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GBC eWire Service Manual

GBC eWire Service Manual

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Table of Contents

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GBC eWire
Service Manual
CAUTION
Certain components in the GBC eWire are susceptible to damage from
electrostatic discharge. Observe all appropriate ESD procedures to avoid
component damage.
GBC eWire
01/26/2018
Service Manual

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Table of Contents
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Summary of Contents for GBC eWire

  • Page 1 GBC eWire Service Manual CAUTION Certain components in the GBC eWire are susceptible to damage from electrostatic discharge. Observe all appropriate ESD procedures to avoid component damage. GBC eWire 01/26/2018 Service Manual...

  • Page 2: Table Of Contents

    Customer releases 3. Book Quality ............3-1 GBC from any and all liability for actions by the Customer, and Customer 4. Repairs/Adjustments ......... 4-1 agrees to indemnify, defend, and hold GBC harmless from any third party claims which arise directly or indirectly from such service.

  • Page 3: Introduction

    Table of Contents ................ii Introduction .................. iii Organization ................iv How to Use This Documentation ..........iv Safety Messages in other Languages ........vi Safety Devices ..............xvii Interlocks ................xvii Operational Safety ..............xvii Warnings and Cautions ............. xvii GBC eWire 01/26/2018 Service Manual...

  • Page 4: Service Call Procedures

    Section 2 was entered. The RAPs in this section are associated with error or status messages that will be indicated on the eWire LCD during a Jam. The service representative should refer to the appropriate RAP based on the error code indicated on the machine.
  • Page 5 This section is used in conjunction with other diagnostic or maintenance procedures that are contained in other sections of the service documentation. Section 8: Installation This section contains service information that describes the GBC eWire Installation. GBC eWire 01/26/2018...

  • Page 6: Safety Messages In Other Languages

    Verletzungen führen können. WAARSCHUWING Voer geen herstellingen uit aan het toestel als het aan staat of als de stroom ingeschakeld is. Sommige onderdelen bevatten gevaarlijke elektrische spanning die kan leiden tot elektrische schokken en ernstige letsels. GBC eWire Service Manual 01/26/2018...
  • Page 7 Bewegende delen, houd uw handen uit de buurt van de Verletzungen führen. spleten en de riemen als de cheater (stukje om Waarschuwing: Trek de stekker van de EWire uit voor u het vergrendeling te omzeilen) van de vergrendeling geplaatst toestel reinigt. Het niet naleven van deze waarschuwing kan de dood of ernstige letsels tot gevolg hebben.
  • Page 8 Spannungen, die zu einem Stromschlag und möglicherweise schweren Verletzungen führen können. WAARSCHUWING Raak geen open terminals van de stroomtoevoer of andere connectoren aan, als de AC voedingskabel is aangesloten. De onderdelen van het toestel bevatten GBC eWire Service Manual 01/26/2018 viii...
  • Page 9 ОСТОРОЖНО: Сенсорный датчик излучает узкий инфракрасный луч высокой интенсивности (940 нм). Луч не виден невооруженным глазом. Необходимо избегать смотреть прямо на датчик при включенном питании устройства. 当心: 传感器发出高强度窄角红外光束( )。 该红外光束肉 940nm 眼无法看到，在机器加电时避免直视传感器。 GBC eWire 01/26/2018 Service Manual...
  • Page 10 Informationen, die für die sichere oder ordnungsgemäße La información relativa a la realización de una tarea de una Durchführung einer Aufgabe relevant sind, werden durch forma segura o cuidadosa se proporcionará en forma die Begriffe Vorsicht, Warnung oder Hinweis angezeigt. GBC eWire Service Manual 01/26/2018...
  • Page 11 Opmerking – Een Opmerking geeft een bedienings- of обслуживания, несоблюдение которого может привести onderhoudsprocedure, een toepassing of situatie aan die к несчастному случаю или летальному исходу. vereist is om een taak goed uit te voeren. GBC eWire 01/26/2018 Service Manual...

  • Page 12: Safety Devices

    法或条件，可导致设备损坏或破坏。 interface. 警告 – 警告声明指示如果不严格遵守操作或维护程序、做 Operational Safety Do not operate the GBC EWire with the interlocks defeated. 法或条件，可导致人员受伤或死亡。 Use care when a procedure in this Manual instructs you to 注释 – 注释声明指示为有效完成任务而需要的一种运行或 “insert an Interlock Cheater into Interlock,” in order to test 维护问题、做法或条件。...
  • Page 13 Sécurité d’utilisation No opere el equipo GBC EWire con los inter-bloqueos Ne pas mettre le “eWire” de GBC en marche si les desactivados. verrouillages ne sont pas en place. Tenga cuidado cuando un procedimiento en este manual le Soyez prudent lorsqu'une procédure dans ce manuel vous...
  • Page 14 “PRONTO” sulla linea superiore „READY“ (bereit) angezeigt. dell’interfaccia. Betriebssicherheit Sicurezza operativa Der GBC EWire darf nicht in Betrieb genommen werden, Non far funzionare l'EWire GBC con gli interblocchi wenn die Verriegelungen außer Kraft gesetzt wurden. disattivati. Vorsichtig vorgehen, wenn ein Verfahren in diesem...
  • Page 15 "PRONTO" na linha superior da interface. Veiligheidsvoorschriften Segurança operacional Bedien de GBC EWire niet als de vergrendelingen Não opere o GBC EWire com dispositivos de bloqueio que uitgeschakeld zijn. apresentem problemas. Wees voorzichtig wanneer een procedure uit deze Tome cuidado quando um procedimento deste manual Handleiding aangeeft dat u “een cheater (stukje om...
  • Page 16 Устройства безопасности Движущиеся части – не прикасаться к ремням при Перфоратор GBC EWire оснащен рядом устройств снятом узле задней крышки. безопасности, предназначенных для предотвращения Ремень электродвигателя модуля перфорирования (PL несчастных случаев в ходе эксплуатации устройства. 3.1) является местом возможного защемления.
  • Page 17 See page number xii for other languages Do not operate the GBC eWire with the interlocks defeated. The GBC EWire has several safety devices designed to prevent personal Use care when a procedure in this Manual instructs you to “insert an injury when operating the machine.
  • Page 18 Rear Cover Assembly are a potential shock hazard. Sharp Edge! Cut Finder with contact. Do not remove cover or place fingers behind it. Moving Gears! Crush fingers if placed in gears. Keep clothing and body parts away from gears. GBC eWire Service Manual 01/26/2018 xviii...
  • Page 19 CALL FLOW..........1-2 INITIAL ACTION .......... 1-3 SYSTEM CHECKS ........1-3 EVERY CALL ACTIVITIES ......1-4 SCHEDULED MAINTENANCE ....1-4 eWIRE MAINTENANCE SCHEDULE ..1-5 Customer Maintenance ..... 1-5 Periodic Maintenance ....... 1-5 Periodic Replacement ....... 1-5 FINAL ACTION ..........1-6...

  • Page 20: Call Flow

    FINAL ACTIONS This step is used to ensure that the machine performance and book quality are satisfactory. It will also provide direction to help complete administrative tasks. GBC eWire Service Call Procedures 09/16/2016...

  • Page 21: Initial Action

    • • If the problem is not repeatable, operate the eWire in the Determine the date of the last preventative maintenance same job conditions the customer used and recheck for a performed on the system. Perform preventative maintenance as problem in the categories listed here.

  • Page 22: Every Call Activities

    EVERY CALL ACTIVITIES SCHEDULED MAINTENANCE Purpose PROCEDURE List service activities required on every service call. • Check the number of Bind Cycles and Sheet Cycles in the eWire PROCEDURE Settings. Refer to GP 6.2.7. • Perform GP 6.10 Internal Inspection. •...

  • Page 23: Ewire Maintenance Schedule

    MAINTENANCE SCHEDULE Customer Maintenance Area/Unit Period Measures Remarks Periodic Maintenance Area/Unit Period Measures Remarks Drag Finger and Closer Pusher 1M cycles Inspect and Clean Alcohol & Cloth Stacker Module Green Belt 1M cycles Inspect and Clean Alcohol & Cloth...

  • Page 24: Final Action

    • Install/close all covers and doors. • Run the eWire using the same settings as the customer was using when the problem occurred. If necessary, run a variety of different paper and spool size configurations to capture different configurations that may have been present during the failure.
  • Page 25 Paper jam in Transport section ........2-22 RAP 5.6 J375- BOOK DROP POSITION TIMEOUT ...... 2-54 RAP 3.6 Jammed sheets in the Stacker module ......2-28 RAP 5.7 J376- CLOSER AT HOLDER STEPS TIMEOUT ..... 2-55 GBC eWire 01/26/2018 RAPS Section Contents...
  • Page 26 RAP 7.1 E501 – LOW VOLTAGE FOR 3.3V ......... 2-79 RAP 7.2 E502 – LOW VOLTAGE FOR 5V........2-79 RAP 7.3 E503 – LOW VOLTAGE FOR 24V........2-79 RAP 7.4 E504 – INTERLOCK OPEN ..........2-79 GBC eWire 01-26-2018 RAPS...

  • Page 27: Introduction

    Section 3. There is a Power Fault. 2. For the entire printing device- Power off, then power on (POPO). Check that eWire runs properly in all modes. eWire runs properly. Go to Step 7. Go to the Table of Contents for Section 2 and locate the RAP for that Go to Step 3.

  • Page 28: Operator Messages

    The Book tray is Full Empty the Book tray CLOSE TRAY The Book tray is pulled out Insert the Book tray READY The eWire is ready for Operation b) Bottom Row of Text Message Description Action ADD ELEMENTS Element spool is almost empty/ not present Replace the element spool with a new one.

  • Page 29: C) Book Tray Full

    6. Inspect the pulley lift mechanism for the Book Drawer. Repair or replace any damaged components. This clears the fault code. Go to step 7. Normal operation. 7. Do GP 6.3.7 to re-flash the firmware. This clears the fault code. Go to step 8 Normal operation GBC eWire 01-26-2018 RAPS...

  • Page 30: D) Close Tray

    5.25) and inspect the connections at the Interlock Switch (see REP 9.2 Interlock switch replacement for photos of the connections). Interlock cable is connected at the Interlock switch. Make the connection and return to Normal operation Go to step 7. GBC eWire 01-26-2018 RAPS...

  • Page 31: E) Add Elements

    REP 9.2 Interlock switch replacement for photos of the connections). Escalate to second level Interlock cable is connected at the Interlock switch. Return to normal operation. Make the connection and return to Normal operation Go to step 7. GBC eWire 01-26-2018 RAPS...

  • Page 32: G) Close Cover

    5.25) and inspect the connections at the Interlock Switch (see REP 9.2 Interlock switch replacement for photos of the connections). Interlock cable is connected at the Interlock switch. Make the connection and return to Normal operation Go to step 7. GBC eWire 01-26-2018 RAPS...
  • Page 33 Replacing the cable clears the fault. Go to Step 10. Return to normal operation. 10. Do REP 11.1 to replace the Main Control Board A. (PL5.27) Replacing the Main Board clears the fault. Escalate to second level. Return to normal operation. GBC eWire 01-26-2018 RAPS...

  • Page 34: Fault Codes

    Area General Location of Text Clear 1 Area 1 Bypass Section Clear 2 Area 2 Bypass to Collection tray Clear 3 Area 3a/3b Wire spool, transfer, holder or closer Clear 4 Area 4 Book drawer GBC eWire 01-26-2018 RAPS 2-10...

  • Page 35: C) Jam Code Classification

    Wire jam- Element feeder module Jam 33x Jam 35x Jam 36x Jam 37x Do RAP 4.x Bind jam- Closer module; Holder module Jam 38x Jam 39x Jam 4xx Do RAP 5.x Book drawer jam- Book drawer module GBC eWire 01-26-2018 RAPS 2-11...

  • Page 36: Power Faults

    RAP 2.1 No AC Power Use this RAP when there is no AC power to the eWire. The Operator Panel does not illuminate and the eWire does not operate. Check if the LEDs on the Main Control Board A and Main Control Board B are lit.
  • Page 37 Replace AC FILTER (REP 11.5). 14. Check for voltage - 110 VAC (60 Hz) or 240 VAC (50 Hz) – on Cable 7716729 (See Section 7, page 7-3). There is AC power on Cable 7716729. Replace Cable 7716729 GBC eWire 01-26-2018 RAPS 2-13...

  • Page 38: Rap 2.2 No Dc Power

    Polarity of the wires 4. If OV! LED (red color) is lit, go to Step 9 24V DC wires is is not correct 5. If REV POL! (red color) is lit, go to Step 7 correct GBC eWire 01-26-2018 RAPS 2-14...
  • Page 39 There is 24 VDC at Connector J1 on the Control Board Normal operation. Replace the Main Control Board (REP 11.1) Go to Step 10 Replace 24V DC power supply (REP 11.4) 10. Replace Cable 7716726. This clears the fault. GBC eWire 01-26-2018 RAPS 2-15...
  • Page 40 RAP 2.3 No Power to Control Board Use this RAP when there is no power to the Control Board. 1. Do RAP 2.2 No DC Power to check DC power. GBC eWire 01-26-2018 RAPS 2-16...

  • Page 41: Rap 2.4 Operator Panel Does Not Illuminate

    9. Check the condition of LCD Cable 7716713 (See Section 7, page 7- Normal operation. LCD Cable 7716713 is okay. 3. Open the Front door. Check if the printer screen shows a eWire related fault. Printer screen shows a eWire related fault Replace LCD Cable 7716713.

  • Page 42: Rap 2.5 Operator Panel Does Not Show Text

    7. Replace the LCD Board on the rear of the User Interface (REP 1.9) Use this RAP when the LCD Display does not show text but illuminates. This clears the fault 1. Power OFF eWire 2. Wait 20 seconds then power ON the device(s). Go to Step 8 The Operator Interface illuminates.

  • Page 43: Rap 2.6 Up, Down, Enter Keys Do Not Respond

    1. Open the Top cover and check that the flat cable from the LCD Panel is connected to the LCD Display (See Section 7, page 7-3). The Cable is connected. Connect the Cable. Do REP 1.10 LCD Membrane switch replacement. GBC eWire 01-26-2018 RAPS 2-19...

  • Page 44: Paper Transport Jam Codes- J1Xx And J2Xx

    J161 is an optional jam code that can be turned on or off through the service menu. When turned on, J161 will occur when the eWire detects a 1. Go to Section 3 3.3 Sheets not Hooking and go through the...

  • Page 45: J261- Excessive Alignment Offset Detected

    J261 is an optional jam code that can be turned on or off through the service menu. When turned on, J261 will occur when the eWire detects a sheet coming into the machine with more alignment offset than eWire is capable of correcting.

  • Page 46: Rap 3.5 Paper Jam In Transport Section

    N4, N5)- Go to RAP 3.6.1 Location of the first jammed sheet is before the stacker module (before the green belt)- Go to RAP 3.6.4 Location of the first jammed sheet is before the Diverter gate- Go to RAP 3.6.2 GBC eWire 01-26-2018 RAPS 2-22...
  • Page 47 This clears the fault 9. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the Yes- Return to normal operation Go to Step 3 firmware for eWire. This clears the fault 3. Do GP 6.4.1 to check sensor S1 Yes- Return to normal operation...
  • Page 48 Yes- Go to Step 2 Set the correct speed 3. Check for any obstructions in the paper path leading to the diverter gate. Remove any obstruction. This clears the fault Yes- Return to normal operation Go to Step 3 GBC eWire 01-26-2018 RAPS 2-24...
  • Page 49 1. Check for any obstructions in the paper path leading to the deflector module 10. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the This clears the fault firmware for eWire. Yes- Return to normal operation Go to Step 2 This clears the fault 2.
  • Page 50 No- Using REP 6.21 Replacing Steering module, make the necessary adjustments. 8. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. 1. Check for any obstructions in the paper path leading to the deflector This clears the fault...
  • Page 51 Yes- Go to Step 7 No- Remove the obstruction, replace the Deflector module if necessary REP 5.1. 7. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire This clears the fault Yes- Return to normal operation No- Go to Step 8 8.

  • Page 52: Rap 3.6 Jammed Sheets In The Stacker Module

    Yes- Return to normal operation Go to Step 6 8. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault 1. Refer to Section 3 to check if the holes are punched correctly by AdvancedPunch Pro.

  • Page 53: Wire Jam Codes

    Yes- Clear the Rewind Spool and reinsert the rewind paper; No- Go to Step 2 9. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. 2. Reinstall the Supply Spool. This clears the fault Replacing the spool with a new one fixes the problem Yes- Return to normal operation;...

  • Page 54: Rap 4.2 J321- S21 Lead Edge Detect Timeout

    Yes- Return to normal operation No- Go to Step 5 4. Perform the steps in RAP 4.1 J320- S20 Spool Element Slack Timeout This clears the fault Yes- Return to normal operation No- Escalate to second level GBC eWire 01-26-2018 RAPS 2-30...

  • Page 55: Rap 4.3 J322- S22 Element At Pyramid Timeout

    Yes- Return to normal operation 12. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the No- Go to step 6 firmware for eWire. This clears the fault 6. Go GP 6.4 to check S25 Belt Home sensor Yes- Return to normal operation;...

  • Page 56: Rap 4.4 J323- S23 Knife Home Timeout

    No- Go to step 3 3. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the 3. Inspect Pushover cams for signs of wear (PL 5.13) firmware for eWire. Pushover cam shows sign of wear This clears the fault Yes- Replace Element Pushover cams (REPs 3.16.5 and 3.16.6) Yes- Return to normal operation;...

  • Page 57: Rap 4.6 J325- S25 Feed Belt Home Timeout

    No- Replace Element feed belt idler (REP 3.11) 6. Inspect Element belt idlers (2x) (PL 5.9) Element belt idlers are in good condition Yes- Go to Step 7 No- Replace Element belt idler (REP 3.11) GBC eWire 01-26-2018 RAPS 2-33...

  • Page 58: Rap 4.7 J332- S32 Expand T Home Timeout

    7. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the RAP 4.7 J332- S32 EXPAND T HOME TIMEOUT firmware for eWire. S32 Expand T Home timeout is the maximum time to wait for the Expand This clears the fault T to reach its home position Yes- Return to normal operation;...

  • Page 59: Rap 4.8 J333- S33 Expand T Out Timeout

    Yes- Return to normal operation; 8. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the No- Go to Step 2 firmware for eWire. This clears the fault 2. Do GP 6.5 to check M13 Expanding T motor Yes- Return to normal operation;...

  • Page 60: Rap 4.9 J334- Feed Belt Jam

    Element belt is in good condition 8. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the Yes- Go to Step 3; firmware for eWire. No- Replace the Element belt (REP 3.6) This clears the fault Yes- Return to normal operation;...

  • Page 61: Rap 4.10 J350- Spool Near Empty

    1. Check if the element spool is loaded properly, and if it contains at 8. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the least one row of elements. Try loading a fresh spool and repeating firmware for eWire. the process. This clears the fault Element spool is loaded properly, it contains at least one row of Yes- Return to normal operation;...

  • Page 62: Rap 4.11 J351- S32 & S33 Both Blocked

    4. Check the Element Feed Belt area for dust and debris. Use compressed air to clean the areas around S21 and S22 4. Do REP 3.15 to remove the Expanding T mechanism from the eWire. This clears the fault Thoroughly inspect and ensure no foreign objects are stuck in the Yes- Return to normal operation;...

  • Page 63: Rap 4.13 J362- Element Failed To Cut

    Element spool is loaded properly Yes- Return to normal operation; Yes- Go to Step 5 No- Go to Step 5 No- Remove the element spool and reinsert it properly 10. Do REP 3.14.3 to replace the Knife Blade. GBC eWire 01-26-2018 RAPS 2-39...
  • Page 64 10. Do GP 6.5 to check M10 Element feed belt motor This clears the fault Yes- Return to normal operation; No- Go to step 11 11. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; GBC eWire 01-26-2018...

  • Page 65: Rap 4.15 J364- M9 Element Backup Steps Timeout

    The Element is not tangled on the sprocket Yes- Go to Step 2 8. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. No- Remove the damaged element and reinstall the spool. This clears the fault Yes- Return to normal operation;...

  • Page 66: Rap 4.16 J365- M9 Mesh Steps Timeout

    RAP 4.16 J365- M9 MESH STEPS TIMEOUT 7. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. J365 is triggered when it takes longer than specified time for the element This clears the fault to lead edge to mesh with the Element belt.

  • Page 67: Rap 4.17 J366- Element At Pushover Steps Timeout

    Pyramid to the position for Pushover. sheet size of books. Follow the procedure in RAP 4.12 Follow the procedure in 3.14 GBC eWire 01-26-2018 RAPS 2-43...

  • Page 68: Rap 4.19 J368- Pushover Fwd Encoder Timeout

    This clears the fault Yes- Return to normal operation; No- Go to Step 4 4. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; No- Go to Step 5...

  • Page 69: Rap 4.20 J369- Pushover Rev Encoder Timeout

    4. Check the tension of the Holder linear drive belt tension- Front and Rear (ADJ 1.6) The tension of the timing belts is good Yes- Go to Step 5 No- Do to ADJ 1.6 to set the belt tension and resume operation GBC eWire 01-26-2018 RAPS 2-45...
  • Page 70 Holder gates springs are present and not damaged Yes- Go to Step 10; No- Replace the missing/damages spring 10. Do 6.3.6 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; No- Go to Step 11 11.

  • Page 71: Rap 5.2 J371- S38 Holder Position Element Timeout

    No- Loosen the cam track assembly and bring the roller inside the metal feature blocks/unblocks S38 Holder Stack position sensor. cam track. Resume operation The sensor is blocked/unblocked properly Yes- Go to Step 7; No- Escalate to second level GBC eWire 01-26-2018 RAPS 2-47...

  • Page 72: Rap 5.3 J372- S39 Detect At Rev Gate Timeout

    The rollers are centered in the cam tracks 9. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware Yes- Go to Step 5; for eWire. No- Loosen the cam track assembly and bring the roller inside the This clears the fault cam track.
  • Page 73 9. Go to RAP 5.20, Step 5 and 6 to ensure the Holder rotate components are in good order. Holder rotate components are in good order Yes- Go to Step 10; No- Follow steps in RAP 5.20 to take the necessary corrective action GBC eWire 01-26-2018 RAPS 2-49...

  • Page 74: Rap 5.4 J373- S40 At Book Drop Position Timeout

    10. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware RAP 5.4 J373- S40 AT BOOK DROP POSITION TIMEOUT for eWire. J373 is triggered when it takes longer than specified time for the Holder to This clears the fault reach S40 Holder at Element feeder sensor from the book drop position.
  • Page 75 Yes- Go to Step 10; No- Follow steps in RAP 5.20 to take the necessary corrective action 10. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; No- Go to Step 11...

  • Page 76: Rap 5.5 J374- S46 Book Drop Timeout

    4. Check if the set screw on the Closer motor pulley and the screws in the drive components are sufficiently tight. The screws are tight Yes- Go to Step 5; No- Tighten the loose set screw(s) and resume operation GBC eWire 01-26-2018 RAPS 2-52...
  • Page 77 The drive system is free of obstructions Yes- Go to Step 8; No- Clear the obstruction/ fasten loose fasteners 8. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; No- Go to Step 9...

  • Page 78: Rap 5.6 J375- Book Drop Position Timeout

    No- Clear the obstruction/ fasten loose fasteners 4. Manually move the Closer linear mechanism and watch if the sheet metal feature blocks/unblocks S46 Closer Home sensor. The sensor is blocked/unblocked properly Yes- Go to Step 5; No- Escalate to second level GBC eWire 01-26-2018 RAPS 2-54...

  • Page 79: Rap 5.7 J376- Closer At Holder Steps Timeout

    9. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware RAP 5.7 J376- CLOSER AT HOLDER STEPS TIMEOUT for eWire. J376 is triggered when it takes longer than specified time for the Closer to This clears the fault move to Holder position from its staged position Yes- Return to normal operation;...
  • Page 80 The drive system is free of obstructions Yes- Go to Step 8; No- Clear the obstruction/ fasten loose fasteners 8. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; No- Go to Step 9...

  • Page 81: Rap 5.8 J377- Closer Carriage Home Timeout

    5. Check if the set screw on the Closer motor gear and the screws in the drive components are sufficiently tight. The screws are tight Yes- Go to Step 6; No- Tighten the loose set screw(s) and resume operation GBC eWire 01-26-2018 RAPS 2-57...
  • Page 82 10. Inspect the closer jaw springs and ensure they are positioned correctly. The closer jaw springs are in good condition and positioned correctly Yes- Go to Step 10; No- Replace closer jaw springs if necessary (REP 6.6) GBC eWire 01-26-2018 RAPS 2-58...

  • Page 83: Rap 5.10 J380- Closer Jaws Home Timeout

    3. Do REP 6.1 to remove the Closer module. 11. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. If the closer jaws are jammed-The closer cam drive for the closer jaws is difficult to rotate manually by hand. The easiest way to clear a...
  • Page 84 Yes- Go to Step 7; No- Replace the damaged part. 9. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; 7. Ensure the sheet metal feature properly blocks/unblocks S47 Closer...

  • Page 85: Rap 5.11 J381- Closer Staged Timeout

    No- Do to ADJ 1.6 to set the belt tension and resume operation 7. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. 4. Check if the set screw on the Closer motor pulley and the screws in This clears the fault the drive components are sufficiently tight.

  • Page 86: Rap 5.12 J382- Full Close Timeout

    5. Check if the set screw on the Closer motor gear and the screws in the drive components are sufficiently tight. The screws are tight Yes- Go to Step 6; No- Tighten the loose set screw(s) and resume operation GBC eWire 01-26-2018 RAPS 2-62...
  • Page 87 10. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware 8. Ensure the encoder disc is properly positioned in relation to S48 for eWire. Closer encoder sensor This clears the fault The encoder disc is positioned properly Yes- Return to normal operation;...

  • Page 88: Rap 5.13 J383- Full Open Timeout

    No- Tighten the loose set screw(s) and resume operation 7. Ensure the sheet metal feature properly blocks/unblocks S47 Closer full open sensor The sheet metal feature properly blocks/unblocks the sensor Yes- Go to Step 8; No- Position the disc correctly GBC eWire 01-26-2018 RAPS 2-64...
  • Page 89 Yes- Go to Step 9; No- Replace closer jaw springs if necessary (REP 6.6) 9. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; No- Go to Step 10...

  • Page 90: Rap 5.14 J384- Holder At Closer Steps Timeout

    4. Visually check if the rollers of the Holder are centered in the cam tracks. The rollers are centered in the cam tracks Yes- Go to Step 5; No- Loosen the cam track assembly and bring the roller inside the cam track. Resume operation GBC eWire 01-26-2018 RAPS 2-66...
  • Page 91 Holder gates springs are present and not damaged Yes- Go to Step 9; No- Replace the missing/damages spring 9. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; No- Go to Step 10...

  • Page 92: Rap 5.16 J386- Holder Full Right Timeout

    4. Visually check if the rollers of the Holder are centered in the cam tracks. The rollers are centered in the cam tracks Yes- Go to Step 5 No- Loosen the cam track assembly and bring the roller inside the cam track. Resume operation GBC eWire 01-26-2018 RAPS 2-68...
  • Page 93 Yes- Go to Step 9; No- Replace the missing/damages spring 9. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; 6. Manually move the Holder linear mechanism and watch if S36 Holder at Closer position sensor is properly blocked/unblocked.

  • Page 94: Rap 5.17 J387- Holder Home Timeout

    J387 is triggered when it takes longer than specified time for the Holder to reach S40 Holder near Element Feeder. reach S40 Holder near Element Feeder. Follow the procedure in RAP 5.4 Follow the procedure in RAP 5.4 GBC eWire 01-26-2018 RAPS 2-70...

  • Page 95: Rap 5.19 J389- Holder Past Home Timeout

    4. Check for the presence and tightness of the fasteners shown in the below image at the Holder rotate pivot The fasteners are sufficiently tight Yes- Go to Step 5; No- Tighten the fasteners and resume normal operation GBC eWire 01-26-2018 RAPS 2-71...
  • Page 96 Brackets are secured correctly Yes- Go to Step 6; No- Replace the missing or damaged components. 7. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; No- Go to Step 8 8.

  • Page 97: Rap 5.21 J391- Holder Rotate Vertical Timeout

    4. Check for the presence and tightness of the fasteners shown in the below image at the Holder rotate pivot The fasteners are sufficiently tight Yes- Go to Step 5; No- Tighten the fasteners and resume normal operation GBC eWire 01-26-2018 RAPS 2-73...

  • Page 98: Rap 5.22 J392- Holder Stack Position Steps Timeout

    The linkages are not damaged Yes- Go to Step 7 No- Replace the damaged components (REP 8.18) 7. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; No- Go to Step 8 8.

  • Page 99: Rap 5.23 J393- Holder Wait Vertical Timeout

    Partial Close position. This is determined by the number of encoder steps through S48 Closer Encoder sensor. Follow the procedure in RAP 5.21 Follow the Procedure in RAP 5.9 GBC eWire 01-26-2018 RAPS 2-75...

  • Page 100: Rap 5.25 J395- S28 Motor Steps Timeout

    J396 occurs when the Closer Encoder Home is not reached after a second attempt. J396 occurs when both attempts to reach home are not successful. The procedure for troubleshooting this jam is identical to the procedure for Closer Home Timeout. Follow the procedure for J379. GBC eWire 01-26-2018 RAPS 2-76...

  • Page 101: Book Drawer Fault Codes

    No- Go to Step 5 Yes- Resume normal operation; No- Go to Step 5 5. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault 11. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire.

  • Page 102: Rap 6.3 J445- Book Drawer Full

    This clears the fault. Yes- Return to normal operation; No- Go to Step 2 2. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for eWire. This clears the fault Yes- Return to normal operation; No- Go to Step 3 3.

  • Page 103: Rap 6.4 J451- S42 & S43 Blocked At Same Time

    This is triggered when the board has 24V power when the interlock is shut, refer to ADJ 1.7 to adjust the Book Tray interlock flag. closed. If this problem persists despite powering on and off the eWire, This clears the fault perform the following operation.
  • Page 104 Notes: GBC eWire 01-26-2018 RAPS 2-80...
  • Page 105 Common Spool Damage ....8 3.4 Element Roundness ........10 3.4.1 Theory of Operation ...... 10 3.4.2 Troubleshooting Steps ....10 3.5 Book Composition ........11 3.5.1 Book Size ........12 3.5.2 Curl ..........12 GBC eWire 02/20/2018 Punch Quality...
  • Page 106 This page intentionally left blank. GBC eWire Punch Quality 02/20/2018...

  • Page 107: Element Closing

    Use the following procedure to correct books that are over-closed diagram above exceeds 2 mm. An over-closed element may also or under-closed by the eWire. To determine if an element is appear to be oval shaped, instead of round. The primary cause of over-closed or under-closed, refer to the diagram below.

  • Page 108: Punched Sheet Quality

    3.2 Punched Sheet Quality All sheets must be punched by the GBC AdvancedPunch Pro prior to being bound into books by the eWire. If punch alignment, skew, or backgauge does not meet the specification in Section 3.2.1, it may be necessary to make adjustments to the AdvancedPunch Pro in order to ensure proper function of eWire.

  • Page 109: Punched Hole Specifications

    AdvancedPunch Pro for all media being used return to the troubleshooting procedure that guided you here. Note that if a different die is used or if the docking position of the AdvancedPunch Pro is changed these steps may need to be repeated. GBC eWire 02/20/2018 Punch Quality...
  • Page 110 Print at 100% Scale and cut along the thick black line. Measure outer dimensions as 185 x 105mm to verify proper printing. GBC eWire Punch Quality 02/20/2018...

  • Page 111: Sheets Not Hooking

    Follow the procedure below to correct a ‘not hooking’ issue on Refer to ADJ 1.9 for info on checking the Holder Rotate eWire. If a change to eWire is made as a result of one of the function. troubleshooting steps below, run additional books to determine if the change has resolved the problem.

  • Page 112: Common Spool Damage

    Common Spool Damage The wire on the spool may become damaged when not properly handled. This may cause jams in eWire. In this section there are examples of common issues you may see on a spool. Any damaged wire must be removed using the wire cutters provide.
  • Page 113 (see above). Loose Element The eWire™ will prompt the user to clear extra elements from 3b after a stoppage occurs. If this is not done the element may fall into the element feeder area and cause a wire jam to occur. The wire could fall on top of the spool as shown below.

  • Page 114: Element Roundness

    Section 3.3.2, Step 2. See if the problem still occurs. 3. Check the printed sheets for excessive curl. If the curl is too large, eWire will be unable to properly process the sheets. If necessary, adjust printer settings to reduce curl.

  • Page 115: Book Composition

    Cover orientation after Tabbed stock weight flipping rear cover ISO sizes A4 - 5,10 tabs Tab width Maximum 13mm Tabs must be Tabbed stock orientation leading on long edge Sheet size tolerance ±0.75mm (0.03”) GBC eWire 02/20/2018 Punch Quality 3-11...

  • Page 116: Book Size

    *Sheet capacity based on 20 lb. (75/80gsm) paper, subtract 10 sheets to accommodate front and rear covers of max 300gsm 3.5.2 Curl When laid on a flat surface, no edge of the paper should be higher than 3/8in (10mm) dimension y below. GBC eWire Punch Quality 02/20/2018 3-12...
  • Page 117 REP 3.14.3 Knife Anvil and Blade Replacement ......4-78 REP 2.16 Alignment Sensor Replacement, S41 ......4-33 REP 3.15 Element Transfer Module Replacement ......4-80 REP 2.17 Motor Driver (Stepper Driver) Replacement, M1 and M2 4-34 GBC eWire 01/26/2018 Repairs/Adjustments Section Contents...
  • Page 118 REP 8.12 Holder Linear Drive Belt – Rear Replacement ....4-155 REP 5.8 Deflector Springs Replacement........4-125 REP 8.13 Holder Gates Spring Lower Replacement ..... 4-156 REP 5.9 Deflector Drive Roller Assembly Replacement ....4-126 REP 8.14 Holder Gates Spring Upper Replacement ..... 4-157 GBC eWire Repairs/Adjustments 01/26/2018...
  • Page 119 ADJ 1.2 Element Slack Detection Adjust ........4-187 ADJ 1.3 Holder Mating To Element Feeder ......... 4-188 ADJ 1.4 Element Feed Belt Home Position ........ 4-191 ADJ 1.5 Book Drawer Closed Position ........4-193 ADJ 1.6 Timing Belt Tension Adjustment ........4-194 GBC eWire 01/26/2018 Repairs/Adjustments...

  • Page 120: External Covers

    See Section 0, page vi for other languages. 1. Switch power OFF to entire eWire. 2. Disconnect the Power Cord from eWire. 3. Raise the Upper Transport by releasing the latch.

  • Page 121: Rep 1.2 Element Feeder Door Replacement

    Use this procedure to install the top cover assembly Use this procedure to remove and install the Element Feeder Door 1. Switch power OFF to eWire. Assembly 2. Disconnect the Power Cord from eWire. Removal Procedure 3. Lower the Upper Transport until the latch engages. WARNING 4.

  • Page 122: Rep 1.3 Door Bottom Hinge Bracket Replacement

    5. Use a nut driver to remove the Screws (2) securing the Door Bottom Hinge Bracket to the machine. 5. Switch power ON to the eWire Installation Procedure 1. Use a nut driver to tighten the Screws (2) mounting the new Door Bottom Hinge Bracket to the machine.

  • Page 123: Rep 1.4 Door Top Hinge Bracket Replacement

    Use this procedure to remove and install the Door Top Hinge Bracket. PARTS LIST ON PL 5.28 Removal Procedure Use this procedure to remove and install the Back Cover. 1. Switch power OFF to eWire. Removal Procedure 2. Disconnect the Power Cord. WARNING 3.

  • Page 124: Rep 1.6 Side Cover Replacement

    See Section 0, page vi for other languages. 1. Switch power OFF to eWire 2. Disconnect the Power Cord. 3. Hold the Side Cover in place so it doesn’t fall as you remove the M4 Screws (2) from the Side Cover.

  • Page 125: Rep 1.7 Book Tray Door Replacement

    See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Slide out the Book Tray by pulling on the handle.

  • Page 126: Rep 1.8 Front Cover Replacement

    See Section 0, page vi for other languages. 5. Plug in the Power Cord. 1. Switch power OFF to eWire. 6. Switch power ON to the eWire 2. Disconnect the Power Cord. 3. Raise the Upper Transport Assembly by releasing the latch on the Top Cover.
  • Page 127 Refer to Removal Procedure for details. 2. Lower the Upper Transport. 3. Plug in the Power Cord. 4. Switch power ON to the eWire 6. Slide the Front Cover off the eWire. GBC eWire 01/26/2018 Repairs/Adjustments 4-11...

  • Page 128: Rep 1.9 Lcd Display Replacement

    6. Power ON the eWire. dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Raise the Upper Transport Assembly.

  • Page 129: Rep 1.10 Lcd Membrane Switch Panel Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire 2. Disconnect the Power Cord. 3. Raise the Upper Transport.

  • Page 130: Rep 1.11 Caster Replacement

    See Section 0, page vi for other languages. 1. Switch power OFF to eWire 2. Disconnect the Power Cord. 3. Carefully lift the corner of the eWire nearest the Caster. Support the eWire so that the machine is secured when Caster is removed. 4. Do REP 1.6...

  • Page 131: Paper Transport

    7. Remove the E-Ring and the Washer from the end of the Drive Roller Removal Procedure Shaft at the front of the machine. 1. Switch power OFF to eWire. 2. Do REP 1.1 Top Cover Replacement to remove the Top Cover.

  • Page 132: Rep 2.2 Drive Roller Replacement - Steering Module

    Top Cover. 8. Connect the Power Cord. 9. Power ON the eWire. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Raise the Upper Bypass Panel 4. Do REP 2.21 Steering Module Replacement to remove the Steering Module from the Machine.
  • Page 133 4. Repeat the procedure for the opposite side. 5. Re-attach the drive panel assembly by securing the M3 nuts (4). 6. Do REP 2.21 Steering Module Replacement to replace the Steering Module. 7. Connect the Power Cord. 8. Power ON the eWire. GBC eWire 01/26/2018 Repairs/Adjustments 4-17...

  • Page 134: Rep 2.3 Drive Roller Bearing Replacement

    3. For Bearings on rear of machine, reverse steps in Removal Removal Procedure Procedure to re-install the Belt and Pulley. 1. Switch power OFF to eWire. 4. If the Timing Belt was replaced, double check the belt tension. Adjust 2. Disconnect the Power Cord.

  • Page 135: Rep 2.4 Idler Roller Replacement, Paper Path

    See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 6. Remove the Idler Roller with the Bearing Housings (2) from the Bushing Forks.

  • Page 136: Rep 2.5 Idler Roller Replacement, Steering Module

    8. Connect the Power Cord. 9. Power ON the eWire. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Raise the Upper Bypass Panel 4. Remove the Extension Spring (2) by unhooking the spring ends from the hooks on the mounting bracket.

  • Page 137: Rep 2.6 Belt Drive Idler Pulley Replacement

    See Section 0, page vi for other languages. 6. Place the hooks on the ends of the Extension Springs (2) into the 1. Switch power OFF to eWire. mounting holes on the Bearing Mount Brackets. 2. Disconnect the Power Cord.

  • Page 138: Rep 2.7 Belt Drive Timing Pulley Replacement

    6. Power ON the eWire. possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.1 Top Cover Replacement to remove the Top Cover.
  • Page 139 Bypass Timing Belt #1 Replacement & Bypass Timing Belt #2 Replacement to install the appropriate Timing Belts. 3. Do REP 1.1 Top Cover Replacement to install the Top Cover. 4. Connect the Power Cord. 5. Power ON the eWire. GBC eWire 01/26/2018 Repairs/Adjustments 4-23...

  • Page 140: Rep 2.8 Bypass Timing Belt #1 Replacement

    6. Relieve tension on the Belt by loosening the M4 screws (2) on the Belt Tensioner. There are two timing belts used at the rear of the eWire Upper Bypass Assembly. The procedure below can be used for the upstream (paper entry side) Belt.

  • Page 141: Rep 2.9 Bypass Timing Belt #2 Replacement

    Installation Procedure REP 2.9 Bypass Timing Belt #2 Replacement There are two timing belts used at the rear of the eWire Upper Bypass Assembly. The procedure below can be used for the downstream (paper 1. Carefully place the new Belt into position around the Driver and Idler exit side) Belt.

  • Page 142: Rep 2.10 Stepper And Mount Assembly Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.1 Top Cover Replacement to remove the Top Cover.
  • Page 143 Top Cover Replacement to install the Top Cover. 7. Connect the Power Cord. 8. Power ON the eWire. 8. Remove the Motor Timing Pulley from the Motor shaft by pulling it off of the shaft. 9. Remove the Stepper Motor from the Motor Bracket by removing the...

  • Page 144: Rep 2.11 Stepper Motor Pulley Replacement

    See Section 0, page vi for other languages. possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord.

  • Page 145: Rep 2.13 Bypass Sensor Replacement, S1, S4, S5 & S16

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.1 Top Cover Replacement to remove the Top Cover.

  • Page 146: Rep 2.14 Skew Measurement Sensor Replacement, S6-S10

    Some machine components contain Screw. dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. Installation Procedure 3. Do REP 1.1 Top Cover Replacement to remove the Top Cover.
  • Page 147 Top Cover Replacement to install the Top Cover. 7. Connect the Power Cord. 8. Power ON the eWire. 9. Release the Skew Sensor PCB by removing the M3 Nuts (4) 10. Remove the old Skew Sensor PCB from the Upper Bypass.
  • Page 148 6. Release the Alignment Sensor PCB by removing the M3 Nuts (2) dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.1 Top Cover Replacement to remove the Top Cover.

  • Page 149: Rep 2.16 Alignment Sensor Replacement, S41

    Top Cover. possible serious injury. See Section 0, page vi for other languages. 6. Connect the Power Cord. 1. Switch power OFF to eWire. 7. Power ON the eWire. 2. Disconnect the Power Cord. 3. Raise the Upper Bypass Lid.

  • Page 150: Rep 2.17 Motor Driver (Stepper Driver) Replacement, M1 And M2

    See Section 0, page vi for other languages. 6. Connect the Power Cord. 1. Switch power OFF to eWire. 7. Power ON the eWire. 2. Disconnect the Power Cord.
  • Page 151 Stepper Driver. Remove the Stepper Driver by releasing it from the plastic standoffs. Connectors 5. Connect the Connectors (3). 6. Do REP 1.1 Top Cover Replacement to install the Top Cover. 7. Connect the Power Cord. 8. Power ON the eWire. GBC eWire 01/26/2018 Repairs/Adjustments 4-35...

  • Page 152: Rep 2.18 Solenoid Replacement, Diverter Solenoid (L1)

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.1 Top Cover Replacement to remove the Top Cover.
  • Page 153 6. Connect the Solenoid Cables, threading the wires through the cable clamps. 7. Re-install the Lower Bypass Rear Cover. to replace the Top Cover. 8. Do REP 1.1 Top Cover Replacement 9. Connect the Power Cord 10. Turn ON the eWire. GBC eWire 01/26/2018 Repairs/Adjustments 4-37...

  • Page 154: Rep 2.19 Solenoid Replacement, Disengaging Roller #1 And #2 (L2 & L3)

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.1 Top Cover Replacement to remove the Top Cover.

  • Page 155: Rep 2.20 Solenoid Replacement, Disengaging Roller #3 (L4)

    6. Connect the Power Cord possible serious injury. See Section 0, page vi for other languages. 7. Turn on the eWire. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.1 Top Cover Replacement to remove the Top Cover.
  • Page 156 4. Install the Cable to the headers on the new sub-assembly. 5. Do REP 1.1 Top Cover Replacement to replace the Top Cover. 6. Connect the Power Cord 7. Turn ON the eWire. 7. Remove the entire Disengaging Roller #3 sub-assembly GBC eWire Repairs/Adjustments 01/26/2018...

  • Page 157: Rep 2.21 Steering Module Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Raise the Upper Bypass Lid 4.

  • Page 158: Rep 2.22 Steering Motor Replacement, M16 And M17

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 2.21...

  • Page 159: Rep 2.23 Alignment Motor Replacement, M18

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 2.21...

  • Page 160: Rep 2.24 Motor Driver (Stepper Driver) Replacement, M16, M17, And M18

    Steering Module Replacement to replace the Steering possible serious injury. See Section 0, page vi for other languages. Module. 1. Switch power OFF to eWire. 6. Connect the Power Cord. 2. Disconnect the Power Cord. 7. Power ON the eWire.
  • Page 161 Stepper Driver. Remove the Stepper Driver by releasing it from the plastic standoffs. Connectors (3) to install the Top Cover. 6. Do REP 1.1 Top Cover Replacement 7. Connect the Power Cord. 8. Power ON the eWire. GBC eWire 01/26/2018 Repairs/Adjustments 4-45...

  • Page 162: Rep 2.25 Anti-Static Brush Replacement

    5. Power ON the eWire. possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.1 Top Cover Replacement to remove the Top Cover.

  • Page 163: Rep 2.26 Upper Transport Latch Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.1 Top Cover Replacement to remove the Top Cover.

  • Page 164: Rep 2.27 Lower Transport Latch Replacement

    See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Raise the Upper Bypass and Lower Bypass.

  • Page 165: Element Feeder

    7. Disconnect the Sensor Cable. Removal Procedure 8. Remove the Sensor Bracket by removing the M3 Screws (2) 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Front Door and slide out the Element Feeder drawer.

  • Page 166: Rep 3.2 Element Detect At Pyramid Sensor Replacement - S22

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Front Door and slide out the Element Feeder drawer.
  • Page 167 Header by tugging gently on the cables. 8. Remove the Feed Track from the Element Feeder by removing the 10. Remove the M2 Screws (2) to remove the Emitter PCB. M4 Screws (3). GBC eWire 01/26/2018 Repairs/Adjustments 4-51...

  • Page 168: Rep 3.3 Element Belt Home Sensor Replacement - S25

    Element Feeder components. possible serious injury. See Section 0, page vi for other languages. 5. Connect the Power Cord. Removal Procedure 6. Power ON the eWire. 1. Do Step 1 through Step 8 of 3.2, Element Detect at Pyramid Sensor Replacement.
  • Page 169 4. Reverse the steps from the Removal Procedure to install the remaining Element Feeder parts. 5. Connect the Power Cord. 6. Power ON the eWire. 5. Peel back the Protective Tape holding the Sensor Cables to the rear of the Track and remove the Cables.
  • Page 170 See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Front Door and slide out the Element Feeder drawer.

  • Page 171: Rep 3.5 Spool Near-Empty Sensor Replacement - S50

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Front Door and slide out the Element Feeder drawer.

  • Page 172: Rep 3.6 Element Feeder Belt Replacement

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Front Door and slide out the Element Feeder drawer.

  • Page 173: Rep 3.7 Element Feed Belt Motor Replacement, M10

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Front Door and slide out the Element Feeder drawer.
  • Page 174 8. Loosen the set screw on the Element Belt Pulley. 9. Remove the M4 Nuts (4) securing the Motor to the frame, and remove the Motor. 7. Disconnect the Motor Cable from the Stepper Motor Driver. GBC eWire Repairs/Adjustments 01/26/2018 4-58...

  • Page 175: Rep 3.8 Element Feed Sprocket Motor Replacement, M9

    5. Re-attach all covers by reversing the steps in the Removal Procedure. Removal Procedure 6. Connect the Power Cord. 1. Switch power OFF to eWire. 7. Power ON the eWire. 2. Disconnect the Power Cord. 3. Open the Front Door and slide out the Element Feeder drawer.
  • Page 176 Screws (4) mounting the Stepper Motor. 10. Remove the Motor. Installation Procedure 1. Reverse the steps in the Removal Procedure. 2. Connect the Power Cord. 3. Power ON the eWire. 7. Loosen the set screw and remove the Element Sprocket Knob. GBC eWire Repairs/Adjustments 01/26/2018...

  • Page 177: Rep 3.9 Spool Rewind Drive Assembly Replacement, M8

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Front Door and slide out the Element Feeder drawer.
  • Page 178 10. Remove the M4 Screws (8) securing the Spindle Frame Assembly to the Element Feeder. Carefully tilt the Spindle Frame Assembly forward to remove it from the Element Feeder Body. 9. Remove the curved Rear Baffle by removing the M4 Screws (6) Spindle Frame Assembly GBC eWire Repairs/Adjustments 01/26/2018 4-62...
  • Page 179 Spool Shaft, and slide the Idler Pulley off of the Shaft. 14. Remove the M3 Screw securing the Liner Tube to the Spool Rewind Hub. 12. Remove the Retaining Ring and Washer from rear side of the Rewind Hub. GBC eWire 01/26/2018 Repairs/Adjustments 4-63...
  • Page 180 Element Feeder. 16. Remove the flanged bearings and slide the Rewind Hub out of the assembly. Slide the Idler Pulley off of the Rewind Hub from the opposite side of the assembly and remove it. GBC eWire Repairs/Adjustments 01/26/2018 4-64...

  • Page 181: Rep 3.10 Element Feed Track Assembly Replacement

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Front Door and slide out the Element Feeder drawer.
  • Page 182 8. Remove the Element Feed Track Assembly. Installation Procedure 1. Reverse the steps in the Removal Procedure. 2. Connect the Power Cord. 3. Power ON the eWire. GBC eWire Repairs/Adjustments 01/26/2018 4-66...

  • Page 183: Rep 3.11 Element Feed Belt Idler Replacement

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Front Door and slide out the Element Feeder drawer.
  • Page 184 1. Reverse the steps in the Removal Procedure to install the new Idler Washer. Pulley Assembly. Note the orientation of the plastic idler component when installing. 2. Do GP 6.8 to install the Supply Spool. 3. Connect the Power Cord. 4. Power ON the eWire. Idler Assembly GBC eWire Repairs/Adjustments 01/26/2018 4-68...

  • Page 185: Rep 3.12 Element Sprocket Nose Replacement

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Front Door and slide out the Element Feeder drawer.

  • Page 186: Rep 3.13 Element Engagement Guide Replacement

    5. Connect the Power Cord. Removal Procedure 6. Power ON the eWire. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Front Door and Slide the Element Feeder out. 4. Remove the M4 Screws (4) securing the Element Engagement Guide to the Element Feeder.

  • Page 187: Rep 3.14 Knife Module Replacement

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. NOTE: Handle the Knife Module carefully and keep fingers clear of the knife blade.
  • Page 188 7. Remove the Element Feeder Belt Cover by removing the M4 Screws 9. Remove the M5 Screw securing the rear of the Knife Module. 8. Unplug the Knife Module harness at the wire header. GBC eWire Repairs/Adjustments 01/26/2018 4-72...
  • Page 189 4. Replace the Element Feeder Back Cover by Securing the M4 Screws (8). The bottom screws can be used as a support to help position the cover. 5. Do GP 6.8 to replace the Element Spool. 6. Connect the Power Cord. 7. Power ON the eWire. GBC eWire 01/26/2018 Repairs/Adjustments 4-73...

  • Page 190: Rep 3.14.1 Element Detect At Knife Sensor Replacement S21

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 3.15 Knife Module Replacement to remove the Knife Module 4.
  • Page 191 8. Remove the Upper Cable Cover by removing the M3 Screws (2). 10. Remove the M2 mounting Screws from the Emitter PCB and remove the Emitter PCB. Emitter Mounting Screws 9. Disconnect the Emitter Cable at the cable header. Emitter Cable Connection GBC eWire 01/26/2018 Repairs/Adjustments 4-75...

  • Page 192: Rep 3.14.2 Knife Home Sensor Replacement S23

    Housing Assembly into place. Secure the Sensor Housing Assembly Removal Procedure using the M2 Screw. 1. Switch power OFF to eWire. 6. Install the Cable Conduit by tightening the M3 Screws (2). 2. Disconnect the Power Cord. 7. Run the Receiver Cable through the cable clamps on the Cable 3.
  • Page 193 4. Secure the Upper Cable Cover by tightening the M3 Screws (2). 5. Do REP 3.15 Knife Module Replacement to install the Knife Module. 6. Connect the Power Cord. 7. Power ON the eWire. Sensor Cable Connection GBC eWire 01/26/2018...

  • Page 194: Rep 3.14.3 Knife Anvil And Blade Replacement

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. NOTE: Handle the Knife Module carefully and keep fingers clear of the knife blade edge.
  • Page 195 1. Reverse the steps in the Removal Procedure. 2. Do REP 3.15 Knife Module Replacement to install the Knife Module. 3. Connect the Power Cord. 4. Power ON the eWire. 8. Remove the Knife Anvil GBC eWire 01/26/2018 Repairs/Adjustments 4-79...

  • Page 196: Rep 3.15 Element Transfer Module Replacement

    See Section 0, page vi for other languages. Removal Procedure 5. Switch power OFF to eWire. 6. Disconnect the Power Cord. 7. Open the Front Door and slide out the Element Feeder drawer.
  • Page 197 18. Replace the Element Feeder Back Cover by Securing the M4 Screws (2). (8). The bottom screws can be used as a support to help position the cover. 19. Replace the Element Feeder Upper Cover 20. Connect the Power Cord. 21. Power ON the eWire. GBC eWire 01/26/2018 Repairs/Adjustments 4-81...

  • Page 198: Rep 3.15.1 Element Pushover Encoder Sensor Replacement S31

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 5. Remove the old sensor by removing the M3 Screw. 2. Disconnect the Power Cord.

  • Page 199: Rep 3.15.2 Pushover Home Sensor Replacement S24

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 3.15 Element Transfer Module Replacement to remove the Element Transfer Module.

  • Page 200: Rep 3.15.3 Expanding T Home And Out Sensor Replacement S32

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Remove the Expanding T top cover by removing the M3 Screws (4).

  • Page 201: Rep 3.15.4 Element Transfer Rack Replacement

    3. Secure the new Sensor using the M3 screw. Removal Procedure 4. Repeat the procedure for the opposing sensor if necessary. 1. Switch power OFF to eWire. 5. Replace the Element Transfer Top Cover. 2. Disconnect the Power Cord. 6. RConnect the Power Cord.

  • Page 202: Rep 3.15.5 Horizontal Pushover Cam Replacement

    6. Power ON the eWire. possible serious injury. See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 3.15 Element Transfer Module Replacement to remove the Element Transfer Module.
  • Page 203 4. Repeat the procedure for the opposite Cam. 5. Do REP 3.15 Element Transfer Module Replacement to install the Element Transfer Module. 6. Connect the Power Cord. 7. Power ON the eWire. 7. Slide the Cam and Washers off the shaft. GBC eWire 01/26/2018 Repairs/Adjustments 4-87...

  • Page 204: Rep 3.15.6 Vertical Pushover Cam Replacement

    Horizontal Pushover Cam Replacement to replace the Horizontal Cam on the idler side. 1. Switch power OFF to eWire. 3. For the drive side Cam, slide the new Cam and Washers onto the 2. Disconnect the Power Cord. Drive Shaft. Slide the Timing Pulley onto the drive shaft and secure it 3.

  • Page 205: Rep 3.15.7 Pushover Motor Assy Replacement M12

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 3.15 Element Transfer Module Replacement to remove the Element Transfer Module.

  • Page 206: Rep 3.15.8 Expanding T Motor Replacement M13

    Drive shaft timing pulleys. Removal Procedure 6. Secure the Pushover Motor Bracket Assembly using (2) M4 Flat Head 1. Switch power OFF to eWire. Screws on the top and (1) M3 Screw on the side. 2. Disconnect the Power Cord.

  • Page 207: Rep 3.15.9 Expanding T Cam Replacement

    See Section 0, page vi for other languages. 5. Power ON the eWire. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 3.15 Element Transfer Module Replacement to remove the Element Transfer Module.

  • Page 208: Rep 3.15.10 Expanding T Spring Replacement

    6. Connect the Power Cord. Removal Procedure 7. Power ON the eWire. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Remove the Expanding T top cover by removing the M3 Screws (4). 4. Remove the old spring by pulling the loop up and off the hook.

  • Page 209: Rep 3.15.11 Expanding T Motor Counterbalance Spring Replacement

    5. Power ON the eWire. possible serious injury. See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Element Feeder door and slide out the Element Feeder drawer.

  • Page 210: Rep 3.15.12 Expanding T Pushover Spring Replacement

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 3.15 Element Transfer Module Replacement to remove the Element Transfer Module.
  • Page 211 See Section 0, page vi for other languages. Removal Procedure 5. Switch power OFF to eWire. 6. Disconnect the Power Cord. 7. Remove the M3 Screws (2) securing the Expanding T Leading Plate.
  • Page 212 11. Align the new Expanding T Trailing Plate to the module and secure it using the M3 Screws (2). 12. Align the new Expanding T Leading Plate to the module and secure it using the M3 Screws (2). 13. Connect the Power Cord. 14. Power ON the eWire. GBC eWire Repairs/Adjustments 01/26/2018 4-96...

  • Page 213: Vacuum Stacker Module

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 15. Turn off Power to the eWire. 16. Disconnect the Power Cord. 17. Raise the Lid.
  • Page 214 22. Repeat the procedure to remove the M4 Screws (2) from the rear Installation Procedure hinge bracket. 1. Reverse Steps for Installation. 23. Disconnect the Ground Strap from the frame by removing the M4 Screw. 24. Carefully lift the Vacuum Stacker out of the machine. GBC eWire Repairs/Adjustments 01/26/2018 4-98...

  • Page 215: Rep 4.2 Solenoid Replacement, Kickdown Solenoid, Rear (L7)

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 4.1...
  • Page 216 9. Use an adjustable wrench to loosen the nut securing the Solenoid to 2. Do REP 4.1 Vacuum Stacker Module Replacement to install the the bracket. Vacuum Stacker. 3. Connect the Power Cord 4. Turn on the eWire. GBC eWire Repairs/Adjustments 01/26/2018 4-100...

  • Page 217: Rep 4.3 Solenoid Replacement, Kickdown Solenoid, Front (L7)

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 4.1...
  • Page 218 Loosen the kick-down retract spring. 9. Loosen and remove the M4 Screws (2) securing the kick-down solenoid mounting bracket, and remove the bracket from the module. 11. Remove the Kick-Down Solenoid Assembly from the Vacuum Stacker. GBC eWire Repairs/Adjustments 01/26/2018 4-102...

  • Page 219: Rep 4.4 Solenoid Replacement, Drag Finger Solenoid (L6)

    4. Turn on the eWire. dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 4.1...
  • Page 220 Carefully slide the top cover out under the green belts. 6. Using a flat head screwdriver, loosen and remove the gas spring socket from the top cover. 8. Unclip the wires from the cable connectors on the solenoid mounting bracket. GBC eWire Repairs/Adjustments 01/26/2018 4-104...
  • Page 221 Vacuum Stacker Module Replacement to install the Vacuum Stacker. 3. Connect the Power Cord 4. Turn on the eWire. 10. Loosen the M4 nuts (2) securing the Solenoid Mounting Bracket and loosen the mounting bracket. Do not remove it completely. GBC eWire...

  • Page 222: Rep 4.5 Motor Replacement, Vacuum Stacker Drive (M5)

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 4.1...

  • Page 223: Rep 4.6 Idler Pulley Assembly Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 4.1...
  • Page 224 Vacuum Stacker. 6. Connect the Power Cord 7. Turn on the eWire. 3. With the Idler Pulley Assembly in place, loosen the tensioning screws until proper tension is achieved on the Vacuum Stacker Belt. Refer to REP 4.8 Vacuum Stacker Belt Replacement additional detail on belt replacement.

  • Page 225: Rep 4.7 Kickdown Weldment Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 8. Switch power OFF to eWire. 9. Disconnect the Power Cord. 10. Do ARP 4.1...
  • Page 226 Kick-Down Weldment. 4. Reverse steps 1-6 from the Removal Procedure. 5. Do ARP 4.1 Vacuum Stacker Module Replacement to install the Vacuum Stacker. 6. Connect the Power Cord 7. Turn on the eWire. GBC eWire Repairs/Adjustments 01/26/2018 4-110...

  • Page 227: Rep 4.8 Vacuum Stacker Belt Replacement

    See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 5. Using a flat head screwdriver, loosen and remove the gas spring 2. Disconnect the Power Cord.
  • Page 228 Remove the Hinge Brackets from the Vacuum Stacker. Installation Procedure 1. Reverse the steps from the Removal Procedure. 2. Do REP 4.1 Vacuum Stacker Module Replacement to install the Vacuum Stacker. 3. Connect the Power Cord 4. Turn on the eWire. GBC eWire Repairs/Adjustments 01/26/2018 4-112...

  • Page 229: Rep 4.9 Stacker Drive Belt Replacement

    Vacuum Stacker. possible serious injury. See Section 0, page vi for other languages. 6. Connect the Power Cord 1. Switch power OFF to eWire. 7. Turn on the eWire. 2. Disconnect the Power Cord. 3. Do REP 4.1...

  • Page 230: Rep 4.10 Drag Finger Adhesive Grip Replacement

    See Section 0, page vi for other languages. 4. Press the new Drag Finger Adhesive Grip to the material and 1. Switch power OFF to eWire. press it down flat. 2. Disconnect the Power Cord.
  • Page 231 GBC eWire 01/26/2018 Repairs/Adjustments 4-115...

  • Page 232: Deflector Module

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Raise the lid.
  • Page 233 Installation Procedure 7. Remove the M4 Screws (2) from the back of the Deflector 1. Place the Deflector Module onto the eWire. Use the pins on the bottom of the Deflector to align the module. 2. Reattach the Deflector Module to the Frame by securing the M4 Screws (4).

  • Page 234: Rep 5.2 Sensor Replacement, Deflector Position S17

    Install the Deflector Module. Removal Procedure 6. Connect the Power Cord. 1. Switch power OFF to eWire. 7. Power ON the eWire. 2. Disconnect the Power Cord. 8. Do GP 6.3.2 to verify sensor function. 3. Do REP 5.1...

  • Page 235: Rep 5.3 Sensor Replacement, Bind Kick Downs S2

    See Section 0, page vi for other languages. 6. Power ON the eWire. Removal Procedure 7. Do GP 6.3.2 to verify sensor function. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 5.1 Deflector Module Replacement to remove the Deflector Module.

  • Page 236: Rep 5.4 Sensor Replacement, Bind Deflect S3

    5. Connect the Power Cord. Removal Procedure 6. Power ON the eWire. 7. Do GP 6.3.2 to verify sensor function. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 5.1 Deflector Module Replacement to remove the Deflector Module.

  • Page 237: Rep 5.5 Bind Path Motor Replacement M3

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 5.1 Deflector Module Replacement to remove the Deflector Module.

  • Page 238: Rep 5.6 Deflector Module Timing Belt Replacement

    5. Connect the Power Cord. possible serious injury. See Section 0, page vi for other languages. 6. Power ON the eWire. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 5.1 Deflector Module Replacement to remove the Deflector Module.

  • Page 239: Rep 5.7 Deflector Solenoid Replacement L5

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 5.1Deflector Module Replacement to remove the Deflector Module.
  • Page 240 Deflector Module Replacement to Install the Deflector Module. 7. Connect the Power Cord. 8. Power ON the eWire. 8. Using an adjustable wrench, loosen the nut securing the Solenoid to the Solenoid Mounting Bracket and remove the Solenoid linkage. GBC eWire...

  • Page 241: Rep 5.8 Deflector Springs Replacement

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 5.1 Deflector Module Replacement to remove the Deflector Module.

  • Page 242: Rep 5.9 Deflector Drive Roller Assembly Replacement

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 5.1 Deflector Module Replacement to remove the Deflector Module.

  • Page 243: Rep 5.10 Deflector Idler Roller Assembly Replacement

    See Section 0, page vi for other languages. 5. Remove the Idler Roller with the Bearing Housings (2) from the Removal Procedure Bushing Forks. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 5.1 Deflector Module Replacement to remove the Deflector Module.

  • Page 244: Closer Module

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Raise the lid.
  • Page 245 5. Disconnect the Closer Cable. The closer cable is located underdeath the closer top plate, as seen through the rectangular opening. 7. Remove the M4 mounting screws (2) from the back of the module. GBC eWire 01/26/2018 Repairs/Adjustments 4-129...
  • Page 246 Installation Procedure 1. Position the Closer module in place in the eWire. Use the pins to align the Closer to the Tube Bushing Assembly. 2. Secure the Closer by tightening the M4 Screws (4) 3. Re-attach the Closer cable. 4. Install the Cable Access Cover.

  • Page 247: Rep 6.2 Closer Encoder Sensor Replacement S48

    See Section 0, page vi for other languages. 6. Power ON the eWire. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 6.1 Closer Module Replacement to remove the Closer.

  • Page 248: Rep 6.3 Closer Full Open Sensor Replacement S47

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 6.1 Closer Module Replacement to remove the Closer.
  • Page 249 Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 6.1 Closer Module Replacement to remove the Closer.

  • Page 250: Rep 6.5 Closer Jaw Insert Replacement

    5. Connect the Power Cord. possible serious injury. See Section 0, page vi for other languages. 6. Power ON the eWire. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 6.1 Closer Module Replacement to remove the Closer.

  • Page 251: Rep 6.6 Closer Spring Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 6.1 Closer Module Replacement to remove the Closer.

  • Page 252: Rep 6.7 Closer Release Solenoid Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 6.1 Closer Module Replacement to remove the Closer.

  • Page 253: Tappers

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Turn off Power to the eWire. 1. Disconnect the Power Cord. 2. Raise the Lid.
  • Page 254 6. Remove the M4 screws (2) securing the Tapper to the eWire Frame Installation Procedure 1. Place the Tapper Assembly into place on the eWire Frame. Two tabs are used to align the Front Tapper Assembly. 2. Secure the Front Tapper with the M4 Screws (2) 3.
  • Page 255 Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 7.1...
  • Page 256 Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 7.1...

  • Page 257: Rep 7.4 Front Tapper Spring Replacement

    6. Turn on the eWire. possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 7.1...

  • Page 258: Rep 7.5 Tapper Finger Replacement

    See Section 0, page vi for other languages. dangerous electrical voltages that can result in electrical shock and 1. Switch power OFF to eWire. possible serious injury. See Section 0, page vi for other languages. 2. Disconnect the Power Cord.

  • Page 259: Holder Module

    See Section 0, page vi for other languages. 1. Turn off Power to the eWire. 2. Disconnect the Power Cord. 3. Raise the Lid and Lower Bypass.

  • Page 260: Rep 8.2 Closer Rotate Horizontal And Vertical Sensor S34 & S35

    See Section 0, page vi for other languages. 1. Turn off Power to the eWire. 2. Disconnect the Power Cord. 3. Raise the Lid and Lower Bypass.

  • Page 261: Rep 8.3 Holder Position Near Element Sensor S40

    4. Connect the Power Cable dangerous electrical voltages that can result in electrical shock and 5. Turn power ON to the eWire. possible serious injury. See Section 0, page vi for other languages. 1. Turn off Power to the eWire.

  • Page 262: Rep 8.4 Holder Position Closer And Holder Position Element Sensor S36 And S38

    4. Connect the Power Cable Do not perform repair activities with the power on or electrical power 5. Turn power ON to the eWire. supplied to the machine. Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury.

  • Page 263: Rep 8.5 Holder At Reverse Gate Sensor S39

    See Section 0, page vi for other languages. 1. Turn off Power to the eWire. 2. Disconnect the Power Cord. 3. Raise the Lid and Lower Bypass.

  • Page 264: Rep 8.6 Holder Position Stack Sensor S37

    3. Close the Lid Sensor S37. 4. Connect the Power Cable DO NOT REPLACE OR ADJUST THIS SENSOR UNLESS DIRECTION 5. Turn power ON to the eWire. TO VIA AN ESCALATION Removal Procedure WARNING Do not perform repair activities with the power on or electrical power supplied to the machine.

  • Page 265: Rep 8.7 Holder Linear Motor Replacement M15

    4. Connect the Power Cable Do not perform repair activities with the power on or electrical power 5. Turn power ON to the eWire. supplied to the machine. Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury.

  • Page 266: Rep 8.8 Holder Linear Motor Replacement M21

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.5 Back Cover Replacement to remove the Back Cover.

  • Page 267: Rep 8.9 Holder Rotate Motor Replacement M14

    See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Raise the Lid and Lower Transport Assembly.
  • Page 268 10. Remove the #4-40 Screws (3) securing the Motor and remove the Holder Rotate Vertical Sensors. Refer to REP 8.2 Closer Rotate Motor from the Holder Rotate Base. Horizontal and Vertical Sensor S34 & S35 GBC eWire Repairs/Adjustments 01/26/2018 4-152...

  • Page 269: Rep 8.10 Closer Linear Drive Belt Replacement

    5. Secure the Holder Rotate Assembly to the Holder frame using the possible serious injury. See Section 0, page vi for other languages. M4 Screws (4). 1. Switch power OFF to eWire. 6. Attach the Sensor Cables. 2. Disconnect the Power Cord.

  • Page 270: Rep 8.11 Holder Linear Drive Belt - Front Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Lid and Lower Bypass.

  • Page 271: Rep 8.12 Holder Linear Drive Belt - Rear Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.1 Back Cover Replacement to remove the Back Cover.

  • Page 272: Rep 8.13 Holder Gates Spring Lower Replacement

    4. Connect the Power Cord Do not perform repair activities with the power on or electrical power 5. Turn power ON to eWire. supplied to the machine. Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury.

  • Page 273: Rep 8.14 Holder Gates Spring Upper Replacement

    4. Connect the Power Cord Do not perform repair activities with the power on or electrical power 5. Turn power ON to eWire. supplied to the machine. Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury.

  • Page 274: Rep 8.15 Linear Spring Plate Assembly

    Do not perform repair activities with the power on or electrical power supplied to the machine. Some machine components contain 5. Turn power ON to eWire. dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages.

  • Page 275: Rep 8.16 Holder Lock Solenoid, L8

    1. Reverse the steps in the Removal Procedure. 2. Connect the Power Cord Removal Procedure 3. Turn power ON to eWire. WARNING Do not perform repair activities with the power on or electrical power supplied to the machine. Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury.
  • Page 276 4. Repeat the Process to install the second L8 Solenoid. 5. Connect the Power Cord 6. Turn power ON to eWire. 7. Remove the M3 Screw securing the Solenoid Clamp to the Holder Lock Sub-Assembly. 8. Remove the Solenoid.

  • Page 277: Rep 8.17 Holder Lock Sub-Assembly Replacement

    1. Reverse the Steps found in the Removal Procedure possible serious injury. See Section 0, page vi for other languages. 2. Connect the Power Cord 1. Switch power OFF to eWire. 3. Turn power ON to eWire. 2. Disconnect the Power Cord.

  • Page 278: Rep 8.18 Holder Link Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 10. Switch power OFF to eWire. 11. Disconnect the Power Cord. 12. Open the Lid and Lower Bypass.

  • Page 279: Frame

    1. Reverse the Steps found in the Removal Procedure REP 9.1 Interlock Switch Replacement, Top Cover 2. Connect the Power Cord PARTS LIST ON PL 5.25 3. Turn power ON to eWire. Use this procedure to remove and install the Interlock Switch for the Top Cover. Removal Procedure...
  • Page 280 Screws and Washers (2). 4. If necessary, adjust the Interlock Switch position so that the Interlock Tabs Flag is centered in the Interlock Switch. 5. Connect the Power Cord 6. Turn power ON to eWire. GBC eWire Repairs/Adjustments 01/26/2018 4-164...

  • Page 281: Rep 9.2 Interlock Switch Replacement, Doors

    See Section 0, page vi for other languages. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Open the Element Feeder and Book Tray Doors.

  • Page 282: Rep 9.3 Upper Bypass Latch Replacement

    See Section 0, page vi for other languages. 5. Connect the Power Cord 1. Switch power OFF to eWire. 6. Turn power ON to eWire. 2. Disconnect the Power Cord.

  • Page 283: Rep 9.4 Book Tray Latch Replacement

    See Section 0, page vi for other languages. 1. Turn off Power to the eWire. 2. Disconnect the Power Cord. 3. Locate the male half of the Latch on the back of the drawer. Remove the Latch by removing the M4 Screws (2) and Washers.

  • Page 284: Rep 9.5 Element Feeder Drawer Latch Replacement

    See Section 0, page vi for other languages. 1. Turn off Power to the eWire. 2. Disconnect the Power Cord. 3. Locate the male half of the Latch on the back of the drawer. Remove the Latch by removing the M4 Screws (2) and Washers.
  • Page 285 M4 Screws (2). 2. Adjust the latch position so that the latch fits together easily. Tighten the screws when latch is properly located. 3. Connect the Power Cord. 4. Turn on power to the eWire. GBC eWire 01/26/2018 Repairs/Adjustments...
  • Page 286 Back Cover, or REP 1.6 Side Cover Replacement to install the Side Cover. 6. Connect the Power Cord. 7. Power ON the eWire. Bind Path Motor Vacuum Drive Motor Holder Linear Motor Closer Linear Motor 7. Remove the Stepper Driver from the mounting bracket by removing...

  • Page 287: Rep 9.7 Vacuum Fan Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Turn off Power to the eWire. 2. Disconnect the Power Cord. 3. Do REP 1.6 Side Cover Replacement to remove the Side Cover.

  • Page 288: Rep 9.8 Vacuum Fan Gasket Replacement

    See Section 0, page vi for other languages. 5. Turn on power to the eWire. 1. Turn off Power to the eWire. 2. Disconnect the Power Cord.

  • Page 289: Rep 9.9 Stacker Paper Detect Sensor S44 Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Turn off Power to the eWire. 2. Disconnect the Power Cord. 3. Do REP 4.1...

  • Page 290: Book Drawer

    See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Pull the Book Tray all the way out of the eWire. 4. Do REP to remove the Book Drawer Door.

  • Page 291: Rep 10.2 Drawer Full Down Sensor Replacement S43

    1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Slide the Book Drawer Tray all the way out of the eWire. 4. Remove the Book Drawer rear cover by removing the M4 Screws (4). 5. Disconnect the Sensor cable from the Sensor.

  • Page 292: Rep 10.3 Book Drawer Full Sensor Replacement S45

    See Section 0, page vi for other languages. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Remove the Book Drawer Side Cover by removing the M4 Screws (4).

  • Page 293: Rep 10.4 Book Drawer Drive Motor Replacement M19

    1. Turn off Power to the eWire. 2. Disconnect the Power Cord. 3. Slide the Book Drawer Tray all the way out of the eWire. 4. Remove the Book Tray Rear Cover by removing the M4 Screws (4). 5. Do REP 10.5...

  • Page 294: Rep 10.5 Book Tray Belt Removal Procedure

    1. Turn off Power to the eWire. 2. Disconnect the Power Cord. 3. Slide the Book Drawer Tray all the way out of the eWire. 4. Remove the Book Tray Rear Cover by removing the M4 Screws (4). 5. Loosen the set screws on the Pulleys on the Motor Shaft and Drive Shaft.

  • Page 295: Electrical Components

    Before replacing the Main Control board, attempt to retrieve the number 3. Secure the Main Control board by tightening M3 Screws (9) of Bind cycles. Do GP 6.2.7 to display the number of Bind cycles. Do GP 6.3.10 to store the eWire Log to USB. Removal Procedure WARNING Do not perform repair activities with the power on or electrical power supplied to the machine.

  • Page 296: Rep 11.2 Communication Board Replacement

    5. Connect the Power Cord. possible serious injury. See Section 0, page vi for other languages. 6. Power ON the eWire. Removal Procedure 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.5 Back Cover Replacement to remove the Back Cover.

  • Page 297: Rep 11.3 Main Control Board B Replacement

    4. Connect the Power Cord. possible serious injury. See Section 0, page vi for other languages. 5. Power ON the eWire. 1. Switch power OFF to eWire. 2. Disconnect the Power Cord. 3. Do REP 1.5 Back Cover Replacement to remove the Back Cover.

  • Page 298: Rep 11.4 24V Power Supply Replacement

    Some machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 1. Turn off Power to the eWire. 2. Disconnect the Power Cord. 3. Do REP 1.5 Back Cover Replacement to remove the Back Cover.

  • Page 299: Rep 11.5 Rfi Filter Replacement

    6. Connect the Power Cord. possible serious injury. See Section 0, page vi for other languages. 7. Turn on power to the eWire. 1. Switch power OFF to eWire. 2. Remove the power cord 3.

  • Page 300: Rep 11.6 Power Switch Replacement

    4. Connect the Power Cord. dangerous electrical voltages that can result in electrical shock and possible serious injury. See Section 0, page vi for other languages. 5. Power ON the eWire. 1. Press the Power switch to OFF position. 2. Disconnect the Power Cord.
  • Page 301 2. Re-connect the wires, maintaining the wire locations as noted during removal. 3. Do REP 1.5 Back Cover Replacement to install the back cover 4. Connect the Power Cord. 5. Power ON the eWire. GBC eWire 01/26/2018 Repairs/Adjustments 4-185...

  • Page 302: Adjustments

    Inspection Procedure 1) Locate the Element Height Setup Tool, which is attached to the eWire Book Tray Door. 2) Locate the screws indicated in the picture below. Loosen the lock nuts with a wrench. Turn the screws clockwise to decrease 2) Pull out the Element Feeder tray, and insert a cheat into the Expanding T Out.

  • Page 303: Adj 1.2 Element Slack Detection Adjust

    4) Reinstall the two covers shown and test the machine using the (A) ADJUST, M3 SCREW size (1/4”) element while ensuring that slack is produced at least 3 times per feed of an A4 or 11” element. GBC eWire 01/26/2018 Repairs/Adjustments 4-187...

  • Page 304: Adj 1.3 Holder Mating To Element Feeder

    If an adjustment is needed, loosen the screws for the element feeder stop latch assembly (Fig 2.C) and adjust the position of the element feeder. ii) After adjustment, attempt to engage the holder into the element feeder by hand again while checking the alignment. GBC eWire Repairs/Adjustments 01/26/2018 4-188...
  • Page 305 (4) Perform the same check and adjustment on the rear of the machine (not shown). (5) After adjustment of the front and rear, by hand move the element holder and check for smooth engagement with GBC eWire 01/26/2018 Repairs/Adjustments 4-189...
  • Page 306 GBC eWire Repairs/Adjustments 01/26/2018 4-190...

  • Page 307: Adj 1.4 Element Feed Belt Home Position

    Inspection Procedure 1) Open the element feeder and cheat the safety interlock. 2) Enter the service menu of the eWire LCD. 3) Navigate through the menus as follows: a) FEED BELT HOME b) Press the ENTER button twice to home the belt.
  • Page 308 Fig 3 8) Once the position is near the correct position, install the cover previously removed (Fig. 3). 9) Perform the Fine Adjustment of the belt home position as defined earlier in this section. Fig 4 GBC eWire Repairs/Adjustments 01/26/2018 4-192...

  • Page 309: Adj 1.5 Book Drawer Closed Position

    3) Shift the bracket in the direction that you desire to move the book drawer, then tighten the screws. 4) Close the book drawer and inspect its position as defined in the Inspection Procedure section mentioned above. GBC eWire 01/26/2018 Repairs/Adjustments 4-193...

  • Page 310: Adj 1.6 Timing Belt Tension Adjustment

    If the belt is too loose, the belt will slip or belt tension. possibly become worn. If the belt is too tight, it will not move freely. This procedure can be used for all belts within the eWire. Inspection Procedure 1) Identify the timing belt.

  • Page 311: Adj 1.7 Interlock Flag Adjustment

    Interlock Flag Plate within the Interlock Switch. The flag should be 1-2 mm short of bottoming out on the Interlock Switch when in the resting position. 4) Tighten the screws and close the door to confirm the Interlock is operating as expected. GBC eWire 01/26/2018 Repairs/Adjustments 4-195...

  • Page 312: Adj 1.8 Element Hook Position Adjustment

    ADJ 1.8 Element Hook Position Adjustment No- Go to Step 8 Use this procedure to adjust the eWire alignment and timing to ensure 8) Do GP 6.3.9 to increase DEFLECTOR by 1mm. Repeat step 5-6. that the punched holes are centered on the wire loops during hooking.
  • Page 313 No- Repeat this step 15) Draw a line from the center of the small holes or indents to the edge of the sheet (try to keep the line perpendicular to the edge of the sheet). GBC eWire 01/26/2018 Repairs/Adjustments 4-197...

  • Page 314: Adj 1.9 Holder Rotate Adjustment

    3) With the linkage in the Horizontal position, ensure that the Holder No- Return to the trouble shooting step that directed you here. face is flat. A small level can be used for this purpose. GBC eWire Repairs/Adjustments 01/26/2018 4-198...

  • Page 315: Adj 1.10 Element Tip Height Adjustment

    1) Do GP 6.3.6 to access the Functional Tests menu. Do the Feed Element functional test. This will cause the eWire to feed one length of wire and move it into the stack position. 2) Locate the Element Height Setup tool on the Book Drawer door.
  • Page 316 6) When the Element wire tip position is correct, return to the procedure that directed you here. NOTE: THIS PROCEDURE ONLY EFFECTS THE ELEMENT SIZE CURRENTLY LOADED AND MAY HAVE TO BE REPEATED FOR OTHER SIZES. GBC eWire Repairs/Adjustments 01/26/2018 4-200...

  • Page 317: Adj 1.11 Closer Chain Tension Adjustment

    9. Return to the RAP that directed you here. 10. collar side of the book is over closed and clockwise if it is under 4. Loosen the M4 cap screw on the collar, do not remove it fully closed. GBC eWire 01/26/2018 Repairs/Adjustments 4-201...

  • Page 318: Adj 1.12 Caster Height Adjustment

    ADJ 1.12 Caster Height Adjustment Use the following procedure to adjust the height of the eWire. Adjustment Procedure 1. Remove the screw securing the docking bracket between the eWire and the upstream punch and disengage the bracket. 11. Before tightening the collar, using a hex key, apply counter-clockwise torque to the collar.

  • Page 319: Adj 1.13 Partial Close Adjustment

    7. After making the required adjustments, check that the top cover 1) Access the Sevice Menu and select Function Tests  Element Cycle of the eWire is level in both the paper path direction, and front to  Feed Element  Partial Close.

  • Page 320: Adj 1.14 Element Xfer Position Adjustment

    4) Run a number of books to verify the adjustment made has solved the problem. 5) If no improvement is seen by changing the value, reset to the original setting and return to the RAP that directed you here. GBC eWire Repairs/Adjustments 01/26/2018 4-204...
  • Page 321 PL 5.26 FRAME – VACUUM & LOCKOUT ...... 27 PL 5.27 ELECTRICAL COMPONENTS ......28 PL 5.28 OUTER COVERS ..........29 PL 5.29 MAIN ASSEMBLY (MODULES) ......30 PL 5.30 TOOLS ..............31 GBC eWire 01/26/2018 PARTS LIST Section Contents...

  • Page 322: Lcd, Interlocks, Casters

    PL 5.1 LCD, INTERLOCKS, CASTERS ITEM GBC PART # XEROX PART # DESCRIPTION 7715527 LCD Display 7715682 LCD Membrane Switch 7706486 Door/Drawer Latches 7718101 Caster Sub-Assembly DET AI L A GBC eWire PARTS LIST 01/26/2018...

  • Page 323: Paper Transport - Sensors

    PL 5.2 PAPER TRANSPORT - SENSORS XEROX ITEM GBC PART # DESCRIPTION PART # 7715193 Bypass Sensors (S1, S4, S5 & S16) 7715692 Skew Sensor PCB (S6 - S10) Alignment Sensor PCB 7715567 Switchable(S12, S13 & S15) Alignment Carriage Home Sensor...

  • Page 324: Paper Transport - Motors & Sol

    XEROX PL 5.3 PAPER TRANSPORT – MOTORS & SOL DESCRIPTION ITEM GBC PART # PART # Diverter Solenoid Assembly 7718102 (L1) Disengaging Roller #1 & 2 7717125 (L2 & L3) 7717128 Disengaging Roller #3 (L4) Bypass Entry and Exit Motors 7715200 (M1 &...

  • Page 325: Paper Transport - Rear Section

    PL 5.4 PAPER TRANSPORT – REAR SECTION XEROX ITEM GBC PART # DESCRIPTION PART # 7717195 Bypass Timing Belt #1 7717204 Bypass Timing Belt #2 7715204 Drive Roller Timing Pulley 7715201 Stepper Motor Pulley 7715383 Drive Roller Idler Pulley 7715245...
  • Page 326 PL 5.5 PAPER TRANSPORT - ROLLERS XEROX DESCRIPTION ITEM GBC PART # PART # 7715093 Drive Roller Assembly 1821116 Roller Bearing Steering Drive Roller 7715039 Assembly 7718381 Idler Roller Assembly Steering Idler Roller 7718103 Assembly 7717802 Delrin Drive Roller Assembly...

  • Page 327: Paper Transport - Other Parts

    XEROX PL 5.6 PAPER TRANSPORT – OTHER PARTS ITEM GBC PART # DESCRIPTION PART # 7717101 Steering Module Assembly 7718593 Anti-Static Brush Long 7718348 Latch Assembly 7715275 Motor Driver Bracket Assembly 7706486 Push to Close Latch GBC eWire 01/26/2018 PARTS LIST...

  • Page 328: Element Feeder - Sensors

    PL 5.7 ELEMENT FEEDER - SENSORS XEROX DESCRIPTION ITEM GBC PART # PART # 7716946 & Element Detect at Pyramid (S22) 7716947 7716946 & Belt Home Sensor Assembly 7716947 (S25) Spool Detect Sensor PCB (S26- 7717206 S30) Spool Near Empty Sensor PCB...

  • Page 329: Element Feeder - Motors & Belts

    PL 5.8 ELEMENT FEEDER – MOTORS & BELTS XEROX ITEM GBC PART # DESCRIPTION PART # 7715200 Element Feed Belt Motor (M10) 7715337 Element Feed Sprocket Motor (M9) 7716993 Element Feeder Belt 7717025 Spool Rewind Belt 7718107 Spool Rewind Drive Assembly (M8)

  • Page 330: Element Feeder - Top Section

    PL 5.9 ELEMENT FEEDER – TOP SECTION XEROX DESCRIPTION ITEM GBC PART # PART # 7716577 Element Feed Track Assembly 7718109 Element Feeder Belt Idler 7718108 Element Engagement Guide Assembly 7717029 Idler Roller, Element Feeder Belt 7718110 Element Sprocket Nose Assembly...
  • Page 331 PL 5.10 ELEMENT FEEDER – BOTTOM SECTION XEROX DESCRIPTION ITEM GBC PART # PART # 7717017 Element Shield Assembly 7716948 Spool Spindle Assembly 7717065 Rewind Spindle Assembly 7717008 Element Slack Detect Lever Assembly 7717781 Finger, Spool Brake GBC eWire 01/26/2018...

  • Page 332: Element Feeder - Knife Module

    PL 5.11 ELEMENT FEEDER – KNIFE MODULE XEROX ITEM GBC PART # DESCRIPTION PART # 7714775, Element Detect at Knife sensor (S21) 7714776 7715340 Knife Home Sensor (S23) 7717070 Knife Anvil 7716864 Knife Blade 1( S2 1- RECEI V ER)
  • Page 333 PL 5.12 ELEMENT TRANSFER - SENSORS XEROX ITEM GBC PART # DESCRIPTION PART # 7715340 Expanding T Encoder Sensor (S31) 7715340 Expanding T Home Sensor (S32) 7715340 Expanding T Out Sensor (S33) 7715340 Pushover Home Sensor (S24) 2 ( S3 2 )
  • Page 334 PL 5.13 ELEMENT TRANSFER – COMPONENTS XEROX DESCRIPTION ITEM GBC PART # PART # 7716901 Expanding T Rack 7716913 Expanding T Gear 7716894 Expanding T CAM 7723853 Expanding T Motor (M13) Pushover Motor Assembly 7717682 (M12) 7717415 Expanding T Spring...

  • Page 335: Vacuum Stacker - Motors & Sol

    PL 5.14 VACUUM STACKER – MOTORS & SOL XEROX ITEM GBC PART # DESCRIPTION PART # 7718112 Kick Down Solenoid Assembly (L7) 7715289 Drag Finger Solenoid (L6) 7715200 Stacker Drive Motor (M5) 1( L 7 ) 1( L 7 )

  • Page 336: Vacuum Stacker - Mechanical

    PL 5.15 VACUUM STACKER – MECHANICAL XEROX ITEM GBC PART # DESCRIPTION PART # 7718111 Idler Pulley Sub Assembly 7716828 Kick Down 7716829 Kick Down, Reverse 7716803 Stacker Drive Belt 7716808 Vacuum Stacker Belt 7718138 Drag Finger Adhesive Grip GBC eWire...

  • Page 337: Deflector Module

    PL 5.16 DEFLECTOR MODULE XEROX ITEM GBC PART # DESCRIPTION PART # 7715193 Bind Kick-Down Sensor (S2) 7715193 Bind Deflect Sensor (S3) 7715340 Deflect Position Sensor (S17) 7715337 Bind Path Motor (M3) Deflector Solenoid Linkage 7718113 (L5) 7717429 Deflector Spring...

  • Page 338: Tapper Module - Front

    PL 5.17 TAPPER MODULE - FRONT XEROX DESCRIPTION ITEM GBC PART # PART # 7723850 Tapper Motor (M6) 7717404 Tapper Spring 7715340 Tapper Sensor (S18) 7716574 Tapper Finger 3 ( S18 ) 1( M6 ) GBC eWire PARTS LIST 01/26/2018...

  • Page 339: Tapper Module - Rear

    XEROX PL 5.18 TAPPER MODULE - REAR ITEM GBC PART # DESCRIPTION PART # 7723850 Tapper Motor (M7) 7717404 Tapper Spring 7715340 Tapper Sensor (S19) 7716860 Finger, Sheet Tapper, Rear 3 ( S19 ) 1( M7 ) GBC eWire 01/26/2018...
  • Page 340 Closer Motor (M20) 7717658 Closer Jaw Insert 7716760 Closer Jaw Spring 7715289 Solenoid, Book Eject 7723074 Tensioner Assembly 7723071 Roller Chain 7716781 Disk Encoder 7723070 Sprocket 15T 1( S4 8 ) 2 ( S4 7 ) GBC eWire PARTS LIST 01/26/2018 5-20...

  • Page 341: Holder - Sensors

    7 ( S4 0) 6 ( S3 9 ) 4 ( S3 7 ) 2 ( S4 6 ) 3 ( S3 6 ) 5 ( S3 8 ) DET AI L A ( BACK SI DE) GBC eWire 01/26/2018 PARTS LIST 5-21...
  • Page 342 XEROX PL 5.21 HOLDER – MOTORS, BELTS & SPRINGS DESCRIPTION ITEM GBC PART # PART # 7715200 Holder Linear Motor (M15) 7715200 Closer Linear Motor (M21) 7718423 Closer Linear Drive Belt 7718427 Holder Linear Drive Belt 7717404 Holder Gates Spring Lower...
  • Page 343 Holder Rotate Horizontal Sensor 7715340 (S35) 7715340 Holder Rotate Vertical Sensor (S34) 7718056 Holder Rotate Motor (M14) 7717746 Holder Lock Solenoid (L8) 7716612 Holder Lock Sub-Assembly 7716674 Hinge, Front, Element Holder 7716675 Link, Holder Rotate GBC eWire 01/26/2018 PARTS LIST 5-23...

  • Page 344: Book Drawer - Sensors

    PART # PART # 7711970 Drawer Full Up Sensors Emitter (S42) 7711973 Drawer Full Up Sensors Receiver (S42) 7717743 Drawer Full Down Sensor(S43) 7717740 Book Drawer Empty Sensor (S45) 7723851 Book Drawer Drive Motor (M19) GBC eWire PARTS LIST 01/26/2018 5-24...

  • Page 345: Book Drawer - Belts & Pulleys

    PL 5.24 BOOK DRAWER – BELTS & PULLEYS XEROX ITEM DESCRIPTION PART # PART # 7717828 Belt, Book Tray Drive Motor 7718022 Pulley, Book Tray Drive Shaft 7717818 Belt, Book Tray Vertical Lift 7717820 Pulley, Book Tray Vertical Lift GBC eWire 01/26/2018 PARTS LIST 5-25...

  • Page 346: Frame - Switches & Latches

    PL 5.25 FRAME - SWITCHES & LATCHES XEROX DESCRIPTION ITEM PART # PART # 7610501 Interlock Switch 7706486 Latch 7723794 Drawer, Lockout, Finger DET AI L A DET AI L B DET AI L C GBC eWire PARTS LIST 01/26/2018 5-26...

  • Page 347: Frame - Vacuum & Lockout

    XEROX ITEM DESCRIPTION PART # PART # 7715275 Stepper Driver Board 7717339 Vacuum Fan 7715193 Stacker Paper Detect Sensor (S44) 7717237 Vacuum Duct Gasket 7723794 Element Drawer Lockout Finger 7717644 Element Drawer Lockout Linkage GBC eWire 01/26/2018 PARTS LIST 5-27...
  • Page 348 PL 5.27 ELECTRICAL COMPONENTS XEROX DESCRIPTION ITEM PART # PART # 7716591 Main Control Board A 7716590 Communication Board 7715583 Main Control Board B 7715637 24 VDC Power Supply 6195001 RFI Filter 7704376 AC Power Rocker Switch GBC eWire PARTS LIST 01/26/2018 5-28...
  • Page 349 Back Cover Assembly 7718316 Side Cover Assembly, Right 7718313 Side Cover Assembly, Left 7718353 Docking Bracket Assembly 7718310 Paper Infeed Guide 7718328 Front Cover Panel Assembly 7718369 Paper Outfeed Guide 7718130 LCD Tower Assembly GBC eWire 01/26/2018 PARTS LIST 5-29...
  • Page 350 PL 5.29 MAIN ASSEMBLY (MODULES) ITEM DESCRIPTION Paper Transport Complete Assy Element Feeder Knife Assy Element Transfer, Module Assy Module, Vacuum, Conveyor Front Tapper Assy Rear Tapper Assy Holder Module Deflector Module, Xerox Closer Module Book Drawer, Complete GBC eWire PARTS LIST 01/26/2018 5-30...

  • Page 351: Tools

    PL 5.30 TOOLS XEROX ITEM DESCRIPTION PART # PART # Element Height Setup Tool 7717881 Punched Hole Position Check 7717879 GBC eWire 01/26/2018 PARTS LIST 5-31...
  • Page 352 6. General Procedures and Information Section Contents Title Page GP 6.4.3 Check S18-S21, S24, S31-S41, S46-S49 .... 6-25 GP 6.1 eWire User Interface Options ........6-3 GP 6.4.4 Check S22, S25, S42 ........6-32 GP 6.1.1 Accessing the User Interface Menu ....6-3 GP 6.4.5...
  • Page 353 GP 6.24 Motor Connections ........... 6-69 GP 6.31 DFA Profile, Versant ........6-72 GP 6.25 List of Solenoids ..........6-70 GP 6.26 Solenoid Connections ........6-70 GP 6.27 Recommended Tool Kit ........6-71 GBC eWire General Procedures and Information 01/26/2018...

  • Page 354: Gp 6.1 Ewire User Interface Options

    The User Interface displays status messages and fault codes on two rows of text. READY TO BIND In the User Interface, the top row of text displays the status of the eWire (Ready, Close Door). The bottom row of text displays the options selected on the User Interface. GBC eWire...

  • Page 355: Gp 6.1.2 User Interface Options Flowchart

    GP 6.1.2 User Interface Options Flowchart GBC eWire General Procedures and Information 01/26/2018...

  • Page 356: Gp 6.1.3 Accessing The Service Interface Menu

    2. Then while still holding down the Up Arrow button and the Down Arrow button, press the Enter button. 3. The Service User Interface screen will appear. 4. Use the procedures in the following pages to use Service User Interface GBC eWire 01/26/2018 General Procedures and Information...

  • Page 357: Gp 6.1.4 User Service Menu Flowchart

    GP 6.1.4 User Service Menu Flowchart GBC eWire General Procedures and Information 01/26/2018...

  • Page 358: Gp 6.2 User Interface Procedures

    GP 6.2.2 Closing Setting Adjustment Procedure The following section describes the options contained in the eWire User Do the following to select the desired closer travel. A higher number Interface. The user interface can be accessed by pressing the up or down indicates increased close/crimp of element.

  • Page 359: Gp 6.2.3 Paper Size Select Procedure

    Press the ENTER button when the return symbol is next to the language you would like to use. You will automatically return to the SETTINGS menu. Select EXIT and press ENTER to return to the top level menu. GBC eWire General Procedures and Information 01/26/2018...

  • Page 360: Gp 6.2.5 Mode Selection Procedure

    GP 6.2.6 Wire Size Display Procedure Do the following to select the operation mode for the eWire. When eWire Do the following to verify the wire size currently selected on the eWire. is in Bypass mode, sheets will pass through the machine without any From the top level screen, action.

  • Page 361: Gp 6.2.7 Counts Display Procedure

    The Firmware feature identifies the level of the firmware currently installed eWire. Books displays the total number of books that have been produced to the eWire. by the eWire. Sheets displays the total number of sheets of paper that From the top level screen, have passed through the eWire.

  • Page 362: Gp 6.3 Service Interface Procedures

    GP 6.3 Service Interface Procedures GP 6.3.2 SENSOR Check Procedure The following section describes the options available via the eWire A sensor can fail in two modes: service menu. The options in this section should only be changes by •...

  • Page 363: Dfa Status Procedure

    9. Select EXIT and press ENTER to return to the top level menu. DFA STATUS. Press the down arrow to scroll through the DFA STATUS values. C6=0 C7=0 S0=0 S1=0 S2=0 Select EXIT and press ENTER to return to the Service Mode Menu. GBC eWire General Procedures and Information 01/26/2018 6-12...

  • Page 364: Gp 6.3.4 Solenoids Procedure

    The Motors feature allows you to test the operation of selected Motors solenoids in the machine. throughout the eWire. Do the following to check the Motors. NOTE: Door needs to be closed or Interlock Cheater inserted to do NOTE: Door needs to be closed or Interlock Cheater inserted to do this.

  • Page 365: Gp 6.3.6 Function Tests Procedure

    Element Feeder. • Align Jam: This causes a jam if the eWire is unable to reach the alignment sensor in the allotted time. If this is off, the sheets that NOTE: Use extreme caution if running any Functional Tests with come in overly misaligned will not cause a jam and will be sent to Interlock Cheaters installed.

  • Page 366: Gp 6.3.8 Element Settings Procedure

    12. Install the Cover for USB port and tighten the Screws (2). 13. Switch off the machine. Wait 10 seconds, and then switch the machine back on again. Do GP 6.2.8 to check the firmware, and verify the Firmware revision is correct. GBC eWire 01/26/2018 General Procedures and Information 6-15...

  • Page 367: Gp 6.3.9 Deflector Procedure

    Enter Service Mode by following the procedure described in GP 6.1.3 on the rear of the eWire. Insert a USB drive to the port. Press the down arrow until the return symbol is next to the words DEFLECTOR. Press Enter.

  • Page 368: Gp 6.3.11 Workflow Procedure

    Do the following to set the maximum bypass sheet length through eWire. modes of operation in the eWire. In job mode, an element will be cut and readied as needed for the next book. In streaming mode, elements will be Using the procedure described in 6.1.3, enter Service mode.

  • Page 369: Gp 6.3.13 Feed Belt Home Setting

    -5 to +5. When the desired value has been selected, press CLOSER TO ENTER to return to the service menu. HOLDER Select EXIT and press ENTER to return to the top level menu GBC eWire General Procedures and Information 01/26/2018 6-18...

  • Page 370: Gp 6.3.16 Elem Xfer Pos

    ROTATE DELAY 24: Status of the 24v coming supplied from the power supply The below screen will appear 24i: Status of the 24v supplied to eWire through the interlocks 5: Status of the 5v power supplied to the eWire HORIZONTAL 3.3: Status of the 3.3v power supplied to the eWire...

  • Page 371: Gp 6.4 Check Sensors

    Locate sensors S2 and S3: Use the information in this section to locate the appropriate sensor(s) on • Raise the Top Cover and the Lower Bypass panel. the eWire. Once you have located the sensor, follow GP 6.3.2 to verify •...
  • Page 372 Sensors S43 and S45 are on the Book Drawer (PL 5.23) 5. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for the eWire. Re-flashing firmware clears the fault Yes- Resume normal operation No- Go to Step 6 GBC eWire...
  • Page 373 No- Go to Step 7 7. Do REP 11.1 or REP 11.3 to replace the Main Control Board (PL 5.27). This clears the fault Yes- Resume normal operation No- Escalate to second level GBC eWire General Procedures and Information 01/26/2018 6-22...

  • Page 374: Check S6-S10, S12, S13, And S15

    Check S6-S10, S12, S13, and S15 Locate Sensors S6, S7, S8, S9, and S10: Use the information in this section to locate the appropriate sensor(s) on the eWire. Once you have located the sensor, follow GP 6.3.2 to verify •...
  • Page 375 6. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the No- Go to Step 2 firmware for the eWire. This clears the fault 2. Make sure the sensor cable is connected securely at the Sensor and Yes- Resume normal operation at the Main Control Board (PL 5.27).
  • Page 376 S18 is located in the front tapper module S19 is located in the tapper at the rear of the machine GBC eWire 01/26/2018 General Procedures and Information 6-25...
  • Page 377 Locate Sensor S21: Locate Sensor S20: • Slide the Element Feeder Drawer all the way out of the • Slide the Element Feeder Drawer all the way out of the eWire. machine. • Remove the Element Spool WARNING • Manually actuate the sensor slack mechanism to block or Moving Parts, keep hands clear of all moving parts when unblock the sensor.
  • Page 378 Locate Sensor S24: Locate Sensor S31: • • Slide the Element Feeder Drawer all the way out of the eWire. Slide the Element Feeder Drawer all the way out of the eWire. • • Manually raise and lower the pushover mechanism to block Locate the Pushover Motor on the rear side of the Element and unblock the sensor.
  • Page 379 This will allow you to block or unblock the sensor manually. S34 and S35 are located on the Holder Module Rotate Mechanism S32 and S33 are located on the Expanding T Module GBC eWire General Procedures and Information 01/26/2018 6-28...
  • Page 380 Manually cycle the holder mechanism if necessary • S38 and S40 are located on the Holder Module. S36, S37 and S39 are located on the Holder Module S38 and S40 are located on the Holder Module GBC eWire 01/26/2018 General Procedures and Information 6-29...
  • Page 381 Insert the cheater which will cause the Aligner to home. S41 should then be blocked. S46 and S49 are located the back frame behind the closer S41 are located on the Alignment Module GBC eWire General Procedures and Information 01/26/2018 6-30...
  • Page 382 No- Go to Step 6 5. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for the eWire. Re-flashing firmware clears the fault Yes- Resume normal operation No- Go to Step 7 6. Do REP 11.1 or REP 11.3 to replace the Main Control Board (PL 5.27).
  • Page 383 Check S22, S25, S42 Locate Sensor S25: Locate Sensor S22: • Slide the Element Feeder tray all the way out of the eWire. • • Remove any remaining Element from the Eleemnt Feeder Slide the Element Feeder tray all the way out of the eWire.
  • Page 384 • meter on the test point with the appropriate sensor label on the AC Slide the book drawer tray all the way out of the eWire. • board, and the other lead on the ground test point.
  • Page 385 Sensors can be blocked using a piece of paper. S50 is located on the side face of the element feeder spindle S26 through S30 are located on the front face of the element feeder assembly spindle assembly GBC eWire General Procedures and Information 01/26/2018 6-34...
  • Page 386 6. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the Rear Cover to gain access to the connector at the Control Board. firmware for the eWire. Refer to Section 7 Wiring and GP 6.22 for details on the Sensor This clears the fault Cable and termination location.
  • Page 387 No- Replace the faulty cable and resume operation. 4. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for the eWire. Re-flashing firmware clears the fault Yes- Resume normal operation No- Go to Step 7 5. Do REP 11.3 to replace the Main Control Board B (PL 5.27).

  • Page 388: Gp 6.5 Motor Checks

    M1 and M2, which do not have set screws. N5- Rear side steering All the set screws are secured tightly roller Yes- Go to Step 6 No- Tighten the loose set screw and repeat Step 1 Alignment Carriage GBC eWire 01/26/2018 General Procedures and Information 6-37...
  • Page 389 DIP 1 DIP 2 DIP 3 DIP 4 DIP 5 firmware for the eWire This clears the fault Yes- Resume normal operation No- Go to Step 11 11. Replace the driver board for the faulty motor, with DIP switch set correctly for the position you are replacing.
  • Page 390 Rear Cover to gain access to the Main Control Board. For Motor M3, the Driver Board is located on the rear of the eWire. For Motor M5, do 6. Check if there is power to the Driver board. LED 1 on the Driver board REP 1.6 to remove the Side Cover.
  • Page 391 Cycle Tappers to cycle both 9. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the Tappers just once. firmware for the eWire This clears the fault 1. Do GP 6.3.5 Motors Procedure to check that the corresponding Yes- Resume normal operation motors turn when activated.
  • Page 392 5. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for the eWire This clears the fault Yes- Resume normal operation No- Go to Step 6 6. Replace the faulty motor. Refer to REP 7.2, Tapper Motor Replacement M6 and M7.

  • Page 393: Check M8

    6. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the GP 6.8 to remove the supply spool firmware for the eWire • Insert a cheater into the element feeder door interlock switch This clears the fault Yes- Resume normal operation 1.
  • Page 394 Rear Cover to gain access to the connector at the Control Board. Continue to Step 7 Refer to REP 3.8 to locate the M9 motor cable connections. All the connectors are securely connected. Yes- Go to Step 3 GBC eWire 01/26/2018 General Procedures and Information 6-43...
  • Page 395 No- Replace the faulty cable and resume normal operation 8. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for the eWire This clears the fault Yes- Resume normal operation No- Go to Step 9 9. Replace the driver board for the faulty motor, with DIP switch set correctly for the position you are replacing.

  • Page 396: Check M11

    FIRMWARE UPGRADE to Re-flash the firmware for the eWire This clears the fault Yes- Resume normal operation; No- Go to Step 4 4. Do REP 3.15 to replace the Knife Module 7716862 GBC eWire 01/26/2018 General Procedures and Information 6-45...

  • Page 397: Check M12 And M13

    No- Make the connection and resume operation 3. Do GP 6.3.7 FIRMWARE UPGRADE to Re-flash the firmware for the eWire This clears the fault Yes- Resume normal operation; No- Go to Step 4 GBC eWire General Procedures and Information 01/26/2018 6-46...
  • Page 398 If LED 2 is lit, it means there is a fault with either the Driver board or Rear Cover to gain access to the connector at the Control Board. The the stepper motor. motor Driver boards are located on the rear of the eWire Frame. Continue to Step 7 All the connectors are securely connected.

  • Page 399: Check M14

    WARNING This clears the fault Moving Parts, keep hands clear of the eWire when performing motor checks. Make sure that power is Yes- Resume normal operation disconnected from the machine before touching any No- Go to Step 10 moving parts.
  • Page 400 No- Tighten up the screws and repeat Step 1. WARNING 5. Replace the cables from the motor to the Main Control Board. Refer Moving Parts, keep hands clear of the eWire when GP 6.24 for cable identification. performing motor checks. Make sure that power is...
  • Page 401 Yes- Resume normal operation WARNING No- Go to Step 5 Moving Parts, keep hands clear of the eWire when performing motor checks. Make sure that power is 5. Inspect the Timing Belt for damage. Make sure that the belt is not disconnected from the machine before touching any frayed or damaged.

  • Page 402: Solenoid Checks

    This clears the fault Yes- Resume normal operation No- Escalate to second level • The corresponding rollers should rise and fall when L2, L3, and L4 are cycled. L2: Nip Rollers N2 GBC eWire 01/26/2018 General Procedures and Information 6-51...
  • Page 403 No- Identify and replace the faulty cable 4. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for the eWire This clears the fault Yes- Return to normal operation No- Go to Step 5 5. Replace the solenoid assembly as indicated below...
  • Page 404 No- Identify and replace the faulty cable 4. Do 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for the eWire This clears the fault Yes- Return to normal operation No- Go to Step 5 5. Replace 7718113 Deflector Solenoid Linkage, refer to REP 5.6...

  • Page 405: Gp 6.6.3 Check L6 And L7 Vacuum Module Solenoids

    To test Solenoid L6, raise the Vacuum Module by lifting the Yes- Go to Step 4 handle and tilting it back towards the infeed side of the eWire. L6 No- Identify and replace the faulty cable. will activate the kick-down paddle.

  • Page 406: Gp 6.6.4 Check L8 Holder Lock Solenoid

    Yes- Go to Step 4 No- Identify and replace the faulty cable 4. Do GP 6.3.7 FIRMWARE UPGRADE Procedure to Re-flash the firmware for the eWire This clears the fault Yes- Return to normal operation No- Go to Step 5 WARNING 5.

  • Page 407: Gp 6.7 Supply Spool Installation

    Do not Do the following procedure to install a new supply spool into the eWire. If you need to remove a spool that is not yet empty first, first do GP 6.8.
  • Page 408 9. While still holding the carrier paper, use the magnetic catch to hold the wire. 11. Attach the loose end of the support paper to the paper feed hub. Secure the paper to the hub via the metal clip. GBC eWire 01/26/2018 General Procedures and Information 6-57...
  • Page 409 13. Adjust the wire end position by using the knob attached to the wire feed sprocket. The wire end should line up in the window on the blade guard. 15. Slide the Element Feeder Drawer back into the eWire and close the door. GBC eWire...

  • Page 410: Gp 6.8 Supply Spool Removal

    Do the following procedure to remove a partially full supply spool from the handle to remove the entire shield, and place the shield safely on top eWire. If the spool is empty, the same general procedure can be used but of the element feeder.
  • Page 411 10. Unscrew the spool retainer. Turn the knob counterclockwise to loosen end of wire is secured to the wound rows. The magnets prevents the and remove the cap. Set the cap aside. wire from slipping when the spool is removed. GBC eWire General Procedures and Information 01/26/2018 6-60...
  • Page 412 14. If a new supply spool is to be installed, refer to GP 6.7. If not, reinstall the Spool Holder Cap and Wire Guide for the next operation. 15. Slide the Element Feeder Drawer back into the eWire and close the door.

  • Page 413: Gp 6.9 Spool Storage

    Spool Storage 3. Never store the spool on its side, as wire twisting could occur Always properly store the eWire Supply Spool when it is not in use. Unopened cartons should always be stored vertically as indicated on the spool packaging. Do not remove the packaging or shrink wrap until you are ready to use the spool.

  • Page 414: Gp 6.10 Internal Inspection

    1. Inspect the rollers for wear, debris, toner marks, unevenness, and components. dents. Warning: Make sure you disconnect the eWire from its power source 2. Inspect springs (2) for each Idler Roller, and make sure they are before cleaning. Failure to observe this warning could result in death or correctly hooked.

  • Page 415: Gp 6.14.1 Roller Cleaning

    The following illustration shows an example of the sensors. to locate and verify 2. If necessary, refer to GP 6.4 Sensor Checks function of the sensors. GP 6.17 Timing Belt Inspection GP 6.16 Bypass Paper Path Inspection and Cleaning GBC eWire General Procedures and Information 01/26/2018 6-64...

  • Page 416: Gp 6.18 Solenoid Cleaning And Inspection

    Use the following procedure to inspect the Timing Belts throughout the GP 6.19 Drawer Slide Rails Cleaning eWire. Inspect the Timing Belts if excessive wear or debris is observed, or Do this procedure to clean the Drawer Slides that are used with the if the function of the components driven by the belt appears to be Element Feeder and Book Tray.
  • Page 417 ELEMENT FEEDER 7717206 SENSOR, SPOOL DETECT 4 ELEMENT FEEDER The table below lists all of the Sensors located in the eWire. Sensors are 7717206 SENSOR, SPOOL DETECT 5 ELEMENT FEEDER indicated by number and by description. For additional information, refer 7715340 to Section 7 Wiring.
  • Page 418 The table below lists the cable connections for each Sensor located in the 7716721 7716718 7716711 J9, B eWire. The Sensor Cable column indicates the cable that connects 7716721 7716718 7716711 J9, B directly to the sensor. The Final Termination Column indicates the...
  • Page 419 GP 6.23 List of Motors The table below lists all of the Motors located in the eWire. Motors are indicated by number and by description. For additional information, refer to Section 7 Wiring. MOTOR PART NO DESCRIPTION LOCATION UPPER 7715200...
  • Page 420 J14, A The table below lists the cable connections for each motor located in the 7716739 J22, A eWire. The Motor Cable column indicates the cable that connects to the 7717197 7716736 J14, A motor or driver board. Note that some stepper motors have separate...
  • Page 421 GP 6.25 List of Solenoids GP 6.26 Solenoid Connections The table below lists all of the Solenoids located in the eWire. Solenoids The table below lists the cable connections for each Solenoid located in are indicated by number and by description. For additional information, the eWire.
  • Page 422 GP 6.27 Recommended Tool Kit GP 6.29 Cleaning Materials Tools recommended for service of the eWire Use a clean, soft, lint-free cloth or a small paint brush to clean the following. Standard Tools (metric) • GP 6.11, External Cleaning •...
  • Page 423 Lead edge Manufactured Assembled in Taiwan Recovery behavior Delivery start adjust Delivery end adjust 30 ms End of set offset Finisher capacity Cycle down delay 20 sec In order delivery delay Same Output GBC eWire General Procedures and Information 01/26/2018 6-72...
  • Page 424 Holder Module ..................7-7 Knife Module ..................7-8 Paper Transport Module ............... 7-9 Stacker Module ..................7-10 Steering Module ................... 7-11 Tappers Module ................... 7-12 Closer Module ..................7-13 Book Drawer Module …………………………………………………….. 7-14 GBC eWire 01/26/2018 Wiring Data Section Contents...

  • Page 425: Cable Location Index

    CABLE STEERING, MTR TO HDR 7716724 CABLE ASSY, 24VDC, ELEM. FEEDER MOVEABLE 7718556 JUMPER, TWIN LOOP, 4 PIN 7-4, 7-5, 7-10 7716725 CABLE ASSY, 24VDC, PCB TO MOTOR DRIVERS #1 7716726 CABLE ASSY, 24VDC, SUPPLY TO PCB Wiring Data 01/26/2018 GBC eWire...

  • Page 426: System Wiring

    System Wiring GBC eWire 01/26/2018 Wiring Data...

  • Page 427: Deflector Module

    Deflector Module Wiring Data 01/26/2018 GBC eWire...

  • Page 428: Element Feeder Module

    Element Feeder Module GBC eWire 01/26/2018 Wiring Data...

  • Page 429: Element Transfer Module

    Element Transfer Module Wiring Data 01/26/2018 GBC eWire...

  • Page 430: Holder Module

    Holder Module GBC eWire 01/26/2018 Wiring Data...

  • Page 431: Knife Module

    Knife Module Wiring Data 01/26/2018 GBC eWire...

  • Page 432: Paper Transport Module

    Paper Transport Module GBC eWire 01/26/2018 Wiring Data...

  • Page 433: Stacker Module

    Stacker Module Wiring Data 01/26/2018 GBC eWire 7-10...

  • Page 434: Steering Module

    Steering Module GBC eWire 01/26/2018 Wiring Data 7-11...

  • Page 435: Tappers Module

    Tappers Module Wiring Data 01/26/2018 GBC eWire 7-12...

  • Page 436: Closer Module

    Closer Module GBC eWire 01/26/2018 Wiring Data 7-13...

  • Page 437: Book Drawer Module

    Book Drawer Module Wiring Data 01/26/2018 GBC eWire 7-14...
  • Page 438 8.8. Power Up the eWire ......8-10 8.9. Configure the eWire ......8-11 8.10. Run in Bypass Mode ......8-11 8.11. Run the eWire in Bind Mode .... 8-12 8.12. Versant Profile Settings ....8-13 8.13. User Manual ........8-13...
  • Page 439 This page intentionally left blank. Installation Instructions 01/26/2018 GBC eWire...

  • Page 440: Introduction

    Pallet with eWire. • Cardboard box containing the Spare Parts Kit. The fully packed eWire measures 1270mm H x 1040mm W x 920mm L (50in H x 41in W x 36 in L) and weighs 274 kgs (605 lbs) EWire System Dimensions 8.2.2 Upstream Device Requirements...

  • Page 441: Remove The Packing Materials

    9. Repeat for the remaining Support Brackets and Bracket Clamps. 10. Remove the M6 Screws securing the Side Bracket to the eWire. Remove the M10 Screws securing the Side Brackets to the pallet. Slide the Side Brackets out from under the eWire and remove it.
  • Page 442 14. Using two people, carefully push the eWire from the back down Place the ramp support blocks under the pallet, lining up the holes the ramp. Make sure the eWire casters stay on the pallet and the in the blocks with the holes in the pallet.
  • Page 443 18. Remove the zip ties securing the closer module the side frame of cable tie from the handle. Lift the handle on the Vacuum Module the eWire. and remove the bubble wrap from beneath the Vacuum Module. 19. Move the closer module by hand to reveal the cable tie on the holder frame.
  • Page 444 When storing them on the element feeder, ensure that they are completely on the flat face of the drawer and are not near the spool. Element Height Punched Hole Setup Tool Position Tool GBC eWire 01/26/2018 Installation Instructions...

  • Page 445: Inspect For Damage

    5. Check the gap between eWire and the Upstream Device. If the gap is too large or too small, the Docking Bracket can be shifted using the slots so that the eWire mating face is closer, or further away from the upstream device. Secure the Nuts to lock in the new position.

  • Page 446: Vertical Alignment

    10. Place the Downstream Docking Bracket under the downstream side of the eWire so the pin side of the bracket is on facing upstream. 2. If the eWire is not vertically level with the upstream device, undock the eWire.

  • Page 447: Level The Ewire

    Loosen the jam nut underneath the caster and raise or lower the caster using an adjustable wrench. 2. Connect the Power Cord to the AC Filter on the rear of the EWire. 4. Repeat the process for all necessary casters. Repeat steps 1 and 3.

  • Page 448: Configure The Ewire

    6. Wait until the User Interface indicates that the eWire is READY. 8.10. Run in Bypass Mode READY Put the eWire into Bypass mode to allow paper to pass through the eWire without being diverted. TO BIND 1. From the top level screen of the LCD User Interface, press either the Up Arrow Button or the Down Arrow Button.

  • Page 449: Run The Ewire In Bind Mode

    4. The EWire is now ready to function in BIND mode. 5. Do GP 6.7 to install a supply spool. 6. Program the printer to feed a book job into the eWire and confirm that the eWire successfully creates a book.

  • Page 450: Versant Profile Settings

    Cycle down delay 170 ms Time between sheets In order delivery delay 2200 ms Sheet jam time Same Output 22000 ms Set complier time 8.13. User Manual Make sure the customer has the User Instructions Manual. GBC eWire 01/26/2018 Installation Instructions 8-13...

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