GBC AdvancedPunch Manual de funcionamiento

Document # 7712571, Rev. C1 (23 08 2013)

AdvancedPunch

Technical Service Manual

GBC

300 Tower Parkway

Lincolnshire, IL 60069

USA

www.gbcconnect.com

No part of this document may be photocopied or reproduced by any means, or

translated to another language without prior written consent of GBC.

All brand names, trademarks and registered trademarks are the property of their

respectiveowners.Informationcontained withinthisdocumentissubjecttochange

without notice.

Table of Contents

Preface P-1

Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-1

Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-2

Setting the Right Expectations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-3

Product Positioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-3

Long Edge Feed (LEF) Only - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-3

Die Sets XC / Letter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-4

Die Sets XE / A4 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-5

Section 1 Maintenance 1-1

Initial Service Action - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

Paper Jam Service Action - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2

Die Set Service - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5

Die Set Life Expectancy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5

Die Set Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5

Serviceable Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Die Set Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7

Die Set Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8

Hole Alignment Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9

Inspection, Cleaning, and Lubrication - - - - - - - - - - - - - - - - - - - - - - - - 1-10

External Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11

Internal Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11

Operational Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11

Internal Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11

Base Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12

Chip Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

Die Guide Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13

Door Latch Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14

Separating Punch From Printer - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14

Rear Cover Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14

Aligner Panel Inspection and Cleaning - - - - - - - - - - - - - - - - - - - - - 1-15

Aligner Idler Roller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .1-16

Aligner Green Drive Belt Maintenance . . . . . . . . . . . . . . . . . . . . . .1-18

Table of Contents

Back Gauge Solenoid Inspection and Cleaning - - - - - - - - - - - - - - - 1-19

Idler Roller Inspection and Cleaning - - - - - - - - - - - - - - - - - - - - - - - 1-20

Idler Roller Removal and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . .1-21

Non-Removable Idler Roller Cleaning . . . . . . . . . . . . . . . . . . . . . .1-22

Drive Roller Inspection and Cleaning - - - - - - - - - - - - - - - - - - - - - - 1-24

Aligner Latch Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-25

Optical Sensor Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-26

Bypass Paper Path Inspection and Cleaning - - - - - - - - - - - - - - - - - 1-28

Punch Paper Path Inspection and Cleaning - - - - - - - - - - - - - - - - - 1-29

Punch Drive Cam Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-30

Timing Belt Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-31

Final Service Action - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-32

Section 2 Fault Analysis Procedures 2-1

040-101 Fault Diagnosis: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2

Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2

Initial Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2

Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2

RAP AC Power - No Indication of Power - - - - - - - - - - - - - - - - - - - - - - - 2-3

Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3

Initial Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3

Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3

RAP DC Power - No Indication of 24V DC - - - - - - - - - - - - - - - - - - - - - 2-4

Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4

Initial Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4

Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4

RAP Paper Jams at Punch, Chad is Present in the Paper Path - - - - - - - 2-5

RAP Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5

RAP Initial Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5

RAP References - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5

RAP Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5

RAP Paper Jams at Punch, Chad is Not Present in the Paper Path - - - - 2-6

RAP Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6

RAP Initial Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6

RAP References - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6

RAP Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6

RAP Paper is Skewed Before It Gets to the Punch. - - - - - - - - - - - - - - - 2-7

RAP Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7

RAP Initial Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7

RAP References - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7

RAP Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7

Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7

General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8

Back Gauge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-10

Die Set - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-10

Table of Contents

Section 3 Output Quality Analysis Procedures 3-1

RAP Hole Alignment Inspection Procedure - - - - - - - - - - - - - - - - - - - - - 3-1

RAP Hole Skew Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

RAP Hole Quality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2

RAP Oil On Paper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2

RAP Skuff Marks On Paper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3

RAP Lead Edge Damage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3

Section 4 Repair and Adjustment Procedures 4-1

Preparing the Advanced Punch for Service - - - - - - - - - - - - - - - - - - - - - 4-1

Separating the Punch From the Printer - - - - - - - - - - - - - - - - - - - - - - 4-1

Removing the Rear Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2

Leveling And Aligning to the Printer - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3

Door Latch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5

Door Latch Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5

Door Latch and Switch Replacement - - - - - - - - - - - - - - - - - - - - - - - 4-6

Bypass Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8

Bypass Panel Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8

Bypass Idler Roller Replacement - - - - - - - - - - - - - - - - - - - - - - - - - 4-13

Punch Idler Rollers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-15

Idler Roller Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-16

Aligner Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17

Aligner Idler Roller Replacement - - - - - - - - - - - - - - - - - - - - - - - - - 4-17

Aligner Panel Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-18

Aligner Drive Belt (Green Belt) Replacement - - - - - - - - - - - - - - - - - 4-20

Paper Entrance Side Green Drive Belt Replacement . . . . . . . . . . 4-21

Green Drive Belt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Entrance Aligner Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Paper Exit Side Green Drive Belt Replacement . . . . . . . . . . . . . . 4-27

Green Drive Belt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Aligner Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Energy Drive Roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-35

Back Gauge Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-36

Back Gauge Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-37

Back Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Solenoid Cleaning and Inspection - - - - - - - - - - - - - - - - - - - - - - - - 4-45

Solenoid Spring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Back Gauge Paddle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-47

Punch Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-48

Punch Module Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-49

Punch Drive Cam Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-54

Clutch Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-55

Punch Module Brake Replacement and Adjustment - - - - - - - - - - - - 4-60

Table of Contents

Punch Module Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . .4-60

Punch Module Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .4-62

Punch Module Motor Replacement - - - - - - - - - - - - - - - - - - - - - - - 4-63

Punch Module Motor Drive Belt Replacement . . . . . . . . . . . . . . . .4-65

Punch Module Drive Roller Cleaning and Replacement - - - - - - - - - 4-66

Belt Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-69

Hole Alignment Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-70

Replacement - ChipTray Microswitch - - - - - - - - - - - - - - - - - - - - - - - - 4-74

Sensor Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-75

Diverter Gate Solenoid Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - 4-80

Section 5 Parts List 5-1

Section 6 General Procedures 6-1

Component Control And Diagnostic Modes Entry and Exit Procedures - 6-2

Entering and Exiting Maintenance/Diagnostic Tools Mode - - - - - - - - 6-2

Component Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-2

NVM Read/Write - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-3

Adjustments and Feature Control General Procedures - - - - - - - - - - - - - 6-4

GBC AdvancedPunch Input Component Control - - - - - - - - - - - - - - - - - 6-5

GBC AdvancedPunch Output Component Control - - - - - - - - - - - - - - - - 6-6

GBC AdvancedPunch NVM Setting List - - - - - - - - - - - - - - - - - - - - - - - 6-7

GBC AdvancedPunch Fault Code List - - - - - - - - - - - - - - - - - - - - - - - - 6-8

Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-9

Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-9

Principle of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-10

Inputs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-10

Outputs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-11

Printer Communication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-11

Serial EEPROM Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-11

Stepper #1 Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-12

Punch Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-12

Stepper #2 Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-12

Paper Flow - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-13

Glossary of Terms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-14

Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15

Section 7 Wiring and Electrical Data 7-1

Service Schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3

AC Motors Punch / Transport - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-4

AC Filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5

Safety Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-6

Door Chiptray DS Switches / Inputs - - - - - - - - - - - - - - - - - - - - - - - - 7-7

Table of Contents

Communication Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8

Boot Load - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9

24 Volts Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10

Steppers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11

Overlay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12

Sensor Inputs Config- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13

PCB Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-14

Section 8 Installation and Set Up 8-1

Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-2

Space Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10

Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11

Test Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11

Preface

1. Safety

These symbols are used in this documentation alert you to danger or important

information.

Warning: Indicates a potentially hazardous situation which, if not avoided, could

result in death or serious Injury.

Warning: Risk of electrical shock. This warning statement indicates situations

where there is a risk of death by electric shock.

Caution: This notice indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury. It may also be used to alert

against unsafe practices.

rtain components in this product are susceptible to damage from electrostatic

discharge. Observe all ESD procedures to avoid component damage.

2. Introduction

This service manual is provided for use by an authorized service technician for the

repair and maintenance of the Advanced Punch.

The Advanced Punch is an innovative, labor saving solution for punching paper

in-line and includes the following design features:

•Maximum productivity saver with punching in-line at the speed of the printer!

Does not slow up or stop the print system.

•Quick-change die sets that are self-latching without tools or levers.

•Advanced Punch die sets are available in all of the most common hole

patterns and include an Identifying Label providing user with the hole pattern

and name.

•Convenient storage area for three extra Die Sets located above the sheet

bypass.

•Accurate hole punching with consistent alignment.

With each Advanced Punch, the customer receives a user manual. They are

encouraged to keep this manual for future reference. The information contained in

the user manual is also helpful to the service technician. Please refer to it for

detailed information regarding dies sets, operationor specifications. You will find a

copy of the User Guide at the end of section 8, Installation and Setup.

Preface

3. Setting the Right Expectations

The following excerpts are copied from sales and marketing literature. This

customer expectation information is helpful for the service technician.

3.1 Product Positioning

The Advanced Punch provides a flexible, cost effective punching solution for light

to medium level production oriented customers.

•Designed for customers that have the need to punch their documents at a

maximum of 60-70% of their overall workflow.

•Recommended punching limit to 200K sheets per month. (600k sheets in

bypass mode)

•Die Sets will decrease in performance over time based on the types of stocks

and weights that are being punched.

•The expected life of a dieset is 500K punches. However, if paper stock

punched is typically 20 lb. bond, then up to 2 million punches can be

achieved.

•Should be regarded as a long-term supply item.

3.2 Long Edge Feed (LEF) Only

The Advanced Punch is designed to punch LEF only. No exceptions. Attempting

to punch a sheet size other than LEF will cause a paper jam.

•Use a colored sheet insert (instead of the tab) in the job workflow for easier

tab insertion after the job has been run.

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