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AdvancedPunch Pro
GBC AdvancedPunch Pro Service Manual
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GBC AdvancedPunch Pro
11/07/20
18
Service M
anu
al
Part Num
ber:
7718
590
Revision Numbe
r:
A1
Issue Dat
e:
Nov
ember
20
18
GBC
AdvancedPu
nch
Pr
o
Service Manual
C
AU
T
I
O
N
Certain c
omponent
s in t
he
G
BC
Advanc
edPunc
h
Pr
o
are s
uscepti
ble to
damage f
rom
electrostat
ic disc
harge.
O
bserv
e all ESD
proced
ures to
avoid com
ponent d
am
age.
2
Table of Contents
Table of Contents
2
Introduction
3
Service Call Procedures
4
Status Indicator Raps
4
Punch Quality
4
Repairs/Adjustments
4
Parts List
4
General Procedures
4
Wiring Data
4
Installation Checklist
4
Introduction
4
Organization
4
Safety Messages in Other Languages
6
The Use of Caution, Warning, and Note Statements
10
Safety Devices
12
Door Interlock
12
Operational Safety
12
Warnings and Cautions
12
Acronyms
18
Reference Symbology
18
1. Service Call Procedures
19
Call Flow
20
Initial Action
21
System Checks
21
Every Call Activities
22
Preventative Maintenance
22
Scheduled Maintenance
22
Advancedpunch Pro Maintenance Schedule
23
Customer Maintenance
23
Periodic Maintenance
23
Periodic Replacement
24
Final Action
25
Hfsi
25
2. Repair Analysis Procedures (Raps)
27
Introduction
29
Symbology
29
Entry RAP
30
Operator Messages
31
Top Row of Text
31
Bottom Row of Text
31
Check die
32
Close Door
34
Chip Tray out
35
Chip Tray out Message Is Not Displayed When the Chip Tray Is out
35
Chip Tray Full
36
Error Codes
37
Error E451 die Encryption Error
37
Error E452 Incompatible die
37
Fault Codes
38
Fault Code Text
38
Fault Code Areas
38
Jam Types
39
1 Power Faults
40
RAP 1.1 no AC Power
40
RAP 1.2 no DC Power
42
RAP 1.3 no Power to Control Board
43
RAP 1.4 Operator Panel Does Not Illuminate
44
RAP 1.5 Operator Panel Does Not Show Text
45
RAP 1.6 Up, Down, Enter Keys Do Not Respond
46
2 Paper Jams
46
RAP 2.1 Jam Type a
46
RAP 2.2 Jam Type B
47
RAP 2.3 Jam Type C
48
RAP 2.4 Jam Type D
50
RAP 2.5 Jam Type E
51
RAP 2.6 Jam Type F
52
Rap 2.6
52
Multiple Sheets Jammed - die Pins Partially through the Sheets
53
RAP 2.8 Checking Obstruction in Paper Path
54
Rap 2.8
54
Paper Jam J431
57
Rap 2.10 Paper Jam J432
57
Rap 2.11 Paper Jam J433
58
3 Sensor Checks
59
Rap 3.1
59
Check Sensors S1, S2, S3, S4, S5, S22, S23, S24
59
Sensor Cables
61
Rap 3.2
62
Check Sensors S6 to S21
62
RAP 3.3 Checking Sensor S28 Align Home Sensor
67
4 Solenoid Checks
69
Rap 4.1
69
Check Solenoid SOL 1
69
Check Solenoid SOL 2
69
Rap 4.3
70
Check Solenoids SOL 3 to SOL 8
70
5 Motor Checks
72
RAP 5.1 Checking Stepper Motors
72
6 Other Faults
74
RAP 6.1 die Set will Not Slide in or out Easily
74
RAP 6.2 Punch Overheats
74
RAP 6.3 Dog Ear Corners in Sheets
75
Appendix
76
Jam Codes
76
3. Punch Quality
77
Defect Entry RAP Procedure
79
Punch Quality
79
Alignment Offset
80
Hole Quality
80
Hanging Chad
80
Holes Are Not Cleanly Cut
80
Oil on Paper
80
Backgage Offset
81
Punching Accuracy Inconsistent
82
Skewed Punch
82
Sheet Without Punched Holes
84
Punched Holes Look Elongated Towards the Trail Edge of the Sheet
85
Clear Cover Media Hole Position
86
Scuff Marks on Paper
86
Sheet Damaged at the Lead Edge of the Sheet
86
Wrinkle in the Sheet
86
Punch Specifications
87
4. Repairs/Adjustments
89
1 Cabinet
91
REP 1.1 Top Cover Replacement
91
REP 1.2 Front Door Replacement
92
REP 1.3 Front Door Bottom Hinge Bracket Replacement
93
REP 1.4 Front Door Top Hinge Bracket Replacement
93
REP 1.5 Panel Open Magnet Replacement
94
REP 1.6 Rear Cover Replacement
95
REP 1.7 Upstream Rear Side Cover Replacement
96
REP 1.8 Upstream Side Frame Cover Replacement
97
REP 1.9 Downstream Front Side Cover Replacement
98
REP 1.10 Downstream Rear Side Cover Replacement
99
REP 1.11 Downstream Side Frame Cover Replacement
100
REP 1.12 Door Latch Replacement
101
REP 1.13 Interlock Switch Replacement
102
REP 1.14 Power Switch Replacement- DFA Configurations Only
103
REP 1.15 LCD Display Replacement
104
REP 1.16 LCD Membrane Switch Panel Replacement
105
REP 1.17 Caster Replacement
106
REP 1.18 Docking Bracket Replacement
107
REP 1.19 Exhaust Fan Replacement
109
REP 1.20 Drive Roller Cover Removal
111
2 Paper Path
112
REP 2.1 Lower Entrance Panel Replacement
112
REP 2.2 Entrance Idler Panel Replacement
114
REP 2.3 Acceleration Roller Idler Assembly Replacement
116
REP 2.4 Entrance Drive Panel Assembly Replacement
118
REP 2.5 Punch Lower Exit Panel Replacement
127
REP 2.8 Lower Exit Panel Replacement
127
REP 2.10 Lower Bypass Panel Replacement
130
REP 2.11 Panel Close Magnet Replacement
131
REP 2.12 Idler Roller Replacement
132
REP 2.13 Flange Ball Bearing Replacement
134
REP 2.14 Snap-In Bearing Replacement
135
REP 2.15 Bearing Housing Replacement
136
REP 2.16 Accel Idler Latch Handle Replacement
137
REP 2.17 Accel Idler Latch Shaft, Rear Latch and Front Latch Assembly Replacement
138
REP 2.18 One Way Clutch and Pulley Sub-Assembly Replacement4-53
141
REP 2.19 Drive Idler Roller Assembly Replacement
141
REP 2.20 Timing Pulley Replacement
142
REP 2.21 Timing Belt Replacement
143
REP 2.21.1 534T Belt Replacement
143
REP 2.21.2 134T Belt Replacement
144
REP 2.21.3 150T Belt Replacement
144
REP 2.21.4 179T Belt Replacement
145
REP 2.22 Drive Roller Assembly Replacement
146
REP 2.22.1 Drive Roller N5 Replacement
148
REP 2.23 Stepper and Mount Assembly Replacement
151
REP 2.24 Bypass Open Sensor Replacement
152
REP 2.25 Paper Path Sensor Replacement
153
REP 2.25.1 Entrance Sensor (S1,) Exit Sensor (S25), and Bypass Middle Sensor (S26) Replacement
153
Top, Middle, & Bottom Exit Sensor (S22, S23, S24) Replacement
154
REP 2.25.3 Accel Sensor (S5) Replacement
155
REP 2.25.4 Align Home Sensor (S28) Replacement
156
(S18, S19) and Double Punch (X-Large) Backage Sensor
157
Board Assembly (S20, S21) Replacement
157
REP 2.25.5 Double Punch (Large) Backage Sensor Board Assembly
157
REP 2.25.6 Skew Sensor Board (S6 - S10) Replacement
158
REP 2.25.7 Alignment Sensor Board (S11 - S15) Replacement
159
REP 2.25.8 Backage Sensor Board (S16, S17) Replacement
161
REP 2.26 Motor Driver (Stepper Driver) Replacement
162
REP 2.27 Bypass Diverter Replacement
164
REP 2.28 Solenoid Replacement
165
REP 2.28.1 Diverter Solenoid Replacement
166
REP 2.28.2 Entrance Idler Solenoid Replacement
167
REP 2.28.3 Acceleration Roller Idler Solenoid Replacement
167
REP 2.28.4 Exit Idler Solenoid Replacement
168
REP 2.29 Upper Bypass Panel Anti-Static Brush Replacement
169
REP 2.30 Chip Tray Home Switch Replacement
169
REP 2.31 Chip Level Emitter Replacement
171
REP 2.32 Chip Level Receiver Replacement
171
3 Punch Module
172
REP 3.1 Punch Module Replacement
172
REP 3.1.1 Punch Module Removal
172
REP 3.1.2 Punch Module Installation
175
REP 3.2 Punch Motor Replacement
176
REP 3.3 Punch Motor Belt Replacement (Timing Belt)
177
REP 3.4 Clutch or Clutch Pulley Replacement
179
REP 3.5 Punch Alignment Stepper Motor and Pulley Replacement
182
REP 3.6 Steering Module Replacement
183
REP 3.7 Alignment Carriage Sub Assembly Replacement
186
REP 3.8 Steering Stepper Motor Replacement
188
REP 3.9 Steering Motor Belt (65 Groove) Replacement
190
REP 3.10 Steering Idler Panel Weldment Replacement
192
REP 3.11 Steering Idler Roller Assembly Replacement
193
REP 3.11.1 Steering Idler Roller Bearing Replacement
195
REP 3.12 Steering Drive Panel Weldment Replacement
196
REP 3.13 die Lock Plunger and Stripper Assembly Replacement
197
REP 3.14 die Lock Shaft Replacement
198
REP 3.15 die Rail Assembly and die Rail Springs Replacement
200
REP 3.16 Backgage Sensor Bracket Weldment and Backgage Sensor Lower Bracket Replacement
203
4 Power Supply
204
REP 4.1 24V Power Supply Replacement
204
REP 4.2 AC Filter Replacement
206
5 Electronics and Control
207
REP 5.1 Main Control Board Replacement
207
REP 5.2 Comm Board Replacement
209
REP 5.3 Dieset Recognition Reader Board Replacement
210
6 Adjustments
211
ADJ 1.1 Door Latch Adjustment
211
ADJ 1.2 Diverter Solenoid Adjustment
212
ADJ 1.3 die Stop Magnet Adjustment
214
ADJ 1.4 Timing Belts Adjustment
215
ADJ 1.5 Punch Cam Indexing
220
ADJ 1.6 Dieset Recognition Board Adjustment
224
ADJ 1.7 Idler Panel Magnetic Latches Adjustment
225
ADJ 1.8 Drive Panel Position Adjustment
226
5. Parts List (Pl)
231
1 Introduction
232
2 Main Assembly
233
2.1. Final Assembly
233
2.2. Cabinet - Covers
234
3 Frame Assembly
235
3.1. Frame Assembly- Paper Path Panels
235
3.2. Frame Assembly- Front Side
236
3.3. Frame Assembly- Rear Side
237
3.4. Frame Assembly- Drive Rollers
238
3.5. Frame Assembly- Internal Parts
239
3.6. Frame Assembly- Motors and Motor Drivers
240
3.7. Frame Assembly- Sensors
241
3.8. Frame Assembly- Solenoids / Switches
242
3.9. Frame Assembly- Belts
243
4 Paper Path
244
4.1. Paper Path- Entrance Drive Panel
244
4.2. Paper Path- Entrance Idler Panel
245
4.3. Paper Path- Acceleration Roller Idler
246
4.4. Paper Path- Exit Idler Panel
247
4.5. Paper Path- Upper Bypass Panel
248
4.6. Paper Path- Disengaging Roller Solenoid
249
5 Punch Module
250
5.1. Punch Module (Continued)
251
5.2. Punch Module- Motors/Sensors
252
5.3. Punch Module- Steering Module
253
Assembly
253
5.5. Punch Module- Steering Module - Drive Panel Steering
255
5.6. Punch Module- Punch Clutch
256
5.7. Punch Module- die Rail, Backgage, Align Sensors, Sub
257
5.8. Punch Module- AC Motor
258
6 Die Sets
259
7 Electronics
260
7.2. Control Board Bracket Sub Assembly
261
7.3. Cable Part Number Index
262
7.4. Wiring Drawing- OEM Configurations
263
7.5. Wiring Drawing- DFA Configurations
264
8 Installation Kit Parts
265
9 Hardware Kits
265
10 Optional Kits
265
11 Part Number Index
266
6. General Procedures and Information
271
General Procedures
273
User Interface
273
Information
274
Settings
274
User Interface Screen Map
275
DFA Configuration Only- User Interface Screen Map
276
GP 6.1 User Interface Procedure
277
GP 6.1.1 BACKGAGE MODE Procedure
277
GP 6.1.2 PUNCH MODE Procedure- for DFA Configurations Only
280
GP 6.1.3 ALIGNMENT MODE Procedure
282
GP 6.1.4 TAB/COVER MODE Procedure
284
GP 6.1.5 CLEAR COVER Procedure
286
GP 6.1.6 LANGUAGE MODE Procedure
288
GP 6.1.7 UNITS MODE Procedure
289
GP 6.1.8 PAPER SIZE Procedure
290
GP 6.1.9 die TYPE Procedure
291
GP 6.1.10 die CYCLES Procedure
292
GP 6.1.11 PUNCH CYCLES Procedure
293
GP 6.1.12 FIRMWARE Procedure
294
Service User Interface
295
Service Interface Screen Map
297
DFA Configurations Only- Service Interface Screen Map
298
GP 6.2 Service User Interface Procedure
299
GP 6.2.1 SPEED ADJUST Procedure
300
GP 6.2.2 SPEED (DFA) Procedure- for DFA Configurations Only
301
GP 6.2.3 PAPER SIZE Procedure
302
GP 6.2.4 MAX BYPASS Setting
303
GP 6.2.5 RUN MODE Setting
304
Gp 6.2.6 die Cycles
305
SENSORS Procedure
306
GP 6.2.8 I/O SIGNALS Procedure
308
GP 6.2.9 DFA STATUS Procedure- DFA Configurations Only
309
GP 6.2.10 SOLENOIDS Procedure
310
GP 6.2.11 MOTORS Procedure
311
GP 6.2.12 FUNCTION TESTS Procedure (Cycle Punch, Aligner Test, Fan Test)
312
GP 6.2.13 SKEW OFFSETS Procedure
314
GP 6.2.14 ALIGN OFFSETS Procedure
318
Gp 6.2.15 Log
320
GP 6.2.16 FIRMWARE UPGRADE Procedure
321
GP 6.3 Undock the Punch (Moving the Punch to Service Position)
323
GP 6.4 Dock the Punch (Moving the Punch to Operating Position)
324
GP 6.5 Operational Inspection
325
GP 6.6 Internal Inspection
325
GP 6.7 die Set Service
326
GP 6.7.1 die Set Life Expectancy
326
Die Set Components
326
GP 6.7.3 die Set Lubrication
327
Die Set Shoulder Bolts
328
GP 6.8 External Cleaning
329
GP 6.9 Internal Cleaning
329
GP 6.10 Base Cleaning
330
GP 6.11 Chip bin Cleaning
330
GP 6.12 die Guide Cleaning
331
GP 6.13 Door Latch Inspection
331
GP 6.14 Idler Roller and Idler Springs Inspection
332
GP 6.14.1 Idler Roller Cleaning
333
GP 6.14.2 Steering Idler Roller and Springs Inspection and Cleaning
334
GP 6.15 Drive Roller and Steering Drive Roller Inspection and Cleaning
335
GP 6.16 Panel Latch Inspection
336
GP 6.17 Optical Sensor Cleaning
339
GP 6.18 Bypass Paper Path Inspection and Cleaning
340
GP 6.19 Punch Paper Path Inspection and Cleaning
341
GP 6.20 Punch Drive Cam Lubrication
342
GP 6.21 Timing Belt Inspection
343
GP 6.22 Solenoid Cleaning and Inspection
344
GP 6.23 Alignment Carriage Rails Cleaning
345
GP 6.24 Punch Clutch Inspection and Cleaning
346
GP 6.25 Diverter Solenoid Assembly Inspection
347
GP 6.26 die Set Recognition Board Clips Inspection
347
GP 6.27 die Lock Mechanism and die Rail Springs Inspection
348
General Information
349
Principle of Operation
349
Punch Path
349
Single Punch
349
Double Punch (MID Punch + Trail Edge Punch)- DFA Configurations Only
350
Bypass Path
350
Glossary of Terms
352
Die Sets
353
Die Sets List
354
Die Sets List (Cont'D)
355
Tools
356
Other Recommended Tools and Supplies
356
Standard Tools (Metric)
356
Lubrication
356
Cleaning Materials
357
Change Tag Index
358
Serial Numbers
358
System Wiring
363
System Wiring- DFA Configurations
364
Plug Jack Connectors
365
Plug Jack Connectors- DFA Configurations
366
8. Installation Instructions- Dfa
382
Introduction
384
Check the Packing List
384
Space Requirements - Dimensions
384
Check that the SEM Module Is in Place
384
Remove the Packing Materials
385
Install the Lift Kit Assembly
387
Rotate the Advancedpunch Pro to the Upright Position
388
Check Input Power
390
DFA Conversion
390
Inspect for Damage
390
Prepare the Docking Brackets
390
Install the Upstream Docking Bracket
390
Install the Downstream Docking Bracket
390
Level the Punch
391
Dock the Advancepunch Pro to the Upstream Device
392
Install the CNC-DFA Circuit Board and Cables
392
Connect the Punch Cables
393
Install the die Set
394
Install the Lift Kit Cover
394
Power up the Punch
395
Configure the Punch
396
Firmware Installation
396
Run the Punch in Bypass Mode
397
Run the Punch in Punch Mode
398
Punch Quality
399
Alignments/Adjustments
399
Center the Punch
399
Operator Manual
400
Tag Matrix
400
Tools
400
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GBC AdvancedPunch Pro Specifications
General
Brand
GBC
Model
AdvancedPunch Pro
Category
Printer Accessories
Language
English
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