GBC PUNCH G2 Service Manual
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GBC PUNCH G2 Service Manual

GBC PUNCH G2 Service Manual

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GBC PUNCH G2
Service Manual
Part Number: 7718806
Revision Number: A1
Issue Date: February 2019
GBC PUNCH G2
02/28/2019
Service Manual

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Summary of Contents for GBC PUNCH G2

  • Page 1 GBC PUNCH G2 Service Manual Part Number: 7718806 Revision Number: A1 Issue Date: February 2019 GBC PUNCH G2 02/28/2019 Service Manual...

  • Page 2: Table Of Contents

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

  • Page 3: Section Contents

    Introduction ..................iii Organization ................iv How to Use This Documentation ..........iv Other Information ..............v The Use of Caution, Warning, and Note statements.... v Safety Devices .................vi CAUTION .................vi Operational Safety..............vi Important safeguards ..............vii Acronyms.................vii GBC PUNCH G2 02/28/2019 Service Manual...

  • Page 4: Service Call Procedures

    This section contains a list of spare parts for the machine. All parts list page reference numbers begin with the letters “PL”, followed by a prefix number, a decimal point, and a sequential number used within the subsystem. GBC PUNCH G2 Service Manual 02/28/2019...

  • Page 5: Section 8: Installation

    Section 8: Installation in damage to, or destruction of, equipment. This section contains service information that supports the GBC PUNCH Warning - A Warning statement indicates an operating or maintenance G2 Installation.

  • Page 6: Operational Safety

    Safety Devices Operational Safety The GBC PUNCH G2 has door interlock to prevent personal injury when Do not operate the GBC PUNCH G2 with the interlocks defeated. operating the machine. Use care when a procedure in this Manual instructs you to “insert an When you open the Front Door, a Safety Interlock device automatically Interlock Cheater into the Punch Door interlock Switch SW1,”...

  • Page 7: Important Safeguards

    ♦ Acronyms are used in the parts list to provide information in a limited Use PUNCH G2 only for its intended purpose of punching paper and amount of space. The following table lists the abbreviations used in this covers according to the indicated specifications.
  • Page 8 Notes: GBC PUNCH G2 Service Manual 02/28/2019 viii...
  • Page 9 Title Page CALL FLOW..........1-2 INITIAL ACTION ..........1-3 SYSTEM CHECKS ........1-3 EVERY CALL ACTIVITIES ......1-4 SCHEDULED MAINTENANCE ....1-4 PREVENTATIVE MAINTENANCE ....1-4 PUNCH G2 Maintenance Schedule ....1-5 Customer Maintenance.....1-5 Periodic Maintenance .......1-5 Periodic Replacement.......1-6 HFSI.............1-7 FINAL ACTION ..........1-7 GBC PUNCH G2 4/14/2017...

  • Page 10: Call Flow

    FINAL ACTIONS This step is used to ensure that the punch quality, the punch performance, and the punch appearance are satisfactory. It will also provide direction to help complete administrative tasks. GBC PUNCH G2 Service Call Procedures 4/14/2017...

  • Page 11: Initial Action

    6. Determine the last time the Die Set was lubricated. Perform GP 6.7.3 • If the problem is not repeatable, operate the PUNCH G2 in the to lubricate die if necessary. same job conditions the customer used and recheck for a 7.

  • Page 12: Every Call Activities

    3. Perform GP 6.8 External Cleaning. Purpose 4. Perform GP 6.9 Internal Cleaning If operating properly, the PUNCH G2 will punch the same types of copy 5. Perform GP 6.10 Base Cleaning paper and cover materials handled by the printer and run at the same 6.

  • Page 13: Punch G2 Maintenance Schedule

    PUNCH G2 Maintenance Schedule Note: cycles = sheets of paper punched, not impressions. Customer Maintenance Area/Unit Period See: Measures Remarks Punch Die 100K Die cycles GP 6.7.3 Lubrication Oil the punch pins Die set shoulder bolts 200k Die cycles GP 6.7.4...

  • Page 14: Periodic Replacement

    Part Number No. of pcs. Rough Standard Remarks Die Set See PL 5-1 750K Cycles Replace as needed Punch Module 7715710 (115V) 15M Cycles Replacement 7715810 (230V) Solenoid module 7715223 5M Cycles Replacement GBC PUNCH G2 Service Call Procedures 4/14/2017...

  • Page 15: Hfsi

    8. Explain to the customer the service work that was performed and ensure they are satisfied before you close the call. Service Call Close 1. Record your service activities along with the Punch Cycle Count. GBC PUNCH G2 4/14/2017 Service Call Procedures...
  • Page 16 Notes: GBC PUNCH G2 Service Call Procedures 4/14/2017...
  • Page 17 PAPER JAM J219 ................. 2-14 Sheets ................2-29 PAPER JAM J305 ................. 2-14 PAPER JAM J316 ................. 2-14 RTP 2.8 Checking Obstruction in Paper Path ........2-30 PAPER JAM J317 ................. 2-14 PAPER JAM J411 ................. 2-14 GBC PUNCH G2 02/28/2019 RTPS Section Contents...
  • Page 18 Check Solenoids SOL 3 to SOL 8........2-44 MOTOR CHECKS................. 2-46 RTP 5.1 Checking Stepper Motors..........2-46 OTHER FAULTS................2-48 RTP 6.1 Die Set Will Not Slide In or Out Easily ......2-48 RTP 6.2 Punch Overheats ............. 2-48 GBC PUNCH G2 02/28/2019 RTPS...
  • Page 19 Codes include a cross reference to the pertinent RTP. To help you locate each component, the Repair and Troubleshooting Procedures include part locators (PL x.y) that refer to the pertinent page in Section 5, Part List. GBC PUNCH G2 02/28/2019 RTPS...
  • Page 20 Fault Code. There is a Fault Code on line 1. Yes- Go to the Table of Contents for Section 2 and locate the RTP for that fault code; No- Go to Step 6. GBC PUNCH G2 02/28/2019 RTPS...

  • Page 21: Operator Messages

    Use the Punch in Bypass Mode. SINGLE PUNCH The machine is in Single Punch Mode Use the machine in Single Punch Mode. DOUBLE PUNCH The machine is in Double Punch Mode The machine is in Double Punch Mode GBC PUNCH G2 02/28/2019 RTPS...
  • Page 22 The CHECK DIE message indicates that the Die Set is either missing or not fully installed. 1. Open the Front Door. 2. Unlock the Dieset, and remove the Dieset (see PUNCH G2 User Manual). 3. Re-insert the Dieset and lock the lock it in place.
  • Page 23 Yes- Normal operation; No- Go to step 10. 10. Do ARP 5.1 Main Control Board Replacement to Replace the Main Control Board (PL 6.1). This clears the fault code. Yes- Normal operation; No- Escalate to next level. GBC PUNCH G2 02/28/2019 RTPS...
  • Page 24 1.2) and inspect the connections at the Interlock Switch (see ARP 1.11 Interlock switch Replacement for photos of the connections). Interlock cable is connected at the Interlock switch. Yes- Go to step 7; Make the connection and return to Normal operation. GBC PUNCH G2 02/28/2019 RTPS...
  • Page 25 No- Do ARP 5.1 Main Control Board Replacement to Replace the This clears the fault. Main Control Board (PL 6.1). Yes- Return to normal operation Do ARP 5.1 Main Control Board Replacement to Replace the Main Control Board (PL 6.1). GBC PUNCH G2 02/28/2019 RTPS...
  • Page 26 Make the connection and return to normal operation. 5. Do GP 6.2.12 Firmware Upgrade procedure to re-flash the Firmware for Advanced Punch Pro, Re-flashing the firmware clears the fault. Yes- Return to normal operation No- Go to Step 6 GBC PUNCH G2 02/28/2019 RTPS 2-10...

  • Page 27: Error Codes

    There are only 3 error codes. 1. Open the Front Door. 2. Remove the Die Set (see PUNCH G2 User Manual). Error Code Description 3. Check that the Die Set is the correct Die Set for the Punch.
  • Page 28 ERROR E452 INCOMPATIBLE DIE ERROR E451 DIE ENCRYPTION ERROR This means the die is not a certified Ricoh die. This means that the die is not a GBC certified die or the dieset was not 1. Open the Front Door. read properly.

  • Page 29: Fault Codes

    Clear 2 Area 2 Entrance Idler Section Clear 3 Area 3 Acceleration Roller Section Clear 4 Area 4 Punch Module Clear 5 Area 5 Lower Punch Exit Section Clear 6 Area 6 Exit Idler Section GBC PUNCH G2 02/28/2019 RTPS 2-13...
  • Page 30 If it does not match the description, chose the appropriate RTP based on the information provided below. If there is no jammed paper in the unit and there is a Fault code, use the RTP based on the jam type specified on the Fault Code and Jam Type table above. GBC PUNCH G2 02/28/2019...
  • Page 31 Do RTP 2.5 Jam Type E The trail edge of the first jammed sheet is past Steering rollers N6 and N7 Jam Type F Do RTP 2.6 Jam Type F The paper jam is in the Bypass Assembly. GBC PUNCH G2 02/28/2019 RTPS 2-15...

  • Page 32: Power Faults

    No AC Power at Pin J14. Use this RTP when there is no AC power to the PUNCH G2. The Cable 7715498 is connected to the Communication board. Operator Panel does not illuminate and the PUNCH G2 does not operate.
  • Page 33 Cable 7715494 at Pin J4 on the Control Board (BLU & BRN wires). There is AC power on Cable 7715494 at Pin J4 the Control Board. Yes- Replace the Main Control Board (ARP 5.1). No- Replace Cable 7715494 GBC PUNCH G2 02/28/2019 RTPS 2-17...
  • Page 34 Do not touch the open terminals of the power supply or any other connector with the AC power cord connected. The machine components contain dangerous electrical voltages that can result in electrical shock and possible serious injury. GBC PUNCH G2 02/28/2019 RTPS 2-18...
  • Page 35 The Operator Interface illuminates. Yes- Normal operation Go to Step 2 2. Close the Front door. Check if the printer screen shows a GBC punch related fault. Printer screen shows a GBC punch related fault Yes- Do RTP1.2 No DC power Go to Step 3 Cable 7715523 is connected at the LCD Panel.
  • Page 36 6. Replace the LCD Board on the rear of the User Interface (ARP 1.12) This clears the fault Yes- Normal operation Go to Step 8 7. Check LCD for normal operation. The Operator Interface shows text. Yes- Normal operation Replace the Main Control Board (ARP 5.1). GBC PUNCH G2 02/28/2019 RTPS 2-20...
  • Page 37 Open the front door. b. Check if flat cable from the membrane switch (green colored) is connected at the LCD panel. The Cable is connected. Yes- Do ARP 1.13 LCD Panel Membrane switch. Connect the Cable. GBC PUNCH G2 02/28/2019 RTPS 2-21...

  • Page 38: Paper Jams

    4. Do GP 6.14 Idler Roller Inspection and Cleaning and GP 6.15 Drive Roller Inspection and Cleaning, to inspect and clean the rollers in Nip N1 (PL 2.6). This clears the fault Yes- Return to normal operation; No- Escalate to next level GBC PUNCH G2 02/28/2019 RTPS 2-22...
  • Page 39 Do GP 6.14 Idler Roller Inspection and Cleaning to inspect the idler roller springs for these rollers. • Do GP 6.15 Drive Roller Inspection and Cleaning to check the Drive Roller condition. Clean if necessary. GBC PUNCH G2 02/28/2019 RTPS 2-23...
  • Page 40 Yes- Return to normal operation; No- Go to Step 6 6. Do RTP 2.8 Checking Obstruction in Paper Path – Area 4 (Punch Module). This clears the fault Yes- Return to normal operation; No- Go to Step 7 GBC PUNCH G2 02/28/2019 RTPS 2-24...
  • Page 41 Do GP 6.15 Drive Roller Inspection and Cleaning to check the Drive Roller condition. Clean if necessary. • Check the Paper Path Drive Panel positions- see ADJ 1.8, Drive Panel Position Adjustment and perform adjustments if necessary. GBC PUNCH G2 02/28/2019 RTPS 2-25...
  • Page 42 15. Inspect the Lower Exit Panel’s magnetic latch, See ADJ 1.7 Idler Panel Magnetic Latches Adjustment. 8. Do GP 6.15 Drive Roller and Steering Drive Roller Inspection and If the fault still exists, escalate to next level. Cleaning, to Inspect and Clean Steering Drive Rollers GBC PUNCH G2 02/28/2019 RTPS 2-26...
  • Page 43 Do GP 6.14 Idler Roller Inspection and Cleaning to inspect the idler roller springs for these rollers • Do GP 6.15 Drive Roller Inspection and Cleaning to check the Drive Roller condition. Clean if necessary. GBC PUNCH G2 02/28/2019 RTPS 2-27...
  • Page 44 • Check the Exit Idler Panel position- see ADJ #1.7 Idler panel Magnetic Latches adjustments, perform adjustment is necessary. This clears the fault Yes- Return to normal operation; No- Escalate to second level GBC PUNCH G2 02/28/2019 RTPS 2-28...
  • Page 45 Remove two screws that hold the Punch Clutch Bracket mode of the LCD screen, run Cycle Punch to verify the punch cam returns to home position. If it does not, do ADJ 1.5 to perform Punch Clutch Indexing. GBC PUNCH G2 02/28/2019 RTPS 2-29...
  • Page 46 3. Inspect the gap between the Drive Roller and the sheet metal panel for any objects. 2. If the Lower entrance panel (PL #) is bent, Replace it (ARP #); If the Inner Entrance panel (PL #) is bent, Replace it (ARP #). GBC PUNCH G2 02/28/2019 RTPS 2-30...
  • Page 47 2. Check the Guide Brackets immediately upstream and downstream of the Die Set. 3. Remove the M4 Nuts (3) and the cover for Area 5. 4. Inspect the paper path for any obstructions closely. (Cont.) GBC PUNCH G2 02/28/2019 RTPS 2-31...
  • Page 48 Steering idler panel weldment- PL 4.4; ARP 3.15 • Steering drive panel weldment- PL 4.5; ARP 3.17 • Alignment sensor bracket- PL 4.10; ARP 3.24 • Alignment sensor lower guide- PL 4.10; ARP 3.24 GBC PUNCH G2 02/28/2019 RTPS 2-32...

  • Page 49: Sensor Checks

    All sensors show “0” when uncovered and “1” when covered Yes- Return to the RTP that directed you here. No- Go to Step 2 Sensors S2, S3, and S4 are on the Entrance Idler Panel (PL 3.2). GBC PUNCH G2 02/28/2019 RTPS 2-33...
  • Page 50 Yes- Use the new sensor and return to normal operation No- Go to Step 4 12. Do GP 6.3 to Undock the PUNCH G2 and visually inspect the Cable from the sensor all the way to the Control Board (PL 6.1). If the Cable is damaged, replace the Cable.
  • Page 51 Shares cable with S1, S26 Bypass Sensor, Middle 7715451 Shares cable with S1, S25 Align Home Sensor 7715519 Header 7715457 Shares cable with S16/S17 Chip Level Sensor - 7715485 Emitter/Receiver Clear Cover Sensor – 7715536 Emitter/Receiver GBC PUNCH G2 02/28/2019 RTPS 2-35...

  • Page 52: Rtp 3.2

    Sensors S6, S7, S8, S9, S10 To Access Sensors S6, S7, S8, S9, S10 • Undock PUNCH G2- This step is optional- if possible reach in through the jam access opening without undocking the punch. • Open Front Door. •...
  • Page 53 Sensors S11, S12, S13, S14 and S15 To Access Sensors S11, S12, S13, S14 and S15 • Undock PUNCH G2- This step is optional- if possible reach in through the jam access opening without undocking the punch. • Locate the Alignment Sensor Board...
  • Page 54 Sensors S16 and S17 To Access Sensors S16 and S17: • Open the Front Door. • Unlatch and open the Acceleration Idler Panel. Sensors S16 and S17 are on Backgage Sensor Board. GBC PUNCH G2 02/28/2019 RTPS 2-38...
  • Page 55 Open the Front Door. • Unlatch and open the Entrance Idler Panel. Sensors S18 and S19 are on Mid Punch Large Backgage Sensor Board. Sensors S20 and S21 are on Mid Punch XL Backgage Sensor Board. GBC PUNCH G2 02/28/2019 RTPS 2-39...
  • Page 56 Yes- Go to Step 3 Do GP 6.2.12 FIRMWARE UPGRADE Procedure to Re-flash the No- Make the connection and return to normal operation. firmware for the PUNCH G2. This clears the fault 3. Light from sensor components can be viewed with a cell phone camera, if the sensor is working you will be able to see a bright light.

  • Page 57: Rtp 3.3 Checking Sensor S28 Align Home Sensor

    Yes- go to Step 7 or 8; No- Go to Step 6 6. Do GP 6.2.12 FIRMWARE UPGRADE Procedure to Re-flash the firmware for the PUNCH G2. This clears the fault Yes- Resume normal operation; No- Go to Step 7...
  • Page 58 Yes- Resume normal operation; No- Go to Step 9 9. Do ARP 5.1 to Replace the Main Control Board (PL 6.1). This clears the fault Yes- Resume normal operation No- Escalate to second level GBC PUNCH G2 02/28/2019 RTPS 2-42...

  • Page 59: Solenoid Checks

    Yes- Return to normal operation No- Go to Step 4 4. Do GP 6.2.12 FIRMWARE UPGRADE Procedure to Re-flash the firmware for the PUNCH G2. This clears the fault Yes- Return to normal operation; No- Go to Step 5 GBC PUNCH G2...

  • Page 60: Rtp 4.3

    If the solenoid does not actuate, go to Step 4 Picture shows Motor running and solenoid actuated. From the service mode solenoid can be actuated using GP 6.2.6 Solenoids Procedure, and the corresponding drive roller rotated manually to check this. GBC PUNCH G2 02/28/2019 RTPS 2-44...
  • Page 61 This clears the fault Yes- Return to normal operation; No- Go to Step 6 6. Do GP 6.2.12 FIRMWARE UPGRADE Procedure to Re-flash the firmware for the PUNCH G2. This clears the fault Yes- Return to normal operation; No- Go to Step 7 7.

  • Page 62: Motor Checks

    All the DIP switch setting are correct M4- Make sure the connector for M3 is inserted into the header at the back of the punch module. Yes- Go to Step 9; No- Correct the DIP switch and resume operation. GBC PUNCH G2 02/28/2019 RTPS 2-46...
  • Page 63 Yes- Go to Step 11; No- Replace the faulty cable and resume normal operation 11. Do GP 6.2.12 FIRMWARE UPGRADE Procedure to Re-flash the firmware for the PUNCH G2. This clears the fault Yes- Resume normal operation; No- Go to Step 12 12.

  • Page 64: Other Faults

    Replace the Exhause fan (PL #) Go to Step 4 4. Check for 24 VDC on Wire 7715267 at Connector J20 on the Control Board. There is 24 VDC Yes- Replace Wire 7715267. Do RTP 1.2 No DC power. GBC PUNCH G2 02/28/2019 RTPS 2-48...
  • Page 65 Notes: GBC PUNCH G2 02/28/2019 RTPS 2-49...

  • Page 66: Section Contents

    3.11 Sheet Damaged at the Lead Edge of the Sheet ....11 3.12 Scuff Marks on Paper............12 3.13 Wrinkle in the sheet............12 3.14 Clear Cover media hole position ........12 3.15 Punch Specifications............13 GBC PUNCH G2 02/28/2019 Punch Quality...
  • Page 67 This page intentionally left blank. GBC PUNCH G2 Punch Quality 02/28/2019...

  • Page 69: Punch Quality

    1. Is the die configured for the correct sheet size? 3.3.1 Hanging Chad See Section 8 of PUNCH G2 User Manual for details. This is caused when the clearance between the pin and hole in a Die-set is configured correctly die-set increases.

  • Page 70: 3.5 Backgage Offset

    Yes- Return to normal operation; Go to Step 4 4. Do RAP 4.3 to check Solenoid SOL 6. This clears the fault Yes- Return to normal operation; Go to Section 3.7 Punching Accuracy Inconsistent GBC PUNCH G2 02/28/2019 Punch Quality...

  • Page 71: 3.6 Skewed Punch

    1. Check if the die is locked down properly. This is described in 1. Check if the die is locked down properly, by inspecting the die Section 4 (A) of the PUNCH G2 User Manual. lock plunger. This is described in Section 4 (A) of the PUNCH G2 User Manual.
  • Page 72 There should not be any play in the mechanism. pin) • Pulley on the other shaft of the Aligner drive (secured with an coiled pin) Make sure all the set screws are tightened securely, and the coiled pins are not broken. (Cont.) GBC PUNCH G2 02/28/2019 Punch Quality...
  • Page 73 The set screws are secured tightly. Yes- Escalate to higher level No- Tighten set screw(s) and return to normal operation GBC PUNCH G2 Punch Quality 02/28/2019...

  • Page 74: Sheets Without Punched Holes

    Motor running, remove the Rear Cover and do step 7. • Do GP 6.2.12 FIRMWARE UPGRADE Procedure to Re- flash the firmware for the PUNCH G2. If you do not hear the punch cycles, but you do hear the AC •...

  • Page 75: Punched Holes Look Elongated Towards The Trail Edge Of The Sheet

    Yes- Go to Step 4; No- Replace the punch module (ARP 3.1) 4. Do GP 6.24 Punch Clutch Inspection and Cleaning. This clears the fault Yes- Return to normal operation; No- Escalate to higher level GBC PUNCH G2 Punch Quality 02/28/2019 3-10...

  • Page 76: 3.10 Sheet Damaged At The Lead Edge Of The Sheet

    Yes- Return to normal operation; No- Go to Step 2 2. Remove the die set and inspect the die set throat for any obstruction. This clears the fault Yes- Return to normal operation; No- Escalate to higher level GBC PUNCH G2 02/28/2019 Punch Quality 3-11...

  • Page 77: 3.11 Scuff Marks On Paper

    Yes- Return to normal operation; No- Go to Step 2 2. Do RTP 4.3 to inspect Solenoids SOL 6, SOL 7, and SOL 8. This clears the fault Yes- Return to normal operation; No- Escalate to higher level GBC PUNCH G2 Punch Quality 02/28/2019 3-12...

  • Page 78: 3.14 Punch Specifications

    ±0.6mm (with 1% ±0.6 to ±1.0mm) Punch Capacity Single Sheet Electrical Amps and 115V: 3.8 A; 60 Hz Frequency 230V: 1.9 A; 50 Hz Safety cULus / GS Dimensions L: 795mm; W: 445mm; H: 1040mm Weight 102 kg GBC PUNCH G2 02/28/2019 Punch Quality 3-13...
  • Page 79 Duty Cycles The GBC PUNCH G2 provides a flexible, cost effective punching solution light medium level punching production environments. It is designed for production print users that typically punch their documents at an average of 20-30% of their overall workflow. For customers that run continuous punching for long runs...
  • Page 80 ARP 2.9 Punch Lower Exit Panel Replacement ......4-37 ARP 2.28.5 Backage Sensor Board Assembly (S18, S19) and Backage Sensor Board Assembly (S20, S21) ARP 2.10 Inner Exit Panel Replacement ......... 4-38 Replacement.............. 4-69 GBC PUNCH G2 02/28/2019 Adjustments/Repairs Section Contents...
  • Page 81 ARP 3.16.1 Steering Idler Roller Bearing Replacement .....4-111 ARP 3.17 Steering Drive Panel Weldment Replacement....4-112 ARP 3.18 Die Lock Plunger and Stripper Assembly Replacement 4-113 ARP 3.19 Punch shaft Ball Bearing Replacement......4-114 ARP 3.20 Die Stop Magnet Replacement ........4-114 GBC PUNCH G2 Adjustments/Repairs 02/28/2019...

  • Page 82: Cabinet

    6. Connect the Power Cord. 3. Do ARP 1.6 to remove the Rear Cover. 4. Remove the Phillips Head Screws (4) from the Top Cover Tabs. (2 screws from front side and 2 screws from rear side) GBC PUNCH G2 02/28/2019 Adjustments/Repairs...

  • Page 83: Arp 1.2 Front Door Replacement

    6. Remove the Interlock Switch (PL 1.2) from the old Door and install it (Cont.) on the new Door. 7. Remove the Magnet Strike Plate from the old Door and install it on the new Door. GBC PUNCH G2 Adjustments/Repairs 02/28/2019...

  • Page 84: Arp 1.3 Front Door Bottom Hinge Bracket Replacement

    4. Remove the Screws (2) and the Front Door Bottom Hinge Bracket 5. Place the new Front Door Bottom Hinge Bracket in position and tighten the Screws (2). 6. Do ARP 1.2 Front Door Replacement to install the Front Door. 7. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs...

  • Page 85: Arp 1.4 Front Door Top Hinge Bracket Replacement

    7. Connect the Power Cord. 5. Place the new Front Door Top Hinge Bracket in position and tighten the Screws (2). 6. Do ARP 1.2 Front Door Replacement to install the Front Door. 7. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019...

  • Page 86: Arp 1.6 Rear Cover Replacement

    4. Grasp the Rear Cover by the handle and remove the Rear Cover. Installation Procedure 1. Place the Rear Cover in position. 2. Tighten the Screws (6) on the Rear Cover. 3. Install the MK 737 boxes 4. Connect the Communication cables. 5. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs...

  • Page 87: Arp 1.7 Upstream Rear Side Cover Replacement

    2. Tighten the Screws (5) holding the Upstream Rear Side Cover. 3. Do ARP 1.6 to install the Rear Cover. 4. Do GP 6.4 to dock the Punch to the upstream and downstream equipment. 5. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019...

  • Page 88: Arp 1.8 Downstream Front Side Cover Replacement

    1. Disconnect the Power Cord. 2. Do GP 6.3 to undock the Punch from the upstream and downstream equipment. 3. Remove the M4 Screws (6). Downstream Front Side Cover 4. Remove the Downstream Front Side Cover. GBC PUNCH G2 02/28/2019 Adjustments/Repairs...

  • Page 89: Arp 1.9 Downstream Rear Side Cover Replacement

    2. Tighten the Screws (7) holding the Downstream Rear Side Cover. 3. Do ARP 1.6 to install the Rear Cover. 4. Do GP 6.4 to dock the Punch to the upstream and downstream equipment. 5. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-10...

  • Page 90: Arp 1.10 Door Latch Replacement

    6. Do ADJ 1.1 to adjust the Door Latch. 7. Tighten the Screws (4). 8. Close the Front Door. 9. Connect the Power Cord. 10. Test the Door Latch operation. 3. Remove the two screws [1] on the Door Latch. Screw (2) GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-11...

  • Page 91: Arp 1.11 Interlock Switch Replacement

    10. Close the Front Door. 5. Press in the Tabs (2) on the sides of the Switch and remove the 11. Connect the Power Cord. Interlock Switch from the Interlock Switch Bracket. Tabs (2) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-12...

  • Page 92: Arp 1.12 Lcd Display Replacement

    LCD Display. Cable Cable 4. From the bottom side of the Top Cover, remove the Screws (3) holding the LCD Display to the Top Cover. Screws 5. Remove the LCD Display. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-13...

  • Page 93: Arp 1.13 Lcd Membrane Switch Panel Replacement

    8. Connect the LCD Membrane Switch Connector from the LCD Display. Display. 9. Install the ground strap with M4 nut. 10. Connect the Power Cord. Connector 4. Remove the M4 nut and release the ground strap 5. Peel off the old LCD Membrane Switch GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-14...

  • Page 94: Arp 1.14 Caster Replacement

    5. Place the new Caster in position and screw it in. 6. Tighten the Jam Nut. 7. Lower the Punch 8. Connect the Power Cord. 5. Remove the Docking Brackets from the upstream device. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-15...
  • Page 95 1. Place the Docking Brackets in position on the upstream devices and tighten the (8x) screws. 2. Do GP 6.4 Dock the Punch to connect the Punch to the upstream and downstream devices. 3. Connect the Communication cable. 4. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-16...

  • Page 96: Arp 1.16 Exhaust Fan And Exhaust Fan Bracket Replacement

    2. Place the Exhaust Fan Bracket Assembly in position and tighten the Screws (2). 3. Connect Cable 7715267 at Connector J20 on the Control Board (PL 5.1). 4. Do ARP 1.6 to install the Rear Cover. 5. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-17...

  • Page 97: Arp 1.17 Drive Roller Cover Removal

    7. Use the same procedure for exit side drive roller cover by removing the corresponding screws. 5. Remove (2) M4 screws from the rear frame. Installation Procedure Reverse steps to re-install the cover. Screws (2) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-18...

  • Page 98: Arp 1.18 Side Cover Removal

    2. Do GP 6.3 to undock the Punch from upstream and downstream equipment 3. Remove (4) M4 screws and the bottom plate and (2) M4 screws on the top. Process is the same for the upstream side. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-19...

  • Page 99: Paper Path

    6. Do GP 6.4 to dock the Punch to the upstream and downstream equipment. 7. Connect the Power Cord. 7. Remove the Screws (2) from the Rear Frame used to mount the 8. Do ADJ 1.2 Diverter Solenoid Adjustment. Lower Entrance Panel. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-20...

  • Page 100: Arp 2.2 Inner Entrance Panel Replacement

    2. Do ARP 1.17 to install the Lower Entrance Panel. 3. Do ARP 1.6 to install the Rear Cover. 4. Do GP 6.4 Dock the Punch to connect the Punch to the upstream and downstream devices. 5. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-21...

  • Page 101: Arp 2.3 Entrance Idler Panel Replacement

    Solenoid SOL3 & SOL4 Connectors Docking Bracket 5. Disconnect the Connectors for Sensors S2, S3, & S4. 8. Remove the E-Ring from the bottom of the Idler Panel Shaft. E-Ring Sensor S2, S3, & S4 Connectors GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-22...
  • Page 102 Idler roller Assembly Replacement • ARP 2.28.3 Sensor (S2, S3, S4) Replacement • ARP 2.30.2 Disengaging Roller Solenoid Replacement 11. Carefully remove the Shaft. Shaft (Cont.) 12. Grasp and remove the Entrance Idler Panel. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-23...
  • Page 103 7. Do ADJ 1.7 Idler Panel Magnetic Latches Adjustment. 8. Do GP 6.4 Dock the Punch to connect the Punch to the upstream and downstream devices. 9. Close the Front Door. 10. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-24...

  • Page 104: Arp 2.4 Acceleration Roller Idler Assembly Replacement

    Clamps Connector Sensor S5 Connector Acceleration Idler panel Handle 6. Disconnect the Accel Sensor S5 Connector at the the sensor 7. Disconnect the Acceleration Idler Roller Solenoid SOL5 Connector at the rear frame. (Cont.) GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-25...
  • Page 105 9. Do GP 6.4 Dock the Punch to connect the Punch to the upstream and downstream devices. 10. Connect the Power cord. Shaft 10. Remove the Acceleration Idler Roller Assembly. Acceleration Idler Roller Assembly GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-26...

  • Page 106: Arp 2.5 Entrance Drive Panel Assembly Replacement

    4. Do GP 6.3 Undock the Punch to separate the Punch from the 1. Disconnect the Power Cord. upstream and downstream devices. 2. Do ARP 1.6 to remove the Rear Cover. 5. Do ARP 2.3 to remove the Entrance Idler Panel. Entrance Idler Panel (Cont.) GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-27...
  • Page 107 7. Unhook the Acceleration Panel Latch Springs (2). 9. Open the Cable Clamps and release the Sensor Cables. Sensor board connectors Cable Clamps 10. Disconnect the Clear Cover Sensor. Clear Cover sensor Acceleration Panel Latch Springs (Cont.) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-28...
  • Page 108 11. Remove the Screws (5) that hold the Entrance Drive Panel to the front Frame. Entrance Drive Panel Screws (5) 12. Remove the Screws (5) that hold the Entrance Drive Panel to the Rear Frame. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-29...
  • Page 109 14. Do ARP 1.6 to install the Rear Cover. 15. Connect the Power Cord. 14. Remove the Entrance Drive Panel. 15. Transfer the sensor Boards and the Clear Cover Sensor to the new Panel Weldment. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-30...

  • Page 110: Arp 2.6 Lower Exit Panel Replacement

    1. Place the Lower Exit Panel in position. 2. Slide the Shaft into place. 3. Install the E-clips (2) on the ends of the Shaft. 4. Close the Front Door. 5. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-31...

  • Page 111: Arp 2.7 Exit Idler Panel Replacement

    5. Open the Cable Clamps to release all the sensor cables. 7. Disconnect the Connectors for Solenoids SOL6, SOL7, & SOL8 from the header at the rear frame. Solenoid SOL6, SOL7 & SOL8 Connectors (Cont.) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-32...
  • Page 112 9. Remove the E-Ring from the bottom of the Idler Panel Shaft. Shaft E-Ring 13. Grasp and remove the Exit Idler Panel. 10. Remove the E-Ring from the top of the Idler Panel Shaft. E-Ring GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-33...
  • Page 113 8. Do ARP 1.18 to install the Downstream side cover. 9. Do GP 6.4 Dock the Punch to connect the Punch to the downstream devices. 10. Close the Front Door. 11. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-34...

  • Page 114: Arp 2.8 Drive Exit Panel Replacement

    6. Remove (3) M4 nuts to remove the Bracket in Area 5 of the machine. 9. Remove (5) screws from the front frame that mount the Exit drive panel. 7. Do ARP 2.27 to remove Motor M7 by removing (4) screws. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-35...
  • Page 115 10. Do ARP 1.18 Side cover removal. to install the downstream docking plate 11. Do GP 6.4 to dock the Punch to the upstream and downstream equipment. 12. Connect the Power Cord. 11. Remove the Drive Exit Panel. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-36...

  • Page 116: Arp 2.9 Punch Lower Exit Panel Replacement

    5. Do ARP 1.17 to install Drive roller cover. 6. Do GP 6.4 to dock the Punch to the upstream and downstream equipment. 7. Connect the Power Cord. 8. Do ADJ 1.2 Diverter Solenoid adjustment. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-37...

  • Page 117: Arp 2.10 Inner Exit Panel Replacement

    4. Do ARP 1.18 to install Downstream side cover 5. Do ARP 1.6 to install the Rear Cover. 6. Do GP 6.4 to dock the Punch to the downstream devices. 7. Connect the Power cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-38...

  • Page 118: Arp 2.11 Upper Bypass Panel Replacement

    4. Unplug the Sensors from the Upper Bypass Panel and release the sensor cables from the cable clamps. 7. Remove (2) Idler panel magnetic latches from the Upper bypass assembly by unscrewing (4) screws. 5. Remove the screw and nut for the ground strap. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-39...
  • Page 119 9. Do ARP 1.6 Rear Cover Replacement to install the Rear Cover. 10. Do GP 6.4 to dock the Punch to the upstream and downstream equipment. 11. Do ADJ 1.7Idler Panel Magnetic Latches adjustment. 12. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-40...

  • Page 120: Arp 2.12 Lower Bypass Panel Replacement

    2. Do ARP 2.11 Upper bypass panel replacement to remove the Upper bypass panel. 3. Remove (4) M4 screws from the Front frame. 4. Remove (4) M4 screws from the Rear frame. Installation Procedure Reverse the Steps in the Removal procedure. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-41...

  • Page 121: Arp 2.13 Bypass Diverter Replacement

    4. Install the E-clip on the Diverter Shaft at the front side. 5. Do ARP 1.6 to install the Rear Cover. 6. Connect the Power Cord. 5. Remove the E-clip from the Diverter Shaft on the rear side. 7. Do ADJ 1.2 Diverter Solenoid Adjustment. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-42...

  • Page 122: Arp 2.14 Panel Close Magnet Replacement

    2. Remove the Screws (2) and Nuts (2). 7. Connect the Power Cord. 3. Remove the Magnet Bracket. 4. Remove the old Magnet. Magnet Bracket Screws (2) 5. Place the Magnet Bracket in position and insert the Screws. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-43...

  • Page 123: Arp 2.15 Idler Roller Replacement

    Roller panel, Exit Idler panel, undock the punch from upstream and downstream devices, GP 6.3 • For the Idler Rollers in the Bypass Panel, Open the Front Door. 5. Remove the Bearing Housing (2) at each end of the Idler Roller Shaft. (Cont.) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-44...
  • Page 124 6. Place the Extension Spring (2) over the Bearing Housings (2). 7. Place the hooks on the ends of the Extension Springs (2) on the notches at the top of the Bushing Forks (2). 8. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-45...

  • Page 125: Arp 2.16 Idler Panel Mount Bracket Replacement

    2. Do ARP 1.6 to install the Rear Cover. 3. Connect the Power Cord. Idler Panel Mount Bracket NOTE: To remove the Entrance Drive Panel (ARP 2.1), you must only remove the lower Idler Panel Mount Bracket.) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-46...

  • Page 126: Arp 2.17 Flange Ball Bearing Replacement

    (PL 2.4).- shown in green color 3. Remove the E-Ring. 4. Remove the Flat Washer. 5. Remove the Flange Ball Bearing. NOTE: To Replace a Bearing from the rear side, do ARP 2.24 to remove the Pulley. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-47...

  • Page 127: Arp 2.18 Snap-In Bearing Replacement

    ARP 2.3 Entrance Idler Panel Replacement • ARP 2.5 Acceleration Roller Idler Assembly Replacement • ARP 2.7 Upper Bypass Panel Replacement • ARP 2.9 Exit Idler Panel Replacement • ARP 2.13 Lower Exit Panel Replacement GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-48...

  • Page 128: Arp 2.19 Bearing Housing Replacement

    3. Place the new Bearing Housings (2) on the ends of the Shaft with the flange of the Bearing facing in toward the Idler Roller. Bearing Housing Bearing flange 4. Do ARP 2.15 to install the Idler Roller. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-49...

  • Page 129: Arp 2.21 Accel Idler Latch Shaft, Rear Latch And Front Latch Assembly Replacement

    4. Unhook the Extension Springs from the Accel Idler Panel Front and Rear Latches. 1. Place the Accel Idler Latch Handle in position and tighten the Screws (2). 2. Close the Front Door. 3. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-50...
  • Page 130 5. Remove the M3 screws (2) from the Accel Idler Panel Front and Rear Latches. 9. For the Accel Idler Panel Rear Latch Assembly, slide the shaft towards the front side to remove. 6. Remove the E-clip from the Accel Idler Shaft on the rear side. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-51...
  • Page 131 10. For the Accel Idler Panel Front Latch Assembly, slide the shaft towards the rear side to remove. 11. Remove Accel Panel Rear and Front Latch assemblies to remove the Accel Idler Latch shaft. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-52...
  • Page 132 8. Hook the Extension Springs to the Accel Idler Panel Front and Rear Latches. 9. Do ARP 3.1.2 to install the Punch Module. 10. Do ARP 1.6 to install the Rear Cover. 11. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-53...

  • Page 133: Arp 2.22 One Way Clutch And Pulley Sub-Assembly Replacement4-54

    4. Place the new One Way Clutch Assembly on to the Shaft. 7. Do ARP 2.25.1 to install the 534T Belt 5. Install the Washer and the E-Clip. 8. Connect the Power Cord. 6. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-54...

  • Page 134: Arp 2.24 Timing Pulley Replacement

    8. Do ADJ 1.4 Timing belt adjustment for the appropriate belt tension adjustment. 9. Do ARP 1.6 to install the Rear Cover. 5. Remove the Timing Pulley by sliding it out. 10. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-55...

  • Page 135: Arp 2.25 Timing Belt Replacement

    ARP 2.25 Timing Belt Replacement ARP 2.25.1 534T Belt Replacement There are eight (8) belts used at the rear of the Frame in the PUNCH G2. PARTS LIST ON PL 2.9 Fie (5) belts connect to motors. Use this procedure to remove and install the 534T Belt for the Bypass Motor (M8).

  • Page 136: Arp 2.25.2 134T Belt Replacement

    4. Place the new Belt in position around the Pulleys. 7. Connect the Power Cord. 5. Adjust the Belt Tension per ADJ 1.4 Timing Belt Adjustment. 6. Do ARP 1.6 to install the Rear Cover. 7. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-57...

  • Page 137: Arp 2.25.4 179T Belt Replacement

    4. Place the new Belt in position around the Pulleys. 5. Adjust the Belt Tension per ADJ 1.4 Timing Belt Adjustment. 6. Do ARP 1.6 to install the Rear Cover. 7. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-58...

  • Page 138: Arp 2.26 Drive Roller Assembly Replacement

    Shaft at the front of the machine. Removal Procedure 1. Do ARP 1.6 to remove the Rear Cover. E-Ring 2. Open the Front Door. 3. Locate the appropriate Drive Roller. Washer Drive Roller Shaft (Cont.) GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-59...
  • Page 139 Drive Roller Shaft 11. Connect the Power Cord. 9. Remove the Drive Roller. Drive Roller 10. Remove the Bearing from the front of the machine. 11. Remove the Bearing from the rear of the machine. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-60...

  • Page 140: Arp 2.26.1 Drive Roller N5 Replacement

    4. Loosen the nuts (2) on the Tensioner of the M2 motor belt. Tensioner 7. Slide the Pulley off the Roller Shaft. Nuts (2) 5. Remove the retaining ring from the shaft of roller N5. (Cont.) GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-61...
  • Page 141 E-Ring and Washer 9. Remove the E-Ring at the front side of the Shaft. Washer and Ball Bearing 11. Remove the Ball Bearing from the rear side of the Shaft. E-Ring Ball Bearing (Cont.) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-62...
  • Page 142 9. Move the Tensioner of the M2 motor belt into position and tighten the Screws (2). 10. Do ARP 3.1 to install the Punch Module. 11. Do ARP 1.6 to install the Rear Cover. 12. Close the Front Door. 13. Connect the Power Cord. Drive Roller. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-63...

  • Page 143: Arp 2.27 Stepper And Mount Assembly Replacement

    Screws (4). 8. Adjust the corresponding belt tension per ADJ 1.4 Timing belt adjustment procedure. 9. Connect the Motor Connector. 10. Do ARP 1.6 to install the Rear Cover. 11. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-64...

  • Page 144: Arp 2.28 Paper Path Sensor Replacement

    ARP 2.25.1 5. Remove the old Sensor. ARP 2.25.7 ARP 2.25.4 6. Place the new Sensor in position, then install the Barrell Screw. 7. Close the Front Door. ARP 2.25.7 8. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-65...

  • Page 145: Top, Middle, & Bottom Exit Sensor (S22, S23, S24) Replacement

    6. Remove the old Sensor. 7. Place the new Sensor in position, then install the Barrell Screw. 8. Do GP 6.4 to dock the Punch to the upstream and downstream equipment. 9. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-66...

  • Page 146: Arp 2.28.3 Accel Sensor (S5) Replacement

    5. Remove the old Sensor. 6. Place the new Sensor in position, then install the Barrell Screw. 7. Do GP 6.4 to dock the Punch to the upstream and downstream equipment. 8. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-67...

  • Page 147: Arp 2.28.4 Align Home Sensor (S28) Replacement

    9. Do GP 6.4 to dock the Punch to the upstream and downstream 4. Remove the M3 Screws (2) that secure the Sensor to the Bracket. equipment. 10. Connect the AC power cord Sensor Bracket Screws (2) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-68...

  • Page 148: Arp 2.28.5 Backage Sensor Board Assembly (S18, S19) And Backage Sensor Board Assembly (S20, S21) Replacement

    11. Do ARP 3.1 to install the Punch Module. 12. Do ARP 1.6 to install the Rear Cover. 13. Connect the Power Cord. Drive Entrance Panel Backage Sensor Board (S18, S19) • The lower board is the Backage Sensor Board (S18, S19). GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-69...

  • Page 149: Arp 2.28.6 Skew Sensor Board (S6 - S10) Replacement

    8. Connect the Sensor Board Connector. 9. Do ARP 3.1 to install the Punch Module. 10. Do ARP 1.6 to install the Rear Cover. 11. Connect the Power Cord. Skew Sensor Board Connector Skew Sensor Board GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-70...

  • Page 150: Arp 2.28.7 Alignment Sensor Board (S11 - S15) Replacement

    5. Release the Cable Clamp and move the Cable out of the way. 6. Remove the M4 Nuts (2) and remove the steering idler roller cover. M4 nuts (2) Washers (2) 11. Remove the Alignment Sensor Board. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-71...
  • Page 151 18. Place the Skew Sensor Board Cable into the Cable Clamps and close the Cable Clamps. 19. Connect the Skew Sensor Board Connector. 20. Do ARP 3.1 to install the Punch Module. 21. Do ARP 1.6 to install the Rear Cover. 22. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-72...

  • Page 152: Arp 2.28.8 Backage Sensor Board (S16, S17) Replacement

    10. Do ARP 1.6 to install the Rear Cover. 11. Connect the Power Cord. Backage Sensor Board 4. Disconnect the Sensor Board Connector at the Board. 5. Remove the Nuts (3), Washers (3), and the Backage Sensor Board. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-73...

  • Page 153: Arp 2.29 Motor Driver (Stepper Board) Replacement

    6. Disconnect the Cables from the Motor Driver Board. 10. Do ARP 1.6 to install the Rear Cover. 7. Set the Dip switches (6) on the new Motor Driver in accordance with 11. Connect the Power Cord. the table below. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-74...

  • Page 154: Arp 2.30 Solenoid Replacement

    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. 5. Disconnect the inline Connector for the Diverter Solenoid sub- assembly. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-75...

  • Page 156: Arp 2.30.2 Entrance Idler Solenoid Replacement

    10. Close the Front Door. Clamps 11. Do GP 6.4 Dock the Punch. 10. Close the Front Door. 12. Connect the Power Cord. 11. Do GP 6.4 Dock the Punch. 12. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-77...

  • Page 157: Arp 2.30.4 Exit Idler Solenoid Replacement

    9. Connect the Solenoid Connector. 10. Place the the Cable into the Cable Clamps and close the Cable Clamps 11. Close the Front Door. 12. Do GP 6.4 Dock the Punch. 13. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-78...

  • Page 158: Punch Module

    3. Open the Front Door. 4. If a die set is installed, remove it and store it in the die storage rack. 6. Remove the M4 X 10 Phillips Head Screw and the Die Lock Handle. GBC PUNCH G2 02/28/2019 Adjustments/Repairs...
  • Page 159 11. Disconnect the Connector for Solenoid SOL2. 8. Go to the rear of the Punch. 9. Disconnect the Connectors (2) for Sensors S6-S10 and S11-S15. 12. Disconnect the Connector for the M5 Motor Driver. (Cont.) (Cont.) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-80...
  • Page 160 13. Disconnect the Connectors (2) for the M3 Header and the M4 15. Disconnect the Connector for Sensors S16 and S17. Header. 16. Disconnect the Connector for Punch Motor M10. 14. Disconnect the Die Set Recognition Connector. (Cont.) GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-81...
  • Page 161 Use a Phillips Head Screwdriver to remove the Screw from the punch. Lift the punch off the rail- DO NOT let it drop on the right Punch Module Mount Bracket. control board. • Remove the right Punch Module Mount Bracket. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-82...

  • Page 162: Arp 3.1.2 Punch Module Installation

    6. Install the Die Lock Handle and tighten the M4 X 10 Phillips Head Screw. 7. Install the Die Set (see Operation Instructions Manual). 8. Close the Front Door. 9. Do ARP 1.6 to install the Rear Cover. 10. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-83...

  • Page 163: Arp 3.2 Chip Tray Home Switch Replacement

    6. Connect Cable 7715485 at the Chip Tray Home Switch. 7. Put the Chip Tray in position and push the Chip Tray Assembly in firmly until it latches. 8. Close the Front Door. Chip Tray 9. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-84...

  • Page 164: Arp 3.3 Chip Level Emitter Replacement

    9. Put the Chip Tray in position and push the Chip Tray Assembly in 10. Close the Front Door. firmly until it latches. 11. Connect the Power Cord. 10. Close the Front Door. 11. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-85...

  • Page 165: Arp 3.5 Punch Motor Replacement

    4. Do ARP 3.6 Punch Motor Belt Replacement (Timing Belt) to install the Punch Motor Belt. 5. Do ARP 3.1 to install the Punch Module. 6. Do ARP 1.6 to install the Rear Cover. 7. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-86...

  • Page 166: Arp 3.6 Punch Motor Belt Replacement (Timing Belt)

    ARP 3.1 4. Remove the JE-10 E-Ring. 8. Remove the old Belt. Clutch Pulley 5. Remove the Nylon Washer. Belt 6. Remove the Ball Bearing. 7. Remove the Screws (2) and the Bearing Bracket. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-87...
  • Page 167 NOTE: The tension on the Belt is set using the reference marks on the punch motor bracket (see ARP 3.5). Mark 14. Do ARP 1.6 to install the Rear Cover. 15. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-88...

  • Page 168: Arp 3.7 Clutch Or Clutch Pulley Replacement

    You can press down on the actuator and turn the punch shaft to orient the set screw in any direction for easy access. Screws Pulley and Flange 6. Remove the Lock Nut and the long M6 Screw. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-89...
  • Page 169 4. Put a drop of Loctite on each Set Screw. 5. Tighten the Set Screws (2). 6. Place the long M6 Screw and the Lock Nuts (2) in position. 9. Recheck the gap. (Cont.) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-90...
  • Page 170 13. Do ARP 3.19 Ball Bearing Replacement to install the Ball Bearing. 14. Do ADJ 1.5 Punch Cam Indexing. 15. Do ARP 3.1.2 Punch Module Installation. 16. Do ARP 1.6 to install the Rear Cover. 17. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-91...

  • Page 171: Arp 3.8 Punch Alignment Stepper Motor And Pulley Replacement, And Alignment Stepper Bracket Replacement

    10. Do ARP 3.1 to install the Punch Module if necessary 11. Close the Front Door. 12. Do ARP 1.6 to install the Rear Cover. 13. Connect the Power Cord. Punch Alignment Stepper Motor (M5) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-92...

  • Page 172: Arp 3.9 Steering Module Replacement

    3. Do ARP 3.1 to remove the Punch Module. Remove the Alignment stepper Belt from the Pulley. 6. Pull the Alignment stepper belt in through the hole in the Frame. 4. Disconnect the Skew Sensor Board Connector. Belt Skew Sensor Board Connector GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-93...
  • Page 173 10. Remove the Phillips Screws (8)- (4) from front side and (4) from rear side • Press down on the top tab to remove it from the top side. Then press the bottom tab to release the connector fully. Screws (8) 8. Release the Cable Clamp GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-94...
  • Page 174 6. Tighten the Phillips Screws (2). 7. Do ARP 3.1 to install the Punch Module. 8. Close the Front Door. 9. Do ARP 1.6 to install the Rear Cover. 10. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-95...
  • Page 176 4. Place the Ground Strap into the Wire Saddles. 5. Do ARP 3.9 to install the Steering Module. 6. Do ARP 3.1 to install the Punch Module. 7. Do ARP 1.6 to install the Rear Cover. 8. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-97...

  • Page 177: Arp 3.11 Alignment Carriage Sub Assembly Replacement

    7. Remove the drive roller shaft and all the components on the drive shaft. (4 plastic washers; 2 springs; 2 drive rollers; 2 belts; 4 e-clips) Steering Module 5. Remove the Steering Idler and Drive Panel assemblies by removing the M3 Nuts (4) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-98...
  • Page 178 Look at the images for selecting the proper cable for the motors: Align Home Sensor Bracket 9. Remove Left and Right Steering Stepper Motors along with their corresponding cables, by removing the Screws (8). 7715529 GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-99...
  • Page 179 7715528 2. Do ARP 3.9 to install the Steering module. 3. Do ARP 3.1.2 to install the Punch Module. 4. Do ARP 1.6 to install the Rear Cover. 5. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-100...

  • Page 180: Arp 3.12 Steering Stepper Motor Replacement

    5.5mm nut driver that will reach the (4) screws through the opening in the punch frame. However to remove the rear side steering motor, Alignment stepper motor sub-assembly needs to be removed- ARP 3.8 GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-101...
  • Page 181 4. Install the Align Home Sensor Bracket and tighten the M3 Screws (2). 5. Do ARP 3.9 to install the Steering Module. 6. Do ARP 3.1 to install the Punch Module. 7. Do ARP 1.6 to install the Rear Cover. 8. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-102...

  • Page 182: Arp 3.13 Steering Motor Belt (65 Groove) Replacement

    3. Do ARP 3.1 to remove the Punch Module. 5. Slide the Shaft in the opposite direction so that the Steering Drive Roller Spring, (2) plastic washers and Steering Drive Roller can be removed (from the side that needs the part replaced). GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-103...
  • Page 183 Steering Drive Roller Spring. 3. Install the E-Rings on the Steering Drive Roller Shaft. 4. Do ARP 3.1 to install the Punch Module. 5. Do ARP 1.6 to install the Rear Cover. 6. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-104...

  • Page 184: Arp 3.14 Steering Drive Roller Shaft Replacement

    2. Do ARP 1.6 to remove the Rear Cover. 3. Do ARP 3.1 to remove the Punch Module. 6. Remove the Shaft from the Drive Panel Steering Sub Assembly. 4. Do ARP 3.9 to remove the Steering Module. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-105...
  • Page 185 Washers (2) on each end of the Shaft. 9. Do ARP 3.9 to install the Steering Module. 10. Do ARP 3.1 to install the Punch Module. 11. Do ARP 1.6 to install the Rear Cover. 12. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-106...

  • Page 186: Arp 3.15 Steering Idler Panel Weldment Replacement

    2. Do ARP 1.6 to remove the Rear Cover. 3. Do ARP 3.1 to remove the Punch Module. 6. Remove the Steering Idler Panel Sub Assembly. 4. Unplug the Skew Senor and release the Cable Clamp. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-107...
  • Page 187 2. Place the Steering Idler Panel Sub Assembly in position on the Drive Panel Steering Sub Assembly. 3. Install the Screws (4). 4. Do ARP 3.1 to install the Punch Module. 5. Do ARP 1.6 to install the Rear Cover. 6. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-108...

  • Page 188: Arp 3.16 Steering Idler Roller Assembly Replacement

    2. Do ARP 1.6 to remove the Rear Cover. 3. Do ARP 3.1 to remove the Punch Module. 7. Remove the Roller Cover. 8. Gently move the Springs (2) off the ends of the Roller. 4. Disconnect the Skew Sensor Board Connector. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-109...
  • Page 189 6. Place the Skew Sensor Board Cable in the Cable Clamp and close the Cable Clamp. 7. Connect the Skew Sensor Board Connector. 8. Do ARP 3.1 to install the Punch Module. 9. Do ARP 1.6 to install the Rear Cover. 10. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-110...

  • Page 190: Arp 3.16.1 Steering Idler Roller Bearing Replacement

    1. Do ARP 3.16 Steering Idler Roller Replacement to remove the Steering Idler Roller. Steering Idler Roller Assembly 2. Remove the Steering Idler Roller Bearing (2) from the ends of Shaft on the Steering Idler Roller Assembly. Steering Idler Roller Bearing GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-111...

  • Page 191: Arp 3.17 Steering Drive Panel Weldment Replacement

    3. Install the Spacers (2). 4. Do ARP 3.15 to install the Steering Idler Panel Sub Assembly. 5. Do ARP 1.6 to install the Rear Cover. 6. Connect the Power Cord. 4. Remove the Spacers (2). Spacer Spacer GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-112...

  • Page 192: Arp 3.18 Die Lock Plunger And Stripper Assembly Replacement

    Plunger Stripper 7. Install the Plunger and Stripper Assy. 8. Do ARP 3.1 to install the Punch Module. Screws (2) 9. Do ARP 1.6 to install the Rear Cover. 10. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-113...

  • Page 193: Arp 3.19 Punch Shaft Ball Bearing Replacement

    6. Place the new Ball Bearing in position. 7. Place the Nylon Washer in position. 8. Place the E-Ring in position. 9. Do ARP 1.6 to install the Rear Cover. 10. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-114...

  • Page 194: Arp 3.21 Die Lock Handle Replacement

    3. Remove the Phillips Screw and the Die Stop Handle. 4. Place the new Die Stop Handle in position and tighten the Phillips Screw. 5. Close the front Door. 6. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-115...

  • Page 195: Arp 3.22 Die Lock Shaft Replacement

    8. Remove the Socket Head Cap Screw and Split Lock Washer from the Cam and the Shaft at the front of the Punch Module. Screw 6. Remove the Shoulder Screw from the hole in the Shaft at the rear of the Punch Module. Shoulder Screw GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-116...
  • Page 196 1. Place a Die Lock Cam inside the Punch Module by the hole at the front of the Punch Module (cam portion against side Frame). 2. Insert the Die Lock Shaft through the hole at the front of the Punch Module and through the hole in the Cam. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-117...

  • Page 197: Arp 3.23 Die Rail Assembly And Die Rail Springs Replacement

    9. Die rail springs can be replaced at this point by unscrewing M2 screws (4) and M2 lockwashers (4). If you are replacing only the springs, go to Installation procedure. 6. Remove the Screws (2) that hold the Dieset Recognition Bracket. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-118...
  • Page 198 Cable Clamps. 10. Do ARP 3.1 to install the Punch Module. 11. Do ADJ 1.6 Die set recognition board adjustment. 12. Do ARP 1.6 to install the Rear Cover. 13. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-119...

  • Page 199: Arp 3.24 Alignment Sensor Bracket And Alignment Sensor Bottom Guide Replacement

    8. Remove both upper and lower brackets as shown, do not pull on the Align sensor wires. 5. Remove the Steering Idler Roller Cover. 9. The lower bracket can be replaced at this time. 6. Unplug the Alignment Sensor Connector GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-120...
  • Page 200 6. Connect the Skew Sensor Connector and place the Cable in the Cable Clamps. 7. Do ARP 3.1 to install the Punch Module. 8. Do ARP 1.6 to install the Rear Cover. 9. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-121...

  • Page 201: Arp 3.25 Punch Module Mount Pin Replacement

    5. Place the new Mount Pin in position and tighten the Screw. 6. Do ARP 3.1 to install the Punch Module. 7. Close the Front Door. 8. Do ARP 1.6 to install the Rear Cover. 9. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-122...

  • Page 202: Arp 3.26 Backgage Sensor Bracket Weldment And Backgage Sensor Lower Bracket Replacement

    6. Connect the Power Cord. 5. If replacing only the lower bracket, replace the Bracket then go to the installation procedure. 6. Unplug the Backgage Sensor and release the wires from the Cable Clamps. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-123...

  • Page 203: Arp 3.27 Die Set Recognition Replacement

    6. Connect the Die Set Recognition Cable. 7. Do ARP 1.6 to install the Rear Cover. 8. Do ADJ 1.6 Die Set Recognition board adjustment procedure. 9. Connect the Power Cord. Die Set Recognition Cable (Cont.) GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-124...

  • Page 204: Power Supply

    3. Dsiconnect Connectors J1 and J3 from the Main Control Board. Grommet Connector 4. Remove the M4 Screw (1) and remove the Ground Cable from the Power Supply. Screw 5. Remove the M4 Screws (4) from the side of the Base Frame. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-125...
  • Page 205 3. Place the Ground Cable in position on the Power Supply and tighten the M4 Screw (1). 4. Connect Connectors J1 and J3 to the Main Control Board. 5. Do ARP 1.6 to install the Rear Cover. 6. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-126...

  • Page 206: Arp 4.2 Ac Filter Replacement

    5. Remove the Wires (3) and the AC Filter. 6. Place the new AC Filter in position and tighten the Screws (2). 7. Do ARP 1.6 to install the Rear Cover. 8. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-127...

  • Page 207: Electronics And Control

    2. Do ARP 1.6 to remove the Rear Cover. 3. Remove the M3 Screws (6) from the Main Control Board and the the Comm Board. 7. Disconnect the plug-in Connector and remove the Comm Board. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-128...
  • Page 208 J16 COMM Board 7715455 7715467 6. Do ARP 1.6 to install the Rear Cover. 7715466 7. Connect the Power Cord. 7715536 7715451 7715485 7715477 7715473 7715453 7715495 7715468 7715457 7715456 7715476 7715493 7715494 7715487 7715492 GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-129...

  • Page 209: Arp 5.2 Comm Board Replacement

    3. Disconnect the Connectors (3). 4. Connect the Power Cord. • Connector J14 • Connector J15 • Connector J16 4. Using pliers release (2) standoffs and remove the Comm board by pulling down on the plug-in connector. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-130...

  • Page 210: Arp 5.3 Dieset Recognition Reader Board Replacement

    6. Connect the Connector to the Dieset Recognition Reader Board. 7. Do ADJ 1.6 Dieset Recognition Board Adjustment to set the Dieset Recognition Reader Board. 8. Do ARP 1.6 to install the Rear Cover. 9. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-131...

  • Page 211: Adjustments

    Some machine components contain 8. Test the Door Latch operation. dangerous electrical voltages that can result in electrical shock and possible serious injury. 1. Disconnect the Power Cord. 2. Open the Front Door. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-132...

  • Page 212: Adj 1.2 Diverter Solenoid Adjustment

    Entrance Panel. Shim (0.25 to 0.5mm) 4. When the solenoid in not actuated, it needs to rest on the Diverter limiter bracket. To properly adjust the position of the limiter bracket do the following: GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-133...
  • Page 213 NOTE: Raising the Limiter Bracket too high will position the diverter gate higher, which will obstruct the paper flow and cause jams. 5. Check the clearance between the Diverter and the cutout in the Lower Entrance Panel at both sides. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-134...

  • Page 214: Adj 1.3 Die Stop Magnet Adjustment

    9. Install the Die Set (see Operator Manual). 10. Close the front Door. 3. Loosen the Nut and Lock Screw. 4. Rotate the Die Set Magnet to adjust the position of the Die Set Stop. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-135...

  • Page 215: Adj 1.4 Timing Belts Adjustment

    7. Do ARP 3.1 to install the Punch Module. 8. Do ARP 1.6 to install the Rear Cover. 9. Connect the Power Cord. 5. Adjust the belt tension such that there is a deflection of 1~2mm. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-136...
  • Page 216 3. Loosen the the tensioner. 4. Adjust the belt tension such that there is a deflection of 6~8mm. 5. Tighten the tensioner 6. Do ARP 1.6 to install the Rear Cover. 7. Connect the Power Cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-137...
  • Page 217 3. Loosen the the tensioner. 4. Adjust the belt tension such that there is a deflection of 3~5mm. 5. Tighten the tensioner 6. Do ARP 1.6 to install the Rear Cover. 7. Connect the Power cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-138...
  • Page 218 3. Loosen the the tensioner. 4. Adjust the belt tension such that there is a deflection of 4~6mm. 5. Tighten the tensioner 6. Do ARP 1.6 to install the Rear Cover. 7. Connect the Power cord. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-139...
  • Page 219 5. Adjust the belt tension such that there is a deflection of 1~2mm. 6. Tighten the Phillips Screws (4). 7. Do ARP 3.1 to install the Punch Module. 8. Do ARP 1.6 to install the Rear Cover. 9. Connect the Power Cord. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-140...

  • Page 220: Adj 1.5 Punch Clutch Indexing

    (±5° from horizontal is acceptable). See below for an image of a properly indexed punch shaft. 3. Disconnect the Power Cord. 4. Do ARP 1.6 to remove the Rear Cover. 5. Do ARP 3.1 to remove the Punch Module. (Cont.) GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-141...
  • Page 221 For some 230v machines, moving the stop collar towards the pulley may not expose the teeth completely. In such instances, remove the pulley off the clutch (3 sets of socket head screws and washers), see ARP 3.7 Clutch Pulley replacement. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-142...
  • Page 222 In this instance the cam needs to stop earlier, therefore rotate the Stop Collar Clockwise (when viewed from the rear side). This is done by manually lowering the pawl and freeing the Stop collar to rotate. GBC PUNCH G2 02/28/2019 Adjustments/Repairs...
  • Page 223 Alternately “Cycle Punch” Function Test from Service mode can be performed. After a punch cycle the flat in the front side would have returned to horizontal position (as shown in the pictures of Step# 1). GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-144...

  • Page 224: Adj 1.6 Dieset Recognition Board Adjustment

    5. Tighten the Screws (2) that hold the Dieset Recognition Reader Board. 3. Insert a die set until the Dieset is about to contact the spring clips in 6. Do ARP 1.6 to install the Rear Cover. the Reader Board. GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-145...

  • Page 225: Adj 1.7 Idler Panel Magnetic Latches Adjustment

    (to eliminate the play in the magnet) and tighten both screws. The screws should be tightened while the panel is closed firmly and the magnet pulled away as shown. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-146...

  • Page 226: Adj 1.8 Drive Panel Position Adjustment

    This drive panel controls the nip forces of N2, N3, N4 and N5. 1. To adjust the position of the drive panel loosen (5) screws from the Front frame and (5) screws from the rear frame. GBC PUNCH G2 02/28/2019 Adjustments/Repairs...
  • Page 227 2. Using the Reference holes in the front/rear frame (5 holes in the front frame and 5 holes in the rear frame) and the sheet metal panel, position the drive panel to ensure the drive rollers protrude 1.5±0.5mm through the drive panel. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-148...
  • Page 228 Front frame and (5) screws from the rear frame (Cover plate of Jam 1.5±0.5mm through the drive panel. area 5 needs to be removed). GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-149...
  • Page 229 1. To adjust the position of the drive panel loosen (4) screws from the position the drive panel to ensure the drive rollers protrude Front frame and (4) screws from the rear frame. 1.5±0.5mm through the drive panel. GBC PUNCH G2 Adjustments/Repairs 02/28/2019 4-150...
  • Page 230 Notes: GBC PUNCH G2 02/28/2019 Adjustments/Repairs 4-151...
  • Page 231 PL 4.11. Punch Module- AC Motor ............. 29 5. Die Sets ....................6. Electronics..................31 PL 6.1. Electronics PCB Assembly........... 31 PL 6.2. Control Board Bracket Sub Assembly........32 PL 6.3. Cable Part Number Index............. 33 GBC PUNCH G2 02/28/2019 Parts List...

  • Page 232: Main Assembly

    Main Assembly ITEM Part # DESCRIPTION PL 1.1. Final Assembly 7718801 PUNCH G2 115V 7718880 PUNCH G2 230V Parts List 02/28/2019 GBC PUNCH G2...

  • Page 233: 1.2. Cabinet- Covers

    COVER WELDMENT, R-BACK, KM 7718856 COVER, POCKET 7718859 BRACKET, EXHAUST FAN, KM COVER, WELDMENT, SIDE, 7718862 DOWNSTREAM, REAR, KM PANEL ASSY, BACK LEFT, 7718867 SPARTA, KM SPACER, KM SPARTA, MTG 7718872 INTERFACE 7718873 FOAM, KM SPARTA GBC PUNCH G2 02/28/2019 Parts List...

  • Page 234: Frame Assembly

    SHAFT,IDLR PANEL HINGE,LONG 7715251 BRACKET, IDLER PANEL MOUNT 7715150 PANEL WELDMENT, DRIVE, EXIT PANEL WLDMNT, 7715128 BYPASS,LOWER SNAP-IN BEARING, 6MM ID 1821209 [Qty. (2) used on all Idler panels- #A, #B, #D, #E and #5 Parts List 02/28/2019 GBC PUNCH G2...

  • Page 235: 2.2. Frame Assembly- Front Side

    CHIP TRAY, ASSEMBLY 7715650 LATCH, BYPASS 7715637 POWER SUPPLY, 24V, MW SP 480, 7715789 MAGNET, PANEL, OPEN, WEAK 7708163 CAP, RUBBER, RAIN BLUE 7723799 CASTER, ADJUSTABLE, ASSY, KM 1823913 SCREW, HX, W/SEMS, M3 X 8 GBC PUNCH G2 02/28/2019 Parts List...

  • Page 236: 2.3. Frame Assembly- Rear Side

    WIRE CLAMP, EDGE 7715445 WIRE CLAMP, EDGE, SMALL 7715813 SOLENOID, BRACKET, DIVERTER, SUB ASSY 7715818 WIRE SADDLE, MEDIUM, LOCKING TOP, V-0 7715819 WIRE SADDLE, LARGE, LOCKING TOP, V-0 7715817 WIRE SADDLE, SMALL, LOCKING TOP, V-0 Parts List 02/28/2019 GBC PUNCH G2...

  • Page 237: 2.4. Frame Assembly- Drive Rollers

    ROLLER ASSY, ONE WAY CLUTCH DRIVE 1821116 BEARING, BALL, FLANGE 6X13X5, SUJ2 1822005 WASHER, FLAT, 6.025 X 8 X 0.75 E-RING, JE-5 1822202 7706532 BEARING BALL FLANGE 1925222 WASHER FLAT, 1/4X3/8X/1/32 7715862 ONE WAY CLUTCH SUB ASSEMBLY GBC PUNCH G2 02/28/2019 Parts List...

  • Page 238: 2.5. Frame Assembly- Internal Parts

    BYPASS DIVERTER 7715186 CHIP TRAY SENSOR MOUNT ASSY 7715213 SHAFT, ACCEL IDLER LATCH 7715216 LATCH, ASSY, REAR, ACCEL IDLER PANEL 7715222 LATCH, ASSY, FRONT, ACCEL IDLER PANEL 7715637 POWER SUPPLY, 24V, MW SP 480, Parts List 02/28/2019 GBC PUNCH G2...

  • Page 239: 2.6. Frame Assembly- Motors And Motor Drivers

    DRIVER AND BRACKET ASSY, TWO PHASE M4 STEPPER DRIVER 7715275 DRIVER AND BRACKET ASSY, TWO PHASE M5 STEPPER DRIVER 7715275 DRIVER AND BRACKET ASSY, TWO PHASE SEE PL 6.3 FOR STEPPER MOTOR M3, M4 AND M5 POSITIONS GBC PUNCH G2 02/28/2019 Parts List...

  • Page 240: 2.7. Frame Assembly- Sensors

    EXIT SENSOR, TOP 7715291 EXIT SENSOR 7715291 BYPASS SENSOR, MIDDLE 7715597 ALIGN HOME SENSOR 7711970 CHIP LEVEL SENSOR - EMITTER 7711973 CHIP LEVEL SENSOR - RECEIVER 7715774 CLEAR COVER SENSOR-EMITTER 7711973 CLEAR COVER SENSOR-RECEIVER Parts List 02/28/2019 GBC PUNCH G2 5-10...

  • Page 241: 2.8. Frame Assembly- Solenoids / Switches

    SOLENOID EXIT IDLER SOLENOID, 7715223 SOL 6 BOTTOM EXIT IDLER SOLENOID, 7715223 SOL 7 MIDDLE 7715223 SOL 8 EXIT IDLER SOLENOID, TOP FRONT DOOR INTERLOCK 7610501 SWITCH CHIP TRAY HOME SWITCH 7715186 ASSEMBLY GBC PUNCH G2 02/28/2019 Parts List 5-11...

  • Page 242: 2.9. Frame Assembly- Belts

    Part # PL 2.9. Frame Assembly- Belts 7715202 BELT, 534T, 2MM 2GT 7715204 PULLEY,TIMING,2MM 2GT,30T 7715206 BELT, 179T, 2MM 2GT 7715243 BELT, 150 T, 2MM 2GT 7715245 TENSIONER ASSEMBLY 7715246 BELT, 134T, 2MM 2GT Parts List 02/28/2019 GBC PUNCH G2 5-12...

  • Page 243: Paper Path

    MID PUNCH, X LARGE, SENSOR BOARD 7715696 BOARD ASSY, BACKGAGE SENSOR 7715871 PANEL WLDMNT,DRIVE,ENTRANCE,SERVICE 1822108 WASHER, FLAT, 4.1X 8X1.5 1822117 WASHER, 3.2ID, 8OD, 0.75MM THICK 1823903 SCREW, PHILLIPS, HX HD M4X8 S20, S21 S18, S19 GBC PUNCH G2 02/28/2019 Parts List 5-13...

  • Page 244: 3.2. Paper Path- Entrance Idler Panel

    BEARING HOUSING 7715384 HANDLE ASSY, IDLER PANELS 7715625 WIRE SADDLE, SHORT 7715629 SCREW, BARREL, M4, 7MM DEEP 7715639 WIRE SADDLE,SMALL,SIDE OPEN 7715873 PANEL WLDMT,IDLER,ENTRY 7714679 GROUND STRAP, M4 7708163 CAP, RUBBER SOL3 SOL4 Parts List 02/28/2019 GBC PUNCH G2 5-14...

  • Page 245: 3.3. Paper Path- Acceleration Roller Idler

    SENSOR AND BRACKET ASSY 7715376 BRUSH, ANTI STATIC 7715380 SPRING,TRANSPORT IDLR ROLLER 7715382 BEARING HOUSING ASSY 7715817 WIRE SADDLE, SMALL 7715629 SCREW, BARREL, M4, 7MM DEEP 7715875 PANEL WLDMNT, IDLER, ACCEL 7714679 GROUND STRAP, M4 SOL5 GBC PUNCH G2 02/28/2019 Parts List 5-15...

  • Page 246: 3.4. Paper Path- Exit Idler Panel

    7715384 HANDLE ASSY, IDLER PANELS 7715382 BEARING HOUSING ASSY 7715625 WIRE SADDLE, SHORT 7715629 SCREW,BARREL,M4,7MM DEEP 7715639 WIRE SADDLE,SM,SIDE OPEN 7715874 PANEL WELDMENT,IDLER,EXIT 7714679 GROUND STRAP, M4 7708163 CAP, RUBBER SOL8 SOL7 SOL6 Parts List 02/28/2019 GBC PUNCH G2 5-16...

  • Page 247: 3.5. Paper Path- Upper Bypass Panel

    HANDLE ASSY, IDLER PANELS 7715627 SENSOR AND BRACKET ASSY,S1 7715629 SCREW, BARREL, M4, 7MM DEEP 7715872 PANEL WELDMENT, BYPASS, UPPER 7714679 GROUND STRAP, M4 7708163 CAP, RUBBER 1822117 WASHER, 3.2ID, 8OD, 0.75MM THICK GBC PUNCH G2 02/28/2019 Parts List 5-17...

  • Page 248: 3.6. Paper Path- Disengaging Roller Solenoid

    ITEM Description Part # PL 3.6. Paper Path- Disengaging Roller Solenoid SOL 3 SOL 4 SOL 5 MODULE, SOLENOID, 7715223 SOL 6 DISENGAGING ROLLER SOL 7 SOL 8 Parts List 02/28/2019 GBC PUNCH G2 5-18...

  • Page 249: Punch Module

    SCREW,SOCKET,M5, 6MM SHOULDER 1823911 SCREW, PHILLIPS W/SEMS M4X10 1824003 NUT, KEPS, M6 7715033 STEERING MODULE SUB ASSY 7715237 SHAFT, DIE LOCK 7715368 HANDLE, DIE LOCK 7715818 WIRE SADDLE,MEDIUM,LOCK TOP,V-0 7715886 PUNCH MODULE SHELL, SERVICE GBC PUNCH G2 02/28/2019 Parts List 5-19...

  • Page 250: 4.2. Punch Module (Continued)

    7715372 230V BELT, TIMING, 80 GROOVE, 5MM HTD 7715238 BRACKET & BEARING ASSY,DIE LOCK 7715239 PLUNGER & STRIPPER ASSY,DIE LOCK 7715320 MAGNET, DIE STOP 7715374 SPRING, DIE LOCK RETURN 1824001 NUT, KEPS M4 Parts List 02/28/2019 GBC PUNCH G2 5-20...

  • Page 251: 4.3. Punch Module- Motors/Sensors

    LEFT / FRONT STEERING 7715857 MOTOR AND PULLEY. RIGHT / REAR STEERING 7715857 MOTOR AND PULLEY. ALIGNMENT STEPPER 7715859 MOTOR AND PULLEY. 7715692 SKEW SENSOR BOARD ALIGNMENT SENSOR 7718567 BOARD, SWITCHABLE 7715696 BACKAGE SENSOR BOARD GBC PUNCH G2 02/28/2019 Parts List 5-21...

  • Page 252: 4.4. Punch Module- Steering Module

    SCREW, PHILLIPS HX W/SEMS, M3X6 1823913 SCREW,PHILIPS-HEX LOCK, M3X8 1824002 NUT, KEPS, M3 7715445 WIRE CLAMP, EDGE, SMALL 7715597 SENSOR, VEIN, BRACKET, SUB ASSLY 7715779 GROUND STRAP, STEERING CARRIAGE ALIGNMENT CARRIAGE,SUB ASSY, 7715877 SERVICE Parts List 02/28/2019 GBC PUNCH G2 5-22...

  • Page 253: Sub Assembly

    WASHER, 3.2ID, 8OD, 0.75MM THK 1824002 NUT, KEPS, M3 7706488 BEARING, DOUBLE "D" FLANGE PANEL 7715062 WELDMENT,IDLER,STEERING 7715379 SPRING, STEERING IDLER ROLLER 7715648 WIRE CLAMP, LOCKING 7715692 BOARD ASSY, SKEW SENSOR 7715816 ROLLER ASSY, IDLER, STEERING GBC PUNCH G2 02/28/2019 Parts List 5-23...

  • Page 254: 4.6. Punch Module- Steering Module - Drive Panel Steering

    BELT,STEERING,65 GROOVES,2MM 2GT 7715053 PANEL WELDMENT, DRIVE, STEERING 7715377 SPRING, STEERING DRIVE ROLLER 7715648 WIRE CLAMP, LOCKING 7715777 SLEEVE,SPIRAL, MOTOR WIRES STEPPER MOTOR AND 7715857 PULLEY,STEERING, SERVICE STEPPER MOTOR AND 7715857 PULLEY,STEERING, SERVICE Parts List 02/28/2019 GBC PUNCH G2 5-24...

  • Page 255: 4.7. Punch Module- Stepper Alignment Bracket

    PL 4.7. Punch Module- Stepper Alignment Bracket ITEM DESCRIPTION Part # 1823906 SCREW,PHILLIPS HX W/SEM M5X10 7715078 BRACKET,ALIGN STEPPER MOUNT STEPPER MOTOR AND PULLEY, 7715859 ALIGNMENT, SERVICE GBC PUNCH G2 02/28/2019 Parts List 5-25...
  • Page 256 Punch Module- Punch Clutch ITEM DESCRIPTION Part # 1821531 SCREW, SHCS, M5X18 1821801 WASHER, SPLIT LOCK, M5 7715020 CLUTCH, WRAP SPRING 7715231 115V PULLEY & FLANGE,5MM HTD,38T 7715371 230V PULLEY & FLANGE,5MM HTD,34T Parts List 02/28/2019 GBC PUNCH G2 5-26...

  • Page 257: 4.9. Punch Module- Die Set Recognition Reader Board

    PL 4.9. Punch Module- Die Set Recognition Reader Board ITEM DESCRIPTION Part # BOARD, READER, DIE SET 7715347 RECOGNITION 1824002 NUT, KEPS, M3 GBC PUNCH G2 02/28/2019 Parts List 5-27...

  • Page 258: Pl 4.10. Punch Module- Die Rail, Backgage, Align Sensors

    7715817 SPRING, DIE RAIL, POSITION, 2 7715986 WIRE SADDLE, SMALL, LOCKING TOP, V-0 7715988 DIE RAIL, ASSEMBLY 7715990 GUIDE, ALIGNMENT SENSOR, BOTTOM 7715787 BRACKET WLDMNT, ALIGNMENT SENSOR BOARD ASSY, ALIGNMENT SENSOR, 7718567 SWITCHABLE Parts List 02/28/2019 GBC PUNCH G2 5-28...

  • Page 259: Pl 4.11. Punch Module- Ac Motor

    1822113 WASHER, FLAT, 8X14X0.5 1823602 SET SCREW, NYLON PATCH, M4X6 1824703 SCREW, HEX CAP, M8, 16MM LONG MOTOR AND PULLEY, PUNCH, 7715860 115V 115V, SERVICE MOTOR AND PULLEY, PUNCH, 7715861 230V 230V, SERVICE GBC PUNCH G2 02/28/2019 Parts List 5-29...

  • Page 260: Die Sets

    DIE, Wire 3:1, Sq 7714914 DIE, Coil, Oval 7714915 DIE, eWire 3:1, Rnd 7714916 DIE, eWire 3:1, Sq 7714917 DIE, Coil, Rnd, 47H HD 7714918 DIE, 3 Hole, 8mm, HD 7714919 DIE, CombBind, 21H HD Parts List 02/28/2019 GBC PUNCH G2 5-30...

  • Page 261: Electronics

    6.Electronics PL 6.1. Electronics PCB Assembly ITEM DESCRIPTION Part # 6195001 RFI POWER FILTER 7718655 BOARD, CONTROL, MAIN 7718799 BOARD, CONTROL, COMM 7715863 FUSE,AC POWER, 250V, 5A GBC PUNCH G2 02/28/2019 Parts List 5-31...

  • Page 262: 6.2. Control Board Bracket Sub Assembly

    PL 6.2. Control Board Bracket Sub Assembly ITEM DESCRIPTION Part # 7715183 STANDOFF, PLASTIC, 2 PHASE DRIVER 7715817 WIRE SADDLE, SMALL, LOCKING TOP, V-0 7715819 WIRE SADDLE, LARGE, LOCKING TOP, V-0 Parts List 02/28/2019 GBC PUNCH G2 5-32...

  • Page 263: 6.3. Cable Part Number Index

    CABLE, COMM TO PANEL 7715487 CABLE, DOOR INTERLOCK 7715531 CABLE, DFA, UPSTREAM, SPARTA 7715490 CABLE, USB 7718876 CABLE, PASSTHROUGH, KM SPARTA 7715492 CABLE, DC POWER 7715493 CABLE, AC TO PSU 7715494 CABLE, AC TO BOARD GBC PUNCH G2 02/28/2019 Parts List 5-33...
  • Page 264 PL 6.4. Wiring Drawing Parts List 02/28/2019 GBC PUNCH G2 5-34...
  • Page 265 PCB’S Main Control Board and Communication Board GBC PUNCH G2 02/28/2019 Parts List 5-35...

  • Page 266: Installation Kit Parts

    DOCKING BRACKET ASSY, REAR, 7723873 SPARTA, KM BRKT SUBASSY, DOCKING, LOWER 7718832 FRNT, KM 7710227 BRACKET, LOCK, FRONT, LOWER BRKT SUBASSY, DOCKING, UPPER 7718834 FRNT, KM Miscellaneous Parts ITEM GBC Part DESCRIPTION 7718648 WIPES, CLEANING, ANTI-STATIC Parts List 02/28/2019 GBC PUNCH G2 5-36...

  • Page 267: Part Number Index

    PANEL ASSEMBLY, LOWER, EXIT 1954032 GROMMET, 1 1/4 I.D. X 1 1/2 O.D. 7715209 SHAFT, IDLER PANEL HINGE 7712703 WIRE HEADER CONNECTOR, 2 POS 7714679 GROUND STRAP, M4 7715210 SHAFT, IDLER PANEL HINGE, LONG GBC PUNCH G2 02/28/2019 Parts List 5-37...
  • Page 268 Backage Sensor Board Assy 1822108 WASHER, FLAT, 4.1X 8X1.5 Mid Punch Large, Sensor Board Backage Sensor 1822117 WASHER, 3.2ID, 8OD, 0.75MM THICK 7715696 Board Assy 1823903 SCREW, PHILLIPS, HX HD M4X8 7711970 EMITTER Parts List 02/28/2019 GBC PUNCH G2 5-38...
  • Page 269 PLUNGER AND STRIPPER ASSY, DIE LOCK 7715103 ROLLER ASSY, IDLER 7715320 MAGNET, DIE STOP 7715291 SENSOR AND BRACKET ASSEMBLY 7715374 SPRING, DIE LOCK RETURN 7715376 BRUSH, ANTI-STATIC 1824001 NUT, KEPS M4 7715380 SPRING, TRANSPORT IDLER ROLLERS GBC PUNCH G2 02/28/2019 Parts List 5-39...
  • Page 270 7715857 7714909 DIE, Ricoh, Velobind®, 11 Holes, Ltr. SERVICE 1823906 SCREW, PHILLIPS HX HD W/SEMS M5 X 10 7714910 DIE, Ricoh, Velobind®, 12 Holes, A4 7715078 BRACKET, ALIGNMENT STEPPER MOUNT 7714911 DIE, CombBind Parts List 02/28/2019 GBC PUNCH G2 5-40...
  • Page 271 CABLE ASSY, INTERFACE (37 PINS) 7723873 DOCKING BRACKET ASSY, REAR, SPARTA, KM 7718832 BRKT SUBASSY, DOCKING, LOWER FRNT, KM 7710227 BRACKET, LOCK, FRONT, LOWER 7718834 BRKT SUBASSY, DOCKING, UPPER FRNT, KM 7718648 WIPES, CLEANING, ANTI-STATIC GBC PUNCH G2 02/28/2019 Parts List 5-41...
  • Page 272 Revision History Date Page# Item# Notes 5/31/2017 Initial Release 6/7/2017 KM Part number columns removed 02/28/2019 5-36 7718648 7718648 added Parts List 02/28/2019 GBC PUNCH G2 5-42...
  • Page 273 Die Set Recognition Board Clips Inspection ..6-66 GP 6.3 Undock the Punch (Moving the punch to Service position) ................. 6-43 GP 6.27 Die Lock Mechanism and Die Rail Springs Inspection6-66 General Information ..............6-68 GBC PUNCH G2 02/28/2019 General Procedures and Information Section Contents...
  • Page 274 Bypass Path ................6-69 Cleaning Materials ..............6-77 Glossary of Terms ..............6-71 Serial Numbers ................ 6-77 Specifications ................6-72 Die Sets 6-73 Die Sets List ................ 6-74 Die Sets List (cont’d) ............6-75 GBC PUNCH G2 General Procedures and Information 02/28/2019...

  • Page 275: General Procedures

    In the User Interface, the top row of text displays the status of the Punch (Ready, Close Door). The bottom row of text displays the options selected on the User Interface (Single Punch). GBC PUNCH G2 02/28/2019 General Procedures and Information...

  • Page 276: Settings

    The language options are: English, Francais, Espanol, Deutsch, and Italiano. Units The Units feature allows you to select the units displayed on the user interface. Select MM for millimeters of IN for inches. GBC PUNCH G2 General Procedures and Information 02/28/2019...

  • Page 277: User Interface Screen Map

    User Interface Screen Map GBC PUNCH G2 02/28/2019 General Procedures and Information...

  • Page 278: Gp 6.1 User Interface Procedure

    GP 6.1.4 LANGUAGE SETTINGS Procedure • GP 6.1.5 UNITS Procedure Information • GP 6.1.8 DIE TYPE Procedure • GP 6.1.9 DIE CYCLES Procedure • GP 6.1.10 PUNCH CYCLES Procedure • GP 6.1.11 FIRMWARE Procedure GBC PUNCH G2 General Procedures and Information 02/28/2019...

  • Page 279: Gp 6.1.1 Backgage Setting Procedure

    MID L and MID XL function the same as the regular backgage depth, but adjust the position of the middle punch. MID L adjusts backgage for SEF letter and A4, while MID XL adjusts backgage for SEF 11x17 and A3 GBC PUNCH G2 02/28/2019 General Procedures and Information...
  • Page 280 8. Press the ENTER button to enter the new Backgage value. for that die. This displays the TRAIL / MID L screen. TRAIL MID L 9. Press the up arrow button to display the PREVIOUS MENU option. PREVIOUS MENU TRAIL GBC PUNCH G2 General Procedures and Information 02/28/2019...

  • Page 281: Gp 6.1.2 Alignment Setting Procedure

    3. Press the down arrow button once so the return symbol is next to the word ALIGNMENT. BACKGAGE ALIGNMENT 4. Press the ENTER button when the return symbol is next to the word Alignment to display the ALIGNMENT OFFSET screen. ALIGNMENT OFFSET 0.0 mm GBC PUNCH G2 02/28/2019 General Procedures and Information...
  • Page 282 CLEAR OFFSET 7. Press the up or down arrow button to display the EXIT option. EXIT PREVIOUS MENU Press the ENTER button to return to the top level screen. READY SINGLE PUNCH GBC PUNCH G2 General Procedures and Information 02/28/2019 6-10...

  • Page 283: Gp 6.1.3 Clear Cover Procedure

    Press the ENTER button to return to the top level screen READY • For CLR BACKGAGE go to step 5. SINGLE PUNCH • For CLR ALIGNMENT go to step 8 (See page Error! Bookmark not defined.). (Cont.) GBC PUNCH G2 02/28/2019 General Procedures and Information 6-11...
  • Page 284 8. Press the ENTER button to display the CLR ALIGNMENT / PREVIOUS MENU screen. CLR ALIGNMENT PREVIOUS MENU 9. Press the ENTER button to display the CLR OFFSET / LANGUAGE screen. CLEAR COVER LANGUAGE GBC PUNCH G2 General Procedures and Information 02/28/2019 6-12...

  • Page 285: Gp 6.1.4 Language Settings Procedure

    8. Press the ENTER button to return to the top level screen READY CLEAR OFFSET SINGLE PUNCH LANGUAGE 4. Press the ENTER button when the return symbol is next to the word Language. to display the LANGUAGE screen. LANGUAGE ENGLISH GBC PUNCH G2 02/28/2019 General Procedures and Information 6-13...

  • Page 286: Units Procedure

    UNITS to display the UNITS screen. UNITS 5. Press either the up arrow button or the down arrow button to change units from mm to inch or vice versa. UNITS INCH GBC PUNCH G2 General Procedures and Information 02/28/2019 6-14...

  • Page 287: Gp 6.1.7 Information Procedure

    4. Press the ENTER button to display the DIE TYPE/DIE CYCLES screen. DIE TYPE DIE CYCLES See the following pages for Die Type Information Die Cycles Information Punch Cycles Information Firmware Information GBC PUNCH G2 02/28/2019 General Procedures and Information 6-15...
  • Page 288 DIE TYPE DIE CYCLES 5. Press the ENTER button when the return symbol down is next to the words DIE TYPE. This displays the DIE TYPE screen, DIE TYPE WIRE 3:1 SQUARE GBC PUNCH G2 General Procedures and Information 02/28/2019 6-16...
  • Page 289 5. Press the ENTER button when the return symbol is next to the words DIE CYCLES to display the DIE CYCLES screen. DIE CYCLES 23,495 6. Press the ENTER button to display the DIE TYPE – DIE CYCLES screen. DIE TYPE DIE CYCLES GBC PUNCH G2 02/28/2019 General Procedures and Information 6-17...

  • Page 290: Gp 6.1.10 Punch Cycles Procedure

    5. Press the ENTER button when the return symbol is next to the words PUNCH CYCLES to display the PUNCH CYCLES screen. PUNCH CYCLES 1,420,428 6. Press the ENTER button to display the DIE TYPE – DIE CYCLES screen. PUNCH CYCLES FIRMWARE GBC PUNCH G2 General Procedures and Information 02/28/2019 6-18...

  • Page 291: Gp 6.1.11 Firmware Procedure

    3. Press the ENTER button to display the DIE TYPE – DIE CYCLES SINGLE PUNCH screen. DIE TYPE DIE CYCLES 4. Press the down arrow button so the return symbol is next to the word FIRMWARE. PUNCH CYCLES FIRMWARE GBC PUNCH G2 02/28/2019 General Procedures and Information 6-19...

  • Page 292: Service User Interface

    The Max Bypass feature allows you to set the maximum sheet length that • View Die cycles and Machine log will be bypassed through PUNCH G2. • Upgrade Firmware When the Service user Interface is open, the top row of text and the...
  • Page 293 The Motors feature allows you to test the operation of each of the 9 The Skew Offsets feature allows you to setup the skew offsets to motors to the PUNCH G2. straighten and offset punch depth. The options are: •...

  • Page 294: Service Interface Screen Map

    Service Interface Screen Map GBC PUNCH G2 General Procedures and Information 02/28/2019 6-22...

  • Page 295: Gp 6.2 Service User Interface Procedure

    • GP 6.2.1 PAPER SIZE • GP 6.2.2 MAX BYPASS • GP 6.2.3 RUN MODE • GP 6.2.4 DIE CYCLES • GP 6.2.5 SENSORS • GP 6.2.6 SOLENOIDS • GP 6.2.7 GBC PUNCH G2 02/28/2019 General Procedures and Information 6-23...

  • Page 296: Gp 6.2.1 Paper Size Setting

    2. Press the down arrow button to move the return symbol next to MAX BYPASS. Press OK to enter the Max Bypass setting PAPER SIZE MAX BYPASS 3. The below screen will appear MAX BYPASS 700mm GBC PUNCH G2 General Procedures and Information 02/28/2019 6-24...

  • Page 297: Run Mode Setting

    AUTO CYCLE – Covering Sensor S25 will enable all components: all motors, all solenoids. It can be used to check the When PUNCH G2 is not connected to a finisher and the punch is functioning of all motors and solenoids.

  • Page 298: Gp 6.2.4 Die Cycles

    OK. RUN MODE DIE CYCLES DIE CYCLES 501, 175 3. Press OK to return to the service menu. Press up or down arrow and exit to the Main screen. GBC PUNCH G2 General Procedures and Information 02/28/2019 6-26...

  • Page 299: Gp 6.2.5 Sensors Check

    The Sensors feature allows you to view the state of each of the 29 Arrow button, press the Enter button. sensors to the PUNCH G2. The Service User Interface screen will appear. Cover each sensor to check if the sensor status changes from “0” to “1””.
  • Page 300 4. Press the down arrow to scroll through the sensor options. S6=0 S7=0 S8=0 S9=0 S10=0 S11=0 S12=0 Sensor S28 covered S13=0 S14=0 S15=0 S16=0 S17=0 S18=0 S19=0 S20=0 S21=0 Sensor S28 uncovered (Cont.) GBC PUNCH G2 General Procedures and Information 02/28/2019 6-28...

  • Page 301: Previous Menu

    When you scroll down from the S26-S27-S28 screen, the system displays the Previous Menu / EXIT screen. PREVIOUS MENU EXIT You can either exit to the Previous Menu or Exit to Main Screen. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-29...

  • Page 302: Gp 6.2.6 Solenoids Check

    Press up or down to display the Previous Menu and Exit Options. MAX BYPASS 2. Press the down arrow so the return symbol is next to the words SOLENOIDS. SENSORS SOLENOIDS GBC PUNCH G2 General Procedures and Information 02/28/2019 6-30...

  • Page 303: Gp 6.2.7 Motors Check

    Do the following to test any of the Stepper Motors. M1 M2 M3 M4 The Motors feature allows you to test the operation of each of the 8 stepper motors to the PUNCH G2. M6 M7 M8 BACK Do the following to check the Motors.

  • Page 304: Gp 6.2.8 Function Tests (Cycle Punch, Aligner Test, Fan Test)

    After the test is complete it stops automatically, you may scroll down to Previous Menu or Exit. FUNCTION TESTS NOTE: The FUNCTION 4 test is not assigned. FUNCTION 4 PREVIOUS MENU (Cont.) GBC PUNCH G2 General Procedures and Information 02/28/2019 6-32...
  • Page 305 From the FAN TEST, press the up arrow four times to display the EXIT / PREVIOUS MENU screen. EXIT PREVIOUS MENU • You may return to the main Service mode menu or Exit to the Main Screen. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-33...

  • Page 306: Gp 6.2.9 Skew Offsets Adjustment

    6. From any Skew Offset screen, you can scroll up or down through the 4. Press the down arrow to scroll through the Skew Offset options. entire list of Skew Offset options. • BG LEFT GBC PUNCH G2 General Procedures and Information 02/28/2019 6-34...
  • Page 307 To check Skew, fold the sheet as shown. EXIT • You may return to the main Service mode menu or Exit to the Top level screen. (Cont.) The last holes should line up. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-35...
  • Page 308 BG LEFT ‘-’ Select 1 1, 2, 3…etc. until the holes are parallel to the BG LEFT ‘+‘ Select 1 1, 2, 3…etc. until the holes are parallel to the edge. edge. GBC PUNCH G2 General Procedures and Information 02/28/2019...
  • Page 309 BG DP L LEFT ‘+’ Select 1, 2, 3…etc. until the holes are parallel to shown below: the edge. BG DP L RIGHT ‘+’ Select 1, 2, 3…etc. until the holes are parallel to the edge. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-37...

  • Page 310: Gp 6.2.10 Align Offsets Adjustment

    ALIGN OFFSETS. The User Alignment setting adjusts the Alignment position of all SKEW OFFSETS sheets (regardless of size) that are processed by PUNCH G2. The ALIGN OFFSETS described here are performed to individual ALIGN OFFSETS sensors. Therefore adjusting a sensor’s Align Offsets will only impact the sheet sizes using that particular sensor.
  • Page 311 Align Offset options, then repeat the entire PREVIOUS MENU step 5 for the other Align Offset option. EXIT From this screen you can: • Return to the Service mode menu • Exit to the Top level screen GBC PUNCH G2 02/28/2019 General Procedures and Information 6-39...

  • Page 312: Gp 6.2.11 Log

    Press and hold both the Up Arrow button and the Down Arrow button for 5 seconds. Then while still holding down the Up Arrow button and the Down Arrow button, press the Enter button. The Service User Interface screen will appear. GBC PUNCH G2 General Procedures and Information 02/28/2019 6-40...

  • Page 313: Gp 6.2.12 Firmware Upgrade Procedure

    Main or Comm firmware upload (in Step 8). • Press ENTER to return to the Main Screen. 5. Press the down arrow button so the return symbol is next to the words FIRMWARE UPGRADE. FIRMWARE UPGRADE GBC PUNCH G2 02/28/2019 General Procedures and Information 6-41...

  • Page 314: Firmware Upgrade

    12. Remove the USB flash drive with the firmware file you uploaded. 13. Install the Cover for USB port and tighten the Screws (2). 14. Switch off the machine. Wait 10 seconds, and then switch the machine back on again. GBC PUNCH G2 General Procedures and Information 02/28/2019 6-42...

  • Page 315: Gp 6.3 Undock The Punch (Moving The Punch To Service Position)

    Dock the punch (Moving the punch to Operating position) 1. Unplug the AC power cord. Use this procedure to move the PUNCH G2 to operating position. 2. Unplug the Communications cable. 1. Slide the punch to Operating position, ensure the positioning stud in the upstream device slides into the positioning plate.

  • Page 316: Internal Inspection

    2. Refer to section 3.13 Punch Specifications. 2. Correct any problems before returning the machine to service. GBC PUNCH G2 General Procedures and Information 02/28/2019 6-44...

  • Page 317: Die Set Service

    GP 6.7.1 Die Set Life Expectancy The PUNCH G2 Die Sets have a minimum life expectancy of 750K cycles (sheets of paper punched, when punching 75 gsm paper). With periodic lubrication and optimum paper types, life can exceed this number.

  • Page 318: Gp 6.7.3 Die Set Lubrication

    3. Wipe clean, leaving a light coat of oil on them. 4. Oil from the die may blemish the first few punched sheets after oil has been applied. Run test punched copies until clean copies can be made. GBC PUNCH G2 General Procedures and Information 02/28/2019 6-46...

  • Page 319: Gp 6.7.4 Die Set Shoulder Bolts

    Holes should be punched completely, leaving no chip attached. • Holes should be straight (no skew) and evenly spaced from the edge of the paper and aligned. (See GP 6.2.9, SKEW OFFSETS GBC PUNCH G2 02/28/2019 General Procedures and Information 6-47...
  • Page 321 2. Vacuum out paper chips and dust from the Chip Bin tray, especially at 2. The customer can also do this between the technician’s visits. the holes on the sides of the Chip Tray. GBC PUNCH G2 02/28/2019 General Procedures and Information...

  • Page 322: Gp 6.13 Door Latch Inspection

    1. Ensure latch holds door closed. 2. Ensure switch is activated when the door is closed. 3. To adjust the door latch, see ADJ 1.1 GBC PUNCH G2 General Procedures and Information 02/28/2019 6-50...

  • Page 323: Gp 6.14 Idler Roller And Idler Springs Inspection

    2. Inspect Springs (2) for each Idler Roller, and make sure they are correctly hooked. Idler Roller Shaft Idler Roller Retaining Spring Bearing Housing 3. Inspect the Bearing Housing. The Bearing Housing should slide freely in the Bearing Forks. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-51...

  • Page 324: Gp 6.14.1 Idler Roller Cleaning

    4. Ensure the rollers turn freely on the shaft and that the idler roller shaft "floats" freely in the bushing forks. 5. Do ARP 2.4 Idler Roller Replacement to install the Idler Roller. GBC PUNCH G2 General Procedures and Information 02/28/2019...

  • Page 325: Gp 6.14.2 Steering Idler Roller And Springs Inspection And Cleaning

    3. The roller surfaces should be free of debris, toner deposits, wear, unevenness, and dents. 4. Inspect the Steering Idler Springs. The Springs should be hooked securely and should be wrapped around the Bushing. 5. Do ARP 3.1.2 Punch Module Installation. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-53...
  • Page 326 3. The Drive Roller should be free of toner deposits, wear marks, scuff marks, dents, etc. 4. Use the above procedure to clean the Steering Drive Rollers Steering Drive Rollers 5. Do ARP 3.1.2# Punch Module Installation. GBC PUNCH G2 General Procedures and Information 02/28/2019 6-54...

  • Page 327: Gp 6.16 Panel Latch Inspection

    2. When the idler panel is latched, the idler panel spacers ((2) spacers for each Idler assembly) should contact the drive panels completely. There should not be any movement in the idler assembly (toward or away from the drive panel). GBC PUNCH G2 02/28/2019 General Procedures and Information 6-55...
  • Page 328 To inspect the Acceleration Idler latch follow the below procedure: 1. Open the Front door. 2. Undock PUNCH G2. 3. When the Acceleration panel latch is fully engaged, the tabs in the Idler panel should contact the drive panel. Inspect this for the latches in the front side and rear side.
  • Page 329 7. When the idler panel is opened and closed, you should be able to see the Idler springs extend, which will ensure proper idler roller pressure. 8. To adjust the Acceleration Idler Panel Latch, do ADJ 1.8 Entrance Drive Panel Position Adjustment. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-57...

  • Page 330: Gp 6.17 Optical Sensor Cleaning

    For sensor locations, refer to: • PL 3.1 • PL 3.2 • PL 3.3 • PL 3.4 • PL 3.5 • PL 4.2 • PL 4.3 • PL 4.4 • PL 4.9 GBC PUNCH G2 General Procedures and Information 02/28/2019 6-58...

  • Page 331: Bypass Paper Path Inspection And Cleaning

    Clean as needed. 4. Close the panel and check that it is flat and that paper will pass under 5. Ensure the bypass diverter moves freely and returns to the bypass position. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-59...

  • Page 332: Gp 6.19 Punch Paper Path Inspection And Cleaning

    If the latch is bent or damaged, replace the Entrance Idler Panel (ARP 2.3), Acceleration Roller Idler Assembly (ARP 2.5), or the Exit Idler Panel (ARP 2.9). 5. Clean as needed. GBC PUNCH G2 General Procedures and Information 02/28/2019 6-60...
  • Page 333 3. Clean the old grease from the cams and then apply a light coat of high quality grease (not oil). 4. Do ARP 3.1.2 Punch Module Replacement to install the Punch Module. 5. Do ARP 1.6 Rear Cover Replacement to install the Rear Cover. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-61...
  • Page 334 GP 6.20 Timing Belt Inspection There are 11 belts used in the PUNCH G2. Assembly # of Belts Punch Module 1 belt Steering Module 1 belt Drive Panel Steering 2 belts Sub Assembly Frame 8 belts Five of the belts at the rear of the Frame have Tensioner Assemblies. It is these five belts that should be checked.
  • Page 335 When the solenoid is fully activated, the idler roller should completely lift off and not be able to drive the drive roller. NOTE: Disengaging solenoid modules need to be replaced every 5 million cycles. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-63...
  • Page 336 It should move when a force less than 2kgf is applied. If there is binding in the rails, replace the Alignment Carriage sub- assembly. 3. Do ARP 3.1.2 to install the Punch Module. GBC PUNCH G2 General Procedures and Information 02/28/2019 6-64...
  • Page 337 Moving Parts, keep hands clear of nips and the belts when the Interlock is cheater is inserted. 8. Do GP 6.2.6 SOLENOIDS to activate and deactivate Solenoid SOL1. The diverter gate should rise and fall when SOL1 is cycled. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-65...
  • Page 338 6. Inspect (4) plastic bushings in the Die lock brackets. (2) in the front and (2) in the back. 5. Wipe the spring clips with a clean cloth. 6. Do ARP1.6 to install rear cover GBC PUNCH G2 General Procedures and Information 02/28/2019 6-66...
  • Page 339 10. Insert a Die set in the die rail and lock the Die set and check if the tip contacts the die set base plate only. The Die lock mechanism should not contact anywhere else. 11. The Die Set should also slide in easily deforming the Die rail springs. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-67...

  • Page 340: General Information

    Principle of Operation the Divert Solenoid SOL 1 is activated to direct the sheets into the punch The GBC PUNCH G2 is a machine that punches various die set hole path. patterns into single sheets of paper. The machine is placed between a There are two modes of operation Single Punch and Double Punch.
  • Page 341 Once the punch cycle is complete the sheet is accelerated by N6 & N7 to the system line speed. Once the lead edge hits S24 (plus a delay to ensure the sheet is in roller N10) the sheet is decelerated to the printer line speed. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-69...
  • Page 342 Sensor S23 Optical Exit Idler Panel Sensor Sensor S24 Sensor S25 Optical Exit Sensor Optical Bypass Sensor Sensor S26 Sensor S28 Optical Align Home Sensor Sensor S29 Emitter/Receiver Chip Tray Full Emitter/Receiver GBC PUNCH G2 General Procedures and Information 02/28/2019 6-70...
  • Page 343 Skew The term used to describe the fact that the sheet of paper is not parallel to the paper path. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-71...
  • Page 344 115V, 60Hz, Single Phase 230V, 50Hz, Single Phase Electrical Amps and Frequency Safety Certification cULus Dimensions L: 775mm; W: 445mm; H: 1020mm L: 30.5"; W: 17.5"; H: 40.2" Weight 95 kg 210 lbs GBC PUNCH G2 General Procedures and Information 02/28/2019 6-72...
  • Page 345 Please note that each punching style listed below requires a separate die set for the PUNCH G2. The PUNCH G2 can hold up to three Die Sets in its cabinet (one in the operating slot and two in the storage area).
  • Page 346 Die Sets List By selecting the appropriate die set, you can use your PUNCH G2 to punch documents in any of the binding styles indicated in the tables below. GBC PUNCH G2 General Procedures and Information 02/28/2019 6-74...
  • Page 347 Die Sets List (cont’d) By selecting the appropriate die set, you can use your PUNCH G2 to punch documents in any of the binding styles indicated in the tables below. GBC PUNCH G2 02/28/2019 General Procedures and Information 6-75...

  • Page 348: Gp 6.20 Punch Drive Cam Lubrication

    Lubrication Tools For General lubrication please see the following sections Tools recommended for service of the GBC PUNCH G2: • GP 6.7.3, Die Set Lubrication Standard Tools (metric) • • 7mm Nut Driver GP 6.20, Punch Drive Cam Lubrication •...

  • Page 349: Gp 6.22 Solenoid Cleaning And Inspection

    Use a soft cloth and alcohol to clean the following. Serial Numbers • The GBC PUNCH G2 Serial Number is located inside the Front Door on GP 6.14, Idler Roller Inspection and Cleaning the front frame just below the Bypass Section •...
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  • Page 351 Notes: GBC PUNCH G2 02/28/2019 General Procedures and Information 6-79...
  • Page 352 7. Wiring Data Section Contents Wiring Data Title Page System Wiring (7715763) ..............7-3 Plug Jack connectors................7-3 GBC PUNCH G2 4/14/2017 Wiring Data Section Contents...
  • Page 353 This page intentionally left blank. Wiring Data 4/14/2017 GBC PUNCH G2...

  • Page 354: System Wiring

    System Wiring (7715998) GBC PUNCH G2 4/14/2017 Wiring Data...

  • Page 355: Communication Board

    Plug Jack connectors Wiring Data 4/14/2017 GBC PUNCH G2...

  • Page 356: Installation Instructions

    8. Installation Instructions Section Contents Title Page 8.1. Required Parts ................8-3 8.2. Unpacking ..................8-4 8.3. Docking Procedure ............... 8-5 GBC PUNCH G2 02/28/2019 Installation Instructions Section Contents...
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  • Page 358: Required Parts

    8.1. Required Parts The PUNCH G2 is shipped with an installation kit containing the following components. Cover Plate, MK737 Description Picture Cables Power Cord (US) Docking Bracket, Rear Power Cord (UK) Docking Bracket, Lower Front Power Cord (EU) Docking Lock, Lower...

  • Page 360: Docking Procedure

    Raise Lower Install the front and rear docking brackets (Items 8, 9, and 11), on the upstream device. Note the rear docking bracket is the same part upper and lower. Item 8 GBC PUNCH G2 02/28/2019 Installation Instructions...
  • Page 361 Push the PUNCH G2 directly upstream so that the brackets slide into the openings Once the brackets are aligned with the holes in the PUNCH G2, push the punch back so that it engages the alignment pins. Install item 10 in the lower right front bracket and secure the upper bracket using a M4 screw.
  • Page 362 Konica Minolta Installation manual for more details. Spacers Spacers Bracket supplied with The PUNCH G2 comes with four spacers installed for the mounting of the downstream device downstream brackets. See the Konica Minolta installation manual for cable connection Spacers instructions.

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