GBC FusionPunch II Service Manual
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GBC FusionPunch II Service Manual

With stacker and bypass
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Table of Contents

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GBC FusionPunch II
With Stacker and Bypass
Service Manual
Revision: 4.0
December 17th, 2003
Part Number: 1722683

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Summary of Contents for GBC FusionPunch II

  • Page 1 GBC FusionPunch II With Stacker and Bypass Service Manual Revision: 4.0 December 17th, 2003 Part Number: 1722683...
  • Page 2 Service documentation is intended for use by certified, product trained service personnel only. GBC does not warrant or represent that such documentation is complete. GBC does not represent or warrant that it will notify or provide to such customer any future changes to this documentation.
  • Page 3 Section Contents- - - - - - - - - - - - - - - - - - 7-1 8. Installation Instructions- - - - - - 8-1 Section Contents- - - - - - - - - - - - - - - - - - 8-1 9. FusionPunch II User Guide Separate publication 12/2003...
  • Page 4 Section 9 FusionPunch II User Guide machine damage. This section contains Repair Analysis The FusionPunch II User Guide is a Procedures (RAPs). You will be directed NOTE: Hints or other information that separate publication that describes to this section to isolate a faulty may assist the user.

  • Page 5: Table Of Contents

    Ordering Procedure - - - - - - - - - - - - - - - - 1-4 Procedure. GBC Training Process - - - - - - - - - - - - - - 1-5 Complete the procedures in this chapter in Initial Actions - - - - - - - - - - - - - - - - - - - - - 1-7 the order given.

  • Page 6: Technical Support Process

    7. The GBC National Technical Specialist Central Time. then asks Xerox CSE for the following: leaves a voice mail for the GBC Director of Service Operations to notify him of the a. CSE’s Service Manager’s name and 1. Xerox CSE contacts GBC National Emergency On-site Request.

  • Page 7: Parts Ordering Process

    Work Order No.: _________________________________ 2. Fax machine pages GBC Material Handler. Customer P.O.#: ___________________________ DSS Initials: _________________________________ 3. The GBC Material Handler picks the Dealer Number: XEROX Ordered by: _________________________________ parts, and places an order Next Flight Out Model Number: ___________________________...

  • Page 8: Gbc Parts Replenishment Ordering Procedure

    2. Fax machine pages GBC Material Date: ___________________________ Work Order No.: _________________________________ Handler. Customer P.O.#: ___________________________ DSS Initials: _________________________________ 3. The GBC Material Handler picks the parts, Dealer Number: XEROX Ordered by: _________________________________ and places an order per Replenishment Model Number: ___________________________ Serial Number: _________________________________ Fax requirements.

  • Page 9: Gbc Training Process

    GBC Training Process GBC Factory Product Training for Xerox CSE’s 1. Xerox contacts GBC National Technical Support at 1-866-259-0101, with the names of CSE’s requiring training. GBC requires thirty (30) days prior notice to schedule training classes. 2. GBC National Technical Support will arrange training schedule.
  • Page 10 Notes 12/2003 GBC Training Process GBC FusionPunch II Service Manual...

  • Page 11: Initial Actions

    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 System Checks. 12/2003 GBC FusionPunch II Service Manual Initial Actions...

  • Page 12: System Checks

    3. Evaluate error messages on the If the backlight is not lit, but the Stacker 1 brightly FusionPunch II Control Panel. Compare LCD Panel is displaying any messages displayed to Table 1-3, and messages, go to RAP 1.3 +5 LOB3 on...
  • Page 13 Covers. Bypass the Interlock the tray down, press the Raise/Lower Switches. Stacker button again to return the tray to the home position. b. Press the Diagnostics button until the following message is displayed: 12/2003 GBC FusionPunch II Service Manual System Checks...
  • Page 14 Table 1-3 FusionPunch II Control Panel Messages FusionPunch II Message Meaning Operator Action Technician Action Jam Entrance Sensor A sheet of paper blocks the Entrance Sensor. Remove the sheet of paper that blocks the Entrance Go to RAP 4.1 Document Sensor.
  • Page 15 Table 1-3 FusionPunch II Control Panel Messages (Continued) FusionPunch II Message Meaning Operator Action Technician Action Jam Bypass Sensor Paper has jammed at the Stacker 1 Bypass Remove any paper from the Stacker Bypass Exit If the job was to stack in Sensor Sensor and press Reset.
  • Page 16 Table 1-3 FusionPunch II Control Panel Messages (Continued) FusionPunch II Message Meaning Operator Action Technician Action Please Empty Stacker The Stacker is full. Lower the Stacker Tray, unload the paper, raise the Go to RAPs 1.2 AC Power to Tray, then press Reset.
  • Page 17 Table 1-3 FusionPunch II Control Panel Messages (Continued) FusionPunch II Message Meaning Operator Action Technician Action Stacker2 Door Open The Stacker 2 Door did not actuate the Close the Stacker 2 Door Go to RAP 3.2 Stacker Stacker 2 Door Interlock Switch.
  • Page 18 Table 1-3 FusionPunch II Control Panel Messages (Continued) FusionPunch II Message Meaning Operator Action Technician Action Stacker 1 Cover Open Failure of +24VDC to Stacker 1 Call for Service Go to RAP 1.5 Stacker +24VDC Power Stacker 1 Door Open...
  • Page 19 Docutech 135, 61xx displays: The FusionPunch II is not in online mode. Press Stop/Reset, then press Online/Offline to check Go to RAP 6.2 Printer that the FusionPunch II is in online mode. Then, press Connectivity Clear External Finisher to run Start.
  • Page 20 NOT BLOCKED, extinguished when the sensor is BLOCKED. If these conditions do not exist, go to RAP 5.5 Stacker Bypass Exit Sensors. Stacker Bypass Go to RAP 5.4 Stacker Bypass Jams 12/2003 System Checks GBC FusionPunch II Service Manual 1-16...
  • Page 21 The Stacker Bypass Gate Solenoid Go to RAP 5.4 Stacker Solenoid (if installed) energizes to direct sheets to the Stacker. It Bypass Jams. de-energizes to direct sheets to the Stacker Bypass. 12/2003 GBC FusionPunch II Service Manual System Checks 1-17...

  • Page 22: Cleaning And Maintenance

    Cleaning and Maintenance The Punch and Stacker require periodic cleaning. When you are servicing the FusionPunch II, perform the following maintenance procedures: Every Call The following maintenance should be completed during each service call: 1. Clean all Sensors and Reflectors.

  • Page 23: Final Actions

    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 Notes 12/2003 Final Actions GBC FusionPunch II Service Manual 1-20...
  • Page 25 RAP 5.4 Stacker Bypass Jams- - - - - - - - 2-44 RAP 5.5 Stacker Bypass Exit Sensors - - 2-50 RAP 6.2 Printer Connectivity - - - - - - - - - 2-53 12/2003 GBC FusionPunch II Service Manual...

  • Page 26: Rap 1.1 Ac Power To The Punch

    AC/DC Distribution PWB, across the Go to Step 6. brown and blue wires. The voltages are within 108 VAC to 120 VAC tolerance. Replace the Punch AC/DC Distribution PWB (PL 3.1). 12/2003 RAP 1.1 AC Power to the Punch GBC FusionPunch II Service Manual...
  • Page 27 MAIN POWER SWITCH/ PL3.1 DISTRIBUTION CIRCUIT BREAKER AC RECEPTICLE/ PL1.1I LINE FILTER PL3.1 LINE LINE PL1.1I AC LINE LINE +24 VDC POWER SUPPLY PWB AC NEUTRAL PL3.1 LINE LINE 12/2003 GBC FusionPunch II Service Manual RAP 1.1 AC Power to the Punch...

  • Page 28: Rap 1.2 Ac Power To The Stacker

    The Stacker Tray Motor, Stacker O-Ring Component Diagnostic RAP will also provide procedures to Motor and Stacker Bypass Motor (if troubleshoot AC Power to a second GBC Stacker 1 Tray OUTC6 StackerDeck installed) in the problem stacker all operate Stacker. This RAP does not contain 0000000000000000 when the outputs are active.
  • Page 29 Distribution PWB (PL 3.2) in the placing the meter leads across P/J problem Stacker. 13-24V and P/J13-0V. * If installed There is +24 VDC at this point. 12/2003 GBC FusionPunch II Service Manual RAP 1.2 AC Power to the Stacker...
  • Page 30 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 Bypass Motor (PL 1.3A). 12/2003 RAP 1.2 AC Power to the Stacker GBC FusionPunch II Service Manual...
  • Page 31 RMTR RMTR is installed and a second Stacker is also present. MAIN POWER SWITCH/ CIRCUIT BREAKER AC RECEPTICLE/ PL1.2A LINE FILTER PL1.2A AC LINE LINE AC NEUTRAL 12/2003 GBC FusionPunch II Service Manual RAP 1.2 AC Power to the Stacker...

  • Page 32: Rap 1.3 +5Vdc Power

    Go to RAP 1.1 AC Power to the Go to Step 11. Punch. 11. On the AC/DC Distribution PWB, check for Go to Step 5. +5 VDC across P/J12-+5V and P/J12-0V. 12/2003 RAP 1.3 +5VDC Power GBC FusionPunch II Service Manual...
  • Page 33 PUNCH AC/DC PUNCH I/O PUNCH AC/DC DISTRIBUTION DISTRIBUTION PL3.1 PL3.1 +5 VDC PL3.1 POWER SUPPLY PWB PL3.1 LINE LINE 12/2003 GBC FusionPunch II Service Manual RAP 1.3 +5VDC Power...

  • Page 34: Rap 1.4 Punch +24Vdc Power

    CN1. On the Punch AC/DC Distribution PWB, the +24 VDC Power Supply PWB. (PL check for +24 VDC between P/J 14-24V 6.1B) and P/J 14-0V. 12/2003 RAP 1.4 Punch +24VDC Power GBC FusionPunch II Service Manual 2-10...
  • Page 35 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. 12/2003 GBC FusionPunch II Service Manual RAP 1.4 Punch +24VDC Power 2-11...
  • Page 36 COVER 1, TOP COVER 2) 24VI 24VI +24V +24V STACKER +24V AC/DC DISTRIBUTION PL 3.2 +24V +24 VDC PUNCH AC/DC POWER DISTRIBUTION SUPPLY PWB PL3.1 PL3.1 LINE LINE +24V 12/2003 RAP 1.4 Punch +24VDC Power GBC FusionPunch II Service Manual 2-12...

  • Page 37: Rap 1.5 Stacker +24Vdc Power

    RAP will also provide procedures to 3. On the Stacker 1 AC/DC Distribution PWB, Replace the harness between P/J 14 troubleshoot +24VDC power to a second GBC disconnect P/J 16B. Check continuity on the Punch AC/DC Distribution Stacker. This RAP does not contain...
  • Page 38 Replace the harness between P/J 28 on the Stacker 2 I/O PWB and P/J 12 on the Stacker 2 AC/DC Distribution PWB (PL 6.2A). The Stacker 2 +24 VDC Power Circuit are 12/2003 RAP 1.5 Stacker +24VDC Power GBC FusionPunch II Service Manual 2-14...
  • Page 39 Single Stacker Configuration, or, Stacker 1 of 2. AC/DC DISTRIBUTION +24V +24V Dual Stacker Configuration, Stacker 2 only. Not PL3.3 installed for Single Stacker Configuration. Stacker with no Bypass 12/2003 GBC FusionPunch II Service Manual RAP 1.5 Stacker +24VDC Power 2-15...
  • Page 40 +24V PL3.1 Notes: STACKER 1 AC/DC Dual Stacker Configuration, Stacker 1 of 2 only. DISTRIBUTION +24V +24V PL3.3 Dual Stacker Configuration, Stacker 2 only. Stacker configured with Bypass 12/2003 RAP 1.5 Stacker +24VDC Power GBC FusionPunch II Service Manual 2-16...

  • Page 41: Rap 2.1 Control Panel

    The problem is still present. The problem is still present. The LCD Panel is working correctly. The LCD Panel is working correctly. Go to Step 1A. Replace the Daughter PWB (PL 3.1). 12/2003 GBC FusionPunch II Service Manual RAP 2.1 Control Panel 2-17...
  • Page 42 7610496 BROWN 7610459 LCD ASS'Y WHITE NOTE: WHITE WIRE PIN NOT CONNECTED OVERLAY 7610273 PLATE 7610299 7610495 LITTLE STAR CONTROLLER PL3.1 7610458 I/O BUS EXPANSION BLACK ORANGE 7610452 DISTRIBUTION 12/2003 RAP 2.1 Control Panel GBC FusionPunch II Service Manual 2-18...

  • Page 43: Rap 3.1 Punch Interlock Switches

    Punch I/O PWB check the LED that Replace the cable between the Punch corresponds with the interlock. I/O PWB and the Little Star Controller Sequentially activate and deactivate the PWB (PL 6.1A). 12/2003 GBC FusionPunch II Service Manual RAP 3.1 Punch Interlock Switches 2-19...
  • Page 44 Distribution PWB. Middle Door 0V and INB2 LIB2 The continuity check is good. Right Door 0V and INB1 LIB1 Replace the harness (PL 6.1B). Go to Step 10. 12/2003 RAP 3.1 Punch Interlock Switches GBC FusionPunch II Service Manual 2-20...
  • Page 45 PL 3.1 PL 3.1 INTERRUPTED +24VI LITTLE STAR CONTROLLER PL 3.1 P24A J24A TOP COVERS INA6 INA6 LEFT DOOR INB3 INB3 MIDDLE DOOR INB2 INB2 RIGHT DOOR INB1 INB1 12/2003 GBC FusionPunch II Service Manual RAP 3.1 Punch Interlock Switches 2-21...

  • Page 46: Rap 3.2 Stacker Interlock Switches

    (Interlock closed = Off, Interlock GBC Stacker. This RAP does not contain the table to enter the Diagnostics mode and open = On). procedures for other downstream devices.
  • Page 47 Stacker 2 I/O PWB. Check the Front Door Punch Daughter PWB 1 corresponding I/O PWB LED to see if it is lit P25-1 when the connector is disconnected. 12/2003 GBC FusionPunch II Service Manual RAP 3.2 Stacker Interlock Switches 2-23...
  • Page 48 Replace the harness (PL 6.2A). Replace the harness (PL 6.2A). Go to Step 19. Go to Step 16. Replace the Interlock Switch (PL 1.2A). Reconnect the NO3 connectors. Go to Step 12. 12/2003 RAP 3.2 Stacker Interlock Switches GBC FusionPunch II Service Manual 2-24...
  • Page 49 The continuity check is good. 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). 12/2003 GBC FusionPunch II Service Manual RAP 3.2 Stacker Interlock Switches 2-25...
  • Page 50 +24 VDC INTERRUPTED Cover), and P/J6B (Front Door). +24V 24VI STACKER I/O PL 3.2 PUNCH DAUGHTER PL 3.1 J24A P24A TOP COVER INA6 INA6 FRONT DOOR INB1 INB1 12/2003 RAP 3.2 Stacker Interlock Switches GBC FusionPunch II Service Manual 2-26...

  • Page 51: Rap 4.1 Document Transport Jams

    Go to Step 1B. 1A. Check the Interface Assembly for This RAP will help isolate document transport obstructions, burrs, bent or missing Output Diagnostic jam problems in the FusionPunch II. components. Repair/replace as required (PL 4.1A - 4.1E). Document OUTA8 XportMotor...
  • Page 52 MT2 on the Punch AC/DC Distribution Go to Step 3A. PWB to the Document Transport Motor. If the harness is OK, replace the Document Go to Step 3B. Transport Motor (PL 1.1B). 12/2003 RAP 4.1 Document Transport Jams GBC FusionPunch II Service Manual 2-28...
  • Page 53 LITTLE STAR PUNCH I/O PWB DISTRIBUTION MOTOR PL 3.1 CONTROLLER PWB PL 3.1 PL 1.1B DOCUMENT TRANSPORT PL 3.1 MOTOR ON 24 VDC RELAY 4 HVO8 OUTB1 OUTA,C8 12/2003 GBC FusionPunch II Service Manual RAP 4.1 Document Transport Jams 2-29...

  • Page 54: Rap 4.2 Punch Jam Sensors

    There is a change in state when the sensor Transport 2 I11 1100110011001100 is blocked and unblocked. Punch INB7 Punch Sensor I10 1100110011001100 Go to Step 4. Exit INB8 Exit Sensor Go to step 3. 1100110011001100 12/2003 RAP 4.2 Punch Jam Sensors GBC FusionPunch II Service Manual 2-30...
  • Page 55 Punch I/O PWB. If the harness is OK, replace the sensor (Entrance - PL 4.1A, Document Transport 1 and 2 - 4.2A, Punch - 4.3A, Exit - 4.3D). 12/2003 GBC FusionPunch II Service Manual RAP 4.2 Punch Jam Sensors 2-31...
  • Page 56 PUNCH INB7 INB7 +24V DOCUMENT EXIT TRANSPORT INB8 INB8 2 SENSOR +24V PL 4.2A +24V +24V PUNCH SENSOR PL 4.3A +24V SIGNAL EXIT SENSOR PL 4.3D +24V SIGNAL 12/2003 RAP 4.2 Punch Jam Sensors GBC FusionPunch II Service Manual 2-32...

  • Page 57: Rap 5.1 Stacker Full, Almost Full, And Upper Switch

    RAP will also provide procedures to PWB with which it corresponds. Check for 1100110011001100 troubleshoot problems in a second GBC shorts to ground or opens in this harness. Stacker. This RAP does not contain The harness is shorted to ground or open.
  • Page 58 I/O PWB to the Stacker Upper Sensor. Replace the harness (PL 6.2A) Check for shorts to ground or opens in this 9. Stacker Upper Switch Checkout harness. 12/2003 RAP 5.1 Stacker Full, Almost Full, and Upper Switch GBC FusionPunch II Service Manual 2-34...
  • Page 59 FULL SWITCH PL 5.1A +5 VDC SIGNAL FULL SWITCH INB5 INB5 ALMOST FULL SWITCH +5 VDC PL 5.1A SIGNAL ALMOST FULL SWITCH INB4 INB4 12/2003 GBC FusionPunch II Service Manual RAP 5.1 Stacker Full, Almost Full, and Upper Switch 2-35...

  • Page 60: Rap 5.2 Stacker Tray Direction

    Stacker Tray. The error message RAP will also provide procedures to returns after the Stacker Tray is lowered troubleshoot problems in a second GBC There is continuity between the cable and raised. Stacker. This RAP does not contain connectors on the Punch I/O Daughter procedures for other downstream devices.
  • Page 61 Stacker 2 I/O PWB and its Punch I/O PWB There is continuity between P24A-INA8 and P-8. Repair or replace the harness (PL 6.2A). Replace the Punch I/O Daughter PWB (PL 3.1). 12/2003 GBC FusionPunch II Service Manual RAP 5.2 Stacker Tray Direction 2-37...
  • Page 62 PL 3.1 STACKER TRAY P23A J23A MOTOR OUTA6 OUTA6 RELAY 2 STACKER TRAY DIRECTION OUTA7 OUTA7 STACKER AC/DC DISTRIBUTION PUNCH DAUGHTER P24A J24A TRAY DIRECTION RLY2 R-ON INC8 INA8 12/2003 RAP 5.2 Stacker Tray Direction GBC FusionPunch II Service Manual 2-38...

  • Page 63: Rap 5.3 Stacker Jams

    Stacker 2: jamming in For machines configured with a Bypass, this Stacker 1 RAP will also provide procedures to troubleshoot problems in a second GBC Motor Diagnostic The paper is Check the lights on the Stacker. This RAP does not contain jamming in Stacker 1 Exit Sensor.
  • Page 64 Stacker tray that would activate and deactivate the Stacker O-Ring cause the paper to stall or jam. Motor output. Observe L0A8 on the Stacker I/O PWB. 12/2003 RAP 5.3 Stacker Jams GBC FusionPunch II Service Manual 2-40...
  • Page 65 +24 VDC with the output deactivated. 14. In the Diagnostics Mode, sequentially activate and deactivate the Stacker Tray Motor output. Observe LED L0A6 on the Stacker I/O PWB. 12/2003 GBC FusionPunch II Service Manual RAP 5.3 Stacker Jams 2-41...
  • Page 66 Tray Output Dist. PWB Position Value Reading 110 VAC J 7-NUI to J7-Rev Down 110 VAC J 7-NUI to J7-Fwd There is 110VAC as described in the above table. 12/2003 RAP 5.3 Stacker Jams GBC FusionPunch II Service Manual 2-42...
  • Page 67 RELAY PL 3.1 STACKER TRAY J23A P23A MOTOR OUTA6 OUTA6 RELAY 2 STACKER TRAY DIRECTION OUTA7 OUTA7 STACKER O-RING O-RING MOTOR OUTA8 OUTA8 MOTOR PL 1.2 B RELAY 3 12/2003 GBC FusionPunch II Service Manual RAP 5.3 Stacker Jams 2-43...

  • Page 68: Rap 5.4 Stacker Bypass Jams

    LED LOB5 illuminates when the output is dialog on the Control Panel. Stacker I/O PWB (PL 3.3). active. Go to Step 2. Go to Step 4. Go to Step 21. Go to Step 7. 12/2003 RAP 5.4 Stacker Bypass Jams GBC FusionPunch II Service Manual 2-44...
  • Page 69 Punch Daughter PWB P/J 22 and Stacker I/O PWB P22 (PL 6.2A). The harness is open or shorted to ground. Replace the Bypass Assembly Belt (PL5.2C). Replace the Stacker Gate Solenoid (PL 5.2A). 12/2003 GBC FusionPunch II Service Manual RAP 5.4 Stacker Bypass Jams 2-45...
  • Page 70 Switches to troubleshoot a problem LED L0B2 remains lit when P/J30 is Replace the Little Star Controller with the Stacker Top Cover Interlock. disconnected. Expansion PWB (PL 3.1). 12/2003 RAP 5.4 Stacker Bypass Jams GBC FusionPunch II Service Manual 2-46...
  • Page 71 P/J 1-INB8 and P/J1-0V. With the Stacker I/O P25-INB8 and the Punch Bypass Exit INB8 BypassSensor Daughter PWB P/J25-8. the jumper in place, LED LIB8 should I16 1100110011001100 extinguish. 12/2003 GBC FusionPunch II Service Manual RAP 5.4 Stacker Bypass Jams 2-47...
  • Page 72 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). 12/2003 RAP 5.4 Stacker Bypass Jams GBC FusionPunch II Service Manual 2-48...
  • Page 73 PUNCH BYPASS DAUGHTER EXIT SENSOR PL 3.2 PL 3.1 PL 1.3A BYPASS INSTALLED ONLY P1 J1 With a Bypass installed, this INB8 connector will be P/J16B INB8 +24V 12/2003 GBC FusionPunch II Service Manual RAP 5.4 Stacker Bypass Jams 2-49...

  • Page 74: Rap 5.5 Stacker Bypass Exit Sensors

    3.1). If the problem is still present, replace place, LED LIB8 should extinguish. the Little Star Controller (PL 3.1). Go to Step 2. Go to Step 3. 12/2003 RAP 5.5 Stacker Bypass Exit Sensors GBC FusionPunch II Service Manual 2-50...
  • Page 75 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). 12/2003 GBC FusionPunch II Service Manual RAP 5.5 Stacker Bypass Exit Sensors 2-51...
  • Page 76 P1 J1 INB8 INB8 +24V PUNCH STACKER 2 I/O STACKER 2 DAUGHTER BYPASS PWB #2 EXIT PL 3.2 SENSOR PL 3.1 PL 1.3A P1 J1 INB8 INB8 +24V 12/2003 RAP 5.5 Stacker Bypass Exit Sensors GBC FusionPunch II Service Manual 2-52...

  • Page 77: Rap 6.2 Printer Connectivity

    Connector “External Finisher Not Ready”, ensure the Punch I/O Output Signal Pins following: • the FusionPunch II is in Cycle Up Mode OUTA1 Printer Stop 4 and 22 OUTA1 Printer Stop LOA1 (except DT135). OUTA2 Printer FAULT 5 and 23...
  • Page 78 If the cable is faulted, replace it (PL 6.1A). Go to Step 6. Go to Step 8. Communication between the FusionPunch II and the host printer is OK. Refer to the Service Manual for the printer. 12/2003 RAP 6.2 Printer Connectivity GBC FusionPunch II Service Manual 2-54...
  • Page 79 OUTA5 J15A C0 SHEET EXIT INA1 C1 SET EXIT INA2 C2 CYCLE UP INA3 INA3 J14A C6 FINISHER FUNC1 INA4 INA4 J13A C7 FINISHER FUNC2 INA5 INA5 J12A P24A J24A 12/2003 GBC FusionPunch II Service Manual RAP 6.2 Printer Connectivity 2-55...
  • Page 80 Notes 12/2003 RAP 6.2 Printer Connectivity GBC FusionPunch II Service Manual 2-56...
  • Page 81 Not Punched - - - - - - - - - - - - - - - - - - - 3-11 Quality RAP 5.7 Documents Punched in Center of Sheet- - - - - - - - - - - - - - - - 3-15 12/2003 GBC FusionPunch II Service Manual...

  • Page 82: Quality Rap 5.3 Sets Do Not Offset

    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. 12/2003 Quality RAP 5.3 Sets Do Not Offset GBC FusionPunch II Service Manual...
  • Page 83 Sequentially activate and deactivate the Solenoids and the corresponding pin on output and observe L0B6 and L0B7 on P22 of the Stacker I/O PWB. the Stacker I/O PWB. 12/2003 GBC FusionPunch II Service Manual Quality RAP 5.3 Sets Do Not Offset...
  • Page 84 Go on to the next page... Reconnect P/J 30 and go to Step 15. Go to Step 12. Reconnect P/J 30 and go to Step 16. Go to Step 14. 12/2003 Quality RAP 5.3 Sets Do Not Offset GBC FusionPunch II Service Manual...
  • Page 85 Stacker. Check the harness between P8 on the Stacker AC/DC Distribution PWB and the O-Ring Motor. If the harness is OK, replace the O-Ring Motor (PL 1.2B). 12/2003 GBC FusionPunch II Service Manual Quality RAP 5.3 Sets Do Not Offset...
  • Page 86 MOTOR RELAY 3 OUTA8 OUTA8 OFFSET 1 SOLENOID PL 5.1C STACKER 24VI OFFSET 1 OUTB7 OUTB7 OFFSET 2 STACKER 24VI SOLENOID OFFSET 2 OUTB6 OUTB6 PL 5.1C 12/2003 Quality RAP 5.3 Sets Do Not Offset GBC FusionPunch II Service Manual...

  • Page 87: Quality Rap 5.4 Trail Edge Torn, Marked, Or Creased

    Advance to Step 2. 5. Using the information in the table below, the output is active, observe L0B7 on the Refer to the FusionPunch II User Guide enter the Diagnostics mode and use the Punch I/O PWB. and ensure that the Side Guide...
  • Page 88 13. Check the 3-60 VDC, 3 amp fuse on the output. Observe L0B7 on the Punch I/O Optical Relay. PWB. The fuse is OK Replace the fuse. Go to Step 14. 12/2003 Quality RAP 5.4 Trail Edge Torn, Marked, or Creased GBC FusionPunch II Service Manual...
  • Page 89 LITTLE STAR PUNCH I/O PWB BACK CONTROLLER GAUGE PL 3.1 SOLENOID PL 3.1 PL 4.3C BACK GAUGE 24VI FINGERS OPTO 2 HVO2 OUTB7 RELAY OUTB7 12/2003 GBC FusionPunch II Service Manual Quality RAP 5.4 Trail Edge Torn, Marked, or Creased...

  • Page 90: Quality Rap 5.5 Document Stack Shingled

    The Stacker Tappers are 1mm +/- 1/2 mm from the Tray. Perform ADJ 5.2 Stacker Tray Stop Position and then ADJ 5.3 Tapper Assembly. Go to Step 3. 12/2003 Quality RAP 5.5 Document Stack Shingled GBC FusionPunch II Service Manual 3-10...

  • Page 91: Quality Rap 5.6 Documents Not Punched

    LED L0B8 remains lit when its Punch I/O PWB connector is disconnected. Output Diagnostic Reconnect P/J 3B and go to Step 6. Punch OUTB8 PunchClutch Clutch 1100110011001100 Go to Step 8. 12/2003 GBC FusionPunch II Service Manual Quality RAP 5.6 Documents Not Punched 3-11...
  • Page 92 Assembly for obstructions, burrs, bent or Replace the fuse (PL 3.1). missing components. Repair/replace as Go to Step 14A. Go to Step 12. required (PL 4.2A to 4.2E). 12/2003 Quality RAP 5.6 Documents Not Punched GBC FusionPunch II Service Manual 3-12...
  • Page 93 P 30-OUTB1 on the Punch I/O PWB and P11-MT3 on the Punch AC/DC Distribution PWB. The harness is OK. Replace the harness (PL 6.1A) Go to Step 15A. 12/2003 GBC FusionPunch II Service Manual Quality RAP 5.6 Documents Not Punched 3-13...
  • Page 94 PL 4.3B PL 3.1 PUNCH 24VI OPTO 1 HVO1 OUTB8 RELAY OUTB8 AC/DC DISTRIBUTION PUNCH MOTOR PL 3.1 PL 1.1F PUNCH MOTOR ON RELAY 5 HVO7 OUTB2 OUTB1 12/2003 Quality RAP 5.6 Documents Not Punched GBC FusionPunch II Service Manual 3-14...

  • Page 95: Quality Rap 5.7 Documents Punched In Center Of Sheet

    Star Controller PWB P1 (PL 6.1A). Replace Optical relay Opto2 on the Replace the Little Star Controller PWB Punch I/O PWB (PL 3.1). (PL 3.1). 12/2003 GBC FusionPunch II Service Manual Quality RAP 5.7 Documents Punched in Center of Sheet 3-15...
  • Page 96 Punch I/O PWB and the Back Gauge Solenoid. The harness is open or shorted to ground. Replace the Back Gauge Solenoid (PL 4.3C). Replace the harness (PL 6.1A). 12/2003 Quality RAP 5.7 Documents Punched in Center of Sheet GBC FusionPunch II Service Manual 3-16...
  • Page 97 ADJ 4.6 Punch Clutch Timing Belt instruct you to do some steps before you can start the adjustment procedure. Tension - - - - - - - - - - - - - - - - - 4-31 12/2003 GBC FusionPunch II Service Manual...
  • Page 98 P15 - Punch I/O PWB P/J 29 3. Remove the 4 Allen Head Cap screws and the Punch AC/DC Distribution PWB. Figure 1. Replacement 1. Reinstall the parts in reverse order. 12/2003 REP 1.1 Punch AC/DC Distribution PWB GBC FusionPunch II Service Manual...
  • Page 99 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 connected. 12/2003 GBC FusionPunch II Service Manual REP 2.1 Control Panel LCD Display PWB...
  • Page 100 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. 12/2003 REP 3.1 Little Star Controller PWB GBC FusionPunch II Service Manual...
  • Page 101 7. Clean the Front and Center Crowned BELTS (2) Rollers with Isopropyl alcohol and then install the new Front and Center Swing LOCKING BEARING Frame Flat Belts. HANDLES (2) Figure 1. COLLARS (4) 12/2003 GBC FusionPunch II Service Manual REP 4.1 Swing Frame Flat Belts...
  • Page 102 Drive Shafts. BELTS (2) 7. Slide the 2 Drive Shafts towards the back of the machine. Figure 1. LOCKING HANDLE (2) 8. Remove the Interface Flat Belts. 12/2003 REP 4.2 Interface Flat Belts GBC FusionPunch II Service Manual...
  • Page 103 Coupler the same distance, but not more than 0.375 in. (1.0 cm). 5. Tighten the 2 setscrews in the Flex Coupler. 6. Install the Document Transport Deck and the 9 Allen screws. 12/2003 GBC FusionPunch II Service Manual REP 4.3 Document Transport Flat Belt...
  • Page 104 COUPLER 6. Loosen: Figure 1. 6.1 the 4 setscrews in the 4 Bearing Collars on the 2 Punch Drive Shafts (Figure 2). Continued from Page 4 - 8. 12/2003 REP 4.4 Punch Infeed Timing Belt GBC FusionPunch II Service Manual...
  • Page 105 Timing Belt Tension before turning the machine on again. NOTE: Ensure that the setscrews in the Crowned Rollers are properly tightened on the flat surfaces of the 2 Drive Shafts. 12/2003 GBC FusionPunch II Service Manual REP 4.4 Punch Infeed Timing Belt...
  • Page 106 This Page Intentionally Left Blank 12/2003 REP 4.4 Punch Infeed Timing Belt GBC FusionPunch II Service Manual 4-10...
  • Page 107 2. Reinstall the parts in reverse order. NOTE: Ensure that the setscrews in the Crowned Rollers are properly tightened on the flat surfaces of the 2 Drive Shafts. 12/2003 GBC FusionPunch II Service Manual REP 4.5 Punch Infeed Flat Belts 4-11...
  • Page 108 12.2 the Front and Rear Flanged Bearings (Figure 2). Stacker(s) aside. 12.3 Punch Clutch Output Timing Belt (Figure 3). 2. Remove the Punch Right Panel (10 screws). 12/2003 REP 4.6 Punch Clutch Output Timing Belt GBC FusionPunch II Service Manual 4-12...
  • Page 109 Punch and that the Stacker(s) SCREWS are resting on the Leveling Pads (see Section 8 Install Procedure). WASHERS PULLEY FLANGED BEARING PUNCH CLUTCH OUTPUT Figure 2. Figure 3. TIMING BELT 12/2003 GBC FusionPunch II Service Manual REP 4.6 Punch Clutch Output Timing Belt 4-13...
  • Page 110 Stackers are level with the Punch and that the Stacker(s) are resting on the Leveling Pads (see Section 8 Install Procedure).ADJ 4.1 Document Transport Timing Belt Tension 12/2003 REP 4.7 Punch Clutch Timing Belt GBC FusionPunch II Service Manual 4-14...
  • Page 111 Punch Motor and install it on the new Figure 1. Punch Motor. Replacement 1. Reinstall the parts in reverse order. 2. Perform ADJ 5.4 Punch Clutch Timing Belt Tension. 12/2003 GBC FusionPunch II Service Manual REP 4.8 Punch Motor 4-15...
  • Page 112 Punch Motor and install it on the new Punch Motor. Replacement 1. Reinstall the parts in reverse order. 2. Perform ADJ 4.1 Document Transport Timing Belt Tension before turning on the machine. 12/2003 REP 4.9 Document Transport Motor GBC FusionPunch II Service Manual 4-16...
  • Page 113 7. Slide the Drive Shaft towards the front of the machine until you can remove the O- ring from the Drive Shaft. Replacement 1. Replace the Stacker Drive O-ring. 2. Reinstall the parts in reverse order. 12/2003 GBC FusionPunch II Service Manual REP 5.1 Stacker Drive O-ring 4-17...
  • Page 114 7. Gently lift out the Bypass Unit. Replacement SENSOR Figure 2. 1. Reinstall the parts in the reverse order. BRACKET 2. Perform ADJ 5.5 Bypass Motor Timing Belt Tension. 12/2003 REP 5.2 Bypass Assy removal GBC FusionPunch II Service Manual 4-18...
  • Page 115 REP 5.2 Bypass Assy removal (continued) BYPASS GATE SOLENOID CONNECTOR ALLEN HEAD CAP SCREWS (2) LOCK WASHERS (2) FLAT WASHERS (2) Figure 3. 12/2003 GBC FusionPunch II Service Manual REP 5.2 Bypass Assy removal 4-19...
  • Page 116 NOTE: Ensure that the Spur Gear on the Solenoid and the Spur Gear on the Deflector Shaft are properly aligned. 2. Perform ADJ 5.4 Bypass Gate Solenoid and Gate Fingers. 12/2003 REP 5.3 Bypass Gate Solenoid GBC FusionPunch II Service Manual 4-20...
  • Page 117 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). 12/2003 GBC FusionPunch II Service Manual REP 5.4 Bypass Gate Fingers 4-21...
  • Page 118 Bypass Motor connection (Figure 2). Figure 2. Figure 3. BLUE 9. Remove the 4 Hex Nuts, 4 Lock Washers and 4 Flat Washers holding the Bypass Motor (Figure 1). 12/2003 REP 5.5 Bypass Motor and Timing Belt GBC FusionPunch II Service Manual 4-22...
  • Page 119 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. 12/2003 GBC FusionPunch II Service Manual REP 5.6 Bypass Flat Belt 4-23...
  • Page 120 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. 12/2003 REP 5.7 Rubber Drive Rollers GBC FusionPunch II Service Manual 4-24...
  • Page 121 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. 12/2003 GBC FusionPunch II Service Manual REP 5.8 Compression Springs 4-25...
  • Page 122 3. Tighten the Allen Head Cap screw in the Idler. NOTE: If the belt skips, tension is too Figure 1. loose. If the Power Switch/Circuit Breaker blows, tension is too tight. 12/2003 ADJ 4.1 Document Transport Timing Belt Tension GBC FusionPunch II Service Manual 4-26...
  • Page 123 Figure 1. 5. Check that the Sheet Eject Idler Rollers are both centered over the Rubber Drive Rollers and at the same distance above the Rubber Drive Rollers. 12/2003 GBC FusionPunch II Service Manual ADJ 4.2 Sheet Eject Solenoid 4-27...
  • Page 124 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). 12/2003 ADJ 4.3 Back Gauge Fingers GBC FusionPunch II Service Manual...
  • Page 125 (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. 12/2003 GBC FusionPunch II Service Manual ADJ 4.4 Punch Clutch Home Position 4-29...
  • Page 126 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 (0.5 mm). STOP PAWL Figure 1. ECCENTRIC STOP 12/2003 ADJ 4.5 Punch Clutch Eccentric Stop GBC FusionPunch II Service Manual 4-30...
  • Page 127 Punch Clutch Timing Belt Tension is 0.10 in. (2-3 mm). PUNCH MOTOR PULLEY 3. Tighten the 4 Hex Nuts. Figure 1. HEX NUTS (4) WASHERS (8) 12/2003 GBC FusionPunch II Service Manual ADJ 4.6 Punch Clutch Timing Belt Tension 4-31...
  • Page 128 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. O-RING ROLLER SKI SCREWS (2) Figure 1. 12/2003 ADJ 5.1 Stacker O-Ring Roller Assembly GBC FusionPunch II Service Manual 4-32...
  • Page 129 0.75 in. 5. Repeat steps 2 - 4, if necessary. (19.0 mm) 6. Tighten the Locknut on the Stacker Upper Switch Assembly (Figure 2). Figure 1. STACKER TRAY 12/2003 GBC FusionPunch II Service Manual ADJ 5.2 Stacker Tray Stop Position 4-33...
  • Page 130 3. Go to Stacker 1 or Stacker 2 Output Test and activate location: Stacker # 1 OUTB8 Stacker Tap STACKER Figure 1. TRAY 1000000000000100 Stacker # 2 OUTB8 Stacker Tap 1000000000000100 12/2003 ADJ 5.3 Tapper Assembly GBC FusionPunch II Service Manual 4-34...
  • Page 131 5. Go to Stacker 1 or Stacker 2 Output Test and activate location: Stacker # 1 OUTB5 Stacker Gate 1000000000000100 10.6 12.6 13.6 Stacker # 2 (INCHES) Figure 2. OUTB5 Stacker Gate 1000000000000100 12/2003 GBC FusionPunch II Service Manual ADJ 5.4 Bypass Gate Solenoid and Gate Fingers 4-35...
  • Page 132 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. 12/2003 ADJ 5.5 Bypass Motor Timing Belt Tension GBC FusionPunch II Service Manual 4-36...
  • Page 133 PL 4.2 D DT Flat Belt Assy. - - - - - - - - - - 60 FusionPunch II Common Hardware List - 123 which the part may be found.
  • Page 134 PL 1.1 A Punch Main Assy. ITEM # 1 REFER TO PL 4.1 A-G PL 1-1A 7610201-C1-2 12/2003 PL 1.1 A Punch Main Assy. GBC FusionPunch II Service Manual...
  • Page 135 7610501 Switch, Punch Interlock (Xerox Part Number 110P2340) ..5 1925061 Washer, Flat 1/4............... 4 1926064 Washer, Lock 1/4 ..............4 1980098 SHCS 1/4-20 x 1 ..............4 12/2003 GBC FusionPunch II Service Manual PL 1.1 A Punch Main Assy.
  • Page 136 PL 1.1 B Punch Main Assy. PL 1-1B 7610201-C1-3 12/2003 PL 1.1 B Punch Main Assy. GBC FusionPunch II Service Manual...
  • Page 137 Cable Assy., Document Transport Motor ......... 1 1914721 Carriage Screw 5/16-18 X 1-1/4 ..........4 1925001 Washer, Flat 5/16..............4 1926065 Washer, Lock 5/16 ..............4 1926706 Nut, Hex 5/16-18..............4 12/2003 GBC FusionPunch II Service Manual PL 1.1 B Punch Main Assy.
  • Page 138 PL 1.1 C Punch Main Assy. ITEM # 1 REFER TO PL 4.2 A-E PL 1-1C 7610201-C1-4 12/2003 PL 1.1 C Punch Main Assy. GBC FusionPunch II Service Manual...
  • Page 139 0130003500 Plate, Interface - Document Transport........2 1925061 Washer, Flat 1/4............... 6 1926064 Washer, Lock 1/4 ..............6 1980096 SHCS 1/4-20 x 3/4 ..............4 1980098 SHCS 1/4-20 x 1 ..............2 12/2003 GBC FusionPunch II Service Manual PL 1.1 C Punch Main Assy.
  • Page 140 PL 1.1 D Punch Main Assy. ITEM # 1 REFER TO PL 4.3 A-N PL 1-1D 7610201-C1-5 12/2003 PL 1.1 D Punch Main Assy. GBC FusionPunch II Service Manual...
  • Page 141 1980029 SHCS 6-32 x 1/2 ..............6 1980030 SHCS 6-32 x 5/8 ..............8 1980096 SHCS 1/4-20 x 3/4 ..............4 1980098 SHCS 1/4-20 x 1 ..............2 12/2003 GBC FusionPunch II Service Manual PL 1.1 D Punch Main Assy.
  • Page 142 PL 1.1 E Punch Main Assy. PL 1-1E 7610201-C1-6 12/2003 PL 1.1 E Punch Main Assy. GBC FusionPunch II Service Manual 5-10...
  • Page 143 Label, Back Gauge Knob ............1 7610437 Label, Edge Guide Knob............1 7610439 Bucket, Slug, Punch Assy............1 1928203 Wing Nut, Punch Assy............. 1 1980505 FHCS 1/4-20 x 3/4 ..............4 12/2003 GBC FusionPunch II Service Manual PL 1.1 E Punch Main Assy. 5-11...
  • Page 144 PL 1.1 F Punch Main Assy. PL 1-1F 7610201-C1-7 12/2003 PL 1.1 F Punch Main Assy. GBC FusionPunch II Service Manual 5-12...
  • Page 145 Carriage Screw 5/16-18 X 1-1/4 ..........4 1925001 Washer, Flat 5/16..............4 1926065 Washer, Lock 5/16 ..............4 1926706 Nut, Hex 5/16-18..............4 1932705 Collar, Split Lock, Punch Motor Pulley........1 12/2003 GBC FusionPunch II Service Manual PL 1.1 F Punch Main Assy. 5-13...
  • Page 146 PL 1.1 G Punch Main Assy. PL 1-1G 7610201-C1-8 12/2003 PL 1.1 G Punch Main Assy. GBC FusionPunch II Service Manual 5-14...
  • Page 147 Pulley, 48 Tooth, Document Transport Main Drive, 6060 / iGen3 (Tag # P5) ..2 7610533 Belt, Timing, Document Transport Main Drive, 6060 / iGen3 (Tag # P5) ....1 12/2003 GBC FusionPunch II Service Manual PL 1.1 G Punch Main Assy. 5-15...
  • Page 148 PL 1.1 H Punch Main Assy. REFER TO PL 2.1 P5 13 ITEM # 5 WRITE SERIAL NO. IN UPPER RIGHT CORNER PL 1-1H 7610201-C1-12 12/2003 PL 1.1 H Punch Main Assy. GBC FusionPunch II Service Manual 5-16...
  • Page 149 Panel, Punch Entrance, 4xxx / 6060 / iGen3 (Tag # P5) ..1 1911106 SEMS Screw 8-32 x 3/8 ............4 1926062 Washer, Lock #8 ..............4 1926701 Nut, Hex 8-32................. 17 12/2003 GBC FusionPunch II Service Manual PL 1.1 H Punch Main Assy. 5-17...
  • Page 150 PL 1.1 I Punch Main Assy. ANA AHR PL 1-1I 7610201-C1-9 12/2003 PL 1.1 I Punch Main Assy. GBC FusionPunch II Service Manual 5-18...
  • Page 151 Washer, Flat #6................ 2 1926060 Washer, Lock #4 ..............2 1926061 Washer, Lock #6 ..............2 1926711 Nut, Hex 4-40................2 1980029 SHCS 6-32 x 1/2 ..............2 12/2003 GBC FusionPunch II Service Manual PL 1.1 I Punch Main Assy. 5-19...
  • Page 152 PL 1.2 A Stacker Main Assy. ITEM # 5 REFER TO PL 5.1D ITEM # 15 REFER TO PL 5.1 A-D ANB AHS PL 1-2A 7610001 C1-1 12/2003 PL 1.2 A Stacker Main Assy. GBC FusionPunch II Service Manual 5-20...
  • Page 153 Nut, Hex 4-40..................2 1926802 Nut, Kep 8-32..................1 1980029 SHCS 6-32 x 1/2 ................. 12 1980072 SHCS 10-32 x 1/2 ................. 4 1980432 FHCS 6-32 X 3/8................... 2 12/2003 GBC FusionPunch II Service Manual PL 1.2 A Stacker Main Assy. 5-21...
  • Page 154 CAPACITOR INCLUDED WITH ITEM # 2 & 4 ANE AHQ CAPACITOR INCLUDED WITH ITEM # 1 & 3 PL 1-2B 7610001 C1-1 GROUND WIRE OF ITEM # 30 ON PL 1.2 C 12/2003 PL 1.2 B Stacker Main Assy. GBC FusionPunch II Service Manual 5-22...
  • Page 155 1926730 Nut, Hex 10-32 ................. 4 1980051 SHCS 8-32 x 5/8 ..............2 1980083 SHCS 10-32 x 2.5 ..............4 1980110 SCHS 1/4-20 x 4.0 ..............4 12/2003 GBC FusionPunch II Service Manual PL 1.2 B Stacker Main Assy. 5-23...
  • Page 156 BLACK STACKER TRAY MOTOR REFER TO PL 1.2 B REFER TO PL 1.2 B FOR GROUND WIRE CONNECTION CAPACITOR INCLUDED WITH STACKER TRAY MOTOR SEE DETAIL A 12/2003 PL 1.2 C Stacker Main Assy. GBC FusionPunch II Service Manual 5-24...
  • Page 157 Cable Assy., Stacker O-ring Motor .......... 1 1952407 Strain Refief, Stacker Cable Assy..........2 1926062 Washer, Lock #8 ..............8 1980046 SHCS 8-32 X 1/4 ..............8 12/2003 GBC FusionPunch II Service Manual PL 1.2 C Stacker Main Assy. 5-25...
  • Page 158 PL 1.2 D Stacker Main Assy. PL 1-2D 7610001 C1-3 12/2003 PL 1.2 D Stacker Main Assy. GBC FusionPunch II Service Manual 5-26...
  • Page 159 Description ........Qty 6009410 Label, Re-install Screw ............2 1911106 SEMS Screw 8-32 x 3/8 ............2 12/2003 GBC FusionPunch II Service Manual PL 1.2 D Stacker Main Assy. 5-27...
  • Page 160 REFER TO PL 5.2 D AHQ ANE BLACK BROWN BYPASS MOTOR CAPACITOR INCLUDED WITH PL 1-3A Bypass Int 7610003-A1-5 ITEM # 6 5 BYPASS MOTOR BLUE 12/2003 PL 1.3 A Bypass Stacker Main Assy. GBC FusionPunch II Service Manual 5-28...
  • Page 161 SHCS 8-32 x 5/8 ..................1 1980077 SHCS 10-32 x 1 ................... 2 1980098 SHCS 1/4-20 x 1 ..................4 1980110 SHCS 1/4-20 x 4 ..................4 12/2003 PL 1.3 A Bypass Stacker Main Assy. GBC FusionPunch II Service Manual 5-29...
  • Page 162 PL 1.3 B Bypass Stacker Assy. BYPASS ONLY ITEM # 5 WRITE SERIAL NO. IN UPPER RIGHT CORNER PL 1-3B Bypass Int 7610003-B1-8 BYPASS EXIT PANEL 12/2003 PL 1.3 B Bypass Stacker Assy. GBC FusionPunch II Service Manual 5-30...
  • Page 163 Plate, Docking, Bypass Stacker Assy. (Tag # S1) ....1 1911106 SEMS Screw 8-32 x 3/8 ............7 1926064 Washer, Lock 1/4 ..............2 1926701 Nut, Hex 8-32................. 10 1980094 SHCS 1/4-20 x 1/2 ..............2 12/2003 PL 1.3 B Bypass Stacker Assy. GBC FusionPunch II Service Manual 5-31...
  • Page 164 PL 2.1 A Control Panel Assy. PL 2-1A 7610201-C1-12 12/2003 PL 2.1 A Control Panel Assy. GBC FusionPunch II Service Manual 5-32...
  • Page 165 Washer, Lock #4 ..............4 1926062 Washer, Lock #8 ..............4 1926701 Nut, Hex 8-32................4 1926802 Nut, Kep 8-32................1 1980215 BHCS 4-40 X 1/4 ..............4 12/2003 GBC FusionPunch II Service Manual PL 2.1 A Control Panel Assy. 5-33...
  • Page 166 PL 3.1 Punch Electronic Assy. ANA AHR ANC AHT AHT ANC ANC AHT PL 3-1 7610201-C1-11 12/2003 PL 3.1 Punch Electronic Assy. GBC FusionPunch II Service Manual 5-34...
  • Page 167 Washer, Flat #4..................................8 1925064 Washer, Flat #8..................................23 1926060 Washer, Lock #4 ..................................8 1926062 Washer, Lock #8 ..................................23 1980015 SHCS 4-40 x 5/8 ..................................8 1980048 SHCS 8-32 x 7/16 ..................................23 12/2003 GBC FusionPunch II Service Manual PL 3.1 Punch Electronic Assy. 5-35...
  • Page 168 BUT ITEM # 4 OPTO RELAY HAS AN AC OUPUT. AND ITEM # 3 HAS A DC OUTPUT. AHS ANB S3 P5 AHS ANB ANB AHS PL 3-2A1 7610001 C1-3 12/2003 PL 3.2 Stacker Electronic Assy. GBC FusionPunch II Service Manual 5-36...
  • Page 169 Washer, Flat #6..............10 1926061 Washer, Lock #6 ..............10 1926062 Washer, Lock #8 ..............1 1980029 SHCS 6-32 x 1/2 ..............10 1980051 SHCS 8-32 x 5/8 ..............1 12/2003 GBC FusionPunch II Service Manual PL 3.2 Stacker Electronic Assy. 5-37...
  • Page 170 BUT ITEM # 7 OPTO RELAY HAS AN AC OUPUT. AND ITEM # 8 HAS A DC OUTPUT. S3 P5 PL 3-3A Bypass Int 7610003-A1-7 BYPASS ONLY BYPASS ONLY 12/2003 PL 3.3 Bypass Stacker Electronics Assy. GBC FusionPunch II Service Manual 5-38...
  • Page 171 Cable Assy., Stacker #1 AC/DC Distribution PWB P/J 13 - Stacker #2 AC/DC Distribution PWB P/J 14 ....1 7610729 Fuse, 3A Slow Blow ..............................3 1926062 Washer, Lock #8 ................................3 1980051 SHCS 8-32 x 5/8 ................................3 12/2003 PL 3.3 Bypass Stacker Electronics Assy. GBC FusionPunch II Service Manual 5-39...
  • Page 172 PL 4.1 A Swing Frame Assy. 13 SE 11 REFER TO PL 4.1 B PL 4-1A 7610378 Assy Inteface MOD 12/2003 PL 4.1 A Swing Frame Assy. GBC FusionPunch II Service Manual 5-40...
  • Page 173 SHCS 10-32 x 1/2 ..............2 1980074 SHCS 10-32 x 5/8 ..............4 1980233 BHCS 6-32 x 1/2 ..............10 1980505 FHCS 1/4-20 x 3/4 ..............8 12/2003 GBC FusionPunch II Service Manual PL 4.1 A Swing Frame Assy. 5-41...
  • Page 174 PL 4.1 B Interface Assy AHQ ANE ANE AHQ PL 4-1B 7610378 Assy Interface MOD 12/2003 PL 4.1 B Interface Assy. GBC FusionPunch II Service Manual 5-42...
  • Page 175 SHSS 10-32 x 3/16 ..............2 1925061 Washer, Flat 1/4..............20 1926064 Washer, Lock 1/4 ..............20 1980098 SHCS 1/4-20 x 1 ..............20 1980233 BHCS 6-32 x 1/2 ..............12 12/2003 GBC FusionPunch II Service Manual PL 4.1 B Interface Assy. 5-43...
  • Page 176 PL 4.1 C Swing Frame/Interface Assy. SEE DETAIL SEE DETAIL DETAIL B DETAIL A (LEFT SIDE KNOB ASSY) PL 4-1C 7610378 Assy Interface MOD 12/2003 PL 4.1 C Swing Frame/Interface Assy. GBC FusionPunch II Service Manual 5-44...
  • Page 177 Handle, Interface, Adjustable 5/16-1/8 THD ......2 1925065 Washer, Flat 3/8 ..............2 1925184 Washer, Flat Extra Thick 3/8............ 2 1926064 Washer, Lock 1/4 ..............2 1980095 SHCS 1/4-20 x 5/8 ..............2 12/2003 GBC FusionPunch II Service Manual PL 4.1 C Swing Frame/Interface Assy. 5-45...
  • Page 178 PL 4.1 D Swing Frame / Interface Assy. ITEM # 4 REFER TO PL 4.1 G ITEM # 3 REFER TO PL 4.1 F PL 4-1D 7610378 Assy Interface MOD 12/2003 PL 4.1 D Swing Frame / Interface Assy. GBC FusionPunch II Service Manual 5-46...
  • Page 179 Washer, Flat, Non-Metallic............2 1926063 Washer, Lock #10 ..............4 1960509 Loctite ................0.001 1980075 SHCS 10-32 x 3/4 ..............4 1980256 BHCS 8-32 x 3/8 ..............3 12/2003 GBC FusionPunch II Service Manual PL 4.1 D Swing Frame / Interface Assy. 5-47...
  • Page 180 PL 4.1 E Swing Frame / Interface Assy. AHP AND PL 4-1E 7610378 Assy InterfaceMOD 12/2003 PL 4.1 E Swing Frame / Interface Assy. GBC FusionPunch II Service Manual 5-48...
  • Page 181 Washer, Lock #10 ..............4 1980051 SHCS 8-32 x 5/8 ..............2 1980075 SHCS 10-32 x 3/4 ..............4 1980256 BHCS 8-32 x 3/8 ..............4 12/2003 GBC FusionPunch II Service Manual PL 4.1 E Swing Frame / Interface Assy. 5-49...
  • Page 182 PL 4.1 F Swing Frame Ball Track Assy. PL 4-1F 7610341 Assy Swing Frame Ball Track 12/2003 PL 4.1 F Swing Frame Ball Track Assy. GBC FusionPunch II Service Manual 5-50...
  • Page 183 Nut, Hex 5/16 - 18..............2 1927302 Nut, Jam 6-32 ................2 1980028 SHCS 6-32 x 3/8 ..............12 1980075 SHCS 10-32 x 3/4 ..............6 12/2003 GBC FusionPunch II Service Manual PL 4.1 F Swing Frame Ball Track Assy. 5-51...
  • Page 184 PL 4.1 G Interface Ball Track Assy. AHT ANC AHP AND AHP AND AHT ANC PL 4-1G 7610325 Assy Interface Ball Track 12/2003 PL 4.1 G Interface Ball Track Assy. GBC FusionPunch II Service Manual 5-52...
  • Page 185 1926062 Washer, Lock #8 ..............4 1926063 Washer, Lock #10 ..............4 1980052 SHCS 8-32 x 3/4 ..............4 1980075 SHCS 10-32 x 3/4 ..............4 12/2003 GBC FusionPunch II Service Manual PL 4.1 G Interface Ball Track Assy. 5-53...
  • Page 186 AHQ ANE ANV ANE AHQ AHQ ANE SEE DETAIL A DETAIL A AHQ ANE ANB AHS AHQ ANE ANE AHQ PL 4-2A 7610380 Assy Documant Transport MOD 12/2003 PL 4.2 A Document Transport Assy. GBC FusionPunch II Service Manual 5-54...
  • Page 187 SHCS 6-32 x 3/8 ........................2 1980096 SHCS 1/4-20 x 3/4 .........................4 1980097 SHCS 1/4-20 x 7/8 .........................2 1980098 SHCS 1/4-20 x 1 ........................14 1980109 SHCS 1/4-20 x 3-1/2 ......................2 12/2003 GBC FusionPunch II Service Manual PL 4.2 A Document Transport Assy. 5-55...
  • Page 188 PL 4.2 B Document Transport Assy. AHQ ANE ITEM # 3 REFER TO PL 4.2 D REFER TO PL 4.2 D PL 4-2B 7610380 Assy Document Transport MOD 12/2003 PL 4.2 B Document Transport Assy. GBC FusionPunch II Service Manual 5-56...
  • Page 189 0130021200 Assy., Document Transport Belt (refer to PL 4.2 D) ....1 1925061 Washer, Flat 1/4............... 7 1926064 Washer, Lock 1/4 ..............7 1980094 SHCS 1/4-20 x 1/2 ..............7 1980233 BHCS 6-32 x 1/2 ..............9 12/2003 GBC FusionPunch II Service Manual PL 4.2 B Document Transport Assy. 5-57...
  • Page 190 PL 4.2 C Document Transport Assy. ITEM # 1 REFER TO PL 4.2 E PL 4-2C 7610380 Assy Document Transport MOD 12/2003 PL 4.2 C Document Transport Assy. GBC FusionPunch II Service Manual 5-58...
  • Page 191 Assy., Document Transport Ball Track (refer to PL 4.2 E) ..1 1925061 Washer, Flat 1/4............... 4 1926064 Washer, Lock 1/4 ..............4 1980096 SHCS 1/4-20 x 3/4 ..............4 12/2003 GBC FusionPunch II Service Manual PL 4.2 C Document Transport Assy. 5-59...
  • Page 192 PL 4.2 D Document Transport Flat Belt Assy. CB ANE AHQ CE ANE AHQ CB ANE AHQ AHQ ANE CB ANE CE ANE CB PL 4-2 D0130021200 Assy Document Transport MOD 12/2003 PL 4.2 D Document Transport Flat Belt Assy. GBC FusionPunch II Service Manual 5-60...
  • Page 193 SHCS 10-32 x 1/2 ..............8 1980094 SHCS 1/4-20 x 1/2 ..............4 1980096 SHCS 1/4-20 x 3/4 ..............2 1980233 BHCS 6-32 x 1/2 ..............2 12/2003 GBC FusionPunch II Service Manual PL 4.2 D Document Transport Flat Belt Assy. 5-61...
  • Page 194 PL 4.2 E Document Transport Ball Track Assy. ANE AHQ AND AHP ANC AHT ANB AHS PL 4-2E 7610358 Assy Doc Trans Ball Track 12/2003 PL 4.2 E Document Transport Ball Track Assy. GBC FusionPunch II Service Manual 5-62...
  • Page 195 SHCS 8-32 x 5/8 ..............8 1980054 SHCS 8-32 x 1 ................. 3 1980075 SHCS 10-32 x 3/4 ..............6 1980095 SHCS 1/4-20 x 5/8 ..............8 12/2003 GBC FusionPunch II Service Manual PL 4.2 E Document Transport Ball Track Assy. 5-63...
  • Page 196 ITEM # 7 REFER TO PL 4.3 K DETAIL C ITEM # 5 REFER TO PL 4.3 K DETAIL A PL4-3A 7610382 Assy Punch ANE AHQ ITEM # 3 REFER TO PL 4.3 I 12/2003 PL 4.3 A Punch Assy. GBC FusionPunch II Service Manual 5-64...
  • Page 197 Washer, Lock #10 ..............3 1926064 Washer, Lock 1/4 ..............18 1930522 E-Ring .5 ................. 2 1980072 SHCS 10-32 x 1/2 ..............3 1980096 SHCS 1/4-20 x 3/4 ..............18 12/2003 GBC FusionPunch II Service Manual PL 4.3 A Punch Assy. 5-65...
  • Page 198 SHAFT ITEM # 5 SHOULD LOCK TO SHAFT. DETAIL A REFER TO PL 4.3 A PL 4-3B 7610382 Assy Punch RIGHT HAND FRAME ASSEMBLY REMOVED FOR CLARITY REFER TO PL 4.3 A 12/2003 PL 4.3 B Punch Assy. GBC FusionPunch II Service Manual 5-66...
  • Page 199 Belt, Flat, Punch Input .06 x 1 x 10.75 Endless ....... 3 1981309 Belt, Timing, Punch Drive ............1 1900028 SHSS 10-32 x 3/16 ..............6 1931528 Roll Pin, 1/8 x 3/4 ..............1 12/2003 GBC FusionPunch II Service Manual PL 4.3 B Punch Assy. 5-67...
  • Page 200 ITEM # 7 REFER TO PL 4.3 L DETAIL B SEE DETAIL A ITEM # 4 REFER TO PL 4.3 L DETAIL A PL4-3 C 7610382 Assy Punch 12/2003 PL 4.3 C Punch Assy. GBC FusionPunch II Service Manual 5-68...
  • Page 201 SHCS 10-32 x 3/8 ..............2 1980075 SHCS 10-32 x 3/4 ..............1 1980080 SHCS 10-32 x 1-1/2..............3 ACJJ 1903010 Truss Head Screw 10-32 X 3/8..........4 12/2003 GBC FusionPunch II Service Manual PL 4.3 C Punch Assy. 5-69...
  • Page 202 ANA AHR FACTORY SET DO NOT ADJUST ITEM # 1 SEE DATAIL A DETAIL A <>8.05 ITEM # 1 SEE DATAIL A (AFTER ASSY) PL 4-3D 7610382 Assy Punch 12/2003 PL 4.3 D Punch Assy. GBC FusionPunch II Service Manual 5-70...
  • Page 203 Roll Pin, 3/32 x 1..............2 1935212 Spring, Comp. 7/32 x 1-3/4 x .23 ..........2 1980014 SHCS 4-40 x 1/2 ..............1 ACJJ 1903010 Truss Head Screw 10-32 X 3/8..........4 12/2003 GBC FusionPunch II Service Manual PL 4.3 D Punch Assy. 5-71...
  • Page 204 PL 4.3 E Punch Assy. PL 4-3E 7610382 Assy Punch 12/2003 PL 4.3 E Punch Assy. GBC FusionPunch II Service Manual 5-72...
  • Page 205 Belt, Timing, Punch Output Idler ..........1 1981306 Belt, Timing, Punch Output Drive..........1 7610352 Gear, Spur, Small, Back Gauge..........1 7610353 Gear, Spur, Large, Back Gauge ..........1 12/2003 GBC FusionPunch II Service Manual PL 4.3 E Punch Assy. 5-73...
  • Page 206 PL 4.3 F Punch Assy. PL4-3 F 7610382 Assy Punch 12/2003 PL 4.3 F Punch Assy. GBC FusionPunch II Service Manual 5-74...
  • Page 207 SHCS 3/8-16 x 1-3/4 ..............2 1925184 Washer, Flat Extra Thick 3/8............ 2 1925230 Washer, Flat, Non-Metallic............2 1926066 Washer, Lock 3/8 ..............2 1932706 Clamp Collar, Punch Slide Assy..........2 12/2003 GBC FusionPunch II Service Manual PL 4.3 F Punch Assy. 5-75...
  • Page 208 PL 4.3 G Punch Assy. PL4-3G 7610382 Assy Punch 12/2003 PL 4.3 G Punch Assy. GBC FusionPunch II Service Manual 5-76...
  • Page 209 0130025100 Assy., Clamp, Punch Output Nip Roller ........2 1925060 Washer, Flat #10..............2 1926063 Washer, Lock #10 ..............2 1980072 SHCS 10-32 x 1/2 ..............2 1980075 SHCS 10-32 x 3/4 ..............2 12/2003 GBC FusionPunch II Service Manual PL 4.3 G Punch Assy. 5-77...
  • Page 210 PL 4.3 H Punch Assy. ITEM # 3 REFER TO PL 4.3 M AHQ ANE ITEM # 2 REFER TO PL 4.3 N PL 4-3H 7610382 Assy Punch 12/2003 PL 4.3 H Punch Assy. GBC FusionPunch II Service Manual 5-78...
  • Page 211 Washer, Flat #10..............1 1925061 Washer, Flat 1/4............... 4 1926063 Washer, Lock #10 ..............1 1926064 Washer, Lock 1/4 ..............4 1980095 SHCS 1/4-20 x 5/8 ..............4 12/2003 GBC FusionPunch II Service Manual PL 4.3 H Punch Assy. 5-79...
  • Page 212 ITEM # 6 SEE NOTE 1 NOTES: 1) MALE PART OF ITEM # 6 REFER TO PL 4.3 N PL 4-3I 7610328 Assy RH Punch Side Frame 12/2003 PL 4.3 I R.H. Punch Side Frame Assy. GBC FusionPunch II Service Manual 5-80...
  • Page 213 SHCS 10-32 x 3/4 ..............4 1980145 SHCS 5/16-18 x 1-1/4 .............. 2 1980432 FHCS 6-32 x 3/8 ..............2 1980509 FHCS 1/4-20 x 1-1/4 ..............1 12/2003 GBC FusionPunch II Service Manual PL 4.3 I R.H. Punch Side Frame Assy. 5-81...
  • Page 214 PL 4.3 J L.H. Punch Side Frame Assy. AND AHP PL 4-3 J 7610327 Assy LH Punch Side Frame 12/2003 PL 4.3 J L.H. Punch Side Frame Assy. GBC FusionPunch II Service Manual 5-82...
  • Page 215 SHCS 10-32 x 1-3/4..............2 1980096 SHCS 1/4-20 x 3/4 ..............2 1980145 SHCS 5/16-18 x 1-1/4 .............. 2 1980509 FHCS 1/4-20 x 1-1/4 ..............1 12/2003 GBC FusionPunch II Service Manual PL 4.3 J L.H. Punch Side Frame Assy. 5-83...
  • Page 216 PL 4.3 K Locking Cam Assy. DETAIL A DETAIL B DETAIL C PL 4-3K Lock Cam Assemblies 12/2003 PL 4.3 K Locking Cam Assy. GBC FusionPunch II Service Manual 5-84...
  • Page 217 0130038000 Yoke, L.H. Locking Cam Assy..........1 7610252 Shaft, Locking Cam Assy............1 0130028900 Cam, Die Locking..............2 1931528 Roll Pin, 1/8 x 3/4 ..............2 1954109 Dowel Pin, 3-16 x 1/2............... 2 12/2003 GBC FusionPunch II Service Manual PL 4.3 K Locking Cam Assy. 5-85...
  • Page 218 PL 4.3 L Assemblies (Punch Clutch & Back Gauge Block). DETAIL A DETAIL B PL 4-3L 0130025900 Punch Clutch Assy & Back Gauge Adj. 12/2003 PL 4.3 L Assemblies (Punch Clutch & Back Gauge GBC FusionPunch II Service Manual 5-86...
  • Page 219 Roll Pin, 3/16 X 1-1/2 ............... 1 1952101 Key, Woodruff #606 ..............1 1953639 Bushing, Flanged, Nylon 1/2 ............ 1 1980096 SHCS 1/4-20 x 3/4 ..............3 12/2003 GBC FusionPunch II Service Manual PL 4.3 L Assemblies (Punch Clutch & Back Gauge 5-87...
  • Page 220 PL 4.3 M Punch Output Nip Roller Assy. PL 4-3M 7610332 Assy Output Nip Roller 12/2003 PL 4.3 M Punch Output Nip Roller Assy. GBC FusionPunch II Service Manual 5-88...
  • Page 221 Thumb Screw, Punch Output Nip Assy........4 1926063 Washer, Lock #10 ..............6 1930516 E-Ring .375 ................8 1980070 SHCS 10-32 x 3/8 ..............6 12/2003 GBC FusionPunch II Service Manual PL 4.3 M Punch Output Nip Roller Assy. 5-89...
  • Page 222 1) FEMALE PART OF ITEM # 8 REFER TO PL 4.3 I ITEM # 8 SEE NOTE 1 PL 4-3N 7610332 - 7610329 Assy Sheet Exit 12/2003 PL 4.3 N Punch Tension Strap Assy. GBC FusionPunch II Service Manual 5-90...
  • Page 223 SHCS 10-32 x 3/8 ..........2 1980077 SHCS 10-32 x 1 ............ 2 1980095 SHCS 1/4-20 x 5/8 ..........2 1980230 BHCS 6-32 x 1/4 ........... 2 12/2003 PL 4.3 N Punch Tension Strap Assy. GBC FusionPunch II Service Manual 5-91...
  • Page 224 PL 5.1 A Stacker Assy. DETAIL A SEE DETAIL A REFER TO PL 6.1 A PL 5-1A 7610002 12/2003 PL 5.1 A Stacker Assy. GBC FusionPunch II Service Manual 5-92...
  • Page 225 Washer, Lock #4 ..........6 1926062 Washer, Lock #8 ..........4 1926063 Washer, Lock #10 ..........15 1926064 Washer, Lock 1/4 ..........12 1926702 Nut, Hex 10-32 ...........1 1927304 Nut, Jam 10-32 ..........3 12/2003 PL 5.1 A Stacker Assy. GBC FusionPunch II Service Manual 5-93...
  • Page 226 PL 5.1 B Stacker Assy. REFER TO PL 5.1 D (Tag # S2) DETAIL A REFER TO PL 5.1 C 3.84 REF. AHT ANC SEE DETAIL A AHT ANC PL 5-1B 7610002 12/2003 PL 5.1 B Stacker Assy. GBC FusionPunch II Service Manual 5-94...
  • Page 227 Roll Pin, 1/8 x 3/4 ..............1 1953636 Bushing, Flanged, Nylon 3/8........... 2 1980030 SHCS 6-32 x 5/8 ..............16 1980054 SHCS 8-32 x 1 ................. 2 1980072 SHCS 10-32 x 1/2 ..............2 12/2003 GBC FusionPunch II Service Manual PL 5.1 B Stacker Assy. 5-95...
  • Page 228 PL 5.1 C Stacker Assy. INCLUDED WITH ITEM # 14 PL 5-1C 7610002 Assy Stacker 12/2003 PL 5.1 C Stacker Assy. GBC FusionPunch II Service Manual 5-96...
  • Page 229 Bushing, Flanged, Nylon 1/2 ............ 2 1953631 Bushing, Flanged, Nylon............1 1980082 SHCS 10-32 x 2 ............... 1 1980254 BHCS 8-32 x 1/4 ..............4 1980479 FHCS 10-32 x 3/8 ..............2 12/2003 GBC FusionPunch II Service Manual PL 5.1 C Stacker Assy. 5-97...
  • Page 230 PL 5.1 D Stacker Assy. AHP AND PL 5-1D 7611920 12/2003 PL 5.1 D Stacker Assy. GBC FusionPunch II Service Manual 5-98...
  • Page 231 1980047 SCHS 8-32 x 3/8 ..............10 1980072 SHCS 10-32 x 1/2 ..............4 1980075 SHCS 10-32 x 3/4 ..............4 1980095 SHCS 1/4-20 x 5/8 ..............2 12/2003 GBC FusionPunch II Service Manual PL 5.1 D Stacker Assy. 5-99...
  • Page 232 PL 5.2 A Bypass Stacker Assy. PL 5-2A Bypass Assy 7611951-B1-2 12/2003 PL 5.2 A Bypass Stacker Assy. GBC FusionPunch II Service Manual 5-100...
  • Page 233 SHCS 8-32 x 3/8 ..............10 1980072 SHCS 10-32 x 1/2 ..............6 1980096 SHCS 1/4-20 x 3/4 ..............14 1980302 BHCS 1/4-20 x 3/8 ..............6 12/2003 PL 5.2 A Bypass Stacker Assy. GBC FusionPunch II Service Manual 5-101...
  • Page 234 PL 5.2 B Bypass Stacker Assy. PL 5-2B Bypass Assy 7611951-B1-3 12/2003 PL 5.2 B Bypass Stacker Assy. GBC FusionPunch II Service Manual 5-102...
  • Page 235 Washer, Flat # 10..............2 1925236 Spacer, Non-Metalic ............... 2 1926063 Washer, Lock #10 ..............18 1980072 SHCS 10-32 x 1/2 ..............10 1980286 BHCS 10-32 x 1 ............... 6 12/2003 PL 5.2 B Bypass Stacker Assy. GBC FusionPunch II Service Manual 5-103...
  • Page 236 PL 5.2 C Bypass Stacker Assy. 17 P5 PL 5-2C Bypass Assy 7611951-B1-4 12/2003 PL 5.2 C Bypass Stacker Assy. GBC FusionPunch II Service Manual 5-104...
  • Page 237 SHCS 8-32 x 3/8 ........................10 1980054 SHCS 8-32 x 1 ........................2 1980094 SHCS 1/4-20 x 1/2 .........................1 1980096 SHCS 10-32 x 1/2 ........................5 1980309 BHCS 1/4-20 x 1-1/4 ......................2 12/2003 PL 5.2 C Bypass Stacker Assy. GBC FusionPunch II Service Manual 5-105...
  • Page 238 PL 5.2 D Bypass Stacker Assy. ANE AHQ Viewed from Operators side PL 5.2 D 7611922_A1MOD 12/2003 PL 5.2 D Bypass Stacker Assy. GBC FusionPunch II Service Manual 5-106...
  • Page 239 Washer, Flat 1/4............... 2 1926063 Washer, Lock #10 ..............4 1926064 Washer, Lock 1/4 ..............2 1980072 SHCS 10-32 x 1/2 ..............4 1980094 SHCS 1/4-20 x 1/2 ..............2 12/2003 PL 5.2 D Bypass Stacker Assy. GBC FusionPunch II Service Manual 5-107...
  • Page 240 Item # 12 To Little Star Controller PWB P/J 3 Item # 14 To Daughter PWB P/J 1 (Cable Assy. Includes Punch I/O P/J 24A and 25) PL 6-1A Cable Assy. 12/2003 PL 6.1 A Punch I/O PWB Cable Assy. GBC FusionPunch II Service Manual 5-108...
  • Page 241 Cable Assy., Punch I/O PWB P/J 27 - Daughter PWB P/J 1 ..........1 7610500 Cable Assy., DFA, Punch I/O PWB - Punch Rear Panel ............1 12/2003 PL 6.1 A Punch I/O PWB Cable Assy. GBC FusionPunch II Service Manual 5-109...
  • Page 242 To Punch Motor LINE BROWN ORANGE BLUE ORANGE BLUE BLACK BLACK POWER SUPPLY, +24 VDC PWB BLACK BLACK PL 6-1B Cable Assy. 12/2003 PL 6.1 B Punch AC/DC PWB & Power Supply PWB’s Ca- GBC FusionPunch II Service Manual 5-110...
  • Page 243 Cable Assy., Punch AC/DC Distribution PWB P/J 12 - Punch I/O PWB P/J 23 ..........1 7610483 Cable Assy., Punch AC/DC Distribution PWB P/J 14 - Stacker AC/DC Distribution PWB P/J 14 ....1 12/2003 PL 6.1 B Punch AC/DC PWB & Power Supply PWB’s Cable As- GBC FusionPunch II Service Manual 5-111...
  • Page 244 Distribution PWB P/J 6 7610472 (14 ") 7610472 (24 ") 7610472 (60 ") WHITE BLACK Item # 4 To Punch I/O PWB P/J 19 & 20 12/2003 PL 6.1 C Punch Interlock & Rear Panel Cable Assy. GBC FusionPunch II Service Manual 5-112...
  • Page 245 Cable Assy., Punch Interlock Low - Punch I/O PWB P/J 19 and 20..............1 7610472 Cable Assy., Punch Interlock Jumpers ......................1 7610500 Cable Assy., DFA, Punch Rear Panel - Punch I/O PWB .................1 12/2003 PL 6.1 C Punch Interlock & Rear Panel Cable Assy. GBC FusionPunch II Service Manual 5-113...
  • Page 246 Item # 4 To Punch I/O PWB P/J 22, 23A, 24A, & 25 P/J 22, 23A, 24A, & 25 P/J 27 Item # 1 To Punch I/O PWB P/ 12/2003 PL 6.1 D Punch LCD, Controller, Expansion, and Daugh- GBC FusionPunch II Service Manual 5-114...
  • Page 247 Cable Assy., Daughter PWB for Second Stacker P/J 22, 23, 24, & 25 - Stacker I/O PWB # 2 P/J 22, 23A, 24A, and 25 ..1 12/2003 PL 6.1 D Punch LCD, Controller, Expansion, and Daughter GBC FusionPunch II Service Manual 5-115...
  • Page 248 EXT OV Interlocks Low EXT 24V WHITE INA6 INB3 7610485 INB2 WHITE INB1 INTER1 NOTE: 1. INSTALL (1) SC SCR MODULE (GBC # BLACK 7610460) IN OTPO 4 (BYPASS STACKER ONLY) TO INTERLOCK SWITCHES BLACK WHITE OUTA6 WHITE INTER2 OUTA7 WHITE...
  • Page 249 Cable Assy., Stacker I/O PWB # 2 P/J 22, 23A, 24A, and 25 - Daughter PWB for Second Stacker P/J 22, 23, 24, & 25 ..1 7610504 Cable Assy., Stacker I/O PWB P/J 6A - Stacker Bypass Solenoid ....................1 12/2003 PL 6.2 A Stacker I/O PWB Cable Assy. GBC FusionPunch II Service Manual 5-117...
  • Page 250 MOVE J16A (TOP COVER CABLE) TO J16B TO FRONT DOOR REMARK CABLE WITH 16B TO TOP COVER MOVE J6A (FRONT DOOR CABLE) TO J6B REMARK CABLE WITH 6B J16A J6A 24VR 12/2003 PL 6.2 B Stacker AC/DC PWB Cable Assy. GBC FusionPunch II Service Manual 5-118...
  • Page 251 Cable Assy., Stacker AC/DC Distribution PWB P/J 10 - Stacker Bypass Motor................1 7610505 Cable Assy., Stacker #1 AC/DC Distribution PWB P/J 13 - Stacker #2 AC/DC Distribution PWB P/J 14 .........1 12/2003 PL 6.2 B Stacker AC/DC PWB Cable Assy. GBC FusionPunch II Service Manual 5-119...
  • Page 252 KEPS NUT NC NO Item # 4 To Stacker I/O PWB P/J 6 Item # 3 To Stacker I/O PWB P/J 19 & 20 12/2003 PL 6.2 C Stacker Interlocks & Rear Panel Cable Assy. GBC FusionPunch II Service Manual 5-120...
  • Page 253 Cable Assy., Stacker Interlocks High - Stacker AC/DC Distribution PWB P/J 6 ................1 7610500 Cable Assy., DFA, Stacker Rear Panel - Stacker I/O PWB .......................1 12/2003 PL 6.2 C Stacker Interlocks & Rear Panel Cable Assy. GBC FusionPunch II Service Manual 5-121...
  • Page 254 Notes This Page Intensionally Left Blank 12/2003 PL 6.2 C Stacker Interlocks & Rear Panel Cable Assy. GBC FusionPunch II Service Manual 5-122...
  • Page 255 7610235 FP II Common Hardware Kit ......1 1925307 Spacer, 1/4 x 3/4 x 3/4 ........10 1925903 Washer, Star Lock #8 ........10 FusionPunch II Common Hardware Kit includes the following: 1926060 Washer, Lock #4...........10 1926061 Washer, Lock #6...........10 Item Part # Description .
  • Page 256 FusionPunch II Common Hardware List Item Part # Description ......Qty Item Part # Description......Qty 1935204 Spring, Comp.
  • Page 257 Tiebar, Swing Frame Ball Track............................4.1 F 0130013500 Deck, Interface, R.H................................4.1 B 0130013600 Deck, Interface, Center ..............................4.1 B 0130013700 Deck, Interface, L.H................................4.1 B 0130013900 Shaft, Detent Ball Track ..............................4.1 F 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-125...
  • Page 258 Assy., Punch Crank Arm (refer to Detail A) ........................4.3 D 0130025900 Assy., Punch Clutch (refer to PL 4.3 L Detail B) ........................ 4.3 C 0130026000 Assy., Mount Block ................................4.3 I 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-126...
  • Page 259 Yoke, Tension Idler Thin ..............................4.3 J 0130039100 Pulley, 17 Tooth, 230 VAC 50 HZ Punch Motor ........................ 1.1 F 0130040200 Pulley, 18 Tooth, Document Transport 230 VAC 50 HZ Motor ................5.1 B, 1.1 G 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-127...
  • Page 260 Bracket, Angle, O-ring Drive Assy............................5.1 C 7610045 Pulley, Stacker Tray Motor ..............................1.2 C 7610046 Tapper, Short, Inside ................................5.1 B 7610047 Shaft, Pivot, O-ring Drive Assy.............................. 5.1 B 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-128...
  • Page 261 Shaft, Transfer, O-ring Drive Assy............................. 5.1 C 7610097 Deck, Slide, Stacker Assy..............................5.1 A 7610098 Pivot, O-ring Drive Assy..............................5.1 C 7610105 Assy., Enclosure, Stacker Assy............................1.2 A 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-129...
  • Page 262 Label, Tag Matrix ................................. 1.1 H, 1.3 B 7610237 Label, Punch Alignment................................1.1 H 7610238 Bracket, Entrance Paper Guide ..............................1.1 H 7610239 Guide, Paper, Document Transport Rail..........................4.2 E 7610244 Paper Guide, Document Transport Long..........................4.2 E 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-130...
  • Page 263 Assy., Locking Cam (refer to PL 4.3 K Detail C)........................ 4.3 A 7610324 Assy., Interface Side Frame, R.H............................4.1 B 7610325 Assy., Ball Track Interface (refer to PL 4.1 G) ........................4.1 D 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-131...
  • Page 264 Belt, Flat, Swing Frame .06 x 1 x 27 Endless........................4.1 A 7610373 Belt, Flat, Document Transport .06 x 1 x 36.75 endless .....................4.2 D 7610374 Ball, Delrin ................................4.1 F, 4.2 D 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-132...
  • Page 265 Deck, Document Transport ..............................4.2 B 7610435 Label, Die Lock Knob................................. 1.1 E 7610436 Label, Back Gauge Knob ..............................1.1 E 7610437 Label, Edge Guide Knob..............................1.1 E 7610439 Bucket, Slug, Punch Assy..............................1.1 E 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-133...
  • Page 266 Cable Assy., Punch AC/DC Distribution PWB P/J 5 - 5 VDC Power Supply P/J CN1 ............6.1 B 7610470 Cable Assy., Punch AC/DC Distribution PWB P/J 6 - Punch Interlock High ...............6.1 B 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-134...
  • Page 267 Cable Assy., Stacker Interlocks Low - Stacker I/O PWB P/J 19 & 20................6.2 C 7610486 Cable Assy., Stacker AC/DC Distribution PWB P/J 6 - Stacker Interlock High..............6.2 B 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-135...
  • Page 268 PWB, Punch I/O (Tag # S3) ..............................3.1 7610518 PWB, Stacker I/O (Tag # S3) ............................3.2, 3.3 7610521 Shaft, Document Transport Main Drive (Tag # P2) ......................1.1 G 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-136...
  • Page 269 Sensor, Stacker Exit, (7610424 = Sensor without Cable Assy.) ..................1.3 A 7611945 Solenoid, Rotary, Bypass Gate............................5.2 A 7611946 Cover, Top, Bypass Motor Pulley ............................1.3 A 7611947 Shield, Bypass Assy................................1.3 A 7611951 Assy., Bypass ..................................1.3 A 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-137...
  • Page 270 7611994 Bar, Docking, Bypass Assy..............................1.3 A 7611995 Screw, Spring Adjust ................................5.2 A 7611996 Belt, Flat, Bypass Assy................................5.2 C 7611997 Finger, Bypass Gate................................5.2 A 7611999 Deflector, Bypass Input ...............................5.2 A 12/2003 Part Number Index GBC FusionPunch II Service Manual 5-138...
  • Page 271 Switch, Upper ....................................1 7610188 Switch, Almost Full & Full................................1 7610193 Solenoid, Rotary....................................2 7610232 Solenoid, Punch Clutch .................................1 7610235 FusionPunch II Common Hardware Kit............................1 7610255 Strap, Paper Hold Down ................................3 7610273 Key Pad, Control Panel.................................1 7610346 Bearing w/Collar 1/2"..................................6 7610352 Gear, Spur, 30 Tooth ..................................1 7610353 Gear, Spur, Large, Back Gauge..............................1...
  • Page 272 Tool, T Handle 0.156 ................................. 1 7610533 Belt, Timing, Document Transport Main Drive, 6060 /iGen3 (Tag # P5) ................... 1 7610729 Fuse, 3A Slow Blow .................................. 5 7611996 Belt, Flat, Bypass Assy................................1 12/2003 Recommended Spare Parts List GBC FusionPunch II Service Manual 5-140...
  • Page 273 Tag Numbers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-85 12/2003 GBC FusionPunch II Service Manual...
  • Page 274 AC, and high voltage power supplies. Always inspect for pinched, out-of-place, or frayed wiring. 7. Replacement component differs from the original. This holds true even though the replacement may be rated for higher voltage, wattage, etc. 12/2003 Precautions GBC FusionPunch II Service Manual...
  • Page 275 Sound Emission = 64.7 db, Idling. (914 mm) Operator Area Sound Emission = 73.7 db, Punch/Stacker. Measured in a near free field environment, at a height of 59.05 in. (1500 mm) over the floor, with machine punching paper. 12/2003 GBC FusionPunch II Service Manual Specifications...
  • Page 276 7 - Beep on Page Signal received from Printer. 8 - Beep on Cycle Up Signal received from Printer. 12/2003 GP-1 Enter / Exit Diagnostic Mode Procedure GBC FusionPunch II Service Manual...
  • Page 277 7 - Signal is offset 60 milliseconds later in the Fusion. 8 - Signal is offset 80 milliseconds later in the Fusion. 9 - Signal is offset 100 milliseconds later in the Fusion. 12/2003 GP-1 Enter / Exit Diagnostic Mode Procedure GBC FusionPunch II Service Manual...
  • Page 278 Not Used 00000000000010 Figure 6-1 Punch I/O PWB OUTA5 PrintSetAck 00000000000010 OUTA4PrintPageAck NOTE: The values shown in Table 6-6 may not correspond 00000000000010 with the values displayed on the LCD. 12/2003 GP-1 Punch Output Test GBC FusionPunch II Service Manual...
  • Page 279 Figure 6-2 Stacker I/O PWB OUTB2 StackByPass 0000000000000000 NOTE: The values shown in Table 6-7 may not correspond Not Used 0000000000000000 with the values displayed on the LCD. Not Used 0000000000000000 12/2003 GP-1 Stacker 1 Output Test GBC FusionPunch II Service Manual...
  • Page 280 Figure 6-3 Stacker I/O PWB 0000000000000000 Not Used 0000000000000000 NOTE: The values shown in Table 6-8 may not correspond Not Used with the values displayed on the LCD. 0000000000000000 12/2003 GP-1 Stacker 2 Output Test GBC FusionPunch II Service Manual...
  • Page 281 Put a piece of paper between the Xport NOTE: The values shown in Table 6-9 may not correspond I11 1101111111111000 Sensor 2 and the Reflector. with the values displayed on the LCD. 12/2003 GP-1 Punch Input Test GBC FusionPunch II Service Manual...
  • Page 282 Figure 6-5 Stacker I/O PWB 1101101101111111 Not Used 1101101101111111 NOTE: The values shown in Table 6-10 may not correspond Not Used with the values displayed on the LCD. 1011111101011000 12/2003 GP-1 Stacker 1 Input Test GBC FusionPunch II Service Manual 6-10...
  • Page 283 Not Used 1101101101111111 Figure 6-6 Stacker I/O PWB Not Used 1101101101111111 NOTE: The values shown in Table 6-11 may not correspond with the values displayed on the LCD. 12/2003 GP-1 Stacker 2 Input Test GBC FusionPunch II Service Manual 6-11...
  • Page 284 Activates when test mode is started and 6. Use the 3 charts to the right to verify proper deactivates when the Bypass Motor operation of each component in each comes on. module. 12/2003 GP-2 Enter / Exit Test Mode Procedure GBC FusionPunch II Service Manual 6-12...
  • Page 285 GND. Voltage should be less than 3 VAC between GND and neutral. If the voltage is not correct, a licensed electrician must correct the voltage. AC Line AC Neutral Figure 6-7 Wall Receptacle 12/2003 GP-3 AC Power Source GBC FusionPunch II Service Manual 6-13...
  • Page 286 STACKER #2 RAISE/LOWER 000000010000 STACKER #1 STOP/RESET 000000001000 ONLINE 000000000100 OFFLINE DIAGNOSTICS 000000000010 START 000000000001 5. Switch off the main power. 6. Remove the jumper wire. 7. Reconnect the DFA Cable. 12/2003 Keypad Test GBC FusionPunch II Service Manual 6-14...
  • Page 287 A profile is a set of values, or system configuration parameters, that are entered into the printer’s operating system from the keyboard. A profile allows the printer to communicate effectively with the FusionPunch II and DocuSP Print its stacker (or multiple stackers). Each model of printer has its own...
  • Page 288 Click on Trusted User and then select System Administrator. d) Type Administ in the password field and then click on OK. Figure 6-13 The Finishing Icon in Printer Manager 12/2003 Host Machine Enablement (DocuSP) GBC FusionPunch II Service Manual 6-16...
  • Page 289 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. 12/2003 Host Machine Enablement (DocuSP) GBC FusionPunch II Service Manual 6-17...
  • Page 290 Figure 6-17 The Timings screen screen open, you are ready to begin entering Personality Profile values for the FusionPunch II and the printer you are using. Perform the following steps: a) Go to page 6-27 and locate the page with the profile sheets for the devices you will be setting up.
  • Page 291 Verify that all of the entered values conform to those in the profile sheet and click OK. Figure 6-18 The Profile Setup Tab Screen Click on the Profile Setup tab, as shown in Figure 6-18, then click on the NEW button. 12/2003 Host Machine Enablement (DocuSP) GBC FusionPunch II Service Manual 6-19...
  • Page 292 Enable NOTE: After entering and/or checking the default values for the Button FusionPunch II, you will need to repeat Steps 5 through 9 for each additional finishing device installed in the system. On-Line Button Figure 6-21 Finishing Window and On-Line Finishers screen 8.
  • Page 293 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. 12/2003 Host Machine Enablement (DocuSP) GBC FusionPunch II Service Manual 6-21...
  • Page 294 The following procedure is to help the System Administrator set up print Queue Manager Icon queues for the FusionPunch II and other finishing devices that are inline to the printer. NOTE: A 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).
  • Page 295 5. Refer to Figure 6 - 27 above and fill in or choose the fields, as Finisher Profile sheet. specified in the table below, for a GBC Punch Queue output. 4. Go to the Extended Options field and select Output, as shown in Figure 6-26.
  • Page 296 7. Refer to Figure 6-29 above and fill in or choose the fields, as specified 6. Refer to Figure 6 - 28 above and fill in or choose the fields, as below, for an SBM 2-sided Punch Queue output. specified in the table below, for a GBC Punch SE Queue output. Item Entry...
  • Page 297 1. Check the 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. Logon Level (System Administrator) Figure 6-30 DocuSP Main Window Logon Level 12/2003 DocuSP 3.xxx Log On GBC FusionPunch II Service Manual 6-25...
  • Page 298 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. Figure 6-32 The Logon Window 12/2003 DocuSP 3.xxx Log On GBC FusionPunch II Service Manual 6-26...
  • Page 299 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. Printer Manager Icon Figure 6-33 DocuSP Main Window 12/2003 DocuSP 3.xxx Profile Setup GBC FusionPunch II Service Manual 6-27...
  • Page 300 This will display the Printer Manager Window, as shown in Figure 6-34. Finishing Figure 6-34 The Printer Manager Window 2. Select the Finishing Tab, as shown in Figure 6-34. 12/2003 DocuSP 3.xxx Profile Setup GBC FusionPunch II Service Manual 6-28...
  • Page 301 The Finishing Tab Screen will display, as shown in Figure 6-35. Device Setup button 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. 12/2003 DocuSP 3.xxx Profile Setup GBC FusionPunch II Service Manual 6-29...
  • Page 302 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 12/2003 DocuSP 3.xxx Profile Setup GBC FusionPunch II Service Manual 6-30...
  • Page 303 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 the values from the profile sheet.
  • Page 304 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 the Device Setup Window. 12/2003 DocuSP 3.xxx Profile Setup GBC FusionPunch II Service Manual 6-32...
  • Page 305 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 12/2003 DocuSP 3.xxx Profile Setup GBC FusionPunch II Service Manual 6-33...
  • Page 306 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. 12/2003 DocuSP 3.xxx Profile Setup GBC FusionPunch II Service Manual 6-34...
  • Page 307 External Finishers box at the bottom of the Finishing Tab Screen, with the 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. Online...
  • Page 308 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. 12/2003 DocuSP 3.xxx Profile Setup GBC FusionPunch II Service Manual 6-36...
  • Page 309 DocuSP 3.xxx Print Queue Setup The following procedure is to help the System Administrator set up Print 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).
  • Page 310 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. 12/2003 DocuSP 3.xxx Print Queue Setup GBC FusionPunch II Service Manual 6-38...
  • Page 311 • GBC Punch Queue Output (for the FusionPunch II) • GBC Short Edge Punch Queue Output (for the FusionPunch II and a Xerox high Capacity Stacker) • SBM1/SBM2 Queue Output (for the Signature Booklet Maker) 12/2003 DocuSP 3.xxx Print Queue Setup...
  • Page 312 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 Check the Override Option 12/2003 DocuSP 3.xxx Print Queue Setup...
  • Page 313 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 GBCSE...
  • Page 314 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 SBM1/SBM2 Check the Override Option 12/2003 DocuSP 3.xxx Print Queue Setup GBC FusionPunch II Service Manual 6-42...
  • Page 315 10. If the system asks you to overwrite the file, press Y for yes. • FBN 191 = 0: This is the lead edge and trail edge trigger The system will save the GBC Punch Profile to the printer. • Lead edge = 0 and Trail edge = 1 You must now load the profile.
  • Page 316 Sun NPS Workstation. Once you have set up the GBC profile, you will be required to configure a GBC Print The system will prompt you for the name of the profile.
  • Page 317 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. 12/2003 Host Machine Enablement (DocuColor 6060) GBC FusionPunch II Service Manual 6-45...
  • Page 318 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. 12/2003 Host Machine Enablement (DocuColor 6060) GBC FusionPunch II Service Manual 6-46...
  • Page 319 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. 12/2003 GBC FusionPunch II Service Manual Host Machine Enablement (DocuColor 6060) 6-47...
  • Page 320 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. 12/2003 Host Machine Enablement (DocuColor 6060) GBC FusionPunch II Service Manual 6-48...
  • Page 321 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. Tools Pathway Figure 6-53 The Pathway Options 12/2003 GBC FusionPunch II Service Manual Host Machine Enablement (DocuColor 6060) 6-49...
  • Page 322 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. 12/2003 Host Machine Enablement (DocuColor 6060) GBC FusionPunch II Service Manual 6-50...
  • Page 323 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 button. 12/2003 GBC FusionPunch II Service Manual Host Machine Enablement (DocuColor 6060) 6-51...
  • Page 324 12/2003 Host Machine Enablement (DocuColor 6060) GBC FusionPunch II Service Manual 6-52...
  • Page 325 1. Go to the Press Status Window, click System, as shown in Figure 6-56. Select Logon from the drop down menu. This will bring up the Logon Window, as shown in Figure 6-57. System Figure 6-56 The Press Status Window 12/2003 GBC FusionPunch II Service Manual Host Machine Enablement (DocuColor iGen3) 6-53...
  • Page 326 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." 12/2003 Host Machine Enablement (DocuColor iGen3) GBC FusionPunch II Service Manual 6-54...
  • Page 327 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. 12/2003 GBC FusionPunch II Service Manual Host Machine Enablement (DocuColor iGen3) 6-55...
  • Page 328 Options 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. 12/2003 Host Machine Enablement (DocuColor iGen3) GBC FusionPunch II Service Manual 6-56...
  • Page 329 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. 12/2003 GBC FusionPunch II Service Manual Host Machine Enablement (DocuColor iGen3) 6-57...
  • Page 330 Profile Assigned Check Box Options Activate Figure 6-61 DFA Profile Activation This completes the Profile Setup; you are now ready to send your jobs to the FusionPunch II. 12/2003 Host Machine Enablement (DocuColor iGen3) GBC FusionPunch II Service Manual 6-58...
  • Page 331 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 12/2003 GBC FusionPunch II Service Manual Host Machine Enablement (DocuColor iGen3) 6-59...
  • Page 332 Notes 12/2003 Notes GBC FusionPunch II Service Manual 6-60...
  • Page 333 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.
  • Page 334 Sh e et S h e et S h e et Sh eet Fin ish er C a p a city C y cle D o w n D ela y 12/2003 Personality Profiles GBC FusionPunch II Service Manual 6-62...
  • Page 335 Rotate Never Never Always Minimum Sheet Length Maximum Sheet Length Minimum Sheet Width Maximum Sheet Width Minimum Sheet Weight Maximum Sheet Weight Minimum Set Size Maximum Set Size 65000 65000 65000 12/2003 GBC FusionPunch II Service Manual Personality Profiles 6-63...
  • Page 336 3 5 0 3 5 0 P erf./R o t an d fo ld is P erf./R o t an d fo ld is u sed u sed 12/2003 C.P. Bourg Down Stream Devices GBC FusionPunch II Service Manual 6-64...
  • Page 337 DocuTech 61XX to FusionPunch II to Bourg Products Device Profile - Properties and Default Limits - Timings Tab DocuTec Models DT 61XX DT 61XX DT 61XX DT 61XX DT 61XX DT 61XX Finishers FP II / FP II / FP II /...
  • Page 338 3 5 0 3 5 0 P e rf./R ot a n d fold is P e rf./R ot a n d fold is u se d u se d 12/2003 C.P. Bourg Down Stream Devices GBC FusionPunch II Service Manual 6-66...
  • Page 339 Always Always Always Always Never Minimum Sheet Length Maximum Sheet Length Minimum Sheet Width Maximum Sheet Width Minimum Sheet Weight Maximum Sheet Weight Minimum Set Size Maximum Set Size 12/2003 GBC FusionPunch II Service Manual Xerox Down Stream Devices 6-67...
  • Page 340 DocuTech 6155/6180 to FusionPunch II to SBM 2 – without CIM Device Profile - Properties and Default Limits - Timings Tab (*) = For Each Hi Cap Stacker on a DT6155 / 6180, Add 656ms To Sheet and Set Jam Times.
  • Page 341 DocuTech 61XX to FusionPunch II to SBM2 – without CIM Finisher Profile - Properties and Limits Paper Sizes 8.5x11/8.5x14/A4 8.5x11/8.5x14/A4 8.5x11/8.5x14/A4 8.5x11/8.5x14/A4 11x17/A3 Set Sizes 1 to 22 Sheet Set 1 to 22 Sheet Set 23 to 27 Sheet Set...
  • Page 342 DocuTech 61XX to FusionPunch II to SBM2 – with CIM Device Profile - Properties and Default Limits Tab DocuTech Model DT 6155 / 6180 DT 6155 / 6180 Paper Sizes 8.5x11/8.5x14/A4 11x17/A3 Set Sizes 1 to 27 Sheet Set 1 to 27 Sheet Set...
  • Page 343 E n d o f S et O ffset (# ) SE T SE T R eco v ery B eh av io r F in ish er C apacity C y cle D o w n D elay 12/2003 GBC FusionPunch II Service Manual Xerox Down Stream Devices 6-71...
  • Page 344 DocuTech 61XX to FusionPunch II to SBM2 – with CIM Finisher Profile - Properties and Limits DocuTech Model DT 6155 / 6180 DT 6155 / 6180 Paper Sizes 8.5x11/8.5x14/A4 11x17/A3 Set Sizes 1 to 27 Sheet Set 1 to 27 Sheet Set...
  • Page 345 # 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" 12/2003 GBC FusionPunch II Service Manual Special Tools 6-73...
  • Page 346 Sheet Recovery as the DT 135 only 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. 12/2003...
  • Page 347 Punch II currently supports 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.
  • Page 348 External Finisher to run jobs to the Bypass Transport”, or “External Fin- isher Not Ready”. This is a 5 VDC signal that is sent from the printer to the FusionPunch II on every sheet of paper, as the lead edge (specified in the Personality Faulted Signal Profile) covers the last sensor in the printer.
  • Page 349 FusionPunch II does not use the S4 signal (Set Acknowledge Signal) as the printer. The time allotted for this signal to be returned is specified by an end Device. The FusionPunch II can support the S4 signal by routing the finishing device’s personality profile. The signal returned to the it to down-line finishers.
  • Page 350 FusionPunch II does not use this signal as an end Device, but can Little Star Controller PWB. If the Little Star Controller does not see a support it to down-line finishers.
  • Page 351 Back Gauge Solenoid. This will bring the Back Gauge Fingers up to make its way to DT1 within the 330ms, the FusionPunch II will turn stop the sheet in the Die, in order to be punched. Once the lead edge of OFF (Low) the S1 signal (Faulted Signal) and then display Jam at that sheet of paper passes DT2, it has 200ms to clear the sensor.
  • Page 352 Exit Sensor. If the sheet of paper does not make it within the 330ms, the FusionPunch II will turn OFF the S1 signal and then display Jam at Exit Sensor on the LCD.
  • Page 353 Bypass Sensor. If the sheet blocks the Stacker Bypass Sensor longer will turn OFF the S1 signal and then display Jam at Exit Sensor on the than 200ms, the FusionPunch II will turn OFF the S1 signal and then LCD.
  • Page 354 Notes 12/2003 Principles of Operation GBC FusionPunch II Service Manual 6-82...
  • Page 355 This section describes the tags issued for the A tag number may be required to identify Schematic diagrams will contain specific FusionPunch II and the Stacker modules, as differences between parts that cannot be symbols that denote a "with" (Figure 6-30) or...
  • Page 356 The Fusion Punch II has two different serial numbers, one for the Punch TAG:1 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 CLASS: begins with the letter product code (KEW).
  • Page 357 Steel Ball with 2nd from left Delrin Ball 0130035700 Side Guide, Punch - Cut notch to resolve interference with Punch Tension Strap Assy. 1925230 Added washer between Pulley and mounting block of the Punch Infeed Idler Pulley. 12/2003 GBC FusionPunch II Service Manual Tag Numbers 6-85...
  • Page 358 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 revision level. 12/2003 Tag Numbers GBC FusionPunch II Service Manual 6-86...
  • Page 359 Short edge Side Guide. 1914082 Added Thumb Screws to mount and adjust new Short edge Side Guide. 7610508 New Eprom (Version A531 or higher) allows selection of new Run Modes. 12/2003 GBC FusionPunch II Service Manual Tag Numbers 6-87...
  • Page 360 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 12/2003 Tag Numbers GBC FusionPunch II Service Manual 6-88...
  • Page 361 7610680 Plate, Docking, Female - moved Pim nuts ¼ inch to the right when viewing from front the machine (Operators side). Allows proper docking of down stream devices. 12/2003 GBC FusionPunch II Service Manual Tag Numbers 6-89...
  • Page 362 E-prom with version A524 or higher changes the timeouts of the sensors when running in the newly released operating modes. It also adds more forgiveness when connecting the FP II to the slower printers for signal variance. 12/2003 Tag Numbers GBC FusionPunch II Service Manual 6-90...
  • Page 363 Added part to the Service Manual and the Engineering print. 1926702 Added part to the Service Manual and the Engineering print. 7610361 Added Tubing to resolve the Upper switch actuator from falling off the Actuation Screw. 12/2003 GBC FusionPunch II Service Manual Tag Numbers 6-91...
  • Page 364 12/2003 Tag Numbers GBC FusionPunch II Service Manual 6-92...
  • Page 365 Stacker Motors and Solenoids - - - - - - - - - 34 Bypass Stacker Motors, Solenoids, and Sensors- - - - - - - - - - - - - - - - - - - - - - 36 10/2001 GBC FusionPunch II Service Manual...
  • Page 366 SUPPLY PWB PL3.1 +24V LINE LINE +24V STACKER STACKER AC/ MAIN POWER SWITCH/ DISTRIBUTION CIRCUIT BREAKER AC RECEPTICLE/ PL1.2A LINE FILTER PL3.2 PL1.2A AC LINE LINE AC NEUTRAL T712001-A-GBC 12/2003 Chain 1.1 Main Power BSD GBC FusionPunch II Service Manual...
  • Page 367 12.1 P16A J16A 24VR BYPASS INSTALLED ONLY NOTE: IF BYPASS STACKER IS INSTALLED: P6A WILL BE CONNECTED J6B (FRONT DOOR) P16A WILL BE CONNECTED J16B (TOP COVER) T712002-A-GBC 12/2003 GBC FusionPunch II Service Manual Chain 1.2 DC Power Distribution BSD...
  • Page 368 P20 J20 LITTLE STAR CONTROLLER PL 3.1 P19 J19 J24A P24A TOP COVERS INA6 INA6 LEFT DOOR INB3 INB3 MIDDLE DOOR INB2 INB2 RIGHT DOOR INB1 INB1 T712003-A-GBC 12/2003 Chain 1.3 Punch Interlock Switches BSD GBC FusionPunch II Service Manual...
  • Page 369 FRONT DOOR INB1 INB1 BYPASS INSTALLED ONLY NOTE: IF BYPASS STACKER IS INSTALLED: P6A WILL BE CONNECTED J6B (FRONT DOOR) P16A WILL BE CONNECTED J16B (TOP COVER) T712004-A-GBC 12/2003 GBC FusionPunch II Service Manual Chain 1.4 Stacker Interlock Switches BSD...
  • Page 370 LCD ASS'Y WHITE NOTE: WHITE WIRE PIN NOT CONNECTED OVERLAY 7610273 PLATE 7610299 7610495 7610458 I/O BUS EXPANSION BLACK ORANGE 7610452 DISTRIBUTION INSTALL JUMPERS (J1 - J4) AS SHOWN 12/2003 Chain 2.1 Control Panel BSD GBC FusionPunch II Service Manual...
  • Page 371 C0 SHEET EXIT INA1 C1 SET EXIT INA2 C2 CYCLE UP INA3 INA3 J14A C6 FINISHER FUNC1 INA4 INA4 J13A C7 FINISHER FUNC2 INA5 INA5 J12A P24A J24A T712005-A-GBC 12/2003 GBC FusionPunch II Service Manual Chain 3.1 Punch/Printer Communications BSD...
  • Page 372 JP32 CYCLE UP OPTO 14 RELAY JP33 OUTC3 JP34 J17B FINISHER FUNC1 OPTO 13 RELAY JP35 OUTC4 J16B JP36 FINISHER FUNC2 OPTO 12 RELAY JP37 OUTC5 J15B T712006-A-GBC 12/2003 Chain 3.2 Stacker/Third Party Communications BSD GBC FusionPunch II Service Manual...
  • Page 373 INB7 INB7 +24V DOCUMENT EXIT TRANSPORT INB8 INB8 2 SENSOR +24V PL 4.2A +24V +24V PUNCH SENSOR PL 4.3A +24V SIGNAL EXIT SENSOR PL 4.3D +24V SIGNAL T712007-A-GBC 12/2003 GBC FusionPunch II Service Manual Chain 4.1 Punch Transport Sensors BSD...
  • Page 374 OUTB1 DOCUMENT TRANSPORT MOTOR ON HVO8 OUTA8 OUTA8 AC/DC DISTRIBUTION PUNCH MOTOR PL 3.1 PL 1.1F RELAY 5 DOCUMENT TRANSPORT MOTOR PL 1.1B 24 VDC RELAY 4 T712008-A-GBC 12/2003 Chain 4.2 Punch Outputs BSD GBC FusionPunch II Service Manual 7-10...
  • Page 375 INB4 STACKER EXIT SENSOR STACKER EXIT SIGNAL SENSOR INB8 INB8 TRAY J24A J24-8 DIRECTION INC8 INA8 STACKER AC/DC DISTRIBUTION PL 3.2 NOTES: BYPASS INSTALLED ONLY RLY2 R-ON T712009-A-GBC 12/2003 GBC FusionPunch II Service Manual Chain 12.1 Stacker Inputs BSD 7-11...
  • Page 376 STACKER 24VI OFFSET 1 OUTB7 OUTB7 OFFSET 2 STACKER 24VI SOLENOID OFFSET 2 OUTB6 OUTB6 PL 5.1C BYPASS 24VI DIVERTERS OUTB5 OUTB5 BYPASS DIVERTER BYPASS INSTALLED ONLY T712010-A-GBC 12/2003 Chain 12.2 Stacker Outputs BSD GBC FusionPunch II Service Manual 7-12...
  • Page 377 DIRECTION OUTA7 OUTA7 STACKER O-RING O-RING MOTOR OUTA8 OUTA8 MOTOR PL 1.2 B STACKER BYPASS MOTOR RELAY 3 OUTB2 OUTB2 BYPASS MOTOR RELAY 3 BYPASS INSTALLED ONLY T712011-A-GBC 12/2003 GBC FusionPunch II Service Manual Chain 12.2 Stacker Outputs BSD 7-13...
  • Page 378 Component Locators Punch Interlocks 12/2003 Component Locators GBC FusionPunch II Service Manual 7-14...
  • Page 379 Switch, Punch Interlock, Top Cover 2 ........1 7610501 Switch, Punch Interlock, Left Door........... 1 7610501 Switch, Punch Interlock, Mid Door ........... 1 7610501 Switch, Punch Interlock, Right Door ........1 12/2003 GBC FusionPunch II Service Manual Component Locators 7-15...
  • Page 380 Component Locators Punch Power Switch and Line Filter 12/2003 Component Locators GBC FusionPunch II Service Manual 7-16...
  • Page 381 Description ....... . Qty 7610455 Punch Main Power Switch / Circuit Breaker....1 7610456 Punch AC Receptical / Line Filter ........1 12/2003 GBC FusionPunch II Service Manual Component Locators 7-17...
  • Page 382 Component Locators Punch PWBs BYPASS ONLY 12/2003 Component Locators GBC FusionPunch II Service Manual 7-18...
  • Page 383 PWB, 5 VDC Power Supply ................. 1 7610457 PWB, Little Star Controller ................1 7610458 PWB, Little Star Controller Expansion ............1 7611943 PWB, Little Star Controller Expansion / Daughter, Bypass Only ....1 12/2003 GBC FusionPunch II Service Manual Component Locators 7-19...
  • Page 384 Component Locators Punch Sensors 12/2003 Component Locators GBC FusionPunch II Service Manual 7-20...
  • Page 385 Description ....... . Qty 7610421 Sensor, Document Transport (1 & 2) ......2 7610423 Sensor, Entrance ............1 7610423 Sensor, Punch ............... 1 7610424 Sensor, Exit..............1 12/2003 GBC FusionPunch II Service Manual Component Locators 7-21...
  • Page 386 Component Locators Punch Motors A 12/2003 Component Locators GBC FusionPunch II Service Manual 7-22...
  • Page 387 Description ....... . Qty 7610418 Motor, 115 VAC 60 HZ, Document Transport ....1 7610425 Motor, 230 VAC 50 HZ, Document Transport ....1 12/2003 GBC FusionPunch II Service Manual Component Locators 7-23...
  • Page 388 Component Locators Punch Motors B 12/2003 Component Locators GBC FusionPunch II Service Manual 7-24...
  • Page 389 Description ....... . Qty 0130032100 Pulley, 14 Tooth, 115 VAC 60 HZ Punch Motor .... 1 0130039100 Pulley, 17 Tooth, 230 VAC 50 HZ Punch Motor .... 1 12/2003 GBC FusionPunch II Service Manual Component Locators 7-25...
  • Page 390 Component Locators Punch Solenoids 12/2003 Component Locators GBC FusionPunch II Service Manual 7-26...
  • Page 391 Description ....... . Qty 7610193 Solenoid, Rotary, Back Gauge ........1 7610193 Solenoid, Rotary, Sheet Exit Assy......... 1 12/2003 GBC FusionPunch II Service Manual Component Locators 7-27...
  • Page 392 Component Locators Stacker Switches A 12/2003 Component Locators GBC FusionPunch II Service Manual 7-28...
  • Page 393 Description ....... . Qty 7610455 Switch / Circuit Breaker, Stacker Main Power....1 7610456 AC Receptical / Line Filter, Stacker Main Power ... 1 7610501 Switch, Stacker Interlock ..........2 12/2003 GBC FusionPunch II Service Manual Component Locators 7-29...
  • Page 394 Component Locators Stacker Switches B 12/2003 Component Locators GBC FusionPunch II Service Manual 7-30...
  • Page 395 Description ....... . Qty 7610089 Bracket, Upper Switch............ 1 7610188 Switch, Almost Full & Full..........2 12/2003 GBC FusionPunch II Service Manual Component Locators 7-31...
  • Page 396 Component Locators Stacker PWBs 12/2003 Component Locators GBC FusionPunch II Service Manual 7-32...
  • Page 397 Description ....... . Qty 7610450 PWB, Stacker AC/DC Power Distribution ...... 1 7610451 PWB, Stacker I/O ............1 12/2003 GBC FusionPunch II Service Manual Component Locators 7-33...
  • Page 398 Component Locators Stacker Motors and Solenoids 12/2003 Component Locators GBC FusionPunch II Service Manual 7-34...
  • Page 399 Motor, 115 VAC 60 HZ, Stacker O-ring ......1 7610193 Solenoid, Rotary, Tapper Assy........1 7610194 Motor, 230 VAC 50 HZ, Stacker Tray ......1 7610195 Motor, 230 VAC 50 HZ, Stacker O-ring......1 12/2003 GBC FusionPunch II Service Manual Component Locators 7-35...
  • Page 400 Component Locators Bypass Stacker Motors, Solenoids, and Sensors 12/2003 Component Locators GBC FusionPunch II Service Manual 7-36...
  • Page 401 Description ..........Qty 7611990 Motor, Bypass, 230V..................1 7611991 Motor, Bypass, 115V..................1 7611945 Solenoid, Rotary, Bypass Gate..............1 7611944 Sensor, Stacker Exit, (7610424 = Sensor without Cable Assy.) ....1 12/2003 GBC FusionPunch II Service Manual Component Locators 7-37...
  • Page 402 Notes 12/2003 Component Locators GBC FusionPunch II Service Manual 7-38...
  • Page 403 Installation Instructions - - - - - - - - - - - - - 8-19 Preparing for installation - - - - - - - - - - - - 8-19 Installation Procedure - - - - - - - - - - - - - - 8-21 12/2003 GBC FusionPunch II Service Manual...
  • Page 404 Description Qty. Note: Tag F99 IOT Kit MUST be installed in all DT61XX machines that will be installed together with the FusionPunch II. (Xerox Kit 0136000000 FP II Dom Punch #600K67500). This kit enables proper Set and Page Ack (S3 and S4) C6 and C7 are not supported by the Fusion Punch II at this time.
  • Page 405 Repeat steps a - f for the Stacker. 4. Remove the Back Panels from the Punch and Stacker. 12/2003 GBC FusionPunch II Service Manual Installation...
  • Page 406 (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. 12/2003 Installation GBC FusionPunch II Service Manual...
  • Page 407 3/16 in. Allen Head Cap adjusting the leveling pads. Screws 15. Connect the DFA Cable from the Host Printer to the FusionPunch II (Figure 8-4). Note: If the DFA Cable is not visible, open the back panel of the bypass...
  • Page 408 Figure 1-70 Stacker Docking Pins and Holes. appropriate Stacker PWBs. 3. Open the front door of the stacker and loosen, but do not remove, the four 3/16 inch Allen head cap screws that hold the docking assembly. 12/2003 Installation GBC FusionPunch II Service Manual...
  • Page 409 # 1 with the holes in the frame use 6180 profiles regardless of what kind of Host Printer the devices are of stacker # 2 (Figure 8-6). connected to. 12/2003 GBC FusionPunch II Service Manual Installation...
  • Page 410 21. Connect the Stacker Main AC Power Cable to the Stacker. pins on stacker # 1 and the holes in the frame of stacker # 2. 22. Plug each of the power cables into a wall receptacle. 12/2003 Installation GBC FusionPunch II Service Manual...
  • Page 411 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. 12/2003 GBC FusionPunch II Service Manual Installation...
  • Page 412 2. Before installing the Bypass kit, 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. 12/2003 Preparing to Install a Bypass Kit GBC FusionPunch II Service Manual 8-10...
  • Page 413 SHCS 1/4-20 x 1/2 1980094 SHCS 1/4-20 x 1/2 7610680 Bracket Assy., Docking 7610680 Bracket Assy., Docking 7611922 Assy., Paper Guide, Bypass Stacker 7611922 Assy., Paper Guide, Bypass Stacker 12/2003 GBC FusionPunch II Service Manual Preparing to Install a Bypass Kit 8-11...
  • Page 414 Notes 12/2003 Preparing to Install a Bypass Kit GBC FusionPunch II Service Manual 8-12...
  • Page 415 Wire Form Guides.).. STACKER INFEED ASSY BYPASS STACKER WIRE FORM ASSY Figure 1-73 Mounting the Docking Brackets Figure 1-72 Stacker Infeed Assy removal 12/2003 GBC FusionPunch II Service Manual Bypass Kit Installation procedure 8-13...
  • Page 416 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. 12/2003 Bypass Kit Installation procedure GBC FusionPunch II Service Manual 8-14...
  • Page 417 BYPASS GATE SOLENOID ALLEN HEAD CAP SCREWS (2) CONNECTOR LOCK WASHERS (2) BYPASS DIVERTER CABLE ASSY Figure 1-77 Connecting the Bypass Gate Solenoid Figure 1-79 Mounting the Bypass Motor 12/2003 GBC FusionPunch II Service Manual Bypass Kit Installation procedure 8-15...
  • Page 418 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 Figure 1-83 Routing the Bypass Sensor Harness Head Cap screws and 2 Lock Washers). 12/2003 Bypass Kit Installation procedure GBC FusionPunch II Service Manual 8-16...
  • Page 419 P/J 16A to P/J 16B on the Stacker AC/DC Distribution PWB. 3. Move the Stacker I/O PWB cables of Stacker 1 from P/J 23A and P/J 24A to P/J 23B and P/J 24B. 12/2003 GBC FusionPunch II Service Manual Bypass Kit Installation procedure 8-17...
  • Page 420 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. 12/2003 Checking the Operation in Offline and Online Mode GBC FusionPunch II Service Manual 8-18...
  • Page 421 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. 12/2003 GBC FusionPunch II Service Manual DocuColor 6006 / iGen3 Kit Installation Instructions 8-19...
  • Page 422 Pulley, 24 Tooth, Stacker Bypass Main Drive, 6060 / iGen3 7610537 Assy., Belt Take Up, Document Transport Timing Belt, 6060 / iGen3 7610621 Panel, Punch Entrance, 4xxx / 6060 / iGen3 12/2003 DocuColor 6006 / iGen3 Kit Installation Instructions GBC FusionPunch II Service Manual 8-20...
  • Page 423 6060 / iGen3 Upgrade Kit. 1. Remove the Entrance Panel and both of Rear Panels on the FP II Punch unit. (Figure 8-19) Rear Panels Entrance Panel Figure 1-84 Removing the Panels 12/2003 GBC FusionPunch II Service Manual Installation Procedure 8-21...
  • Page 424 New Bottom Entrance Paper Guide Figure 1-85 Setting up the New Entrance Panel 3. Lower the Swing Frame all the way to the bottom of its tolerance and the reinstall the New Entrance Panel. 12/2003 Installation Procedure GBC FusionPunch II Service Manual 8-22...
  • Page 425 Take Up Assy. Refer to section 4 of the FP II Service Manual for Belt Tension adjustments, if needed. Document Transport Timing Belt Take Up Assy. Main Drive Pulleys Figure 1-86 Replacing the Document Transport Main Drive Assy. 12/2003 GBC FusionPunch II Service Manual Installation Procedure 8-23...
  • Page 426 5.5 Ensure the jumpers in the top right corner of the Punch I/O PWB set across the A and B pins. 7 Allen Head Cap Screws Punch I/O PW B Figure 1-87 Replace the Punch I/O PWB. 12/2003 Installation Procedure GBC FusionPunch II Service Manual 8-24...
  • Page 427 6.1 Remove the existing Eprom and Install the new Eprom (7610508) from the Kit. Be sure to install it with the notch on the Eprom facing up and lined up with the notch on the socket. Little Star Controller PWB 7610457 Eprom Figure 1-88 Replacing the Eprom 12/2003 GBC FusionPunch II Service Manual Installation Procedure 8-25...
  • Page 428 7. If your system has a GBC FP II Bypass Stacker unit configured in it, then go to Step 8 of this installation procedure. If your system only has a GBC FP II Stacker unit configured without a Bypass, then go to Step 12 of this installation procedure.
  • Page 429 9. Remove the Stacker Bypass Assy. perform REP 5.2 (Bypass Assy. Removal) in the GBC FP II Service Manual. 10. Remove and replace the Bypass Stacker Main Drive Pulley with the new Pulley (7610535) from the Kit. 11. Replace the Stacker Bypass Assy., the Stacker Bypass Timing Belt, tighten the Stacker Bypass Motor, and install the Stacker Bypass Pulley Covers.
  • Page 430 Notes 12/2003 Notes GBC FusionPunch II Service Manual 8-28...

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