUTION PWB PL 3 2 OPTO 1 RELAY NUI FWD J7 BRN BLU STACKER I O PWB OUTA6 PL 3 2 OUTA7 OUTA7 J30 P30 OUTA6 P23A J23A STACKER TRAY MOTOR P11 J11 6 7 P23 STACKER TRAY DIRECTION MT1 MOT GRN REV RELAY 2 DIR P7 BLU BLK WHT WHT STACKER AC DC DISTRIBUTION PWB PUNCH DAUGHTER PWB RLY2 J15 R ON P15 P29 J29 INC8 INA8 P24 J24 8 WHT TRAY DIRECTION BLK ...

Page 63: ...e Stacker 2 Bypass to the downstream device If paper is not jamming in the Stacker or the Punch refer to RAP 4 2 Punch Jam Sensors Procedure 1 Refer to the following table of conditions to isolate the problem 2 Perform a visual inspection of the Stacker O Ring Assembly PL 5 1B and C Ensure that the assembly O rings are in proper position and are in good condition The O Rings on the Stacker O Ring ...

Page 64: ...eplace the harness between the Punch Daughter PWB P23 and Stacker I O PWB P23 PL 6 1D Replace the Little Star Controller Expansion PWB PL 3 1 9 On the Stacker I O PWB disconnect P J 30 In the Diagnostics Mode repeatedly activate and deactivate the Stacker O Ring Motor output Observe L0A8 on the Stacker I O PWB LED L0A8 lights when the output is activated Y N Reconnect P J 30 and go to Step 10 Reco...

Page 65: ...u are checking to see if the LED remains LIT when the P J is disconnected NOT flashing LED L0A6 remains lit when P J30 is disconnected Y N Reconnect P J 30 and go to Step 16 Go to Step 19 16 Check the continuity of the harness between the Punch Daughter PWB P23 6 and Stacker I O PWB P23A OUTA6 The continuity is OK Y N Replace the harness between the Punch Daughter PWB P23 and Stacker I O PWB P23 P...

Page 66: ...AC DC Distribution PWB PL 3 2 Go to Step 21 21 In the Diagnostics Mode activate the Stacker Tray Motor output Disconnect P J 7 on the Stacker AC DC Distribution PWB Using the information in the following table check for 110VAC to the Stacker Tray Motor There is 110VAC as described in the above table Y N Go to Section 2 RAP 1 2 AC Power to the Stacker Check the harness between P7 on the Stacker AC ...

Page 67: ...DC DISTRIBUTION PWB PL 3 2 OPTO 1 RELAY NUI FWD J7 BLK WHT STACKER I O PWB OUTA6 PL 3 2 OUTA7 OUTA7 J30 P30 OUTA6 P23A J23A STACKER TRAY MOTOR P11 J11 6 7 P23 STACKER TRAY DIRECTION MT1 MOT RED REV RELAY 2 DIR P7 BLU BLK WHT WHT O RING MOTOR PL 1 2 B RELAY 3 MT2 NUI J8 BRN BLU MOT OUTA8 OUTA8 8 STACKER O RING MOTOR MT2 P8 WHT WHT ...

Page 68: ...Mode GP1 and select the Stacker Gate output Stacker 1 Stacker 2 Toggle the Stacker Gate Solenoid and watch the gate fingers as the output is toggled The Stacker Gate fingers move up and down normally as the output is toggled Y N Go to Step 3 Go to Step 12 3 In the Diagnostics Mode sequentially activate and deactivate the Stacker Gate output for the Stacker in which the jam is occurring Observe LED...

Page 69: ...4 on the Stacker I O PWB in the problem Stacker The light on the relay is lit when the output is active Y N Replace Optical Relay Opto4 on the Stacker I O PWB PL 3 3 Go to Step 10 10 Check the 3 60 VDC 3 amp fuse on the Optical Relay The fuse is OK Y N Replace the fuse PL 3 2 Go to Step 11 11 With the output active check for 24VDC supplied to the Stacker Gate Solenoid in the problem Stacker by pla...

Page 70: ... the problem Stacker disconnect P J 30 In the Diagnostics Mode repeatedly activate and deactivate the Stacker Bypass Motor output Observe L0B2 on the Stacker I O PWB LED L0B2 lights when the output is activated Y N Reconnect P J 30 and go to Step 17 Reconnect P J 30 and go to Step 18 17 Check the continuity of the harness between the Punch Daughter PWB P22 2 and Stacker I O PWB P22 OUTB2 in the pr...

Page 71: ...ve the LED for a change in state Blocked Off Unblocked On There is a change in state when the sensor is blocked and unblocked Y N Go to Step 25 Go to step 24 24 Check the continuity of the cable between the Stacker I O P25 INB8 and the Punch Daughter PWB P J25 8 The continuity is OK Y N Replace the cable between the Stacker I O PWB P J 25 and the Punch Daughter PWB P J 25 PL 6 2A Replace the Punch...

Page 72: ...the Stacker I O PWB PL 3 3 Leave the connector disconnected and go to Step 28 28 Check for 24 VDC between P J 1 0 V and the P J 1 24 V There is 24 VDC at this point Y N Replace the Stacker I O PWB PL 3 3 Check the harness between the sensor and its plug on the Stacker I O PWB If the harness is OK replace the Bypass Exit sensor PL1 3A ...

Page 73: ... BYPASS MOTOR OUTB5 STACKER BYPASS GATE BLK RELAY 5 OPTO 4 RELAY J6B 24VP P6B OUTB5 STACKER BYPASS GATE SOLENOID PL 5 3A P16A J16A 24V 24VI PUNCH DAUGHTER PWB STACKER I O PWB PL 3 1 PL 3 2 BYPASS EXIT SENSOR PL 1 3A J22 2 P22 5 J25 P25 8 J25 P25 INB8 INB8 24V 0V P1 J1 BLK BLU BRN WHT YEL ORN P2 P1 3 4 BRN GRN BLU PL1 2A AC RECEPTICLE LINE FILTER PL1 2A AC LINE AC NEUTRAL MAIN POWER SWITCH CIRCUIT ...

Page 74: ...m Stacker replace the cable between the Stacker I O PWB P J 25 and the Punch Daughter PWB P J 25 PL 6 2A Replace the Punch Daughter PWB associated with the problem Stacker PL 3 1 If the problem is still present replace the Little Star Controller PL 3 1 4 On the Stacker I O PWB in the problem Stacker disconnect P J 1 Check LED LIB8 to see if it is lit when the connector is disconnected NOTE In this...

Page 75: ...Stacker I O PWB PL 3 3 Leave the connector disconnected and go to Step 7 7 On the problem Stacker check for 24 VDC between P J 1 0 V and P J 1 24 V There is 24 VDC at this point Y N Replace the Stacker I O PWB PL 3 3 Check the harness between the sensor and its plug on the Stacker I O PWB If the harness is OK replace the Bypass Exit sensor PL1 3A ...

Page 76: ...H DAUGHTER PWB 1 STACKER 1 I O PWB PL 3 1 PL 3 2 STACKER 1 BYPASS EXIT SENSOR PL 1 3A J25 P25 8 J25 P25 INB8 INB8 24V 0V P1 J1 BLK BLU BRN WHT PUNCH DAUGHTER PWB 2 STACKER 2 I O PWB PL 3 1 PL 3 2 STACKER 2 BYPASS EXIT SENSOR PL 1 3A J25 P25 8 J25 P25 INB8 INB8 24V 0V P1 J1 BLK BLU BRN WHT ...

Page 77: ...he Punch I O PWB The LED for each output lit when the output was activated Y N Check the wiring harness between P J23A on the Punch I O PWB and P J1 on the Little Star Controller If the harness is open or shorted replace it PL 6 1A If the harness is OK replace the Little Star Controller PWB PL 3 1 Go to Step 3 3 Unplug the DFA cable at the rear panel to the punch Using the information in the table...

Page 78: ... pins listed The LED for each input EXTINGUISHED when the pins for the input were jumpered Y N Go to Step 7 Replace the Little Star Controller PWB PL 3 1 7 Check the Internal DFA Cable that runs from the rear panel to P1 on the Punch I O PWB for proper seating opens or shorts The continuity of the cable is OK Y N If the cable is faulted replace it PL 6 1A Go to Step 8 8 Check the wiring harness be...

Page 79: ... S4 SET ACK C0 SHEET EXIT C1 SET EXIT C2 CYCLE UP C6 FINISHER FUNC1 C7 FINISHER FUNC2 OUTA1 OUTA2 OUTA3 OUTA4 OUTA5 INA1 INA2 INA3 INA4 INA5 P23A J23A A B C 5 VDC 5 VDC 5 VDC 5 VDC OUTA3 J17A OUTA4 J16A OUTA5 J15A 5 VDC 0V 0V 0V 0V 0V INA3 J14A INA4 J13A INA5 J12A JP18 22 4 23 5 24 6 25 7 26 8 30 12 31 13 32 14 36 18 37 19 1 P1 DFA FROM HOST PRINTER BRN RED ORN GRN YEL BRN RED ORN YEL GRN PL 3 1 J...

Page 80: ...GBC FusionPunch II Service Manual RAP 6 2 Printer Connectivity 12 2003 2 56 Notes ...

Page 81: ...ection Contents Title Page Quality RAP 5 3 Sets Do Not Offset 3 2 Quality RAP 5 4 Trail Edge Torn Marked or Creased 3 7 Quality RAP 5 5 Document Stack Shingled 3 10 Quality RAP 5 6 Documents Not Punched 3 11 Quality RAP 5 7 Documents Punched in Center of Sheet 3 15 ...

Page 82: ...n the sensor is blocked and unblocked Y N Go to RAP 4 2 Punch Jam Sensors Go to Step 3 3 In the Diagnostics Mode select End of Set Beeper and set the value to 1 Run a job from the host printer consisting of 5 sets While the job is running listen for the beep tone at the end of each set A beep is heard at the end of each set Y N Go to RAP 6 2 Printer Connectivity Go to Step 4 4 In Diagnostic Mode s...

Page 83: ...Using the information in the table below enter the Diagnostics mode and use the left right keys to underscore each offset solenoid Sequentially activate and deactivate the output and observe L0B6 and L0B7 on the Stacker I O PWB LEDs L0B7 and L0B6 illuminate when their outputs are active Y N Reconnect P J 4A and P J 5A go to Step 9 Reconnect P J 4A and P J 5A go to Step 10 9 Using the information i...

Page 84: ...s between the Punch Daughter PWB P23 and Stacker I O PWB P23 PL 6 1D Replace the Little Star Controller Expansion PWB PL 3 1 14 On the Stacker I O PWB disconnect P J 30 In the Diagnostics Mode repeatedly activate and deactivate the Stacker O Ring Motor output Observe L0A8 on the Stacker I O PWB LED L0A8 lights when the output is activated Y N Reconnect P J 30 and go to Step 15 Reconnect P J 30 and...

Page 85: ...erve Relay3 on the Stacker AC DC Distribution PWB The Relay activates and deactivates as the output is toggled Y N Replace the Stacker AC DC Distribution PWB PL 3 2 Go to Step 18 18 In the Diagnostics Mode activate the Stacker O Ring Motor output Disconnect P J 8 on the Stacker AC DC Distribution PWB Check for 110VAC across J8 NUI and J8 MT2 There is 110VAC at this point Y N Go to Section 2 RAP 1 ...

Page 86: ... PL 3 2 STACKER I O PWB PL 3 2 J30 P30 P23A J23A P11 J11 P23 O RING MOTOR PL 1 2 B RELAY 3 MT2 NUI J8 BRN BLU MOT OUTA8 OUTA8 8 STACKER O RING MOTOR MT2 P8 WHT WHT OFFSET 2 SOLENOID OUTB7 OUTB6 YEL WHT YEL WHT OFFSET 1 SOLENOID PL 5 1C PL 5 1C P22 J22 STACKER OFFSET 1 7 6 STACKER OFFSET 2 BLU BLK P22 J22 OUTB7 OUTB6 24VI 24VI J4A J5A P4A P5A ...

Page 87: ...ents are still torn marked or creased Y N Problem resolved Return the Clutch On Set Value to its original value and go to Step 5 5 Using the information in the table below enter the Diagnostics mode and use the left right keys to underscore the test for the Back Gauge Fingers Sequentially activate and deactivate the output and observe the action of the Back Gauge Fingers The Back Gauge Fingers act...

Page 88: ...nguishes when the output is toggled Y N Reconnect P J 4B reinstall the Optical Relay and go to Step 11 Reconnect P J 4B reinstall the Optical Relay and go to Step 12 11 Check the continuity of the harness between the Little Star Controller PWB P1 HV02 and Punch I O PWB P22 OUTB7 The continuity is OK Y N Replace the harness between the Punch I O PWB P J22 and the Little Star Controller PWB P1 PL 6 ...

Page 89: ...Marked or Creased GBC FusionPunch II Service Manual 12 2003 3 9 LITTLE STAR CONTROLLER PWB PL 3 1 HVO2 PUNCH I O PWB PL 3 1 OUTB7 OPTO 2 RELAY OUTB7 24VI J4B P4B YEL WHT BACK GAUGE SOLENOID PL 4 3C P22 J22 BACK GAUGE FINGERS BLU J1 P1 ...

Page 90: ...ne Sided Print Queue The document stack is still shingled Y N Problem resolved Load paper in the Host Printer in the opposite direction to correct for curl up curl down The document stack is still shingled Y N Problem resolved Instruct the operator to watch for this condition in the future Go to Step 2 2 With no paper in the Stacker Tray observe the distance between the Stacker Tapper and the Tray...

Page 91: ...ctivate and deactivate the Punch Clutch output Observe LED L0B8 on the Punch I O PWB LED L0B8 illuminates when the output is active Y N Go to Step 5 Go to Step 8 5 On the Punch I O PWB disconnect P J 3B In the Diagnostics Mode activate the Punch Clutch output While the output is active observe L0B8 on the Punch I O PWB NOTE In this step you are checking to see if the LED remains LIT when the P J i...

Page 92: ...nch Clutch Solenoid PL 4 3C Replace the harness PL 6 1A 13 Using the information in the table below enter the Diagnostics mode and use the left right keys to underscore the Punch Motor output Activate the Punch Motor The motor activates Y N Activate the motor output again Check LED L0B1 on the Punch I O PWB If the LED is lit when the output is on go to Step 14 If it is off when the output is on go...

Page 93: ...ler PWB PL 3 1 Check continuity and for shorts to ground between P 30 OUTB1 on the Punch I O PWB and P11 MT3 on the Punch AC DC Distribution PWB The harness is OK Y N Replace the harness PL 6 1A Go to Step 15A 15A The Punch Motor is enabled with a ground on P J11 MT4 When the output is activated there should be 0VDC at this point When the output is deactivated there should be 24 VDC Activate and t...

Page 94: ...TAR CONTROLLER PWB PL 3 1 HVO1 HVO7 PUNCH I O PWB OUTB8 PL 3 1 OUTB2 OPTO 1 RELAY J3B P3B OUTB8 24VI YEL WHT OUTB1 J30 P30 P22 J22 PUNCH PUNCH MOTOR ON WHT RED J1 PUNCH MOTOR PL 1 1F AC DC DISTRIBUTION PWB PL 3 1 RELAY 5 NUI MT3 J9 BRN BLU MOT MT3 P11 J11 WHT PUNCH CLUTCH SOLENOID PL 4 3B P1 P9 ...

Page 95: ... is disconnected Y N Reconnect P J 4B and go to Step 4 Go to Step 6 4 On the Punch I O PWB disconnect Optical Relay Opto2 Activate the Back Gauge Fingers output and observe LED L0B7 NOTE In this step you are checking to see if the LED remains LIT when the relay is disconnected NOT flashing LED L0B7 remains lit when its Punch I O PWB optical relay is disconnected Y N Reconnect the relay and go to S...

Page 96: ...utput active check for 24VDC supplied to the Back Gauge Solenoid by placing the meter leads across P J 4B 24VI and P J 4B OUTB7 There is 24VDC across these points Y N Replace the Punch I O PWB PL3 1 Check continuity and shorts to ground in the harness between the P J 4B on the Punch I O PWB and the Back Gauge Solenoid The harness is open or shorted to ground Y N Replace the Back Gauge Solenoid PL ...

Page 97: ...ition 4 33 ADJ 5 3 Tapper Assembly 4 34 ADJ 5 4 Bypass Gate Solenoid and Gate Fingers 4 35 ADJ 5 5 Bypass Motor Timing Belt Tension 4 36 Introduction The Section Contents gives references for all procedures in the repair section The repair section contains removal and replacement procedures If a part procedure cannot be found in this section it means that removal or replacement is supported by the...

Page 98: ...C Distribution PWB P1 AC Receptacle Line Filter P2 24 VDC Power Supply PWB CN1 P4 24 VDC Power Supply PWB CN2 P6 Punch Interlock High P8 Document Transport Motor P9 Punch Motor P11 Punch I O PWB P J 30 P12 Punch I O PWB P J 28 P14 Stacker AC DC Distribution PWB P J 14 P15 Punch I O PWB P J 29 3 Remove the 4 Allen Head Cap screws and the Punch AC DC Distribution PWB Replacement 1 Reinstall the part...

Page 99: ...component damage Removal 1 Remove 2 Allen Head Cap screws to remove Access Plate 2 Remove 6 Hex Nuts and Lock Washers 3 Disconnect the LCD Display Connector and the Keypad Connector 4 Remove the 4 Allen Head Cap screws from the LCD Display PWB Replacement 1 Reinstall the components in the reverse order NOTE Make sure that the white wire on the connector going to the Button Flat Cable is not connec...

Page 100: ...n Head Cap screws and the Little Star Controller PWB 5 Remove the EPROM and the RAM chip from the old PWB Replacement 1 Install the EPROM and the RAM chip with the notch on the chips aligned with the notch on the socket 2 Compare the Jumpers on the existing PWB with the Jumpers on the new PWB Install Jumpers to configure the new PWB 3 Reinstall the components in the reverse order BLACK GREEN 1 JP6...

Page 101: ...Center Crowned Rollers with Isopropyl alcohol and then install the new Front and Center Swing Frame Flat Belts 8 Slide the 2 Drive Shafts towards the front of the machine through the Bearing Collars and the Crowned Rollers 9 Loosen the Locking Handles and lower the Swing Frame Assembly 10 Slide the 2 Drive Shafts further to the front of the machine to remove the Swing Frame Rear Flat Belt 11 Clean...

Page 102: ...eft loosen 5 1 the 4 setscrews in the 4 Bearing Collars 5 2 the 5 setscrews in the 5 Crowned Rollers 6 Loosen the Allen Head Cap screw on the Document Transport Timing Belt Take Up Assembly and remove the Document Transport Timing Belt NOTE All Crowned Rollers are mounted on a flat surface on the Drive Shaft Ensure that the Rollers slide without obstructions on the Drive Shafts 7 Slide the 2 Drive...

Page 103: ...he Document Transport Flat Belt NOTE Before replacing the Belt clean the surface of the Crowned Rollers with Isopropyl alcohol Replacement 1 Replace the Document Transport Flat Belt 2 Install the Document Transport Flat Belt Assembly Tighten the 4 Allen Head Cap screws 3 Move the Flex Coupler onto the Shaft 4 Ensure that the two Shafts extend into the Coupler the same distance but not more than 0 ...

Page 104: ...6 1 the 4 setscrews in the 4 Bearing Collars on the 2 Punch Drive Shafts Figure 2 6 2 the 6 setscrews in the 6 Crowned Rollers Figure 1 6 3 the 2 setcrews in the 2 Rubber Drive Rollers Figure 1 6 4 the 2 setscrews in the Punch Output Drive Timing Belt Pulley Figure 3 NOTE Ensure that the setscrews in the Punch Output Timing Belt Pulley are loosened enough to clear the round part of the shaft All C...

Page 105: ...s in the 2 Rubber Drive Rollers and the 6 setscrews in the 6 Crowned Rollers 4 Adjust the Punch Infeed Timing Belt Idler Pulley Assembly to take up the tension in the Timing Belt If tightened too much the belt may walk off the pulley If too loose the belt may skip 5 Perform ADJ 4 1 Document Transport Timing Belt Tension before turning the machine on again NOTE Ensure that the setscrews in the Crow...

Page 106: ...GBC FusionPunch II Service Manual REP 4 4 Punch Infeed Timing Belt 12 2003 4 10 This Page Intentionally Left Blank ...

Page 107: ...he Female Latch Assembly Figure 2 2 4 the 4 Allen screws in the Deck Plates 3 Remove the Punch Infeed Flat Belts by sliding them off the Punch Infeed Deck towards the back of the machine 4 Clean the Crowned Rollers with Isopropyl alcohol Replacement 1 Install the new Punch Infeed Flat Belts 2 Reinstall the parts in reverse order NOTE Ensure that the setscrews in the Crowned Rollers are properly ti...

Page 108: ...ugh the hole in the frame and secure them in the back of Stacker 1 1 7 Unlatch Stacker 1 and push the Stacker s aside 2 Remove the Punch Right Panel 10 screws 3 Remove the Die Set 4 Remove 4 1 the Allen Head Cap screw and 3 Washers on the Front Punch Crank Arm Figure 1 4 2 the Front Punch Crank Arm Figure 1 5 Remove the Roll Pin in the Front Crank Arm Block Figure 1 6 Remove the Front Crank Arm Bl...

Page 109: ...Crank Arm Block when tightening the Allen Head Cap screw on the Crank Arm Failure to do so might result in damage to the new Punch Clutch Output Timing Belt Check that the Stacker s are level with the Punch and that the Stacker s are resting on the Leveling Pads see Section 8 Install Procedure BEARING COLLARS 2 SHAFT ALLEN HEAD CAP SCREWS 2 WASHERS 4 ANTI ROTATION SCREW PULLEY PUNCH CLUTCH OUTPUT ...

Page 110: ...Clutch Assembly out of the machine 4 Remove the Punch Clutch Timing Belt Replacement 1 Replace the Punch Clutch Timing Belt 2 Reinstall the parts in reverse order 3 Before reinstalling the Punch Right Panel perform ADJ 4 4 Punch Clutch Home Position NOTE Check that the Stacker Stackers are level with the Punch and that the Stacker s are resting on the Leveling Pads see Section 8 Install Procedure ...

Page 111: ...hers holding the Punch Motor 5 Remove the Punch Clutch Timing Belt from the Punch Motor Pulley and slide the Punch Motor out of the Punch Main Assembly 6 Remove the Punch Motor Pulley from the old Punch Motor and install it on the new Punch Motor Replacement 1 Reinstall the parts in reverse order 2 Perform ADJ 5 4 Punch Clutch Timing Belt Tension Make sure that the Punch Motor Cable Assembly is be...

Page 112: ...onnectors for the Document Transport Motor Cable Assembly 5 Record the location of the wires and then remove the connectors from the Document Transport Motor 6 Remove the 4 Carriage screws the 4 Hex Nuts and the 8 Washers holding the Document Transport Motor 7 Remove the Punch Motor Pulley from the old Punch Motor and install it on the new Punch Motor Replacement 1 Reinstall the parts in reverse o...

Page 113: ...he 2 V pulleys Figure 2 4 2 the 2 setscrews in the 2 Clamp Collars Figure 2 4 3 the setscrew in the Clamp Collar holding the O ring Drive Belt Pulley Figure 1 5 Remove the e clip Figure 2 6 Slide the Transfer Shaft towards the back of the machine and remove the Stacker Drive O ring from that Shaft Figure 2 7 Slide the Drive Shaft towards the front of the machine until you can remove the O ring fro...

Page 114: ...lding the Bypass Gate Solenoid connector and disconnect the Bypass Gate Solenoid connector Figure 3 4 Remove the 2 Allen screws and the 2 Lock Washers holding the Sensor Bracket Figure 2 5 Gently move the Sensor Bracket and Exit Sensor Assy to the side without unplugging the Exit Sensor 6 Remove the 2 Allen Head Cap screws 2 Lock Washers and 2 Flat Washers holding the Bypass Assy Figure 3 7 Gently...

Page 115: ...P 5 2 Bypass Assy removal GBC FusionPunch II Service Manual 12 2003 4 19 REP 5 2 Bypass Assy removal continued Figure 3 ALLEN HEAD CAP SCREWS 2 LOCK WASHERS 2 FLAT WASHERS 2 BYPASS GATE SOLENOID CONNECTOR ...

Page 116: ... Figure 1 4 Remove the 2 Allen Head Cap screws and 2 Lock Washers holding the Bypass Gate Solenoid Mounting Bracket Figure 1 5 Remove the Bypass Gate Solenoid from the Bypass Gate Solenoid Mounting Bracket Figure 1 2 Hex Nuts and 2 Lock Washers Replacement 1 Reinstall the parts in the reverse order NOTE Ensure that the Spur Gear on the Solenoid and the Spur Gear on the Deflector Shaft are properly...

Page 117: ...ure 1 3 Loosen 3 1 the 7 Allen screws in the 7 Gate Fingers 3 2 the Allen screw in the Bearing Collar Figure 1 NOTE Ensure that the setscrews in the Gate Fingers are loosened enough to clear the round part of the shaft 4 Remove the Bearing Collar 5 Slide the Bypass Gate Shaft towards the back of the machine until you can remove the Gate Fingers Figure 1 Replacement 1 Reinstall the parts in the rev...

Page 118: ...otor Pulley and remove the Bypass Motor Pulley Figure 1 6 Remove the 4 Allen Head Cap screws and 4 Lock Washers holding the Bypass Motor Cover Figure 1 7 Gently slide the Bypass Motor Cover to the side 8 Disconnect the Bypass Motor Harness from the Bypass Motor connection Figure 2 9 Remove the 4 Hex Nuts 4 Lock Washers and 4 Flat Washers holding the Bypass Motor Figure 1 NOTE Be aware that after r...

Page 119: ... the Drive Shaft next to the Clamp Collar Figure 1 5 Loosen 6 1 the 3 Allen screws in the 3 Rubber Drive Rollers Figure 1 6 2 the 2 Allen screws in the 2 Clamp Collars Figure 1 6 Remove the E ring on the Drive Shaft Figure 1 7 Slide the Drive Shaft towards the front of the machine 8 Remove the Bypass Flat Belt 9 Clean the Idler Rollers with Isopropyl alcohol Replacement 1 Reinstall the parts in th...

Page 120: ...gure 1 4 Loosen 4 1 the 2 Allen screws in the Timing Belt Pulley Figure 1 4 2 the 3 Allen screws in the 3 Rubber Drive Rollers Figure 1 4 3 the 2 Allen screws in the 2 Clamp Collars Figure 1 5 Remove 5 1 the Timing Belt Pulley Figure 1 5 2 the E ring Figure 1 6 Slide the Drive Shaft towards the front of the machine 7 Clean the Idler Rollers with Isopropyl alcohol Replacement 1 Reinstall the parts ...

Page 121: ...2 Place the Bypass Assy upside down Figure 1 3 Remove the 4 Allen Head Cap screws and the 4 Lock Washers holding the 2 Nut Plates Figure 1 NOTE Do not loosen the Hex Nuts on the Spring Adjustment screws Replacement 1 Reinstall the parts in the reverse order 2 Perform ADJ 5 5 Bypass Motor Timing Belt Tension Figure 1 NUT PLATES 2 ALLEN HEAD CAP SCREWS 4 LOCK WASHERS 4 HEX NUT AND SPRING ADJUSTMENT ...

Page 122: ...t the Document Transport Timing Belt operates smoothly and deflects 0 25 in 6 mm Adjust Sequence 1 Loosen the Allen Head Cap screw in the Idler 2 Adjust the Idler until the Document transport Timing Belt deflects 0 25 in 6 mm 3 Tighten the Allen Head Cap screw in the Idler NOTE If the belt skips tension is too loose If the Power Switch Circuit Breaker blows tension is too tight Figure 1 0 25 in 6 ...

Page 123: ...x 3 4 mm 2 To adjust slightly loosen the 2 Allen Head Cap screws and raise or lower the Sheet Eject Idler Rollers until the distance is equal between the back and front rollers 3 Manually press the Sheet Eject Idler Rollers down so that they touch the Rubber Drive Rollers Make sure that the Idler Rollers are centered over the Rubber Drive Rollers 4 To adjust slightly loosen the 2 Allen Head Cap sc...

Page 124: ...the GBC Cerlox Adjust Sequence WARNING Switch off the main power Disconnect the Power Cord 1 Rotate the Back Gauge Stop Adjustment Knob until the Cam is in the minimum position Figure 1 2 Loosen the setscrew in the Back Gauge Stop Collar Figure 1 3 Rotate the Back Gauge Gear until the Back Gauge Fingers are against the GBC Die Set if GBC Die Set is available Figure 2 4 Hold the Back Gauge Fingers ...

Page 125: ...wer Cord 1 Move the Retaining Ring toward the Pulley Figure 3 2 Move the Clutch Housing toward the Pulley Figure 3 3 Rotate the Clutch Housing a couple of teeth according to figure 3 to achieve the Top Dead Center 1 specifications shown in figure 2 4 Slide the Retaining Ring all the way back into the grove on the Punch Clutch to secure the Punch Clutch Housing 5 Check the over travel and then retu...

Page 126: ... 1 and 2 Check Check the Clutch actuation Adjust Sequence 1 Rotate the Punch Clutch Housing at the same time as you press the Punch Stop Pawl 2 Check the clearance between the Punch Clutch Stop Pawl and both stops on the Punch Clutch Housing Figure 2 3 With the Stop Pawl pressed in rotate the Eccentric Stop until the clearance between the Stop Pawl and the Punch Clutch Housing Stops are 0 05 in 0 ...

Page 127: ...lt from wearing down and or damaging the Punch Motor Prerequisite Perform REP 4 6 Steps 1 and 2 Check Check that the Punch Clutch Timing Belt operates smoothly and deflects 0 10 in 2 3 mm Also check alignment of the Punch Clutch Pulley and the Punch Motor Pulley Adjust Sequence 1 Slightly loosen the 4 Hex Nuts under the Punch Motor 2 Slide the Punch motor backward or forward until the Punch Clutch...

Page 128: ...ring Assembly PL 5 1 C NOTE Keep the washer on the top of the Stacker O ring Assembly 2 Loosen the two screws 3 Press down and hold the Front Roller 4 Adjust the O Ring Roller Ski until the Ski is at the same height or just below the Roller 5 Tighten the two screws 6 Rotate the O Ring Roller Ski upwards to an 45 angle 7 Retighten the two screws to ensure that they do not work loose WASHER FRONT RO...

Page 129: ...mbly Figure 2 2 To adjust the Stacker Tray Stop position turn the screw clockwise to decrease the measured distance or counterclockwise to increase the measured distance Figure 2 3 Press RAISE LOWER STACKER 1 or 2 if a second Stacker is installed and needs to be adjusted on the Control Panel once to lower the Stacker Tray and once again to raise the Stacker Tray 4 Recheck the adjustment 5 Repeat s...

Page 130: ... the Stacker Tray to its maximum up position 2 Enter Diagnostics GP 1 open Stacker Top Cover and install a cheater in the Interlock Switch 3 Go to Stacker 1 or Stacker 2 Output Test and activate location Stacker 1 Stacker 2 S1 OUTB8 Stacker Tap 016 1000000000000100 S2 OUTB8 Stacker Tap 016 1000000000000100 4 Loosen the setscrew in the Gear on the Tapper Solenoid 5 Rotate the Tapper Shaft clockwise...

Page 131: ...ker Rear Panel 2 Loosen the Allen screw in the Bypass Gate Solenoid Spur Gear 3 Manually raise or lower the Gate Fingers until they are just below the out feed slot in the Punch or Stacker Right Panel 4 Tighten the Allen screw in the Bypass Gate Solenoid Spur Gear 5 Go to Stacker 1 or Stacker 2 Output Test and activate location Stacker 1 Stacker 2 S1 OUTB5 Stacker Gate 013 1000000000000100 S2 OUTB...

Page 132: ...maging the Bypass Motor Check Check that the Bypass Motor Timing Belt operates smoothly and deflects 0 10 in 2 3 mm Check the alignment of the Bypass Motor Pulley and the Timing Belt Pulley Adjust sequence 1 Perform REP 5 5 Bypass Motor and Timing Belt Steps 1 to 3 2 Slide the Bypass Motor up or down until the Bypass Motor Timing Belt deflects 0 10 in 2 3 mm 3 Tighten the 4 Hex Nuts Figure 1 HEX N...

Page 133: ...nsion Strap Assy 90 PL 5 1 A Stacker Assy 92 PL 5 1 B Stacker Assy 94 PL 5 1 C Stacker Assy 96 PL 5 1 D Stacker Assy 98 PL 5 2 A Bypass Stacker Assy 100 PL 5 2 B Bypass Stacker Assy 102 PL 5 2 C Bypass Stacker Assy 104 PL 5 2 D Bypass Stacker Assy 106 PL 6 1 A Punch I O PWB Cable Assy 108 PL 6 1 B Punch AC DC PWB Power Supply PWB s Cable Assy 110 PL 6 1 C Punch Interlock Rear Panel Cable Assy 112 ...

Page 134: ...GBC FusionPunch II Service Manual PL 1 1 A Punch Main Assy 12 2003 5 2 PL 1 1 A Punch Main Assy AHQ 1 2 ANE CG 4 3 6 5 6 ITEM 1 REFER TO PL 4 1 A G PL 1 1A 7610201 C1 2 ...

Page 135: ...ace refer to PL 4 1 A G NA 2 7610599 Enclosure Punch Assy 1 3 7610470 Cable Assy Punch Interlock High 1 4 7610471 Cable Assy Punch Interlock Low 1 5 7610472 Cable Assy Punch Interlock Jumpers 1 6 7610501 Switch Punch Interlock Xerox Part Number 110P2340 5 AHQ 1925061 Washer Flat 1 4 4 ANE 1926064 Washer Lock 1 4 4 CG 1980098 SHCS 1 4 20 x 1 4 ...

Page 136: ...GBC FusionPunch II Service Manual PL 1 1 B Punch Main Assy 12 2003 5 4 PL 1 1 B Punch Main Assy 3 BJW 2 1 ANT AFB ANF PL 1 1B 7610201 C1 3 ...

Page 137: ...rt Description Qty 1 7610418 Motor 115 VAC 60 HZ Document Transport 1 2 7610425 Motor 230 VAC 50 HZ Document Transport 1 3 7610473 Cable Assy Document Transport Motor 1 BJW 1914721 Carriage Screw 5 16 18 X 1 1 4 4 AFB 1925001 Washer Flat 5 16 4 ANF 1926065 Washer Lock 5 16 4 ANT 1926706 Nut Hex 5 16 18 4 ...

Page 138: ...GBC FusionPunch II Service Manual PL 1 1 C Punch Main Assy 12 2003 5 6 PL 1 1 C Punch Main Assy CG AHQ ANE AHQ CE ANE AHQ CE ANE 1 2 2 ITEM 1 REFER TO PL 4 2 A E PL 1 1C 7610201 C1 4 ...

Page 139: ... 1 1 C Punch Main Assy Item Part Description Qty 1 7610380 Assy Document Transport refer to PL 4 2 A E 1 2 0130003500 Plate Interface Document Transport 2 AHQ 1925061 Washer Flat 1 4 6 ANE 1926064 Washer Lock 1 4 6 CE 1980096 SHCS 1 4 20 x 3 4 4 CG 1980098 SHCS 1 4 20 x 1 2 ...

Page 140: ...onPunch II Service Manual PL 1 1 D Punch Main Assy 12 2003 5 8 PL 1 1 D Punch Main Assy CE ANE AHQ ITEM 1 REFER TO PL 4 3 A N CG ANE AHQ CE ANE AHQ z ANB AHS ANB AA 1 4 4 ANB 2 3 AA AHQ AQQ PL 1 1D 7610201 C1 5 ...

Page 141: ... Rail Punch Slide Assy 1 3 7610415 Rail Linear Punch Slide Support 1 4 7610189 Bearing Pillow Block Punch Slide Assy 2 AHQ 1925061 Washer Flat 1 4 8 AHS 1925063 Washer Flat 6 6 ANB 1926061 Washer Lock 6 14 ANE 1926064 Washer Lock 1 4 6 AQQ 1927300 Nut Jam 1 4 20 2 Z 1980029 SHCS 6 32 x 1 2 6 AA 1980030 SHCS 6 32 x 5 8 8 CE 1980096 SHCS 1 4 20 x 3 4 4 CG 1980098 SHCS 1 4 20 x 1 2 ...

Page 142: ...GBC FusionPunch II Service Manual PL 1 1 E Punch Main Assy 12 2003 5 10 PL 1 1 E Punch Main Assy NT NT 6 4 1 3 1 5 2 1 PL 1 1E 7610201 C1 6 ...

Page 143: ...L 1 1 E Punch Main Assy Item Part Description Qty 1 7610112 Knob Punch Assy 3 2 7610435 Label Die Lock Knob 1 3 7610436 Label Back Gauge Knob 1 4 7610437 Label Edge Guide Knob 1 5 7610439 Bucket Slug Punch Assy 1 6 1928203 Wing Nut Punch Assy 1 NT 1980505 FHCS 1 4 20 x 3 4 4 ...

Page 144: ...GBC FusionPunch II Service Manual PL 1 1 F Punch Main Assy 12 2003 5 12 PL 1 1 F Punch Main Assy ANF AFB 5 ANT 2 1 BJW BHE 4 3 PL 1 1F 7610201 C1 7 ...

Page 145: ...unch Motor 1 2 0130039100 Pulley 17 Tooth 230 VAC 50 HZ Punch Motor 1 3 7610418 Motor 115 VAC 60 HZ Punch 1 4 7610425 Motor 230 VAC 50 HZ Punch 1 5 7610474 Cable Assy Punch Motor 1 BJW 1914721 Carriage Screw 5 16 18 X 1 1 4 4 AFB 1925001 Washer Flat 5 16 4 ANF 1926065 Washer Lock 5 16 4 ANT 1926706 Nut Hex 5 16 18 4 BHE 1932705 Collar Split Lock Punch Motor Pulley 1 ...

Page 146: ...GBC FusionPunch II Service Manual PL 1 1 G Punch Main Assy 12 2003 5 14 PL 1 1 G Punch Main Assy 1 2 1 4 3 5 PL 1 1G 7610201 C1 8 P1 P2 7 P5 6 P5 6 P5 ...

Page 147: ...P1 2 2 7610521 Shaft Document Transport Main Drive Tag P2 1 3 7610743 Pulley 15 Tooth Document Transport 115 VAC 60 HZ Motor 1 4 0130040200 Pulley 18 Tooth Document Transport 230 VAC 50 HZ Motor 1 5 1981350 Belt Timing Document Transport Main Drive 1 6 7610532 Pulley 48 Tooth Document Transport Main Drive 6060 iGen3 Tag P5 2 7 7610533 Belt Timing Document Transport Main Drive 6060 iGen3 Tag P5 1 ...

Page 148: ...nual PL 1 1 H Punch Main Assy 12 2003 5 16 PL 1 1 H Punch Main Assy AEF 9 4 AEF ANM 4 ANM 10 ANC REFER TO PL 2 1 ITEM 5 WRITE SERIAL NO IN UPPER RIGHT CORNER AEF 4 AEF 4 8 7 3 3 ANM 3 1 2 6 PL 1 1H 7610201 C1 12 5 P5 13 11 12 P5 P5 ...

Page 149: ...de Paper Input Panel 2 6 7610236 Label Tag Matrix 1 7 7610237 Label Punch Alingment 1 8 7610238 Backet Entrance Paper Guide 1 9 7610318 Brush Anti Static Punch R H Side Panel 2 10 7610440 Label LOGO 1 11 7610530 Paper Guide Entrance Top 6060 iGen3 Tag P5 1 12 7610531 Paper Guide Entrance Bottom 6060 iGen3 Tag P5 1 13 7610621 Panel Punch Entrance 4xxx 6060 iGen3 Tag P5 1 AEF 1911106 SEMS Screw 8 32...

Page 150: ...GBC FusionPunch II Service Manual PL 1 1 I Punch Main Assy 12 2003 5 18 PL 1 1 I Punch Main Assy AHS Z 2 ANY 1 6 8 ANB 5 3 7 4 ANA AHR PL 1 1I 7610201 C1 9 ...

Page 151: ... Power 1 3 7610464 Cable Assy Line Filter Power Switch 1 4 7610465 Cable Assy Power Switch AC DC Power Distribution PWB 1 5 7610500 Cable Assy DFA From Printer 1 6 1128416 Label Ground Symbol 1 7 6009160 Label Stacker On Off 1 8 7610228 Standoff Hex 4 40 2 AHR 1925062 Washer Flat 4 2 AHS 1925063 Washer Flat 6 2 ANA 1926060 Washer Lock 4 2 ANB 1926061 Washer Lock 6 2 ANY 1926711 Nut Hex 4 40 2 Z 19...

Page 152: ...2 A Stacker Main Assy 12 2003 5 20 PL 1 2 A Stacker Main Assy 3 AHS Z ANB 12 14 14 11 4 8 10 7 15 2 13 AQF 9 1 ITEM 15 REFER TO PL 5 1 A D 6 ANA AHR ANY LN ANB AHS 12 11 5 ITEM 5 REFER TO PL 5 1D AND BJ AHP AND AHP BJ PL 1 2A 7610001 C1 1 S2 ...

Page 153: ...in Power 1 9 7610464 Cable Assy Line Filter Power Switch 1 10 7610465 Cable Assy Power Switch AC DC Power Distribution PWB 1 11 7610485 Cable Assy Stacker Interlock Low 2 12 7610486 Cable Stacker Interlock High 2 13 7610500 Cable Assy Downstream DFA 1 14 7610501 Switch Stacker Interlock Xerox Part Number 11P2340 2 15 7611002 Assy Stacker refer to PL 5 1 A D 1 AHP 1925060 Washer Flat 10 4 AHR 19250...

Page 154: ... 2 B Stacker Main Assy AEF AHT AS ANC 2 AHP APT AND ANE AHQ ANV BV ALQ 5 AEF 1 AHT ANV ALQ CU ANC AS ANE AHQ 2 CAPACITOR INCLUDED WITH ITEM 2 4 GROUND WIRE OF ITEM 28 ON PL 1 2 C 1 GROUND WIRE OF ITEM 30 ON PL 1 2 C 5 CAPACITOR INCLUDED WITH ITEM 1 3 4 4 3 3 PL 1 2B 7610001 C1 1 ...

Page 155: ... Tray 1 4 7610195 Motor 230 VAC 50 HZ Stacker O ring 1 5 7610065 Collar Clamp Stacker Slide Assy 2 AEF 1911106 SEMS Screw 8 32 x 3 8 2 AHP 1925060 Washer Flat 10 4 AHQ 1925061 Washer Flat 1 4 4 AHT 1925064 Washer Flat 8 2 ALQ 1925903 Washer Star Lock 8 2 ANC 1926062 Washer Lock 8 2 AND 1926063 Washer Lock 10 4 ANV 1926708 Nut Hex 1 4 20 4 APT 1926730 Nut Hex 10 32 4 AS 1980051 SHCS 8 32 x 5 8 2 BV...

Page 156: ... A SEE DETAIL A BLACK WHITE R E D BLACK WHITE R E D STACKER TRAY MOTOR REFER TO PL 1 2 B FOR GROUND WIRE CONNECTION CAPACITOR INCLUDED WITH STACKER TRAY MOTOR 5 B L U E B R O W N R E D WHITE BLACK REFER TO PL 1 2 B FOR GROUND WIRE CONNECTION STACKER O RING MOTOR CAPACITOR INCLUDED WITH STACKER O RING MOTOR 6 DETAIL A REFER TO PL 1 2 B REFER TO PL 1 2 B S1 ...

Page 157: ...ey 18 Tooth Stacker O ring Motor Tag S1 1 2 7610045 Pulley Stacker Tray Motor 1 3 7610113 Cover Stacker O ring Motor 1 4 7610114 Cover Stacker Tray Motor 1 5 7610487 Cable Assy Stacker Tray Motor 1 6 7610488 Cable Assy Stacker O ring Motor 1 7 1952407 Strain Refief Stacker Cable Assy 2 ANC 1926062 Washer Lock 8 8 AM 1980046 SHCS 8 32 X 1 4 8 ...

Page 158: ...GBC FusionPunch II Service Manual PL 1 2 D Stacker Main Assy 12 2003 5 26 PL 1 2 D Stacker Main Assy AEF 1 1 AEF PL 1 2D 7610001 C1 3 ...

Page 159: ...PL 1 2 D Stacker Main Assy GBC FusionPunch II Service Manual 12 2003 5 27 PL 1 2 D Stacker Main Assy Item Part Description Qty 1 6009410 Label Re install Screw 2 AEF 1911106 SEMS Screw 8 32 x 3 8 2 ...

Page 160: ...NC AM 12 6 13 3 ANC AM ANC AM 10 ANA Q 8 11 9 ANC AM 14 2 ANC AM ANE APS 5 1 ANC AS AND BP 17 15 CU AHQ ANE CG 21 4 APT AND Y ANB ANE APS 20 CG 16 19 AND APT PL 1 3A Bypass Int 7610003 A1 5 BLUE RED BLACK WHITE BROWN BYPASS MOTOR CAPACITOR INCLUDED WITH ITEM 65 BYPASS MOTOR 17 5 18 18 ITEM 7 REFER TO PL 5 2 D 7 23 P5 ...

Page 161: ...13 7611951 Assy Bypass 1 14 7611956 Pulley Bypass Motor 1 15 7611969 Plate Bypass Motor 1 16 7611989 Pin Docking Bypass Assy 2 17 7611990 Motor Bypass 230V 1 18 7611991 Motor Bypass 115V 1 19 7611992 Bracket Docking LH Bypass Assy 1 20 7611993 Bracket Docking RH Bypass Assy 1 21 7611994 Bar Docking Bypass Assy 1 22 7610516 Cable Assy Downstream DFA Tag S3 1 23 7610534 Pulley 32 Tooth Bypass Motor ...

Page 162: ... 1 3 B Bypass Stacker Assy 12 2003 5 30 PL 1 3 B Bypass Stacker Assy AEF 5 CB ANE 1 3 4 2 AEF 8 6 ANM 4 10 7 AEF 3 AEF 9 PL 1 3B Bypass Int 7610003 B1 8 ITEM 5 WRITE SERIAL NO IN UPPER RIGHT CORNER BYPASS EXIT PANEL BYPASS ONLY 3 4 11 S1 ...

Page 163: ... Re install Screw 3 5 7610236 Label Tag Matrix Card 1 6 7610318 Brush Static Bypass Stacker Output 2 7 7610573 Panel Bypass Stacker Output 1 8 7610638 Panel Stacker Output 1 9 7610678 Pin Docking Top Alignment 2 10 7610679 Cover Plate Bypass Stacker Output Panel 1 11 7610680 Plate Docking Bypass Stacker Assy Tag S1 1 AEF 1911106 SEMS Screw 8 32 x 3 8 7 ANE 1926064 Washer Lock 1 4 2 ANM 1926701 Nut...

Page 164: ...GBC FusionPunch II Service Manual PL 2 1 A Control Panel Assy 12 2003 5 32 PL 2 1 A Control Panel Assy 1 2 ALQ 4 5 3 ANA ANM ET ANC AQF PL 2 1A 7610201 C1 12 ...

Page 165: ...273 Key Pad Control Panel 1 2 7610299 Plate Backer Control Panel Key Pad 1 3 7610459 LCD Display 1 4 7610495 Cable Assy Key Pad 1 5 7610496 Cable Assy LCD Display 1 ALQ 1925903 Washer Star Lock 8 1 ANA 1926060 Washer Lock 4 4 ANC 1926062 Washer Lock 8 4 ANM 1926701 Nut Hex 8 32 4 AQF 1926802 Nut Kep 8 32 1 ET 1980215 BHCS 4 40 X 1 4 4 ...

Page 166: ... Service Manual PL 3 1 Punch Electronic Assy 12 2003 5 34 PL 3 1 Punch Electronic Assy ANC 4 AP AP 8 2 ANC AHT 7 AHT 5 Q 3 ANA AHR AP ANC AHT AP ANC AHT AHT ANC AP 9 10 6 1 11 PL 3 1 7610201 C1 11 P1 12 P1 S3 S4 P5 P4 P5 ...

Page 167: ... Supply 1 6 7610457 PWB Little Star Controller Tag P1 S4 P4 P5 1 7 7610458 PWB Little Star Controller Expansion Tag P1 2 8 7610460 Relay DC Punch I O Opto 3 9 6009406 Label Electrical Shock Triangle 1 10 6009409 Label Earth Ground 1 11 7610729 Fuse 3A Slow Blow 3 12 7610508 Eprom with latest version programmed Tag P1 S4 P4 P5 1 AHR 1925062 Washer Flat 4 8 AHT 1925064 Washer Flat 8 23 ANA 1926060 W...

Page 168: ...ectronic Assy 12 2003 5 36 PL 3 2 Stacker Electronic Assy 1 8 7 ANC AS 9 4 5 6 Z 2 ANB AHS Z AHS ANB AHS ANB Z 3 J7 J8 P8 P7 10 NOTE ITEM 3 4 USE THE SAME FUSE BUT ITEM 4 OPTO RELAY HAS AN AC OUPUT AND ITEM 3 HAS A DC OUTPUT PL 3 2A1 7610001 C1 3 S3 P5 ...

Page 169: ...y DC Stacker I O Opto 1 4 7610461 Relay AC Stacker AC DC Distribution Opto 1 5 7610487 Cable Assy Stacker Tray Motor 1 6 7610488 Cable Assy Stacker O ring Motor 1 7 6009406 Label Electrical Shock Triangle 1 8 6009409 Label Earth Ground 1 9 1952407 Strain Relief 2 10 7610729 Fuse 3A Slow Blow 2 AHS 1925063 Washer Flat 6 10 ANB 1926061 Washer Lock 6 10 ANC 1926062 Washer Lock 8 1 Z 1980029 SHCS 6 32...

Page 170: ...onics Assy 12 2003 5 38 PL 3 3 Bypass Stacker Electronics Assy 5 3 2 1 8 9 10 6 7 P8 P7 13 NOTE ITEM 7 8 USE THE SAME FUSE BUT ITEM 7 OPTO RELAY HAS AN AC OUPUT AND ITEM 8 HAS A DC OUTPUT PL 3 3A Bypass Int 7610003 A1 7 11 12 BYPASS ONLY BYPASS ONLY 4 AS ANC S3 P5 ...

Page 171: ... 2 5 7610450 PWB Stacker AC DC Power Distribution 1 6 7610529 PWB Stacker I O Tag S3 P5 1 7 7610460 Relay DC Stacker I O Opto 8 8 7610461 Relay AC Stacker AC DC Distribution Opto 1 9 7610487 Cable Assy Tray Motor 1 10 7610488 Cable Assy O Ring Motor 1 11 7610503 Cable Assy Bypass Motor 1 12 7610505 Cable Assy Stacker 1 AC DC Distribution PWB P J 13 Stacker 2 AC DC Distribution PWB P J 14 1 13 7610...

Page 172: ...ice Manual PL 4 1 A Swing Frame Assy 12 2003 5 40 PL 4 1 A Swing Frame Assy REFER TO PL 4 1 B 12 SE 11 10 2 3 NT NT BL FF 4 SE 11 11 SE 3 NT 1 BL NT 4 15 14 BJ 5 13 SE 11 FF FF 6 9 8 FF 7 FF PL 4 1A 7610378 Assy Inteface MOD ...

Page 173: ...ame R H 1 7 0130013100 Deck Swing Frame R H Center 1 8 0130013200 Deck Swing Frame L H Center 1 9 0130013300 Deck Swing Frame L H 1 10 0130015100 Shaft Swing Frame Exit 1 11 0130002200 Roller Crowned Swing Frame 8 12 0130016400 Sensor Mounting Bracket Entrance 1 13 7610372 Belt Flat Swing Frame 06 x 1 x 27 Endless 3 14 7610423 Sensor Entrance 1 15 1951309 Connector Entrance Sensor 1 SE 1900028 SHS...

Page 174: ...I Service Manual PL 4 1 B Interface Assy 12 2003 5 42 PL 4 1 B Interface Assy FF 6 1 CG AHQ ANE AHQ CG ANE 7 8 11 8 10 SE 11 10 SE 8 9 CG ANE AHQ CG ANE AHQ CG ANE AHQ 1 2 FF 5 FF 4 3 PL 4 1B 7610378 Assy Interface MOD ...

Page 175: ...rface Center 1 5 0130013700 Deck Interface L H 1 6 7610326 Assy Interface Side Frame L H 1 7 0130003600 Shaft Interface Exit 1 8 0130002100 Assy Roller Interface 4 9 7610324 Assy Interface Side Frame R H 1 10 0130017800 Roller Crowned Interface Exit 2 11 7610371 Belt Flat Interface 06 x 1 x 14 4 Endless 2 SE 1900028 SHSS 10 32 x 3 16 2 AHQ 1925061 Washer Flat 1 4 20 ANE 1926064 Washer Lock 1 4 20 ...

Page 176: ... 4 1 C Swing Frame Interface Assy 12 2003 5 44 PL 4 1 C Swing Frame Interface Assy 3 LEFT SIDE KNOB ASSY DETAIL A DETAIL B REF B SEE DETAIL A SEE DETAIL REF 2 6 4 AJD AHU 5 CD ANE CD ANE 5 AHU 1 6 4 AJD PL 4 1C 7610378 Assy Interface MOD ...

Page 177: ...1900 Assy L H Swing Frame 1 2 0130022000 Assy R H Swing Frame 1 3 0130015100 Shaft Swing Frame Exit 1 4 0130007100 Extension Small 2 5 0130014800 Strap Nut Swing Frame 2 6 7610407 Handle Interface Adjustable 5 16 1 8 THD 2 AHU 1925065 Washer Flat 3 8 2 AJD 1925184 Washer Flat Extra Thick 3 8 2 ANE 1926064 Washer Lock 1 4 2 CD 1980095 SHCS 1 4 20 x 5 8 2 ...

Page 178: ...anual PL 4 1 D Swing Frame Interface Assy 12 2003 5 46 PL 4 1 D Swing Frame Interface Assy AJN ITEM 3 REFER TO PL 4 1 F ITEM 4 REFER TO PL 4 1 G 2 ACQ 4 5 BAX FU AND BM AHT AND BM AHT ACQ 1 AJN 3 PL 4 1D 7610378 Assy Interface MOD ...

Page 179: ...700 Assy Pivot Block L H 1 3 7610341 Assy Ball Track Swing Frame refer to PL 4 1 F 1 4 7610325 Assy Ball Track Interface refer to PL 4 1 G 1 5 7610303 Refeed Deck 1 ACQ 1903026 Truss Head Screw PH 10 32 x 1 2 4 AHT 1925064 Washer Flat 8 4 AJN 1925203 Washer Flat Non Metallic 2 AND 1926063 Washer Lock 10 4 BAX 1960509 Loctite 0 001 BM 1980075 SHCS 10 32 x 3 4 4 FU 1980256 BHCS 8 32 x 3 8 3 ...

Page 180: ...onPunch II Service Manual PL 4 1 E Swing Frame Interface Assy 12 2003 5 48 PL 4 1 E Swing Frame Interface Assy BFF 1 FU FU 7 1 5 1 4 BFF 3 AS 2 BM AHP AND 6 BM AHP AND AJN AJN PL 4 1E 7610378 Assy InterfaceMOD ...

Page 181: ...023000 Assy R H Interface Idler Arm Short 1 4 7610267 Shaft Interface Idler Arm Long 1 5 7610427 Bracket Static Brush Interface 1 6 7610377 Handle Aluminum Interface Idler Assy 1 7 7610402 Brush Anti static Interface 1 AJN 1925203 Washer Flat Non Metallic 4 BFF 1925307 Spacer 1 4 x 3 4 x 3 4 2 AHP 1925060 Washer Flat 10 4 AND 1926063 Washer Lock 10 4 AS 1980051 SHCS 8 32 x 5 8 2 BM 1980075 SHCS 10...

Page 182: ...Service Manual PL 4 1 F Swing Frame Ball Track Assy 12 2003 5 50 PL 4 1 F Swing Frame Ball Track Assy Y 5 AQS Y 6 8 ANT ANF AFB 9 ACQ ACQ 2 ACQ 7 1 3 AFB ANT ANF AND BM 4 9 Y Y PL 4 1F 7610341 Assy Swing Frame Ball Track ...

Page 183: ...rame Ball Track Short 3 5 0130014100 Cover Swing Frame Ball Track Long 2 6 0130014300 Cover Swing Frame Ball Track Reflector Bracket 1 7 7610374 Ball Delrin 24 8 7610365 Reflector Coner Cube Entrance Sensor 1 9 7610360 Plunger Spring Bolt 2 ACQ 1903026 Truss Head Screw 10 32 x 1 2 6 AFB 1925001 Washer Flat 5 16 2 ANF 1926065 Washer Lock 5 16 2 AND 1926063 Washer Lock 10 6 ANT 1926706 Nut Hex 5 16 ...

Page 184: ...nPunch II Service Manual PL 4 1 G Interface Ball Track Assy 12 2003 5 52 PL 4 1 G Interface Ball Track Assy AHP AND BM 1 2 3 4 PL 4 1G 7610325 Assy Interface Ball Track AHT ANC AT AHT ANC AT AHP AND BM P1 P1 P1 ...

Page 185: ...0014700 Tie Bar Interface Ball Track Assy Tag P1 1 2 7610248 Interface Ball Track 2 3 7610224 Guide Paper Interface Left Tag P1 1 4 7610225 Guide Paper Interface Right Tag P1 1 AHP 1925060 Washer Flat 10 4 AHT 1925064 Washer Flat 8 4 ANC 1926062 Washer Lock 8 4 AND 1926063 Washer Lock 10 4 AT 1980052 SHCS 8 32 x 3 4 4 BM 1980075 SHCS 10 32 x 3 4 4 ...

Page 186: ...A Document Transport Assy 5 CG ANE AHQ AJC CT AHQ ANE CG CG ANE AHQ CE ANE AHQ 2 6 ARW ANV ANE AHQ 4 T AHR Y ANB AHS 1 10 CE ANE AHQ AHQ ANE CG AHQ ANE CG 11 12 2 AHQ ANE CF AHQ ANE CG T 10 3 AHR 9 4 AHQ ANE CG SEE DETAIL A 8 7 DETAIL A PL 4 2A 7610380 Assy Documant Transport MOD 9 13 P5 ...

Page 187: ...1 2 1 9 0130021500 Assy Belt Take Up Document Transport Timing Belt 2 10 7610421 Sensor Document Transport 1 2 2 11 7610287 Latch Block Document Transport 1 12 7610367 Latch Female Document Transport 1 13 7610537 Assy Belt Take Up Document Transport Timing Belt 6060 iGen3 Tag P5 1 AHQ 1925061 Washer Flat 1 4 21 AHR 1925062 Washer Flat 4 4 AHS 1925063 Washer Flat 6 2 AJC 1925183 Washer Flat Extra T...

Page 188: ...nPunch II Service Manual PL 4 2 B Document Transport Assy 12 2003 5 56 PL 4 2 B Document Transport Assy 1 FF AHQ ANE CB 3 2 REFER TO PL 4 2 D ITEM 3 REFER TO PL 4 2 D PL 4 2B 7610380 Assy Document Transport MOD ...

Page 189: ...port Assy Item Part Description Qty 1 7610428 Deck Document Transport 1 2 0130015500 Shield Document Transport Belt Assy 1 3 0130021200 Assy Document Transport Belt refer to PL 4 2 D 1 AHQ 1925061 Washer Flat 1 4 7 ANE 1926064 Washer Lock 1 4 7 CB 1980094 SHCS 1 4 20 x 1 2 7 FF 1980233 BHCS 6 32 x 1 2 9 ...

Page 190: ...GBC FusionPunch II Service Manual PL 4 2 C Document Transport Assy 12 2003 5 58 PL 4 2 C Document Transport Assy AHQ 1 CE ANE ITEM 1 REFER TO PL 4 2 E PL 4 2C 7610380 Assy Document Transport MOD ...

Page 191: ...ch II Service Manual 12 2003 5 59 PL 4 2 C Document Transport Assy Item Part Description Qty 1 7610358 Assy Document Transport Ball Track refer to PL 4 2 E 1 AHQ 1925061 Washer Flat 1 4 4 ANE 1926064 Washer Lock 1 4 4 CE 1980096 SHCS 1 4 20 x 3 4 4 ...

Page 192: ...ment Transport Flat Belt Assy 12 2003 5 60 PL 4 2 D Document Transport Flat Belt Assy FF BJ BJ BJ 6 7 5 SE 8 2 3 8 AHQ ANE CB AHQ ANE CB AHQ 3 2 8 SE 7 4 10 1 CB ANE AHQ CE ANE AHQ CB ANE AHQ 9 ANE CE 8 PL 4 2 D0130021200 Assy Document Transport MOD ...

Page 193: ...rt Belt Assy 1 5 0130006200 Deck Rail Document Transport Belt Assy 1 6 0130005100 Bracket Seperator Document Transport Belt Assy 2 7 0130017800 Roller Crowned Document Transport Belt Assy 2 8 7610346 Bearing w Collar 1 2 4 9 7610357 Coupling Flex Beam Document Transport Belt Assy 1 10 7610373 Belt Flat Document Transport 06 x 1 x 36 75 endless 1 SE 1900028 SHSS 10 32 x 3 16 2 AHQ 1925061 Washer Fl...

Page 194: ...03 5 62 PL 4 2 E Document Transport Ball Track Assy 6 CD ANE AHQ 14 AS ANC AHT 7 10 ANB Z Z ANB AHS 8 12 2 11 1 ANB Z 3 ANC AV AHS AHT ANB Z AHS ANB Z AHS AV 4 ANM ANB Z 9 13 7 5 AND BM AHP ANC AS AHT ANE CD AHQ 14 10 BM AND AHP 15 16 PL 4 2E 7610358 Assy Doc Trans Ball Track P1 P1 P1 ...

Page 195: ...Paper Guide Document Transport Short 1 10 7610365 Reflector Document Transport Sensor 1 and 2 2 11 7610374 Ball Delrin Tag P1 10 12 7610375 Ball Steel Tag P1 2 13 7610377 Handle Aluminum Document Transport Ball Track Assy 1 14 7610376 Hinge Plastic Document Transport Ball Track Assy 2 15 7610367 Latch Male Document Transport Assy 1 16 7610239 Guide Paper Document Transport Rail 1 AHP 1925060 Washe...

Page 196: ... CE 14 ANE SEE DETAIL A BJ AND AHP 9 8 12 CE AHQ ANE BDM 10 CE ANE AHQ 2 5 7 1 3 ANE CE AHQ ARG AKR 6 2 4 AKZ ARG ANE CE AHQ ANE CE AHQ ANE CE AHQ ITEM 3 REFER TO PL 4 3 I ITEM 5 REFER TO PL 4 3 K DETAIL A ITEM 7 REFER TO PL 4 3 K DETAIL C ITEM 6 REFER TO PL 4 3 K DETAIL B 15 PL4 3A 7610382 Assy Punch ...

Page 197: ...m refer to PL 4 3 K Detail C 1 8 0130019400 Shaft Back Gauge 1 9 0130031100 Finger Back Gauge 3 10 7610337 Assy Slug Chute 1 11 0130031400 Cross Plate Punch Assy 1 12 0130026900 Assy Slug Plate 1 13 7610423 Sensor Punch 1 14 7610393 Strap Bracket Punch Sensor Assy 1 15 7610447 Bracket Punch Crank Arm Non Op Side 1 BDM 1924818 Spacer 1 4 x 1 2 x 1 4 2 AHP 1925060 Washer Flat 10 3 AHQ 1925061 Washer...

Page 198: ... Assy SHAFT ITEM 5 SHOULD LOCK TO SHAFT 1 WHEN ROTATING SHAFT CCW FACING NOTES DETAIL A SEE DETAIL A 9 RIGHT HAND FRAME ASSEMBLY REMOVED FOR CLARITY ITEM 3 SEE NOTE 1 5 3 7 4 6 8 SE 2 SE 2 1 1 REFER TO PL 4 3 A REFER TO PL 4 3 A PL 4 3B 7610382 Assy Punch ITEM 5 SEE NOTE 1 P1 P2 ARS ...

Page 199: ...ed Punch Assy 6 3 0130019600 Shaft Idler Punch Assy 1 4 0130019700 Shaft Punch Assy 3 5 7610517 Assy One Way Clutch Pulley 16 Tooth Tag P1 P2 1 6 0130034600 Input Deck Punch Assy 1 7 0130037000 Driver Pulley Punch Assy 1 8 7610370 Belt Flat Punch Input 06 x 1 x 10 75 Endless 3 9 1981309 Belt Timing Punch Drive 1 SE 1900028 SHSS 10 32 x 3 16 6 ARS 1931528 Roll Pin 1 8 x 3 4 1 ...

Page 200: ...h Assy SEE DETAIL A ACJJ AND AHP DETAIL A 1 ARK 12 ANP 2 3 BS AND BG ANC AHT AVX 10 BM AND AHP ARK 6 4 BDM AND AHP BS ARP AHT ANC ANG AJD XM 8 11 9 7 11 AJD ANG XM ANG AJD YU 5 ARK 6 ITEM 4 REFER TO PL 4 3 L DETAIL A ITEM 7 REFER TO PL 4 3 L DETAIL B PL4 3 C 7610382 Assy Punch APN ...

Page 201: ...h 1 10 7610193 Solenoid Rotary Back Gauge 1 11 7610343 Bearing Flanged Punch Clutch Assy 2 12 7610361 Tubbing Polyurethane 1 YU 1900589 SHCS 3 8 16 x 2 1 XM 1900559 SHCS 3 8 16 x 1 3 4 4 BDM 1924818 Spacer 1 4 x 1 2 x 1 4 1 AHP 1925060 Washer Flat 10 7 AHT 1925064 Washer Flat 8 4 AJD 1925184 Washer Flat Extra Thick 3 8 6 ANC 1926062 Washer Lock 8 4 AND 1926063 Washer Lock 10 8 ANG 1926066 Washer L...

Page 202: ...3 D Punch Assy ACJJ AHP AND ACJJ AND 2 1 3 AHP ANA AHR P AHU AJD XD ANG ITEM 1 SEE DATAIL A AHU ANG AJD XD 1 ITEM 1 SEE DATAIL A DETAIL B ARU 7 AFTER ASSY 8 05 7 SEE DETAIL B 4 5 6 ANG ANW ASS 8 ANG ANW DETAIL A PL 4 3D 7610382 Assy Punch FACTORY SET DO NOT ADJUST 9 9 9 10 ...

Page 203: ...l Pin Punch Crank Arm Latch 2 8 7610381 Rod End Punch Crank Arm 2 9 7610449 Label Factory Set Do Not Adjust 2 10 0480070300 Cap Vinyl 2 XD 1900551 SHCS 3 8 16 x 1 1 4 2 AHP 1925060 Washer Flat 10 4 AHR 1925062 Washer Flat 4 1 AHU 1925065 Washer Flat 3 8 2 AJD 1925184 Washer Flat Extra Thick 3 8 4 ANG 1926066 Washer Lock 3 8 6 ANA 1926060 Washer Lock 4 1 AND 1926063 Washer Lock 10 4 ANW 1926709 Nut...

Page 204: ...GBC FusionPunch II Service Manual PL 4 3 E Punch Assy 12 2003 5 72 PL 4 3 E Punch Assy 1 1 3 1 2 1 4 5 PL 4 3E 7610382 Assy Punch ...

Page 205: ...3 5 73 PL 4 3 E Punch Assy Item Part Description Qty 1 7610348 Pulley Timing 20 Tooth Punch Assy 4 2 1981303 Belt Timing Punch Output Idler 1 3 1981306 Belt Timing Punch Output Drive 1 4 7610352 Gear Spur Small Back Gauge 1 5 7610353 Gear Spur Large Back Gauge 1 ...

Page 206: ...GBC FusionPunch II Service Manual PL 4 3 F Punch Assy 12 2003 5 74 PL 4 3 F Punch Assy XM AJD AKR BHF 2 6 1 5 4 BHF AKR XM AJD 3 ANG ANG PL4 3 F 7610382 Assy Punch ...

Page 207: ... R H Punch Slide Assy 1 3 7610296 Post Mount L H Punch Slide Assy 1 4 0130035800 Spacer Short Punch Slide Assy 1 5 7610257 Lead Screw Punch Slide Assy 1 6 1928203 Wing Nut Punch Slide Assy 1 XM 1900559 SHCS 3 8 16 x 1 3 4 2 AJD 1925184 Washer Flat Extra Thick 3 8 2 AKR 1925230 Washer Flat Non Metallic 2 ANG 1926066 Washer Lock 3 8 2 BHF 1932706 Clamp Collar Punch Slide Assy 2 ...

Page 208: ...GBC FusionPunch II Service Manual PL 4 3 G Punch Assy 12 2003 5 76 PL 4 3 G Punch Assy 1 BJ AHP AND BM BM AND AHP 2 PL4 3G 7610382 Assy Punch ...

Page 209: ...3 5 77 PL 4 3 G Punch Assy Item Part Description Qty 1 0130035600 Side Guide Mounting Block 1 2 0130025100 Assy Clamp Punch Output Nip Roller 2 AHP 1925060 Washer Flat 10 2 AND 1926063 Washer Lock 10 2 BJ 1980072 SHCS 10 32 x 1 2 2 BM 1980075 SHCS 10 32 x 3 4 2 ...

Page 210: ... FusionPunch II Service Manual PL 4 3 H Punch Assy 12 2003 5 78 PL 4 3 H Punch Assy 3 2 ITEM 2 REFER TO PL 4 3 N AHP ITEM 3 REFER TO PL 4 3 M AHQ AND 6 CC ANE CC 5 AHQ ANE 1 4 P1 PL 4 3H 7610382 Assy Punch ...

Page 211: ...nch Tension Strap refer to PL 4 3 M 1 3 7610332 Assy Punch Output Nip Roller refer to PL 4 3 M 1 4 7610359 Assy Side Guide Infeed Strip 1 5 7610283 Block Hinge Punch Tension Strap Assy 1 6 7610404 Thumb Screw Side Guide Assy 1 AHP 1925060 Washer Flat 10 1 AHQ 1925061 Washer Flat 1 4 4 AND 1926063 Washer Lock 10 1 ANE 1926064 Washer Lock 1 4 4 CC 1980095 SHCS 1 4 20 x 5 8 4 ...

Page 212: ...L 4 3 I R H Punch Side Frame Assy 12 2003 5 80 PL 4 3 I R H Punch Side Frame Assy NOTES 1 MALE PART OF ITEM 6 REFER TO PL 4 3 N 1 ITEM 6 SEE NOTE 1 2 3 4 5 6 AND AHP BM AND AHP BM ANF AFB DW LN NX PL 4 3I 7610328 Assy RH Punch Side Frame ...

Page 213: ...utput Deck 1 3 0130034900 Mount Input Deck 1 4 0130031600 Guide Diver Bar 1 5 0130026000 Assy Mount Block 1 6 7610368 Latch Female Punch Tension Strap Assy 1 AFB 1925001 Washer Flat 5 16 2 AHP 1925060 Washer Flat 10 4 AND 1926063 Washer Lock 10 4 ANF 1926065 Washer Lock 5 16 2 BM 1980075 SHCS 10 32 x 3 4 4 DW 1980145 SHCS 5 16 18 x 1 1 4 2 LN 1980432 FHCS 6 32 x 3 8 2 NX 1980509 FHCS 1 4 20 x 1 1 ...

Page 214: ...rvice Manual PL 4 3 J L H Punch Side Frame Assy 12 2003 5 82 PL 4 3 J L H Punch Side Frame Assy BM 1 2 3 4 5 6 7 8 9 9 BM AHP AND AND AHP BT AND AHP ANE CE AHQ DW AFB ANF NX PL 4 3 J 7610327 Assy LH Punch Side Frame AKJ P1 ...

Page 215: ...6 0130002300 Spacer 1 7 0130025500 Block Tension Idler 1 8 0130025600 Pulley Tension Idler 1 9 0130038100 Yoke Tension Idler Thin 2 AFB 1925001 Washer Flat 5 16 2 AHP 1925060 Washer Flat 10 6 AHQ 1925061 Washer Flat 1 4 2 AKJ 1925223 Washer Flat Non Metallic 1 AND 1926063 Washer Lock 10 6 ANE 1926064 Washer Lock 1 4 2 ANF 1926065 Washer Lock 5 16 2 BM 1980075 SHCS 10 32 x 3 4 4 BT 1980081 SHCS 10 ...

Page 216: ...GBC FusionPunch II Service Manual PL 4 3 K Locking Cam Assy 12 2003 5 84 PL 4 3 K Locking Cam Assy DETAIL C 4 ARS 3 ARS 4 1 AXY DETAIL A DETAIL B 2 AXU PL 4 3K Lock Cam Assemblies ...

Page 217: ... 85 PL 4 3 K Locking Cam Assy Item Part Description Qty 1 0130037900 Yoke R H Locking Cam Assy 1 2 0130038000 Yoke L H Locking Cam Assy 1 3 7610252 Shaft Locking Cam Assy 1 4 0130028900 Cam Die Locking 2 ARS 1931528 Roll Pin 1 8 x 3 4 2 AXU 1954109 Dowel Pin 3 16 x 1 2 2 ...

Page 218: ... 4 3 L Assemblies Punch Clutch Back Gauge 12 2003 5 86 PL 4 3 L Assemblies Punch Clutch Back Gauge Block 4 ARL 2 REF ARL 3 2 AVX 1 DETAIL A ARK ARK AXA 8 ARV 5 8 6 CE ANE AHQ 7 DETAIL B PL 4 3L 0130025900 Punch Clutch Assy Back Gauge Adj ...

Page 219: ...Cam Back Gauge Setting 1 4 7610279 Spring Plunger Delrin Nose 1 5 0130019500 Shaft Punch Clutch 1 6 0130019900 Pulley Punch Clutch 1 7 0130033800 Pulley Punch Clutch Output 1 8 7610347 Clutch Punch Assy 1 AHQ 1925061 Washer Flat 1 4 3 ANE 1926064 Washer Lock 1 4 3 ARK 1931521 Roll Pin 3 16 x 1 2 ARL 1931522 Roll Pin 1 8 x 1 2 ARV 1931531 Roll Pin 3 16 X 1 1 2 1 AXA 1952101 Key Woodruff 606 1 AVX 1...

Page 220: ...C FusionPunch II Service Manual PL 4 3 M Punch Output Nip Roller Assy 12 2003 5 88 PL 4 3 M Punch Output Nip Roller Assy 3 AND BG 6 5 2 1 4 ARD BG ARD 6 AND 4 ARD 1 PL 4 3M 7610332 Assy Output Nip Roller ...

Page 221: ...ion Qty 1 0130026400 Roller Punch Output Idler 4 2 0130032200 Shaft Punch Output Nip Assy 1 3 0130032300 Spring Punch Output Nip Assy 1 4 7610276 Runner Punch Output Nip Assy 2 5 7610277 Shaft Punch Output Idler 2 6 7610388 Thumb Screw Punch Output Nip Assy 4 AND 1926063 Washer Lock 10 6 ARD 1930516 E Ring 375 8 BG 1980070 SHCS 10 32 x 3 8 6 ...

Page 222: ...sy AND TT 16 15 14 Z AQT AHT 12 ZM TT 14 ZM 16 Z 15 AHP AHT GP AQT 2 AN 9 ANC FC AHT 4 AND BG 3 5 BP CL ANE CD ANE AHQ 6 8 GA LN BP 1 7 10 11 13 SEE DETAIL A DETAIL A ITEM 8 SEE NOTE 1 NOTES 1 FEMALE PART OF ITEM 8 REFER TO PL 4 3 I 17 18 18 PL 4 3N 7610332 7610329 Assy Sheet Exit ANC ANC 21 19 20 P4 P4 P4 P4 P4 ...

Page 223: ...sy 1 14 7610445 Shaft Sheet Eject Assy 2 15 7610444 Arm Sheet Eject Assy 2 16 7610442 Assy Idler Roller Sheet Eject Assy 2 17 7610234 Guide R H Punch Infeed 1 18 7610388 Thumb Screw 2 19 7610524 Paper Guide Punch SE 1 20 7610525 Bracket SE Paper Guide 1 21 1914082 Thumb Screw 3 TT 1900066 SHSS 6 32 2 ZM 1900807 SHLDR Screw 10 24 2 AHP 1925060 Washer Flat 10 3 AHQ 1925061 Washer Flat 1 4 2 AHT 1925...

Page 224: ...SR AND BJ AHP 21 ANA P ANP ASS BS 17 16 SEE DETAIL A DETAIL A REFER TO PL 6 1 A Q Q AVU 12 13 23 AKG 18 1 22 19 18 13 12 ANE 4 CD 14 2 AHQ ANE CE AHQ ANC AP AHT CE 15 20 20 ANA Q AHR BH 8 AND AKW AQU 9 10 AND BH 3 8 ANE CD AHQ AND BH BJ 6 AHP AND 5 AKW PL 5 1A 7610002 AKG ANE CE AHQ ANE CE AHQ ANE AHQ ...

Page 225: ...afety Stop 2 19 7610029 Pulley Timing 20 Tooth Stacker Assy 1 20 7610188 Switch Almost Full Full 2 21 7610187 Switch Upper 1 22 1981303 Belt Timing 90xl Stacker Tray 1 23 7610158 Bearing Flanged 3 8 1 AAQ 1900834 SHLDR Screw 1 4 x 3 8 1 AHP 1925060 Washer Flat 10 3 AHQ 1925061 Washer Flat 1 4 12 AHR 1925062 Washer Flat 4 6 AHT 1925064 Washer Flat 8 4 AKG 1925221 Washer Flat Non Metallic 2 AKW 1925...

Page 226: ... 94 PL 5 1 B Stacker Assy SEE DETAIL A REFER TO PL 5 1 C REFER TO PL 5 1 D Tag S2 DETAIL A 7 2 4 5 4 4 SE 9 AHQ AV AA 11 AHQ AA 11 11 AHQ AA AHQ AA AHT ANC 13 8 ARS 13 AHP 12 AHT ANC 6 ANM BJ AND ARD AVU AJN 10 ARG 1 ARG 3 AJN 10 PL 5 1B 7610002 S1 S1 S2 S2 3 84 REF ...

Page 227: ...y 1 9 7610152 Knob Stacker Slide Assy 1 10 7610157 Bearing Flanged 1 2 2 11 7610189 Bearing Pillow Block Stacker Assy 4 12 7610193 Solenoid Rotary Tapper Assy 1 13 7610352 Gear Spur 30 Tooth 2 SE 1900028 SHSS 10 32 x 3 16 5 AHP 1925060 Washer Flat 10 2 AHQ 1925061 Washer Flat 1 4 16 AHT 1925064 Washer Flat 8 4 AJN 1925203 Washer Flat Non Metallic 2 ANC 1926062 Washer Lock 8 2 AND 1926063 Washer Lo...

Page 228: ...C Stacker Assy 12 2003 5 96 PL 5 1 C Stacker Assy 13 AVD 4 BHB 1 14 9 MW 15 RH 3 5 RH 10 15 AUV 12 AKH FS 2 15 AUV RH 11 4 AKW 8 AKH AAY AVP 7 12 AKW ABA 6 AVD BHB ARR INCLUDED WITH ITEM 14 PL 5 1C 7610002 Assy Stacker S1 S5 AND ANP BU 16 AKW ...

Page 229: ...ivot O ring Drive Assy 1 12 7610142 Braket O ring Roller Assy 2 13 7610144 Arm O ring Drive Assy 1 14 7610172 Solenoid Tubular Offset 2 15 7610258 Pulley V O ring Drive Assy 3 16 7610361 Tubbing Polyurethane 1 RH 1900008 SHSS 6 32 x 1 8 4 AAY 1900841 SHLDR Screw 3 16 x 1 8 2 ABA 1900843 SHLDR Screw 3 16 x 1 2 1 AKH 1925222 Washer Flat Non Metallic 3 AKW 1925236 Washer Flat Non Metallic 4 AND 19260...

Page 230: ...II Service Manual PL 5 1 D Stacker Assy 12 2003 5 98 PL 5 1 D Stacker Assy AN ANC 4 3 AN ANC 2 AND BJ 3 AHP 1 8 AHP ANE CD AHQ AND BJ AHP 5 7 ANE CD AHQ 1 AHP PL 5 1D 7611920 3 AN ANC 10 AN ANC APT AN ANC 9 AHP AND BM ...

Page 231: ... H Infeed Assy 1 6 7611917 Bracket Extension L H Infeed Assy 1 7 7611918 Bracket R H Infeed Assy 1 8 7611919 Bracket L H Infeed Assy 1 9 7611923 Guide Wire Form Long Stacker Infeed Assy 4 10 7611924 Cross Bar Long Wire Form Assy 1 AHP 1925060 Washer Flat 10 10 AHQ 1925061 Washer Flat 1 4 2 ANC 1926062 Washer Lock 8 10 AND 1926063 Washer Lock 10 8 ANE 1926064 Washer Lock 1 4 2 APT 1926730 Nut Hex 1...

Page 232: ...tacker Assy 12 2003 5 100 PL 5 2 A Bypass Stacker Assy 7 HH ANC 1 ANM AND 3 BJ 2 CE ANE 5 ARK 9 Q ASJ 14 8 CAK AND BJ BHB 12 5 ARK 13 BHB ASJ 14 CAK 8 BJ AND 12 CE ANE 10 15 6 11 4 16 UM ANC AN CE ANE ARK BHB PL 5 2A Bypass Assy 7611951 B1 2 AHQ AHQ AHQ ...

Page 233: ...y Side Plate RH 1 11 7611984 Shaft Bypass Gate 1 12 7611985 Slide Bypass Assy 2 13 7611987 Shaft Idler Bypass Ouput 1 14 7611995 Screw Spring Adjust 2 15 7611997 Finger Bypass Gate 7 16 7611999 Deflector Bypass Input 5 UM 1900084 SHSS 8 32 x 3 16 7 AHQ 1925061 Washer Flat 1 4 14 AKR 1925230 Spacer Non Metallic 5 12 ANC 1926062 Washer Lock 8 12 AND 1926063 Washer Lock 10 6 ANE 1926064 Washer Lock 1...

Page 234: ...GBC FusionPunch II Service Manual PL 5 2 B Bypass Stacker Assy 12 2003 5 102 PL 5 2 B Bypass Stacker Assy BJ AND AKX BJ AND 3 AND 4 GV AND GV AHP 2 AND 1 PL 5 2B Bypass Assy 7611951 B1 3 ...

Page 235: ...em Part Description Qty 1 7610390 Thumb Screw 10 32 2 2 7611957 Guide Paper Bypass Assy 2 3 7611958 Cross Bar Bypass Assy 2 4 7611963 Assy Hub Bypass Output 2 AHP 1925060 Washer Flat 10 2 AKX 1925236 Spacer Non Metalic 2 AND 1926063 Washer Lock 10 18 BJ 1980072 SHCS 10 32 x 1 2 10 GV 1980286 BHCS 10 32 x 1 6 ...

Page 236: ... 12 2003 5 104 PL 5 2 C Bypass Stacker Assy CE ANE 9 7 3 6 ANC 3 AN 8 AHQ 11 CB ANE AKR ANE HQ AHQ ANE HQ ANE 12 CE 15 ARG RA AKR 1 13 AKR BHB AKR 10 BHB 1 12 14 2 BHB RA AKR CE ANE PL 5 2C Bypass Assy 7611951 B1 4 5 4 10 UM AKR AV ANC ANC AM 16 AHQ AHQ AHQ 17 P5 ...

Page 237: ... 7611970 Shaft Input Idler Roller Assy 1 12 7611982 Assy Idler Roller 3 13 7611983 Assy Drive Roller Bypass Belt 1 14 7611987 Shaft Idler Bypass Assy 1 15 7611996 Belt Flat Bypass Assy 1 16 7611947 Shield Bypass 1 17 7610535 Pulley Timing 24 Tooth Stacker Bypass Main Drive 6060 iGen3 Tag P5 1 RA 1900001 SHSS 10 32 x 38 2 UM 1900084 SHSS 8 32 x 3 16 Long 2 AHQ 1925061 Washer Flat 1 4 8 AKR 1925230 ...

Page 238: ...GBC FusionPunch II Service Manual PL 5 2 D Bypass Stacker Assy 12 2003 5 106 PL 5 2 D Bypass Stacker Assy PL 5 2 D 7611922_A1MOD 2 ANE 3 1 1 AHQ CB AND AHP BJ Viewed from Operators side ANE AHQ CB ...

Page 239: ... Qty 1 7611925 Link Cross Bar Short Wire Form Assy 2 2 7611926 Cross Bar Short Wire Form Assy 1 3 7611927 Guide Wire Form Short Bypass Stacker Assy 4 AHP 1925060 Washer Flat 10 4 AHQ 1925061 Washer Flat 1 4 2 AND 1926063 Washer Lock 10 4 ANE 1926064 Washer Lock 1 4 2 BJ 1980072 SHCS 10 32 x 1 2 4 CB 1980094 SHCS 1 4 20 x 1 2 2 ...

Page 240: ...INC4 OV 24V OV J11 RED 24V J9 24VI OUTB3 J8B OV INB6 J8A WHITE BLACK INB5 OV 24V J10 WHITE BLACK RED BLUE 24V J12B J12A 24V INB4 OV INA5 BLACK BROWN J13B OV INA4 OV 24V J13A INA8 INA7 INTER2 INTER1 OUTB2 OUTB1 OUTA8 OUTA7 OUTA6 24V J28 24V J27 OV OV 5V 24VI OV 5V 24VI INC3 24V 24VI OUTC5 24VI OUTC4 OUTC3 WHITE WHITE WHITE WHITE WHITE WHITE WHITE 24VI J16B J16A J15B INA3 24V 24VI OUTA5 J15A 24VI J1...

Page 241: ... DC Distribution PWB P J 15 1 7 7610476 Cable Assy Punch I O PWB P J 30 Punch AC DC Distribution PWB P J 11 1 8 7610477 Cable Assy Punch I O PWB P J 28 Punch AC DC Distribution PWB P J 12 1 9 7610478 Cable Assy Punch I O PWB P J 3B Punch Clutch Solenoid 1 10 7610479 Cable Assy Punch I O PWB P J 4B Back Gauge Solenoid 1 11 7610480 Cable Assy Punch I O PWB P J 5B Sheet Eject Solenoid 1 12 7610481 Ca...

Page 242: ... REV FWD NUI J7 J6B MT1 WHITE WHITE J15 WHITE WHITE ORANGE YELLOW J6 24VI 24VI 24V OV NEU MT4 MT3 MT2 NEU LINE LINE J1 5V OV 5V J13 WHITE WHITE WHITE J11 YELLOW BLACK RED J12 ORANGE 24V OV J5 LINE NEU OV J2 24V 5V 5V 5V OV J14 BLUE BROWN BLACK BLACK BLACK RED RED RED POWER SUPPLY 5 VDC PWB RED RED 5V 5V BLACK BLACK OV OV NEU LINE NEU LINE BLUE BROWN BLUE BROWN CN2 CN1 CN2 CN1 1 Item 1 To Main Powe...

Page 243: ...WB P J 3 5 VDC Power Supply P J CN2 1 5 7610469 Cable Assy Punch AC DC Distribution PWB P J 5 5 VDC Power Supply P J CN1 1 6 7610470 Cable Assy Punch AC DC Distribution PWB P J 6 Punch Interlock High 1 7 7610473 Cable Assy Punch AC DC Distribution PWB P J 8 Document Transport Motor 1 8 7610474 Cable Assy Punch AC DC Distribution PWB P J 9 Punch Motor 1 9 7610475 Cable Assy Punch AC DC Distribution...

Page 244: ...NO NC 7610501 NO NC NO 7610472 60 7610472 34 140 BLACK YELLOW YELLOW 118 118 WHITE BLACK YELLOW NO NC NO LEFT DOOR NO NO NC NO 7610501 NO NC BLACK YELLOW 100 WHITE WHITE NO NC LEFT COVER NO NO NO NC 7610501 ORANGE WHITE WITH STAR WASHER AND CONNECTED TO BACK FRAME AC Receptical Line Filter Assy 7610463 KEPS NUT BROWN BLUE BROWN BLUE MOUNTED ON REAR LEG 7610455 CIRCUIT BREAKER 6 Item 6 To Punch I O...

Page 245: ...witch Circuit Breaker Punch AC Receptical Line Filter 1 2 7610465 Cable Assy Punch Main Power Switch Circuit Breaker Punch AC DC Distribution PWB P J 1 1 3 7610470 Cable Assy Punch Interlock High Punch AC DC Distribution PWB P J 6 1 4 7610471 Cable Assy Punch Interlock Low Punch I O PWB P J 19 and 20 1 5 7610472 Cable Assy Punch Interlock Jumpers 1 6 7610500 Cable Assy DFA Punch Rear Panel Punch I...

Page 246: ...PWB BRN RED ORN YEL GRN BLK BLU WHT RED BRN 7610452 J22 ORN YEL GRN BLK BLU WHT J23 BRN RED ORN YEL GRN J25 J24 J1 J5 1 BLACK RED ORANGE 1 BLU WHT J2 J3 Expansion PWB 7610458 BLACK GREEN 1 JP6 JP1 1 1 JP4 ORANGE BLUE WHITE YELLOW GREEN BLACK BROWN RED BLUE WHITE Little Star Controller PWB 7610457 1 JP2 GREEN LCD BLACK ORANGE ORANGE BLUE WHITE BLACK BROWN RED ORG YEL BLUE WHITE ORANGE YELLOW GREEN ...

Page 247: ...roller PWB P J 1 Punch I O PWB P J 22 23A 26 1 3 7610484 Cable Assy Daughter PWB P J 22 23 24 25 Stacker I O PWB P J 22 23A 24A and 25 1 4 7610494 Cable Assy Daughter PWB P J 1 Punch I O PWB P J 27 1 5 7610495 Cable Assy Daughter PWB P J 5 Control Panel Key Pad 1 6 7610496 Cable Assy Daughter PWB P J 3 Control Panel LCD Display 1 7 7610497 Cable Assy Little Star Cotrller PWB P J H1 Daghter PWB P J...

Page 248: ...BLACK J26 J14B J14A INA5 INC5 J24 B J24A INA8 INA7 INA6 INC8 INC7 INC6 INA2 INA4 INA3 INA1 INC2 INC4 INC3 INC1 24VP OUTB3 INB3 INB6 INB8 INB7 INB5 INB4 J25 24V 24V INB2 INB1 24V OV INC5 OV INC4 OV 24V OV 24V 24VI OUTB3 J8B OV INB6 J8A WHITE BLACK J9 INB5 OV 24V J10 WHITE BLACK BLACK 24V 24V INB4 OV INA5 J12B WHITE J11 J12A OV INA4 J13B OV 24V J13A INA8 INA7 INTER2 INTER1 OUTB2 OUTB1 OUTA8 OUTA7 OU...

Page 249: ...r PWB P J 22 23 24 25 1 5 7610485 Cable Assy Stacker I O PWB P J 19 20 Stacker Interlock Low 1 6 7610490 Cable Assy Stacker I O PWB P J 30 Stacker AC DC Distribution PWB P J 11 1 7 7610491 Cable Assy Stacker I O PWB P J 3B 4A 5A 9 Stacker Tapper and Offset Solenoids and Upper Switch 1 8 7610493 Cable Assy Stacker I O PWB P J Almost Full and Full Switches 1 9 7610500 Cable Assy DFA Stacker I O PWB ...

Page 250: ...NE LINE J1 5V OV 5V RED J13 BLACK WHITE WHITE J11 ORANGE YELLOW BLACK RED J12 ORANGE 24V OV J5 LINE NEU OV J2 24V 5V 5V 5V OV J14 BLACK RED FROM PUNCH 2 Item 2 To Stacker I O PWB P J 29 3 Item 3 To Stacker I O PWB P J 28 8 Item 8 To Stacker I O PWB P J 30 4 Item 4 To Punch Distribution PWB P J 14 1 Item 1 To Stacker Main Power Switch Circuit Breaker 10 Item 10 To Stacker 2 AC DC Distribution PWB P...

Page 251: ...23 1 4 7610483 Cable Assy Stacker AC DC Distribution PWB P J 14 Punch AC DC Distribution PWB P J 14 1 5 7610486 Cable Assy Stacker AC DC Distribution PWB P J 6 Stacker Interlock High 1 6 7610487 Cable Assy Stacker AC DC Distribution PWB P J 7 Stacker Tray Motor 1 7 7610488 Cable Assy Stacker AC DC Distribution PWB P J 8 Stacker O ring Motor 1 8 7610490 Cable Assy Stacker AC DC Distribution PWB P J...

Page 252: ...NGE NO NO NC YELLOW 84 WHITE NO NC NO 7610501 84 BLACK ORANGE NO NO NC WITH STAR WASHER AND CONNECTED TO BACK FRAME AC Recptical Line Filter 7610456 KEPS NUT BROWN BLUE BROWN BLUE MOUNTED ON REAR LEG 7610455 Power Switch Circuit Breaker 4 3 Item 4 To Stacker I O PWB P J 6 Item 3 To Stacker I O PWB P J 19 20 Item 2 To Stacker AC DC Distribution PWB P J 1 2 5 Item 5 DFA To Stacker I O PWB 1 STACKER ...

Page 253: ...Stacker Main Power Switch Circuit Breaker Stacker AC Receptical Line Filter 1 2 7610465 Cable Assy Stacker Main Power Switch Circuit Breaker Stacker AC DC Distribution PWB P J 1 1 3 7610485 Cable Assy Stacker Interlocks Low Stacker I O PWB P J 19 20 1 4 7610486 Cable Assy Stacker Interlocks High Stacker AC DC Distribution PWB P J 6 1 5 7610500 Cable Assy DFA Stacker Rear Panel Stacker I O PWB 1 ...

Page 254: ...GBC FusionPunch II Service Manual PL 6 2 C Stacker Interlocks Rear Panel Cable Assy 12 2003 5 122 Notes This Page Intensionally Left Blank ...

Page 255: ...21 Washer Flat Non Metallic 10 AKH 1925222 Washer Flat Non Metallic 10 AKL 1925225 Washer Flat Non Metallic 10 AKR 1925230 Washer Flat Non Metallic 10 AKU 1925233 Washer Flat Non Metallic 10 AKX 1925236 Washer Flat Non Metallic 10 Item Part Description Qty BFF 1925307 Spacer 1 4 x 3 4 x 3 4 10 ALQ 1925903 Washer Star Lock 8 10 ANA 1926060 Washer Lock 4 10 ANB 1926061 Washer Lock 6 10 ANC 1926062 W...

Page 256: ...1980070 SHCS 10 32 x 3 8 10 BH 1980071 SCHS 10 32 x 7 16 10 BJ 1980072 SHCS 10 32 x 1 2 10 BM 1980075 SHCS 10 32 x 3 4 10 BP 1980077 SHCS 10 32 x 1 10 BS 1980080 SHCS 10 32 x 1 1 2 10 BT 1980081 SHCS 10 32 x 1 3 4 10 BV 1980083 SHCS 10 32 x 2 5 10 CB 1980094 SHCS 1 4 20 x 1 2 10 CD 1980095 SHCS 1 4 20 x 5 8 10 CE 1980096 SHCS 1 4 20 x 3 4 10 CF 1980097 SHCS 1 4 20 x 7 8 10 CG 1980098 SHCS 1 4 20 x...

Page 257: ...ument Transport 4 2 A 0130004900 Nut Washer Belt Take Up 4 2 A 0130005100 Bracket Seperator Document Transport Belt Assy 4 2 D 0130005200 Side Frame Document Transport Belt Assy 4 2 D 0130005400 Support Bearing Plate Document Transport 4 2 A 0130005500 Ball Track Document Transport 4 2 E 0130005600 Shaft Document Transport Belt Assy 4 2 D 0130005800 Bracket Angle Document Transport Belt Assy 4 2 D...

Page 258: ... F 0130019100 Cross Member Swing Frame 4 1 A 0130019300 Block Punch Crank Arm 4 3 C 0130019400 Shaft Back Gauge 4 3 A 0130019500 Shaft Punch Clutch 4 3 L 0130019600 Shaft Idler Punch Assy 4 3 B 0130019700 Shaft Punch Assy 4 3 B 0130019800 Solenoid Mount Back Gauge 4 3 C 0130019900 Pulley Punch Clutch 4 3 L 0130021200 Assy Document Transport Belt refer to PL 4 2 D 4 2 B 0130021300 Side Frame R H Do...

Page 259: ... Spring Punch Output Nip Assy 4 3 M 0130032400 Latch Keeper Punch Crank Arm 4 3 D 0130033400 Block Back Gauge Control 4 3 L 0130033800 Pulley Punch Clutch Output 4 3 L 0130033900 Shaft Punch Clutch 4 3 C 0130034600 Input Deck Punch Assy 4 3 B 0130034900 Mount Input Deck 4 3 I 4 3 J 0130035000 Mount Output Deck 4 3 I 4 3 J 0130035400 Shaft Back Gauge Adjustment 4 3 L 0130035500 Cam Back Gauge Setti...

Page 260: ...ve Assy 5 1 B 1981306 Belt Timing Punch Output Drive 4 3 E 1981309 Belt Timing Punch Drive 4 3 B 1981311 Belt Timing 85T Bypass Drive 1 3 A 1981350 Belt Timing Document Transport Main Drive 1 1 G 1981400 Belt Timing Punch Clutch Output 4 3 C 1981401 Belt Timing Punch Clutch 4 3 C 6009160 Label Stacker On Off 1 1 I 1 2 A 6009401 Label Electical Shock 1 1 H 1 3 B 6009406 Label Electrical Shock Trian...

Page 261: ...B 7610066 Shaft Tapper Assy 5 1 B 7610067 Cross Support Stacker Assy 5 1 A 7610069 Pivot O ring Drvie Assy 5 1 C 7610072 Base Angle Stacker Assy 5 1 A 7610073 Nut Acme Stacker Assy 5 1 A 7610074 Screw Acme Stacker Assy 5 1 A 7610075 Bracket Stacker Tray 5 1 A 7610083 Bushing Stacker Tray Stop 5 1 A 7610085 Deck Stacker Assy 5 1 A 7610087 Shaft Linear Stacker Assy 5 1 A 7610088 Frame O ring Drive A...

Page 262: ...ring Pillow Block Stacker Assy 5 1 B 7610190 Rail Linear Stacker Assy Support 1 2 A 7610191 Motor 115 VAC 60 HZ Stacker Tray 1 2 B 7610192 Motor 115 VAC 60 HZ Stacker O ring 1 2 B 7610193 Solenoid Rotary Back Gauge 4 3 C 7610193 Solenoid Rotary Sheet Eject Assy 4 3 N 7610193 Solenoid Rotary Tapper Assy 5 1 B 7610194 Motor 230 VAC 50 HZ Stacker Tray 1 2 B 7610195 Motor 230 VAC 50 HZ Stacker O ring ...

Page 263: ...Punch Output Idler 4 3 M 7610279 Spring Plunger Delrin Nose 4 3 L 7610282 Paper Guide Document Transport Short 4 2 E 7610283 Block Hinge Punch Tension Strap Assy 4 3 H 7610284 Bracket Hinge Support 4 2 E 7610285 Paper Guide Support Plate 4 2 E 7610286 Support Document Transport Ball Track Assy Front 4 2 E 7610287 Latch Block Document Transport 4 2 A 7610289 Bar Punch Tension Strap Assy 4 3 N 76102...

Page 264: ...nt Transport Main Drive 1 1 G 7610352 Gear Spur 30 Tooth 5 1 B 5 2 A 7610352 Gear Spur Small Back Gauge 4 3 E 7610353 Gear Spur Large Back Gauge 4 3 E 7610357 Coupling Flex Beam Document Transport Belt Assy 4 2 D 7610358 Assy Document Transport Ball Track refer to PL 4 2 E 4 2 C 7610359 Assy Side Guide Infeed Strip 4 3 H 7610360 Plunger Spring Bolt 4 1 F 7610361 Tubbing Polyurethane 4 3 C 7610365 ...

Page 265: ...404 Thumb Screw Side Guide Assy 4 3 H 7610407 Handle Interface Adjustable 5 16 1 8 THD 4 1 C 7610414 Plate Rail Punch Slide Assy 1 1 D 7610415 Rail Linear Punch Slide Support 1 1 D 7610416 Standoff Hex 4 40 3 3 7610418 Motor 115 VAC 60 HZ Document Transport 1 1 B 7610418 Motor 115 VAC 60 HZ Punch 1 1 F 7610421 Sensor Document Transport 1 2 4 2 A 7610421 Sensor Document Transport 1 2 Cable Assy inc...

Page 266: ...C DC Distribution Opto 3 2 3 3 7610464 Cable Assy Line Filter Power Switch 1 1 I 1 2 A 7610464 Cable Assy Punch Main Power Switch Circuit Breaker Punch AC Receptical Line Filter 6 1 C 7610464 Cable Assy Stacker Main Power Switch Circuit Breaker Stacker AC Receptical Line Filter 6 1 C 7610465 Cable Assy Power Switch AC DC Power Distribution PWB 1 1 I 1 2 A 7610465 Cable Assy Punch AC DC Distributio...

Page 267: ...on PWB P J 12 Punch I O PWB P J 23 6 1 B 7610477 Cable Assy Punch I O PWB P J 28 Punch AC DC Distribution PWB P J 12 6 1 A 7610477 Cable Assy Stacker AC DC Distribution PWB P J 12 Stacker I O PWB P J 23 6 2 B 7610477 Cable Assy Stacker I O PWB P J 23 Stacker AC DC Distribution PWB P J 12 6 2 A 7610478 Cable Assy Punch I O PWB P J 3B Punch Clutch Solenoid 6 1 A 7610479 Cable Assy Punch I O PWB P J ...

Page 268: ...ter PWB P J 3 Control Panel LCD Display 6 1 D 7610496 Cable Assy LCD Display 2 1 A 7610497 Cable Assy Little Star Cotrller PWB P J H1 Daghter PWB P J 2 6 1 D 7610500 Cable Assy DFA From Printer 1 1 I 7610500 Cable Assy DFA Punch I O PWB Punch Rear Panel 6 1 A 7610500 Cable Assy DFA Punch Rear Panel Punch I O PWB 6 1 C 7610500 Cable Assy DFA Stacker I O PWB Stacker Rear Panel 6 2 A 7610500 Cable As...

Page 269: ...ypass Stacker Assy 1 3 B 7610729 Fuse 3A Slow Blow 3 2 3 1 3 3 7610743 Pulley 15 Tooth Document Transport 115 VAC 60 HZ Motor 1 1 G 7611002 Assy Stacker refer to PL 5 1 A D 1 2 A 7611198 Guide Paper Bypass Assy 5 2 C 7611914 Paper Guide Long Stacker Infeed Assy Tag S4 5 1 D 7611915 Paper Guide Short Stacker Infeed Assy Tag S4 5 1 D 7611916 Bracket Extension R H Infeed Assy Tag S4 5 1 D 7611917 Bra...

Page 270: ...sy 5 2 C 7611969 Plate Bypass Deck Motor 1 3 A 7611970 Shaft Input Idler Roller Assy 5 2 C 7611972 Deck Bypass 5 2 A 7611976 Plate Nut Bypass Assy 5 2 A 7611980 Assy Side Plate LH 5 2 A 7611981 Assy Side Plate RH 5 2 A 7611982 Assy Idler Roller 5 2 C 7611983 Assy Drive Roller Bypass Belt 5 2 C 7611984 Shaft Bypass Gate 5 2 A 7611985 Slide Bypass Assy 5 2 A 7611987 Shaft Idler Bypass Ouput 5 2 A 76...

Page 271: ... 1 1981350 Belt Timing Document Transport Main Drive 1 1981400 Belt Timing Punch Clutch Output 1 1981401 Belt Timing Punch Clutch 1 7610053 O ring O ring Roller Assy 2 7610056 O ring O ring Drive Assy 1 7610157 Bearing Flanged 1 2 2 7610158 Bearing Flanged 3 8 1 7610172 Solenoid Tubular Offset 2 7610187 Switch Upper 1 7610188 Switch Almost Full Full 1 7610193 Solenoid Rotary 2 7610232 Solenoid Pun...

Page 272: ...nsor 1 7610423 Sensor 1 7610424 Sensor 1 7610442 Assy Idler Roller Sheet Eject Assy 2 7610450 PWB AC DC Distribution 1 7610452 PWB Daughter 1 7610453 PWB 24 VDC Power Supply 1 7610454 PWB 5 VDC Power Supply 1 7610455 Switch Circuit Breaker Main Power 1 7610456 AC Receptical Line Filter Main Power 1 7610457 PWB Little Star Controller 1 7610458 PWB Little Star Controller Expansion 1 7610459 LCD Disp...

Page 273: ...cuSP 1 4 xxx to 2 xxx Profile Setup 6 16 DocuSP 1 4 xxx to 2 xxx Print Queue Setup 6 22 DocuSP 3 xxx Logon 6 25 DocuSP 3 xxx Profile Setup 6 27 DocuSP 3 xxx Print Queue Setup 6 37 Host Machine Enablement DT135 4XXX 6 43 Host Machine Enablement DocuColor 6060 6 45 Host Machine Enablement DocuColor iGen3 6 53 Personality Profiles 6 61 C P Bourg Down Stream Devices 6 64 Xerox Down Stream Devices 6 67...

Page 274: ...ect transistors and semiconductor components The techniques outlined below should be followed to help reduce the incidence of component damage caused by static electricity 1 Immediately before handling a semiconductor component or semiconductor equipped assembly drain off any electrostatic charge on your body by touching a known earth ground Alternatively employ a commercially available wrist stra...

Page 275: ...6 8 A Stacker 115V 60 Hz 1 0 A 230V 50 Hz 0 25A Dedicated outlet s recommended Relative Humidity 30 95 non condensing Ambient Air Temperature 41 104 F 5 40 C Altitude Rating 3280 ft 1 000 meters minimum Heat Output 1198 btu hour 115 V 60Hz Heat Output 2150 btu hour 230 V 50 Hz This figure represents heat output for both the Punch and Stacker combined Floor Plan including Operating and Overall Main...

Page 276: ...e LCD will change according to Table 6 5 each time you press the Diagnostics button NOTE To change the values of each Diagnostics function in Table 6 5 press the Up or Down Arrow accordingly 6 To exit Diagnostics mode turn Punch Main Power Switch Circuit Breaker OFF and then ON Table 6 5 LCD Display Diagnostic Function Offset Mode On Current 1 0 No Offsetting 1 Normal Offsetting 2 Test Offset ever...

Page 277: ...ier in the Fusion 1 Signal is offset 60 milliseconds earlier in the Fusion 2 Signal is offset 40 milliseconds earlier in the Fusion 3 Signal is offset 20 milliseconds earlier in the Fusion 4 Signal is offset 0 milliseconds in the Fusion 5 Signal is offset 20 milliseconds later in the Fusion 6 Signal is offset 40 milliseconds later in the Fusion 7 Signal is offset 60 milliseconds later in the Fusio...

Page 278: ... Arrow when the cursor is under a selected output Table 6 6 Punch Outputs Figure 6 1 Punch I O PWB NOTE The values shown in Table 6 6 may not correspond with the values displayed on the LCD P OUTB8 Punch Clutch 01 00000000000010 P OUTB7 Backgauge 02 00000000000010 P OUTB6 Sheet Eject 03 00000000000010 P OUTB5 Not Used 04 00000000000010 P OUTB4 Not Used 05 00000000000010 P Not Used 06 0000000000001...

Page 279: ... 7 Stacker 1 Outputs Figure 6 2 Stacker I O PWB NOTE The values shown in Table 6 7 may not correspond with the values displayed on the LCD S1 OUTC1 SheetExit 01 0000000000000000 S1 OUTC2 EndSetExit 02 0000000000000000 S1 OUTC3 Cycle Up 03 0000000000000000 S1 OUTC4 Finisher 1 04 0000000000000000 S1 OUTC5 Finisher 2 04 0000000000000000 S1 OUTC6 StackerDeck 06 0000000000000000 S1 OUTC7 Stacker Dir 07...

Page 280: ...able 6 8 Stacker 2 Outputs Figure 6 3 Stacker I O PWB NOTE The values shown in Table 6 8 may not correspond with the values displayed on the LCD S2 OUTC1 SheetExit 01 0000000000000000 S2 OUTC2 EndSetExit 02 0000000000000000 S2 OUTC3 Cycle Up 03 0000000000000000 S2 OUTC4 Finisher 1 04 0000000000000000 S2 OUTC5 Finisher 2 04 0000000000000000 S2 OUTC6 StackerDeck 06 0000000000000000 S2 OUTC7 Stacker ...

Page 281: ...1101111111111000 P INA3 Cycle Up I6 1101111111111000 Cycle Up signal from the Printer will change state every time the printer starts up P INA2 Set Signal I7 1101111111111000 End of Set signal from the Printer will change state on the last page of every book P INA1 Page Signal I8 1101111111111000 Page signal from the Printer will change state on every page of a book P INB8 Exit Sensor I9 110111111...

Page 282: ... on the LCD Input Sensor Status Action to change the Status S1 INC1 Fin Online I1 1101101101111111 S1 INC2 Fin NoFault I2 1101101101111111 S1 INC3 Fin NotFull I3 1011111101011000 S1 INC4 Fin SheetOut I4 1011111101011000 S1 INC5 Fin SetOut I5 1011111101011000 S1 INB1 Front Door I6 1011111101011000 Open and close the Front Door S1 INA6 Top Cover I7 1101101101111111 Open and close the Top Cover S1 IN...

Page 283: ... on the LCD Input Sensor Status Action to change the Status S2 INC1 Fin Online I1 1101101101111111 S2 INC2 Fin NoFault I2 1101101101111111 S2 INC3 Fin NotFull I3 1011111101011000 S2 INC4 Fin SheetOut I4 1011111101011000 S2 INC5 Fin SetOut I5 1011111101011000 S2 INB1 Front Door I6 1011111101011000 Open and close the Front Door S2 INA6 Top Cover I7 1101101101111111 Open and close the Top Cover S2 IN...

Page 284: ...ride the Interlocks and press START While in test mode the machine performs all normal operations 6 Use the 3 charts to the right to verify proper operation of each component in each module 7 To exit the Test mode press the STOP RESET button and then turn Punch Main Power Switch Circuit Breaker OFF and then back ON Punch Component Normal Operation Transport Motor The Document Transport Timing Belt...

Page 285: ...tained by the customer must make the required repairs If you later find the condition is not corrected inform your manager in writing of the improper wiring 110 VAC Voltage at the wall receptacle must be from 100 VAC to 120 VAC between AC line and AC neutral and between AC line and GND Voltage should be less than 3 VAC between GND and neutral If the voltage is not correct a licensed electrician mu...

Page 286: ...nd observe the values displayed on the LCD 5 Switch off the main power 6 Remove the jumper wire 7 Reconnect the DFA Cable Key Value Left Arrow 100000000000 Down Arrow 010000000000 Right Arrow 001000000000 Up Arrow 000100000000 PAUSE INTERRUPT 000001000000 RAISE LOWER STACKER 2 000000100000 RAISE LOWER STACKER 1 000000010000 STOP RESET 000000001000 ONLINE OFFLINE 000000000100 DIAGNOSTICS 0000000000...

Page 287: ...set of values or system configuration parameters that communicates input and output information from the printer to a finishing device The FusionPunch II is a finishing device System Access for Setup Profile and Print Queue configuration is performed at the same time and is normally the responsibility of the System Administrator The following information is provided for use by the System Administr...

Page 288: ...n the password field and then click on OK DocuSP 1 4 xxx to 2 xxx Profile Setup 1 From the DocuSP Monitor go to the Printer Manager window as shown already open in Figure 6 12 If it is not open go to the DocuSP Print Services window and click the Printer Manager button Figure 6 12 DocuSP Monitor and Printer Manager window 2 Click the Finishing Icon in the Printer Manager Window as shown in Figure ...

Page 289: ...the Finishing Window 3 Click on the Device Setup Tab as shown in Figure 6 14 The Device Setup Tab screen will display as shown in Figure 6 15 Figure 6 15 The Device Setup Tab screen 4 Click on the NEW button as shown in Figure 6 15 The Device Profile Window will display with the Properties and Default Limits tab screen showing as shown in Figure 6 16 Device Setup Tab New ...

Page 290: ... page with the profile sheets for the devices you will be setting up b Begin with the sheet for the Properties and Default Limits values c Enter the name and type of the finishing device for example Punch for name and External for type d Verify that all of the entered values conform to those in the profile sheet If they do not enter the values from the profile sheet NOTE Do not click OK at this po...

Page 291: ...Setup Tab screen displayed Figure 6 18 The Profile Setup Tab Screen 8 Click on the Profile Setup tab as shown in Figure 6 18 then click on the NEW button The Finisher Profile Window Properties and Limits screen will display as shown in Figure 6 19 Figure 6 19 The Properties and Limits Screen 5 Perform the following steps a Go to page 6 27 and locate the page with the profile sheets for the same de...

Page 292: ...5 through 9 for each additional finishing device installed in the system Figure 6 20 The Finishing Window and Profile Setup screen 6 Highlight GBC and click On Line 7 Select the On Line Finishers tab in the Finishing Window The On Line Finishers screen displays as shown in Figure 6 21 Figure 6 21 Finishing Window and On Line Finishers screen 8 Highlight GBC again and then click the Enable button 9...

Page 293: ... Checkbox is checked and the name of the device appears in parentheses to the right of External Finisher as shown in Figure 6 22 This completes the Profile setup Go now to the Print Queue setup procedure that follows NOTE If you have more than one finishing device inline with the printer you must set up a profile for each To do so repeat this profile setup procedure for each finishing device Exter...

Page 294: ...nature Booklet Maker SBM 1 From the DocuSP Monitor go to the Queue Manager window as shown already open in Figure 6 23 If it is not open go to the DocuSP Print Services window and click the Queue Manager button Figure 6 23 DocuSP Monitor and Queue Manager Window If the Queue Manager screen is not open click on the Queue Manager icon as shown in Figure 6 24 Figure 6 24 Queue Manager Icon 2 Pull dow...

Page 295: ...formation consists of Print Queue Setup procedures for the following finishing devices GBC Punch Queue Output for the FusionPunch II GBC Punch Short Edge Queue Output for the FusionPunch II SBM1 SBM2 Queue Output for the Signature Booklet Maker GBC Punch Queue Output Figure 6 27 The Print Queue Output Window 5 Refer to Figure 6 27 above and fill in or choose the fields as specified in the table be...

Page 296: ...low for an SBM 2 sided Punch Queue output This completes the Print Queue setup Item Entry a 2 Sided Do not check the override option b System Specified c Check the Override option d System Specified e Check the Override option f GBC SE g Check the Override option h Click OK then OK again in new Queue Setup window a d e f g b c h Item Entry a 2 Sided Do not check the override option b System Specif...

Page 297: ...e Logon level at the top of the DocuSP Main Window as shown in the Figure 6 30 If you are already logged on as System Administrator go to the Profile Setup Procedure If not Log on as System Administrator as described below Figure 6 30 DocuSP Main Window Logon Level Logon Level System Administrator ...

Page 298: ...p a drop down list as shown in Figure 6 31 Figure 6 31 The System Option Menu 3 Click Logon the Logon Window will display as shown in Figure 6 32 Figure 6 32 The Logon Window 4 Click Trusted User from the User options and then select System Administrator 5 Type the System Administrator password in the password field and then click on OK System Option Logon ...

Page 299: ...II Service Manual 12 2003 6 27 DocuSP 3 xxx Profile Setup 1 Once you are logged on as the System Administrator click the Printer Manager Icon from the DocuSP Main Window as shown in Figure 6 33 Figure 6 33 DocuSP Main Window Printer Manager Icon ...

Page 300: ...vice Manual DocuSP 3 xxx Profile Setup 12 2003 6 28 This will display the Printer Manager Window as shown in Figure 6 34 Figure 6 34 The Printer Manager Window 2 Select the Finishing Tab as shown in Figure 6 34 Finishing Tab ...

Page 301: ...I Service Manual 12 2003 6 29 The Finishing Tab Screen will display as shown in Figure 6 35 Figure 6 35 The Finishing Tab Screen 3 Click the Device Setup button at the bottom right corner of this screen as shown in Figure 6 35 Device Setup button ...

Page 302: ...The Device Setup Window will display as shown in Figure 6 36 Figure 6 36 The Device Setup Window 4 Right click in a blank portion of the Device Setup Window this will bring up a drop down list select NEW as shown in Figure 6 37 Figure 6 37 The Device Setup Drop Down List New ...

Page 303: ...a Go to Personality Profiles and use the profile sheets labeled for the DocuTech 61xx to set up the iGen3 or the Docutech 61xx b Enter the values for the Properties and Default Limits c Enter the name and type of the finishing device for example FusionPunch II for the name and External for the type d Verify that all of the entered values conform to those in the profile sheet If they do not enter t...

Page 304: ...6 39 The Timings Screen f Go back to Personality Profiles and locate the profile sheets for the same device as you did in the previous steps this time using the sheet for the Timings values g Verify that all of the entered values conform to those in the profile sheet and click OK This will bring you back to the Device Setup Window with the new profile showing in that window Click Close to close th...

Page 305: ... Service Manual 12 2003 6 33 6 Right click in a blank part of the External Finishers box at the bottom of the Finishing Tab Screen Then select New from the drop down list as shown in Figure 6 40 Figure 6 40 The External Finisher Drop Down List New ...

Page 306: ... The Finisher Profile Window Properties and Limits Screen 7 Perform the following steps a Go to Appendix A in this Users Guide and locate the profile sheets for the same device as in the previous steps but this time with the sheet for the Finisher Profile Properties and Limits values b Ensure that all of the entered values conform to those in the profile sheet and then click OK ...

Page 307: ...e Status set to Disabled and Online set to Offline as shown in Figure 6 42 Note After setting up the profile for the FusionPunch II you need to repeat steps 1 through 10 for each additional finishing device installed in the system Figure 6 42 The Finishing Tab Screen 8 Right click the profile you setup and the select Online from the drop down list as shown in Figure 6 42 9 Right click the profile ...

Page 308: ...nline with the host printer then you must setup a Profile for each finisher and train your customer how to switch back and forth between each Profile Now you can setup the Print Queues to work with the Profile s that you just setup This will allow your customer to send all Finishing jobs to the Print Queues with the correct profiles attached to each Queue ...

Page 309: ...int Queues for the FusionPunch II and other fishing devices that are inline to the printer Note One print queue is required for the FusionPunch II and one for each additional finishing device down the line such as a Signature Booklet Maker SBM 1 Click the Queue Manager Icon from the DocuSP Main Window as shown in Figure 6 43 Figure 6 43 The DocuSP Main Window Queue Manager Icon ...

Page 310: ...int Queue Setup 12 2003 6 38 The Queue Manager Screen will be displayed as shown in Figure 6 44 Figure 6 44 The Queue Manager 2 Right click in a blank part of the Queue Manager Screen and select New from the drop down list as shown in Figure 6 44 New ...

Page 311: ...ishing device enter the name as it appears in its Finisher Profile sheet 4 Click the OutputTab as shown in Figure 6 45 The Output Tab Screen will display as shown in the information that follows This information consists of Print Queue Setup values for the following finishing devices GBC Punch Queue Output for the FusionPunch II GBC Short Edge Punch Queue Output for the FusionPunch II and a Xerox ...

Page 312: ...eue Setup 12 2003 6 40 GBC Punch Queue Output Figure 6 46 The Print Queue Ouput Window Refer to Figure 6 46 above and fill in or choose the fields as specified in the table below for a GBC Punch Queue Output Item Entry a GBC b Check the Override Option a b ...

Page 313: ...ual 12 2003 6 41 GBC Short Edge Queue Output Figure 6 47 The Print Queue Ouput Window Refer to Figure 6 47 above and fill in or choose the fields as specified in the table below for a GBC Short Edge Queue Output Item Entry a GBCSE b Check the Override Option a b ...

Page 314: ...etup 12 2003 6 42 SBM1 SBM2 Queue Output Figure 6 48 The Print Queue Output Window SBM Setup Refer to Figure 6 48 above and fill in or choose the fields as specified in the table below for a SBM Queue Output Item Entry a SBM1 SBM2 b Check the Override Option a b ...

Page 315: ... corner of the screen and click Close Call 6 Click Yes to close call Click the Printer icon and then Reset The End of Set signal will be timed correctly with the Fusion Punch and the Offset stacker Xerox 4xxx LPS Host Machine Enablement 1 Stop any job that is currently running and take the system offline 2 Log in at the log4 level Type log 4 and press Enter 3 Type Field Engineer and press Enter 4 ...

Page 316: ...file and press Enter The system prompts you to enter a name 6 Type GBCPunch and press Enter The prompt P1 displays This is the first profile parameter 7 Answer the parameter prompts as follows P1 0 P2 0 P3 0 P4 0 P5 0 P6 0 P7 7 P8 0 P9 0 P10 0 P11 0 8 Repeat Step 2 to reboot the Workstation After the system has rebooted go to Step 9 9 Type Set Output Profile and press Enter The system will prompt ...

Page 317: ... Select the Basic Features Tab as shown in Figure 6 49 3 Click the Finishing Module button and the selected Finisher Profile will be displayed in the bottom right corner of the screen as shown in Figure 6 49 4 To Review or change the Finisher Profile or other Finishing Features press the Settings button as shown in Figure 6 49 Basic Features Note If this box is not on the display then the IOT is n...

Page 318: ...layed as shown in Figure 6 50 Figure 6 50 The Settings Screen 5 To change the profile to be used click one of the profile options under the Finishing System Profile Heading as shown in Figure 6 50 6 To view the profiles click the Profile List button as shown in Figure 6 50 Profile List button Finishing System Heading ...

Page 319: ...60 GBC FusionPunch II Service Manual 12 2003 6 47 The Profile List Screen will be displayed as shown in Figure 6 51 Figure 6 51 The Profile List Screen 7 Select any of the profile buttons to display the information for each Profile listed ...

Page 320: ...s shown in Figure 6 52 Figure 6 52 The Timings Values Screen NOTE You will only be able to view the current profile loaded in to the system or change which one is active 8 Select the Close button all previous screens when you have finished reviewing the profiles if you changed which profile is active please ensure to select the Save option when directed ...

Page 321: ...r at any time after the CSE has installed the DFA Device The value and usage of the profiles and functions are the responsibility of the DFD 1 Use the Access button to activate the pathway options After entering the password correctly the Tools Pathway window will display as shown in Figure 6 53 2 Click the Tools Pathway option as shown in Figure 6 53 Figure 6 53 The Pathway Options Tools Pathway ...

Page 322: ...3 tab if your DocuColor 6060 has a scanner Select Machine Defaults 2 tab if your DocuColor 6060 does not have a scanner as shown in Figure 6 54 4 If you would like to review the currently loaded profiles click the Finishing System Module Profile button as shown in Figure 6 54 5 Click the NVM Read Write option as shown in Figure 6 54 NVM Read Write Machine Default 2 System Module button Machine Def...

Page 323: ... Link Number box please ensure to type in the full location number ie 700072 7 Press Start and the Current Value will be displayed To change value type in the new value and press enter The New Value will become the Current Value after pressing Start 8 Press the Input Chain Link button to select a different NVM number or use the up down arrows to move to next number 9 When finished press the Close ...

Page 324: ...GBC FusionPunch II Service Manual Host Machine Enablement DocuColor 6060 12 2003 6 52 ...

Page 325: ...rder to setup the Finishing Profiles the DFA module must installed and recognized by the host printer upon boot up NOTE You must first logon as custact or higher in order to set up the finishing profiles The following information is for the System Administrator or the System Analyst 1 Go to the Press Status Window click System as shown in Figure 6 56 Select Logon from the drop down menu This will ...

Page 326: ...achine Enablement DocuColor iGen3 12 2003 6 54 Figure 6 57 The Logon Window 2 Enter custact for the User ID and the custact password and then click Logon Please Note you must logon at a minimum of custact level in order to setup the profiles ...

Page 327: ...ration Icon This will open the Administration window as shown in Figure 6 58 Figure 6 58 The Administration Window 4 In the Administration window select the DFA Timing Profiles tab as shown in Figure 6 58 The DFA Timings Profiles tab will be displayed as shown in Figure 6 59 Administration Icon DFA Timing Tab ...

Page 328: ...ch II Service Manual Host Machine Enablement DocuColor iGen3 12 2003 6 56 Figure 6 59 The Dfa Timings Profile Tab 5 Click Options and select New from the drop down list to create a new DFA Finishing Profile Options ...

Page 329: ...Settings window will be displayed as shown in Figure 6 60 Figure 6 60 The DFA Timing Profile Settings Window 6 Enter the values for all DFA Timing Profile Attributes from the Finishing Profiles sheets at the end of this procedure 7 Click Apply and then click Save to close the window DFA Timing Profile Settings ...

Page 330: ... select Options this will bring up a drop down list now select Activate If this is completed correctly you will see a check mark in the assigned box as shown in Figure 6 61 Figure 6 61 DFA Profile Activation This completes the Profile Setup you are now ready to send your jobs to the FusionPunch II Hilighted Profile Assigned Check Box Activate Options ...

Page 331: ...n 0 Finisher Capacity 0 Recovery Behavior Sheet Time Between Sheets 0 Sheet Jam Time 2200 Time Between Sets 0 Set Jam Time 2600 Set Processing Time 0 Offline S0 Enabled Faulted S1 Enabled Full S2 Enabled Sheet Delivered S3 Enabled Set Delivered S4 Disabled Empty S5 Disabled Not Ready S6 Disabled Sheet Fed S7 Disabled Delivery Signal Type Lead Edge Delivery Start Adjust 0 Delivery End Adjust 100 En...

Page 332: ...GBC FusionPunch II Service Manual Notes 12 2003 6 60 Notes ...

Page 333: ...f the speed of the Host Printer Add 2200 to the Sheet Jam time and 2600 to the Set Jam time of the downstream device s profile even if you have more than one GBC Bypass Stacker installed Besure to add any extra times specified by their profiles NOTE N B C P Bourg 1 If one or more Hi Cap Stackers is used do not forget ot add 656ms to the Sheet and Set Jam times for each stacker When connected on a ...

Page 334: ...656m s To Sheet and Set Jam Tim es For Each H i Cap Stacker in fron t the FP II on a 6100 6115 6135 Add 861m s To Sheet an d Set Jam Tim es For Each H i Cap Stacker in front the FP II Add 50m s To End of Set Offset D ocuTech M o dels Fin ishers C on figu ratio n D evice N am e 61 X X Fu sion Pu nch II Sin gle Sta cker Fu sion Pu nch II 61 XX Fusio n Pu nch II Du al Stack er Fusio n Pu nch II 6 10 ...

Page 335: ...onPunch II FusionPunch II Punch SE Function 1 Line Off Line Off Line Off Function 2 Line Off Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Face Up and Face Down Rotate Never Never Always Minimum Sheet Length 254 254 254 Maximum Sheet Length 364 364 364 Minimum Sheet Width 203 203 203 Maximum Sheet Width 432 432 432...

Page 336: ...N 1 1 N and N 1 1 N and N 1 Side 1 D irection Face U p and Face D ow n Face U p and Face D ow n Face Up and Face D own Face U p and Face D ow n Face U p and Face D ow n Face U p and Face D ow n Rotate System Specified N ever N B Rotation needed if glue m ust be applied on short edge N ever N B Rotation needed if glue m ust be applied on short edge N ever N B Rotation needed if glue m ust be applie...

Page 337: ...essing Time 1300 15000 15000 15000 15000 600 Set Jam Time 8000 32760 32760 32760 32760 7168 Time to Cycle Up 0 0 0 0 0 0 S0 Enabled Enabled Enabled Enabled Enabled Enabled S1 Enabled Enabled Enabled Enabled Enabled Enabled S2 Enabled Enabled Enabled Enabled Enabled Enabled S3 Disabled Disabled on request Disabled on request Disabled on request Disabled on request Enabled S4 Disabled Disabled on re...

Page 338: ...and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Face Up and Face Down Face Up and Face Down Face Up and Face Down Face Up and Face Down Rotate S ystem Specified Never NB Rotation needed if glue m ust be applied on short edge Never NB Rotation needed if glue m ust be applied on short edge Never NB Rotation needed if glue m ust be applied on short edge Never NB Rotation needed i...

Page 339: ...BM2Bk23to27 SBM2Bk23to27S SBM2Ldgr1to27 Type External External External External External Function 1 Line Off Line Off Line Off Line Off Line Off Function 2 Line Off Line Off Line Off Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 1 N and N 1 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Face Up and Face Down Face Up and Face Down Face Up and Face D...

Page 340: ...A3 1 to 27 Sheet Set Non Stream Feed Stream Feed Timing Between Sheets 120 120 120 120 120 Sheet Jam Time 800 800 800 800 800 Set Compiler Processing Time 150 150 400 600 150 Maximum Set Processing Time 1200 1800 0 0 2400 Set Jam Time 7168 7168 7168 7168 7168 Time to Cycle Up 0 0 0 0 0 S0 Enabled Enabled Enabled Enabled Enabled S1 Enabled Enabled Enabled Enabled Enabled S2 Enabled Enabled Enabled ...

Page 341: ...2Ldgr1to27 Type SBM2Bk1to22 SBM2Bk1to22S SBM2Bk23to27 SBM2Bk23to27S SBM2Ldgr1to27 Function 1 Line Off Line Off Line Off Line Off Line Off Function 2 Line Off Line Off Line Off Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 1 N and N 1 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Face Up and Face Down Face Up and Face Down Face Up and Face Down Rota...

Page 342: ... 11x17 A3 1 to 27 Sheet Set Non Stream Feed Stream Feed Device Name SBM2Bk1to27C SBM2Ldgr1to27C Type External External Function 1 Line Off Line Off Function 2 Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Rotate Always Never Minimum Sheet Length 254 254 Maximum Sheet Length 364 364 Minimum Sheet Width 203 203 Maximum Sheet Wid...

Page 343: ... Set Sizes Non Stream Feed Stream Feed DT 6155 6180 8 5x11 8 5x14 A4 1 to 27 Sheet Set Stream Feed DT 6155 6180 11x17 A3 1 to 27 Sheet Set Non Stream Feed Stream Feed Tim ing Between Sheets 120 120 Sheet Jam Tim e 800 800 Set Com piler Processing Tim e 400 600 M axim um Set Processing Tim e 1200 2400 Set Jam Tim e 7168 7168 Tim e to Cycle Up 0 0 S0 Enabled Enabled S1 Enabled Enabled S2 Enabled Ena...

Page 344: ... to 27 Sheet Set Non Stream Feed Stream Feed Profile Name SBM2Bk1to27C SBM2Ldgr1to27C Type SBM2Bk1to27C SBM2Ldgr1to27C Function 1 Line Off Line Off Function 2 Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Rotate Always Never Minimum Sheet Length 254 254 Maximum Sheet Length 364 364 Minimum Sheet Width 203 203 Maximum Sheet Wid...

Page 345: ...ecial Tools Ball End Allen Wrench Set L Shape 050 through 3 8 6 Adjustable Wrench 2 Phillips Head Screw Driver 1 Phillips Head Screw Driver 6 Diagonal Wire Cutter 6 Needle Nose Pliers Standard Slotted Screw Driver Miniature Combination Wrench Set 5 32 through 7 16 ...

Page 346: ...allows its own version of Set Recovery Note If you are running the FusionPunch II inline with a DT135 then you must run the FusionPunch II in Online Mode and NOT the Cycle Up Mode Personality Profiles The full benefit of the Personality Profiles is that they profile arrays of information related to the External Finishing Devices Each profile con tains data on an external finishing device s timing ...

Page 347: ...pports most DFA signals In the following tables is a list of the printer families Statuses and supported Command Signals The most commonly used signals with the FusionPunch II as an end device last External Finishing Device in the line are as follows Note The DT 61xx Family is not listed as it supports all DFA sig nals Note All Sx Signals are known as Status Signals and All Cx are known as Command...

Page 348: ... Shut Down stops printing instantly and usually purges remaining sheet in the paper path out to the Top Tray of the Printer The printer also displays a message stating External Finisher Jam or Jam in Area 20 S2 Full Signal This is a 5 VDC signal that is sent to the printer to notify the printer that the finishing device is NOT full When the FusionPunch II turns this signal ON High the printer then...

Page 349: ...cessed that sheet of paper It will therefore not reprint that sheet of paper if the printer or the finisher detects a jam S4 Set Acknowledge Signal Set Delivered Signal This is a 5 VDC signal that is sent from a finishing device to the printer This signal is normally Low Off and active High ON It works much like the S3 signal Sheet Acknowledge Signal explained above except that it only applies to ...

Page 350: ...rt the Document Transport Motor the Punch Motor and be ready to accept paper Printer Exit Sensor FusionPunch II Entrance Sensor As the lead edge of a sheet of paper covers the last sensor in the printer the printer sends the C0 signal to the finisher When the FusionPunch II receives the C0 signal from the printer the Entrance Sensor has 330ms to see the lead edge of that sheet of paper and send a ...

Page 351: ... paper will begin to make its way to the Document Transport Sensor 2 Document Transport Sensor 1 Document Transport Sensor 2 The sheet of paper has no specified time in which it must arrive at DT2 Document Transport Sensor 2 When the lead edge of the sheet of paper arrives at DT2 the Little Star Controller PWB will turn ON the Back Gauge Solenoid This will bring the Back Gauge Fingers up to stop t...

Page 352: ... Little Star Controller will turn ON the Stacker O ring Motor and hold it on for 325ms If a Second Stacker is active then the Stacker 2 O ring Motor is activated 20ms after the lead edge of that sheet of paper reaches the Bypass Sensor It will remain active for 325ms 5 If the sheet of paper was the last sheet in a Set the Little Star Controller would have received the C1 signal when the sheet of w...

Page 353: ...then sends the S3 signal back to the printer If a Second Stacker is active the S3 will be sent as the trail edge clears the Stacker Bypass Sensor When all requirements are met as specified above the sheet will begin to make its way to the Stacker Bypass Sensor explained below Exit Sensor Stacker Bypass Sensor Note There is no check for the sheet of paper to make it from Exit sen sor to the Stacker...

Page 354: ...GBC FusionPunch II Service Manual Principles of Operation 12 2003 6 82 Notes ...

Page 355: ...ample P Punch Module S Stacker Module B Bypass Module Tag Identification for Configuration Differences Schematic diagrams will contain specific symbols that denote a with Figure 6 30 or without Figure 6 31 tag configuration for parts and wiring A tag symbol representing a configuration that includes a modification or retrofit Figure 6 62 With Modification A tag symbol representing a configuration ...

Page 356: ... an example of a Tag Matrix Card that would be attached to the Punch middle door and the Stacker door of the Fusion Punch II Figure 6 65 Tag Matrix Card Serial number location The Fusion Punch II has two different serial numbers one for the Punch module and one for the Stacker module as well as a Xerox serial number listed below the GBC serial number Please note the Xerox serial number begins with...

Page 357: ...nfiguration 0130017200 Was 30 Tooth Pulley Changed to 32 Tooth Pulley for consistent speeds 0130021000 7610517 Was 18 Tooth Pulley Changed to 16 Tooth Pulley with One Way Clutch Bearing 7610458 Addition of second Little Star Controller Expansion PWB to support all configurations 7610452 Addition of second Daughter PWB to support all configurations 1980015 SHCS 4 40 x 5 8 Addition of hardware to mo...

Page 358: ...rts are not interchangeable between the FP 1 and the FP II 0130017400 was revised back to the FP 1 revision level 0130021000 7610517 Part number change only reflected in the FP II Service Manual revision 3 0 Part was originally 0130021000 It has been changed to 7610517 because the old and new parts are not interchangeable between the FP 1 and the FP II 0130021000 was revised back to the FP 1 revis...

Page 359: ...de Weldment SE 1 7610289 Spring Bar Holder 1 7610334 Static Brush 1 1914082 Thumb Screw 3 7610508 Eprom Version A531 or higher 1 Description of change Part Number Description of change 7610525 Added Short edge Side Guide Bracket 7610524 Added Short edge Side Guide 7610289 Changed Spring Bar Holder to allow the mounting of the Short edge Side Guide 7610334 Changed Static Brush to allow the mounting...

Page 360: ...ng Document Transport Main Drive 6060 iGen3 1 7610534 Pulley 32 Tooth Stacker Bypass Motor 6060 iGen3 1 7610535 Pulley 24 Tooth Stacker Bypass Main Drive 6060 iGen3 1 7610537 Assy Belt Take Up Document Transport Timing Belt 6060 iGen3 1 7610621 Panel Punch Entrance 4xxx 6060 iGen3 1 Description of change Part Number Description of change 7610508 Eprom Version C147 or higher 7610529 PWB Punch I O 7...

Page 361: ...ing of stack 7610680 Plate Docking Female moved Pim nuts inch to the right when viewing from front the machine Operators side Allows proper docking of down stream devices Tag S2 Date 10 01 01 Class M Mandatory MFG Serial Numbers NG01644 Name Curl Up Stacking Quality Kit Purpose Improves Curl Up Stacking Quality Retrofit Kit 7610512 Reference Parts included in kit Part Number Description Qnty 76102...

Page 362: ...turing O Optional for the field MFG Serial Numbers NA Name 11x17 A3 punching and stacking Kit Purpose This Kit enables a Standard Stacker Stacker without a Bypass kit installed to accept 11x17 and A3 running the Short edge punch or no punch Includes the softeware upgrade to enable the punching or Non punching of 11x17 and A3 on the short edge Retrofit Kit 7610520 Reference Parts included in kit Pa...

Page 363: ...Part Number Description Qnty 1980082 SHCS 10 32 x 2 1 1926063 Washer Lock 10 1 1926702 Nut Hex 10 32 1 7610361 Tubing Stacker Upper Switch Actuating Screw 1 Description of change Part Number Description of change 1980082 Changed from 1980080 SHCS 10 32 x 1 12 Changed to 1980082 SCHS 10 32 x 2 Added longer screw for easier adjustment Also added to the Service Manual Parts List 1926063 Added part to...

Page 364: ...GBC FusionPunch II Service Manual Tag Numbers 12 2003 6 92 ...

Page 365: ...1 Stacker Inputs BSD 11 Chain 12 2 Stacker Outputs BSD 12 Chain 12 2 Stacker Outputs BSD 13 Component Locators Punch Interlocks 14 Punch Power Switch and Line Filters 16 Punch PWBs 18 Punch Sensors 20 Punch Motors A 22 Punch Motors B 24 Punch Solenoids 26 Stacker Switches A 28 Stacker Switches B 30 Stacker PWBs 32 Stacker Motors and Solenoids 34 Bypass Stacker Motors Solenoids and Sensors 36 Intro...

Page 366: ...ECEPTICLE LINE FILTER PL1 2A AC LINE AC NEUTRAL MAIN POWER SWITCH CIRCUIT BREAKER 24V 0V PUNCH AC DC DISTRIBUTION PWB P2 P1 3 4 LINE NEU P1 J1 PUNCH BRN GRN BLU 24 VDC POWER SUPPLY PWB NEU LINE BRN BLU LINE NEU CN1 CN2 24V 0V 1 2 1 2 ORN BLK PL3 1 PL1 1I PL3 1 P2 J2 AC RECEPTICLE LINE FILTER PL1 1I AC LINE AC NEUTRAL MAIN POWER SWITCH CIRCUIT BREAKER 1 2 1 2 5V 0V 5 VDC POWER SUPPLY PWB NEU LINE B...

Page 367: ...24V 5V P28 J28 J14 P14 P14 J14 24VI 1 4 24V INTERRUPTED 0V YEL P12 J12 24VI 0V 5V 24V STACKER I O PWB 24VI 0V 5V 24V J28 P28 YEL BLK RED ORN YEL BLK RED ORN ORN RED BLK BLK RED ORN 24V 0V 12 1 12 1 ORN BLK 24V 0V PL 3 1 PL3 1 PL 3 2 PL 3 2 24VR P16A J16A 1 4 24V RET BYPASS INSTALLED ONLY 1 1 1 5V 0V 1 1 1 1 P5 J5 5V 0V BLK RED DAUGHTER PWB PL 3 1 ORN BLK J1 P1 0V 5V 24V RED P26 J26 24V 24V 0V LITT...

Page 368: ... P6 J6 ORN PUNCH I O PWB 0V P20 J20 RIGHT DOOR INTERLOCK SW1 1 3 MIDDLE DOOR INTERLOCK SW2 LEFT DOOR INTERLOCK SW3 TOP COVER 1 INTERLOCK SW4 TOP COVER 2 INTERLOCK SW5 1 1 3 1 1 3 3 1 1 3 3 1 1 3 1 1 2 3 3 24V INTERRUPTED YEL P19 J19 INB1 INB1 INB2 INB2 INB3 INB3 INA6 INA6 RIGHT DOOR TOP COVERS LEFT DOOR MIDDLE DOOR LITTLE STAR CONTROLLER PWB P25 J25 J3 P3 13 14 15 16 0V 0V 0V 3 PL 1 1A PL 1 1A PL ...

Page 369: ...TOP COVER INTERLOCK SW2 1 3 3 P19 J19 WHT INB1 INB1 INA6 INA6 FRONT DOOR PUNCH DAUGHTER PWB PL 3 1 P24A J24A 6 1 BLK 0V BLK J25 P25 24 VDC 24V P6A J6A ORN FRONT DOOR INTERLOCK SW1 PL 1 1A 1 3 3 24V P16A J16A 24V INTERRUPTED YEL 24V INTERRUPTED YEL 1 P24 J24 P25 J25 STACKER AC DC DISTRIBUTION PWB PL 3 2 PL 1 2A 1 2 1 2 NOTE IF BYPASS STACKER IS INSTALLED P6A WILL BE CONNECTED J6B FRONT DOOR AND P16...

Page 370: ...N RED ORN YEL GRN PLATE 7610299 BLU WHT BLK INSTALL JUMPERS J1 J4 AS SHOWN DISTRIBUTION BRN RED ORN YEL GRN BLK BLU WHT RED BRN 7610452 J22 ORN YEL GRN BLK BLU WHT J23 BRN RED ORN YEL GRN J25 J24 J1 J5 1 BLACK RED ORANGE 1 BLU WHT J2 J3 EXPANSION I O BUS 7610458 7610495 1 7610459 LCD ASS Y 1 NOT CONNECTED WHITE NOTE WHITE WIRE PIN BROWN 7610496 LCD DISPLAY ASSEMBLY ...

Page 371: ... HV11 HV10 8 J 3 7 6 5 4 S0 OFFLINE S1 FAULTED S2 FULL S3 SHEET ACK S4 SET ACK C0 SHEET EXIT C1 SET EXIT C2 CYCLE UP C6 FINISHER FUNC1 C7 FINISHER FUNC2 OUTA1 OUTA2 OUTA3 OUTA4 OUTA5 INA1 INA2 INA3 INA4 INA5 P23A J23A A B C 5 VDC 5 VDC 5 VDC 5 VDC OUTA3 J17A OUTA4 J16A OUTA5 J15A 5 VDC 0V 0V 0V 0V 0V INA3 J14A INA4 J13A INA5 J12A JP18 22 4 23 5 24 6 25 7 26 8 30 12 31 13 32 14 36 18 37 19 1 P1 DFA...

Page 372: ...FINISHER FUNC1 FINISHER FUNC2 INC1 INC4 INC5 PL 3 2 P24A J24A J23A A B C J14B J13B J12B J17B J16B J15B JP18 22 4 23 5 24 6 25 7 26 8 30 12 31 13 32 14 36 18 37 19 1 P1 DFA TO DOWNSTREAM DEVICE 1 2 3 4 5 P J 23 1 2 3 4 5 INC2 INC3 P23A OUTC1 OUTC2 OUTC3 OUTC4 OUTC5 OPTO 11 RELAY OPTO 10 RELAY 0V 0V OPTO 8 RELAY 0V OPTO 9 RELAY 0V OPTO 7 RELAY 0V OPTO 16 RELAY 0V OPTO 15 RELAY 0V OPTO 14 RELAY 0V OP...

Page 373: ...NSOR PL 4 1A DOCUMENT TRANSPORT 1 SENSOR DOCUMENT TRANSPORT 2 SENSOR PUNCH SENSOR EXIT SENSOR P10 J10 24V 0V P9 J9 24V 0V P1 J1 24V 0V P2 J2 24V 0V PL 4 2A PL 4 2A PL 4 3A PL 4 3D P11 J11 INB4 P10 J10 INB5 P9 J9 INB6 P2 J2 INB7 P1 J1 INB8 P25 J25 INB4 INB5 INB6 INB7 INB8 LITTLE STAR CONTROLLER PWB 13 J 3 12 11 10 9 EXIT PUNCH ENTRANCE SENSOR DOC XPORT 2 SENSOR DOC XPORT 1 SENSOR SIGNAL SIGNAL SIGN...

Page 374: ...AY 5 RELAY 4 NUI MT3 MT2 NUI J9 J8 BRN BRN BLU BLU MOT MOT PUNCH I O PWB OUTB8 PL 3 1 OUTB7 OUTB6 OUTB1 OUTA8 OPTO 1 RELAY OPTO 2 RELAY OPTO 3 RELAY OUTB7 OUTB6 24VI 24VI J3B P3B OUTB8 24VI J4B P4B J5B P5B YEL WHT YEL WHT YEL WHT PUNCH CLUTCH SOLENOID PL 4 3B BACK GAUGE SOLENOID PL 4 3C SHEET EJECT SOLENOID PL 4 3N OUTB1 J30 P30 OUTA8 MT2 MT3 P22 J22 PUNCH BACK GAUGE FINGERS SHEET EJECT SOLENOID P...

Page 375: ...5 1A FULL SWITCH PL 5 1A ALMOST FULL SWITCH PL 5 1A 0V 0V STACKER I O PWB PL 3 2 INB6 INB5 INB4 STACKER AC DC DISTRIBUTION PWB PL 3 2 RLY2 J15 R ON STACKER EXIT SENSOR 24V 0V 1 1 NOTES BYPASS INSTALLED ONLY SIGNAL SIGNAL SIGNAL SIGNAL 24V 0V 1 2 1 2 ORN BLK 24V 0V INB8 INC8 INB6 INB5 INB4 INB8 INA8 DAUGHTER PWB PL 3 1 6 5 4 8 8 UPPER SWITCH FULL SWITCH ALMOST FULL SWITCH STACKER EXIT SENSOR TRAY D...

Page 376: ...I O PWB OUTB8 PL 3 2 OUTB7 OUTB6 OPTO 1 RELAY OUTB7 OUTB6 24VI 24VI J3B P3B OUTB8 24VI YEL WHT YEL WHT YEL WHT TAPPER SOLENOID PL 5 1B OFFSET 1 SOLENOID PL 5 1C OFFSET 2 SOLENOID PL 5 1C P22 J22 STACKER TAPPERS STACKER OFFSET 1 YEL YEL YEL WHT WHT WHT 8 7 6 STACKER OFFSET 2 5 BYPASS DIVERTERS OUTB5 BYPASS DIVERTER PL YEL WHT OUTB5 24VI YEL WHT P J22 WHT BLU BLK GRN J4A J5A J6A P4A P5A P6A 1 1 BYPA...

Page 377: ... DC DISTRIBUTION PWB PL 3 2 OPTO 1 RELAY RELAY 3 NUI FWD MT2 NUI J7 J8 BLK BRN WHT BLU MOT STACKER I O PWB OUTA6 PL 3 2 OUTA7 OUTA8 OUTA7 OUTA8 J30 P30 OUTA6 P23A J23A STACKER TRAY MOTOR P11 J11 6 7 8 P23 STACKER O RING MOTOR 2 STACKER BYPASS MOTOR OUTB2 OUTB2 J22 STACKER TRAY DIRECTION BYPASS MOTOR MT2 NUI J10 BRN BLU MOT MT1 MOT RED REV RELAY 2 DIR MT2 RELAY 3 MT4 P7 P8 P10 RED WHT BLU BLK P22 W...

Page 378: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 14 Component Locators Punch Interlocks 3 2 1 5 4 ...

Page 379: ...ocators Punch Interlocks Item Part Description Qty 1 7610501 Switch Punch Interlock Top Cover 1 1 2 7610501 Switch Punch Interlock Top Cover 2 1 3 7610501 Switch Punch Interlock Left Door 1 4 7610501 Switch Punch Interlock Mid Door 1 5 7610501 Switch Punch Interlock Right Door 1 ...

Page 380: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 16 Component Locators Punch Power Switch and Line Filter 1 2 ...

Page 381: ...BC FusionPunch II Service Manual 12 2003 7 17 Component Locators Punch Power Switch and Line Filter Item Part Description Qty 1 7610455 Punch Main Power Switch Circuit Breaker 1 2 7610456 Punch AC Receptical Line Filter 1 ...

Page 382: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 18 Component Locators Punch PWBs 4 2 7 5 3 6 1 8 BYPASS ONLY ...

Page 383: ...y 1 7610450 PWB Punch AC DC Distribution 1 2 7610451 PWB Punch I O 1 3 7610452 PWB Daughter 1 4 7610453 PWB 24 VDC Power Supply 1 5 7610454 PWB 5 VDC Power Supply 1 6 7610457 PWB Little Star Controller 1 7 7610458 PWB Little Star Controller Expansion 1 8 7611943 PWB Little Star Controller Expansion Daughter Bypass Only 1 ...

Page 384: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 20 Component Locators Punch Sensors 3 4 1 2 ...

Page 385: ...C FusionPunch II Service Manual 12 2003 7 21 Component Locators Punch Sensors Item Part Description Qty 1 7610421 Sensor Document Transport 1 2 2 2 7610423 Sensor Entrance 1 3 7610423 Sensor Punch 1 4 7610424 Sensor Exit 1 ...

Page 386: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 22 Component Locators Punch Motors A 1 2 ...

Page 387: ...ators GBC FusionPunch II Service Manual 12 2003 7 23 Component Locators Punch Motors A Item Part Description Qty 1 7610418 Motor 115 VAC 60 HZ Document Transport 1 2 7610425 Motor 230 VAC 50 HZ Document Transport 1 ...

Page 388: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 24 Component Locators Punch Motors B 1 2 ...

Page 389: ...GBC FusionPunch II Service Manual 12 2003 7 25 Component Locators Punch Motors B Item Part Description Qty 1 0130032100 Pulley 14 Tooth 115 VAC 60 HZ Punch Motor 1 2 0130039100 Pulley 17 Tooth 230 VAC 50 HZ Punch Motor 1 ...

Page 390: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 26 Component Locators Punch Solenoids 2 1 ...

Page 391: ...onent Locators GBC FusionPunch II Service Manual 12 2003 7 27 Component Locators Punch Solenoids Item Part Description Qty 1 7610193 Solenoid Rotary Back Gauge 1 2 7610193 Solenoid Rotary Sheet Exit Assy 1 ...

Page 392: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 28 Component Locators Stacker Switches A 1 2 3 ...

Page 393: ...Service Manual 12 2003 7 29 Component Locators Stacker Switches A Item Part Description Qty 1 7610455 Switch Circuit Breaker Stacker Main Power 1 2 7610456 AC Receptical Line Filter Stacker Main Power 1 3 7610501 Switch Stacker Interlock 2 ...

Page 394: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 30 Component Locators Stacker Switches B 1 2 ...

Page 395: ...Component Locators GBC FusionPunch II Service Manual 12 2003 7 31 Component Locators Stacker Switches B Item Part Description Qty 1 7610089 Bracket Upper Switch 1 2 7610188 Switch Almost Full Full 2 ...

Page 396: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 32 Component Locators Stacker PWBs 1 2 ...

Page 397: ...Component Locators GBC FusionPunch II Service Manual 12 2003 7 33 Component Locators Stacker PWBs Item Part Description Qty 1 7610450 PWB Stacker AC DC Power Distribution 1 2 7610451 PWB Stacker I O 1 ...

Page 398: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 34 Component Locators Stacker Motors and Solenoids 2 6 3 5 4 1 ...

Page 399: ... Solenoids Item Part Description Qty 1 7610172 Solenoid Tubular Offset 1 and 2 2 2 7610191 Motor 115 VAC 60 HZ Stacker Tray 1 3 7610192 Motor 115 VAC 60 HZ Stacker O ring 1 4 7610193 Solenoid Rotary Tapper Assy 1 5 7610194 Motor 230 VAC 50 HZ Stacker Tray 1 6 7610195 Motor 230 VAC 50 HZ Stacker O ring 1 ...

Page 400: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 36 Component Locators Bypass Stacker Motors Solenoids and Sensors 2 1 3 ...

Page 401: ...3 7 37 Component Locators Bypass Stacker Motors Solenoids and Sensors Item Part Description Qty 1 7611990 Motor Bypass 230V 1 1 7611991 Motor Bypass 115V 1 2 7611945 Solenoid Rotary Bypass Gate 1 3 7611944 Sensor Stacker Exit 7610424 Sensor without Cable Assy 1 ...

Page 402: ...GBC FusionPunch II Service Manual Component Locators 12 2003 7 38 Notes ...

Page 403: ...stallation 8 2 Installing the Punch 8 4 Installing a Single Offset Stacker 8 6 Installing a Second Offset Stacker 8 7 Preparing to Install a Bypass Kit 8 10 Bypass Kit Installation procedure 8 13 Checking the Operation in Offline and Online Mode 8 18 DocuColor 6060 iGen3 Kit Installation Instructions 8 19 Preparing for installation 8 19 Installation Procedure 8 21 ...

Page 404: ...shipper before proceeding b Compare the contents of the shipping crates and the packing list 2 Before Installing the system ensure that Tag P1 and S1 have been installed in the Punch and each Stacker Refer to the Service Manual Section 6 for the Tag Matrix information Domestic International Product Code Description Qty 0136000000 FP II Dom Punch 1 7610462 FP II Punch Power Cord 1 7610205 FP II Use...

Page 405: ... Stay behind the machine when rolling it down the ramp Note Bottom of ramped section has Male Hinge which will connect with the Female portion of the hinge attached to the bottom of the front of the crate e When the Hinges are connected drop the front of the ramped section to the floor f Slide out the Fusion Punch down the ramp Note Fusion Punch or Stacker is NOT mechanically connected to the insi...

Page 406: ...he punch docking assembly with the female docking assembly on the printer Figure 8 2 Without docking it move the punch into a position close enough to the printer to allow the card stock to be aligned with the input to the punch Figure 1 67 Punch and Printer Docking Assemblies 4 Remove the rear covers from the punch to access the left and right rear caster adjustment bolts 5 Using a 1 2 inch wrenc...

Page 407: ...inch Allen head cap screws that hold the docking assembly If the docking latch tension is not correct adjust the docking assembly by moving it to the left or right before tightening the remaining four Allen head cap screws 13 On the right side of the punch lower the front and rear leveling pads until they are touching the floor Screw the right front and right rear casters up so that the weight of ...

Page 408: ...acker by using a 1 2 inch wrench to adjust the front and rear casters on the right side of the stacker 8 Move the stacker to adjust the front to rear alignment of the locating pins on the punch and the holes in the stacker frame 9 Adjust the front to rear alignment of the docking assembly and tighten the two 3 16 inch Allen head cap screws on the left side of the stacker 10 Move the stacker to the...

Page 409: ... Refer to Section 6 General Procedures for more information Note All down steam devices must be set up for 6180 speed and must use 6180 profiles regardless of what kind of Host Printer the devices are connected to Installing a Second Offset Stacker Prerequisite Ensure that Stacker 1 is equipped with a Bypass Assy If the installed stacker DOES NOT have a Bypass Assy installed it has to be either a ...

Page 410: ...e remaining four 3 16 inch Allen head cap screws that hold the docking assembly If the docking latch tension is not correct move the docking assembly to the left or right before tightening the remaining four screws 13 On the right side of stacker 2 lower the front and rear leveling pads until they are touching the floor Using the 1 2 inch wrench screw the right front and right rear casters up so t...

Page 411: ...cedure 25 Enter the Offline mode 26 Insert some paper into the Manual Paper Feed Tray to ensure correct alignment and operation 27 Ensure the correct host and personality profiles are enabled Refer to Section 6 General Procedures for more information Note All down steam devices must be set up for 6180 speed and must use 6180 profiles regardless of what kind of Host Printer the devices are connecte...

Page 412: ...amage from electrostatic discharge Observe all ESD procedures to avoid component damage Preparing for installation 1 Prepare for installation a Inspect all shipments for damage If significant damage exists contact the shipper before proceeding b Compare the contents of the packages and the packing list 2 Before installing the Bypass kit ensure that Tag P1 and S1 have been installed in the Punch an...

Page 413: ... 7610678 Pin Docking Top Alignment 2 1981311 Belt Timing Bypass Motor 1 1980094 SHCS 1 4 20 x 1 2 2 7610680 Bracket Assy Docking 1 7611922 Assy Paper Guide Bypass Stacker 1 Product Code Description Qty 7611951 Bypass Assy 1 7611932 Bypass Motor Assy International 1 1980077 Screw Socket Cap SS 1 2 1980098 Screw Socket Cap SS 1 2 7611937 Bracket Docking Assy 1 7611936 Bracket Assy Docking 1 7611933 ...

Page 414: ...GBC FusionPunch II Service Manual Preparing to Install a Bypass Kit 12 2003 8 12 Notes ...

Page 415: ...ass Stacker Wire Form Assy ensure to align the Wire Form Guides to the side of the each associated tapper You may have to move the tappers over so that they do not interfere with the Wire Form Guides Figure 1 72 Stacker Infeed Assy removal 3 Mount the RH and LH Docking Brackets and the Docking Bar Figure 8 8 3 1 Mount the RH and LH Docking Brackets using 2 Lock Washers and 2 Hex Nuts on each Brack...

Page 416: ... Lock and slide the Stacker Assy to the middle of the Stacker Slide Rail then tighten the Stacker Slide Lock 5 2 Gently swing down the Infeed side of the Bypass Assy and fit the LH and RH Locating Pins into the LH and RH cutouts in the Bypass Assy 5 3 Gently swing down the Exit side of the Bypass Assy until it rests on the Docking Bar Figure 1 75 Mounting the Bypass Assy in the Stacker LH CUTOUT R...

Page 417: ... 8 12 Figure 1 77 Connecting the Bypass Gate Solenoid 8 Route the Bypass Diverter Cable Assy through the hole in the Stacker I O PWB mounting plate and connect it to the Stacker I O PWB connector J6B 9 Remove the Bypass Motor Cover 4 Allen Head cap screws and 4 Lock Washers Figure 1 78 Removing the Bypass Motor Cover 10 Mount the Bypass Motor to the Bypass Frame 2 Allen Head Cap screws and 2 Lock ...

Page 418: ...pass Motor Timing Belt 14 Slide the Bypass Motor up or down until the Bypass Timing Belt deflects 0 10 in 2 3 mm 15 Tighten the 4 Hex Nuts 16 Mount the Top Bypass Motor Pulley Cover 4 Allen Head Cap screws and 4 Lock Washers and Bottom Bypass Motor Pulley Cover 2 Allen Head Cap screws and 2 Lock Washers 17 Mount the Bypass Exit Sensor Bracket Assembly 2 Allen Head Cap screws and 2 Lock Washers Fig...

Page 419: ...PWB cables of Stacker 1 from P J 23A and P J 24A to P J 23B and P J 24B 4 Connect the I O Cables that you received in the Bypass Kit to the Second Punch Daughter PWB at P J 22 23 24 and 25 5 Connect the other end of the I O Cables to the Second Stacker I O PWB at P J 22A 23A 24A and 25A 6 Connect the DC Power Cable that you received in the Bypass Kit to P J 13 on the Stacker 1 AC DC Distribution P...

Page 420: ...apter 1 of the User Guide for details on setting up and operating the FusionPunch II 1 Start the Punch in offline mode 2 Feed sample sheets into the machine to ensure proper operation and alignment 3 Enable the Host Printer Refer to Section 6 for enablement procedures 4 Start the Punch in online mode and have the customer send a job from the Host Printer ...

Page 421: ...are susceptible to damage from electrostatic discharge Observe all ESD procedures to avoid component damage Preparing for installation 1 Prepare for installation a Inspect all shipments for damage If significant damage exists contact the shipper before proceeding b Compare the contents of the packages and the packing list 2 Before installing the DocuColor 6060 iGen3 Upgrade kit ensure that Tag P1 ...

Page 422: ...uide Entrance Top 6060 iGen3 1 7610531 Paper Guide entrance Bottom 6060 iGen3 1 7610532 Pulley 48 Tooth Document Transport Main Drive 6060 iGen3 2 7610533 Belt Timing Document Transport Main Drive 6060 iGen3 1 7610534 Pulley 32 Tooth Stacker Bypass Motor 6060 iGen3 1 7610535 Pulley 24 Tooth Stacker Bypass Main Drive 6060 iGen3 1 7610537 Assy Belt Take Up Document Transport Timing Belt 6060 iGen3 1...

Page 423: ... power cord Note If the FP II is already connected to a host printer then disconnect it from the host printer and each of FP II s Stackers prior to installing the DocuColor 6060 iGen3 Upgrade Kit 1 Remove the Entrance Panel and both of Rear Panels on the FP II Punch unit Figure 8 19 Figure 1 84 Removing the Panels Rear Panels Entrance Panel ...

Page 424: ...he kit on top of the Input Baffles 2 4 Mount the Input Baffles and the Entrance Paper Guides using the 6 Hex Nuts you removed from the Original Panel 2 5 Store the old Entrance Top Paper Guide inside the FP II this will ensure that the unit can be connected to Docutech in the future if needed 2 6 The old Entrance Panel is of no use anymore it may be thrown out Figure 1 85 Setting up the New Entran...

Page 425: ...p Assy 4 2 Remove the 2 Main Drive Pulleys by loosening both Set Screws on each Pulley 4 3 Install the 2 new Drive Pulleys 7610532 from the Kit 4 4 Install the new Document Transport Timing Belt 7610533 and mount the new Take Up Assy 7610537 using the hardware from the original Take Up Assy Refer to section 4 of the FP II Service Manual for Belt Tension adjustments if needed Figure 1 86 Replacing ...

Page 426: ...ead Cap Screws from the Punch I O PWB 5 3 Install the new Punch I O PWB 7610529 from the Kit using the 7 Allen Head Cap Screws from the original Punch I O PWB 5 4 Connect the DFA cable and all of the P J connectors in their appropriate location 5 5 Ensure the jumpers in the top right corner of the Punch I O PWB set across the A and B pins Figure 1 87 Replace the Punch I O PWB Punch I O PWB 7 Allen...

Page 427: ...l it with the notch on the Eprom facing up and lined up with the notch on the socket Figure 1 88 Replacing the Eprom BLACK GREEN 1 JP6 JP1 1 JP4 ORANGE BLUE WHITE YELLOW GREEN BLACK BROWN RED BLUE WHITE Little Star Controller PWB 7610457 1 JP2 GREEN LCD BLACK ORANGE ORANGE BLUE WHITE BLACK BROWN RED ORG YEL BLUE WHITE ORANGE YELLOW GREEN BROWN RED JP5 SRAM EPROM 1 JP3 RED ORANGE YELLOW BROWN Eprom...

Page 428: ...the Stacker Rear Panel 8 2 Remove the Bypass Pulley Top Cover 4 Allen Head Cap screws and 4 Lock Washers and the Bypass Pulley Bottom Cover 2 Allen Head Cap Screws and 2 Lock Washers Figure 8 24 8 3 Loosen the 4 Hex Nuts holding the Bypass Motor Figure 8 24 8 4 Remove the Bypass Motor Timing Belt Figure 8 24 Figure 1 89 Replacing the Stacker Bypass Motor Pulley 8 5 Install the new Stacker Bypass M...

Page 429: ...e Stacker Bypass Timing Belt tighten the Stacker Bypass Motor and install the Stacker Bypass Pulley Covers 12 Connect the main Power Cord to the Punch Unit and Power the Punch ON 13 Go to the Control Panel and enter the Service Diagnostics 14 Keep pressing the Diagnostics button until you get the Printer Select Function and the use the arrows to scroll to desired printer to be connected to 15 Exit...

Page 430: ...GBC FusionPunch II Service Manual Notes 12 2003 8 28 Notes ...

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