GCC Technologies Expert Pro Series Page 3 Maintenance Manual Download | Manualshive

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3

Introduction and Component

Overview

This Maintenance Guide provides step-by-step instructions for replacing and maintaining the
components of the Puma Cutting plotter. It also includes a troubleshooting chapter
with some handy hints when problems arise or if the plotter does not operate properly.
This Maintenance Guide provides system diagrams, wiring diagrams and numerous flow
charts detailing the maintenance diagnostics built into the Expert Pro Cutting plotter.
Finally
there is a parts list and spare parts order form for convenience of ordering replacement parts.

For further Tech Support enquiries and assistance please contact the following Email

address:

[email protected]

The following diagrams represent all of the maintainable mechanical and electronic
components of the Expert Pro Cutting Plotter with corresponding parts lists for
convenient identification.

To the Contents Page

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Summary of Contents for Expert Pro Series

Page 1: ... and stand on a dry surface If during the use of electrical equipment you feel an electrical discharge e g a tickling sensation on your skin immediately stop using that tool Label it and send it for repair GENERAL SITE SAFETY REQUIREMENTS Fire extinguishers must be in working order and within easy reach The main power supply switch must be easily accessible The system site must be suitably illumin...

Page 2: ...ntenance 30 Removing the Front Back End and Top Covers 30 Replacing the Pinch Roller Sets 32 Replacing the Tool Carriage 34 Replacing the Y Motor 36 Replacing the VCM PC Board 38 Main board Connection or Replacement 39 Replacement of Fuses 40 Adjusting the Tool Carriage Transmission Belt 41 Adjusting the X Motor Tension Belt 42 Adjusting the Y Motor Tension Belt 43 3 Troubleshooting 45 Maintenance...

Page 3: ...iring diagrams and numerous flow charts detailing the maintenance diagnostics built into the Expert Pro Cutting plotter Finally there is a parts list and spare parts order form for convenience of ordering replacement parts For further Tech Support enquiries and assistance please contact the following Email address Tech support gcc com tw The following diagrams represent all of the maintainable mec...

Page 4: ...4 Main Unit Assembly 29006178G ...

Page 5: ...bly 1 5 22800705G Top rail 1 6 22801070G Square Bar 1 7 29001473G Pinch roller assembly 2 8 29004690G Carriage assembly 1 9 22802168G Top cover 1 10 24100499G Left cover 1 11 24100491G Right cover 1 12 24100492G Front platen extension 1 13 24100493G Rear platen extension 1 14 24100333G Lever 1 15 29005498G Main board 1 16 29004692G Control panel assembly 1 ...

Page 6: ... Assembly 29004693G Item Part Number Part Name Quality 1 24401210G Unit base box 1 2 29005498G Main board 1 3 29001488G Power board 1 4 25700075G ON OFF Power switch 1 5 22300021G Fuse holder 1 6 21800034G AC plug 1 ...

Page 7: ...7 Left End Assembly 7 1 ...

Page 8: ...lity 1 29003810G X Axis Motor Assembly 1 2 24100189G X Axis actively belt gear 1 3 20600039G X Axis belt 1 4 24100175G Idle pulley 1 5 24400288G X motor adjusting bracket 1 6 24400761G X motor bracket 1 7 22300021G Fuse Holder Type 1 ...

Page 9: ...9 Right End Assembly 7 8 ...

Page 10: ...1 24400264G Active pulley s bracket 1 2 24100176G Active pulley 1 3 22800288G Active pully s shaft 1 4 24400066G Cable basket 1 5 24400265G Y motor bracket 1 6 29003812G Y Motor Assembly 1 7 24100258G Switch cam 1 8 25700002G Lever switch 1 ...

Page 11: ... 20200085G Blade holder slider bracket assembly 1 5 29000940G VCM assembly 1 6 20200065G VCM coil 1 7 25500043G Tool carriage spring 2 8 29001467G VCM PCB assembly 1 9 22800838G Blade holder bracket screw 1 10 22800048G Spacer for carriage guide roller 2 11 20700040G Flange bearing 4 12 22801680G Carriage guide roller flute A 2 13 22800049G Carriage guide roller 2 14 22800411G Spacer for Carriage ...

Page 12: ...0029G Bearing 4 16 22800710G Carriage guide roller flute 4 17 22801464G White spring bracket for carriage guide roller 2 18 25500041G Spring for carriage guide roller 4 19 22800717G Carriage guide roller shaft 2 ...

Page 13: ...13 Complete X motor Assembly 29003820G ...

Page 14: ...14 Item Part Number Part Name Quality 6 1 29003820G Motor assembly 1 6 1 1 29003810G Motor 1 6 2 24400761G X motor bracket 1 6 3 24400288G X motor adjusting bracket 1 ...

Page 15: ...15 Y Axis Idel Pulley Assembly 29003820G ...

Page 16: ...24900006G E shape retaining ring 4 8 1 5 22801465G White pulley Washer 1 8 1 6 25200345G M3 14 Pan Screw Spring 1 8 1 7 23500004G Nut M3xt2 4xS5 5 1 8 2 24400287G Idle pulley Assembly adjusting bracket 1 8 3 24400286G Idle pulley Assembly bracket 1 8 4 25200117G Hexagonal Socket Head including spring flat washer 1 8 5 25200157G Hexagonal Socket Head including spring flat washer 2 ...

Page 17: ...17 Pinch Roller Assembly 29001437G 4 1 8 ...

Page 18: ...er base 1 2 24100286G Pinch roller arm 1 3 22800310G Lynx Cam Roller 1 4 20200003G Pinch roller wheel 1 5 22800029G Pinch roller shaft 1 6 25500040G Pinch Roller Spring Lynx 2 7 24900006G E shape retaining ring 4 8 22800294G Pinch roller active arm shaft Lynx 1 ...

Page 19: ...19 Grid Drum Assembly 29005441G ...

Page 20: ...tem Part Number Part Name Quality 1 22802167G Grid Drum shaft Puma III 60 1 2 22800564G Bearing Blocker 2 3 20700039G Bearing L 1910ZZ 5 4 23300362G long drum 50mm 6 5 24100189G X axis actively belt gear 1 ...

Page 21: ...Item Part Number Part Name Quality 1 22802169G Main beam Puma III 60 1 2 21700021G Bearing Support 5 3 29005441G Grid Drum Assembly 1 4 24402320G Paper platten 1 5 24000543G SPACE PE styrofoam Puma III 1 22200040G DC FAN AD7524UB LF 1 ...

Page 22: ...22 1 System Diagram and Components of Main Board ...

Page 23: ...5206EFT54 FPGA SRAM 64K 32Bit DRAM 16MB TIMER PWM Generator X Motor Driver Y Motor Driver VCM Driver Driver System Feedback Sensor Motor Phase Decoder X Motor Encoder Y Motor Encoder Direction Control Media Sensor x2 Carriage Sensor Lever Sensor Parallel Port USB Port Keyboard Set Up Switch Pen Force ...

Page 24: ...24 1 2 Connection of Electrical Components 1 2 1 Machine Base and Components Main board Fan Power Cable Fuse Power Switch Transformer ...

Page 25: ...25 J JP15 AC Input 100V 240V Front Paper Sensor 3A FUSE JP38 JP10 JP8 JP7 JP15 JP14 JP19 U5 On Off Switch JP39 DRAM SIMM Power Board JP18 Main Board JP13 JP40 JP12 JP16 JP17 JP11 Control Panel Lever SW ...

Page 26: ...ve the two screws that fix the bracket to the carriage guide beam 2 Remove Pinch Roller Set Step 1 Move the Pincher Roller Set to the furtherest end view from rear where a notch is on the guide beam Step 2 Remove the Pinch Roller Set from the notch To install please keep the inside Cam Roller of the Pinch Roller Set downward squarely and Lever up Front Square Bar Holding Bracket Cam roller pointin...

Page 27: ...the Lever If you just need to replace Lever please refer to Step 3 to install the Lever Assembly please make sure Switch Cam and Lever Switch are well positioned then follow by Step 3a Lever is down Step 3b Make sure the Switch Cam is holding the switch down Step 3c Fix the E snap Ring back 4 Remove the Lever Switch Remove the screws Fig 1 3 on the switch while the Lever in up position Y Motor Swi...

Page 28: ...he Carriage Cover Push down the cover s top then pull it downward Step 4 Loosen the screws of the Small Roller lower about 2 3 revolutions to release the Carriage Step 5 Unscrew both DU rollers and remove them Step6 To remove the Tool Carriage tilt and pull down Be careful not to damage the Carriage PCB Carriage PCB Carriage Guide Beam Carriage Cover DU roller Blade Holder Screw Fig 1 4 Small Roll...

Page 29: ...ge to one end of the guide beam Step 2 First place the top arm gauge in the top track of guide beam Then the bottom arm will click into the bottom track see Fig 1 5 Step 3 Make the white cylinder is flush with the belt surface Tug on the wire a couple times to ensure full contact between both surfaces Step 4 The desire tension is 4g To change belt tension adjust the screws as per Step 5 Fasten the...

Page 30: ...ion on how to replace or adjust the components of this machine Components Replacement and Belt Tension Adjustment Removing the Front Back End and Top Covers The following steps are those involved in removal of the front back end and top covers To Remove the End Covers 1 Remove the end cover screws 2 Put equal pressure on both sides of the End Cover and pull to remove ...

Page 31: ...ont and Back Covers 1 Unscrew the 7 Front Cover and 7 Back Cover screws Remove the Top Cover 1 Unscrew the two screws at each end of the Top Cover 2 Unplug the Control Panel Cable before removing the top cover completely ...

Page 32: ...eps are those involved in replacing pinch roller sets To Unlatch the Pinch Roller Lever 1 Pull down the Square Bar Lever to unlatch the Pinch Rollers To Remove the Square Bar Holding Bracket 2 Unscrew the 2 bracket screws 3 Remove the bracket and washer ...

Page 33: ...r Sets 3 Slide the pinch roller to the notch at the right end of the Square Bar 3 Remove the pinch roller set through the notch Note When re installing the Pinch Roller Set the Cam Roller must be aligned squarely to the Square Bar ...

Page 34: ...arriage cover 1 Depress the two locking clips at the top of the Tool Carriage Cover and pull the Cover away To Prepare the Tool Carriage for Removal 1 Pop up the plastic locking pins using a flathead screwdriver 2 Disconnect the Flat Sensor Cable Bolt B ...

Page 35: ...wn and out while keeping the Sprung Washer Rollers apart Note 1 To install a new Tool Carriage or replace the original Tool Carriage simply reverse the steps for Tool Carriage removal 2 Remember to separate the Sprung Washer Rollers and then place them on the Carriage track before you swing the Tool Carriage back into place ...

Page 36: ...ent of the Y motor 1 Loosen the all 3 tension bracket retaining screws as well as the tension adjustment screw but do not remove them 2 Depress the jumper clips and pull to unplug the 2 Y motor Jumpers 3 Lift the belt off of the Y motor then unscrew and remove the 4 Y motor screws ...

Page 37: ...he Y motor is in place you must adjust the Y motor belt tension as described in the Y motor belt tension adjustment section of this chapter Note 3 Make the Y motor jumper reconnection the last step after the Y motor tension belt adjustment when you have finished installing or replacing the Y motor ...

Page 38: ...ed in replacement of the VCM PC board 1 Unplug the two sensor connectors and then unscrew the two PC board screws to remove the board Note If the Pinch Roller Sensor is still not effective after replacement the Tool Carriage or the Flat Cable may need replacement ...

Page 39: ...se follow the safety instruction at the beginning of this manual before installing or replacing any current carrying components T Parallel Port Connector o unplug the jumpers and connectors from the main board 1 Unplug all of the jumpers and connectors attached to all off board components Note Please refer to the Puma Wiring Diagram for more detail on jumper and connector attachment Y Motor Y Enco...

Page 40: ...he main board Note To install or replace the main board simply reverse the steps to remove it Replacement of Fuses The Fuse pops out for easy replacement as follows Holding clip Holding clip 1 With your fingers apply equal pressure to both of the holding clips on the Fuse housing and push it out ...

Page 41: ...3 Use a tension gauge to measure the belt s tension by placing the gauge s push arm to the center of the belt as seen in the figure above 4 To change belt tension adjust the belt tension screw on the side of the carriage belt roller housing 5 To tighten the tension turn the belt tens ion screw clockwise To loosen the tension turn the belt tension screw anticlockwise until the desired adjustment te...

Page 42: ...hook arm at the hole of X motor bracket and pull the motor toward yourself along the direction parallel to the racket edge and keep it at the 4kg tension position 3 Tighten the 4 retaining screws to lock the bracket in place 4 Fix the tension retaining screw Note The belt connecting the drum and X motor needs to be tightened to a tension of 4 kg ...

Page 43: ...ove them 2 Place the push pull tension gauge s hook arm at the hole of Y motor bracket and pull the motor toward yourself along the direction parallel to the line that passes through the motor shaft and the pulley shaft 3 Once the desired tension is found tighten the 3 retaining screws to lock the tension bracket in place ...

Page 44: ...44 4 Tighten the tension screw to retain the tension Note The belt connecting the pulley and Y motor needs to be tightened up with a tension of 4 kg ...

Page 45: ...Using this diagnostic test facility enables the diagnosing of the hardware components How to Begin Maintenance Diagnostics Diagnostic test for the media sensors Diagnostic test for the width sensor Diagnostic test for the motor encoder and tool holder encoder Diagnostic test for Tool Force VCM Diagnostic test for motor movement Diagnostic test for the RS 232 interface Problems and Solutions To the...

Page 46: ...iagnostics To start the Maintenance Diagnostics facility hold down the On Off Line button and CUT TEST button while turning on the cutter The following sub sections will explain the function of each maintenance diagnostic sequence ...

Page 47: ...nch rollers have been lowered or not If the lever sensor is down you will see a lift the lever message on the LCM If the lever is up you will see a lower the lever message on the LCM You can use the ON OFF LINE KEY to abort your test when you have finished the lever sensor test Cancel Key Display lever sesor condition messages Previous Next Test item Note that LCM will display one of following mes...

Page 48: ...rent front and rear sensor condition you can turn it on or off to see if sensors are out of order or not Cancel Key Previous Next Test item Display Current Sensor Condition Messages Change Sensor Condition Note that the LCM displays one of following messages 1 Now Open Front Eye Cover Rear Eye CANCEL 2 Now Cover Front Eye Open Rear Eye CANCEL 3 Now Open Front Eye Cover Rear Eye CANCEL 4 Now Cover ...

Page 49: ...ne please move the tool carriage to left Be careful when moving the tool carriage close to the pinch roller since the message changes quickly when sensor is between on and off Check Width Sensor Enter Key Move Carriage To Rightmost delay 3 seconds delay 3 seconds No Lever up or not Now Lever is Up Lower the lever Yes Move Carriage Slowly To Left Hard Stop Pinch Roller Sensor No Yes on or not Now S...

Page 50: ...is defective the cutting plotter cannot work properly To check if the encoder is bad or good you can apply a slight force to the tested part such as a drum the tool carriage or the tool holder then examine the readings If the encoder reading changes dramatically the encoder is bad Refer to the maintenance chapter to replace the motor or tool carriage X Motor Encoder Test ...

Page 51: ...CM means Voice Coil Motor that generates tool force Diagnostic Test for Motor Movement This feature is to diagnose the X and Y motors and drIIIers If you encounter a motor movement problem try to change the main board first If the problem still remains after replacing the main board try replacing the motor Drum Moves Forward Up Down Key Cancel Key Enter Key X Motor Moving Now Forward CANCEL Previo...

Page 52: ...xt test item Carriage Goes Left Up Down Key Cancel Key Enter Key Y Motor Moving Now Forward CANCEL Previous Next test item Carriage Goes Right Up Down Key Cancel Key Enter Key Y Motor Moving Now Backward CANCEL Previous Next test item Note The X motor controls the Drum The Y motor controls the Carriage ...

Page 53: ...ot press keys too quickly or it may cause an overrun error Diagnostic Test for the RS 232 Interface This feature provides the ability to diagnose RS 232 interface and checks communication between the cutter and computer ...

Page 54: ...PCB set is damaged Change carriage set The function of Set New Origin does not work Causation and recovery The origin point will be set by pressing the ENTER button when the Puma is in an OFFLINE state only then will the LCD display the distance between the new and old origin Media shifts away when plotting a long drawing Causation and recovery The media is not accurately aligned Reload the media ...

Page 55: ...st the carriage belt tension The drIIIer board set is damaged Change it The machine makes abnormal noise from the drum set when it is running Causation and recovery X or Y motor belt is loose Adjust the belt tension The drIIIer board set is damaged Change it The gear at the left of drum set is not tightly mounted on the shaft Change it The screws that fasten the drum to the shaft are loose Fasten ...

Page 56: ... force setting is wrong Reset the initial force please contact the manufacturer VCM is damaged Change the carriage set VCM encoder is damaged Change the carriage set Media drops sometimes Causation and to recovery Media is loaded askew Re load the media The position of pinch roller is not on the top of drum Move the pinch roller to a right position The edge of media is broken Change the media The ...

Page 57: ...57 Appendix Parts and Accessory List Spare Parts Customer Service Request Form To the Contents Page ...

Page 58: ...ase Part No Part Name Qty Payment U Price Ship date F O B F O C SAS US 195 00 F O B F O C SAS F O B F O C SAS F O B F O C SAS F O B F O C SAS F O B F O C SAS F O B F O C SAS F O B F O C SAS F O B F O C SAS F O B F O C SAS Problem Description Correct Action Taken Current Condition Comment below filled out by G C C Shipping way EMS DHL UPS FEDEX With Sales Order Others Freight Charge Collect Prepaid...

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