GBC PUNCH G2 Manuals

Manuals and User Guides for GBC PUNCH G2. We have 1 GBC PUNCH G2 manual available for free PDF download: Service Manual

GBC PUNCH G2 Service Manual (362 pages)

Brand: GBC | Category: Industrial Equipment | Size: 59 MB

Table of Contents
2
Section Contents
3
Introduction
3
Service Call Procedures
4
Punch Quality
4
Parts List
4
General Procedures
4
Wiring Data
4
Introduction
4
Organization
4
How to Use this Documentation
4
Section 8: Installation
5
Other Information
5
The Use of Caution, Warning, and Note Statements
5
Operational Safety
6
Caution
6
Important Safeguards
7
Acronyms
7
Call Flow
10
Initial Action
11
System Checks
11
Every Call Activities
12
Scheduled Maintenance
12
Preventative Maintenance
12
PUNCH G2 Maintenance Schedule
13
Customer Maintenance
13
Periodic Maintenance
13
Periodic Replacement
14
Hfsi
15
Final Action
15
Operator Messages
21
Error Codes
27
Fault Codes
29
Power Faults
32
Paper Jams
38
Sensor Checks
49
Rtp 3.1
49
Check Sensors S1, S2, S3, S4, S5, S22, S23, S24
49
Rtp 3.2
52
Check Sensors S6 to S21
52
RTP 3.3 Checking Sensor S28 Align Home Sensor
57
Solenoid Checks
59
Rtp 4.1
59
Check Solenoid SOL 1
59
Check Solenoid SOL 2
59
Rtp 4.3
60
Check Solenoids SOL 3 to SOL 8
60
Motor Checks
62
RTP 5.1 Checking Stepper Motors
62
Other Faults
64
RTP 6.1 die Set will Not Slide in or out Easily
64
RTP 6.2 Punch Overheats
64
Section Contents
66
Punch Quality
69
3.3 Hole Quality
69
Hanging Chad
69
Holes Are Not Cleanly Cut
69
Oil on Paper
69
3.4 Alignment Offset
69
3.5 Backgage Offset
70
3.6 Skewed Punch
71
3.7 Punching Accuracy Inconsistent
71
Sheets Without Punched Holes
74
Punched Holes Look Elongated Towards the Trail Edge of the Sheet
75
3.10 Sheet Damaged at the Lead Edge of the Sheet
76
3.11 Scuff Marks on Paper
77
3.12 Wrinkle in the Sheet
77
3.13 Clear Cover Media Hole Position
77
3.14 Punch Specifications
78
Cabinet
82
ARP 1.1 Top Cover Replacement
82
ARP 1.2 Front Door Replacement
83
ARP 1.3 Front Door Bottom Hinge Bracket Replacement
84
ARP 1.4 Front Door Top Hinge Bracket Replacement
85
ARP 1.5 Panel Open Magnet Replacement
85
ARP 1.6 Rear Cover Replacement
86
ARP 1.7 Upstream Rear Side Cover Replacement
87
ARP 1.8 Downstream Front Side Cover Replacement
88
ARP 1.9 Downstream Rear Side Cover Replacement
89
ARP 1.10 Door Latch Replacement
90
ARP 1.11 Interlock Switch Replacement
91
ARP 1.12 LCD Display Replacement
92
ARP 1.13 LCD Membrane Switch Panel Replacement
93
ARP 1.14 Caster Replacement
94
ARP 1.15 Docking Bracket Replacement
94
ARP 1.16 Exhaust Fan and Exhaust Fan Bracket Replacement
96
ARP 1.17 Drive Roller Cover Removal
97
ARP 1.18 Side Cover Removal
98
Paper Path
99
ARP 2.1 Lower Entrance Panel Replacement
99
ARP 2.2 Inner Entrance Panel Replacement
100
ARP 2.3 Entrance Idler Panel Replacement
101
ARP 2.4 Acceleration Roller Idler Assembly Replacement
104
ARP 2.5 Entrance Drive Panel Assembly Replacement
106
ARP 2.6 Lower Exit Panel Replacement
110
ARP 2.7 Exit Idler Panel Replacement
111
ARP 2.8 Drive Exit Panel Replacement
114
ARP 2.9 Punch Lower Exit Panel Replacement
116
ARP 2.10 Inner Exit Panel Replacement
117
ARP 2.11 Upper Bypass Panel Replacement
118
ARP 2.12 Lower Bypass Panel Replacement
120
ARP 2.13 Bypass Diverter Replacement
121
ARP 2.14 Panel Close Magnet Replacement
122
ARP 2.15 Idler Roller Replacement
123
ARP 2.16 Idler Panel Mount Bracket Replacement
125
ARP 2.17 Flange Ball Bearing Replacement
126
ARP 2.18 Snap-In Bearing Replacement
127
ARP 2.19 Bearing Housing Replacement
128
ARP 2.20 Accel Idler Latch Handle Replacement
128
ARP 2.21 Accel Idler Latch Shaft, Rear Latch and Front Latch Assembly Replacement
129
ARP 2.22 One Way Clutch and Pulley Sub-Assembly Replacement4-54
133
ARP 2.23 Drive Idler Roller Assembly Replacement
133
ARP 2.24 Timing Pulley Replacement
134
ARP 2.25 Timing Belt Replacement
135
ARP 2.25.1 534T Belt Replacement
135
ARP 2.25.2 134T Belt Replacement
136
ARP 2.25.3 150T Belt Replacement
136
ARP 2.25.4 179T Belt Replacement
137
ARP 2.26 Drive Roller Assembly Replacement
138
ARP 2.26.1 Drive Roller N5 Replacement
140
ARP 2.27 Stepper and Mount Assembly Replacement
143
ARP 2.28 Paper Path Sensor Replacement
144
ARP 2.28.1 Entrance Sensor (S1,) Exit Sensor (S25), and Bypass
144
Middle Sensor (S26) Replacement
144
Top, Middle, & Bottom Exit Sensor (S22, S23, S24) Replacement
145
ARP 2.28.3 Accel Sensor (S5) Replacement
146
ARP 2.28.4 Align Home Sensor (S28) Replacement
147
ARP 2.28.5 Backage Sensor Board Assembly (S18, S19) and Backage Sensor Board Assembly (S20, S21) Replacement
148
ARP 2.28.6 Skew Sensor Board (S6 - S10) Replacement
149
ARP 2.28.7 Alignment Sensor Board (S11 - S15) Replacement
150
ARP 2.28.8 Backage Sensor Board (S16, S17) Replacement
152
ARP 2.29 Motor Driver (Stepper Board) Replacement
153
ARP 2.30 Solenoid Replacement
154
ARP 2.30.1 Diverter Solenoid Replacement
154
ARP 2.30.2 Entrance Idler Solenoid Replacement
156
ARP 2.30.3 Acceleration Roller Idler Solenoid Replacement
156
ARP 2.30.4 Exit Idler Solenoid Replacement
157
ARP 2.31 Upper Bypass Panel Anti-Static Brush Replacement
157
Punch Module
158
ARP 3.1 Punch Module Replacement
158
ARP 3.1.1 Punch Module Removal
158
ARP 3.1.2 Punch Module Installation
162
ARP 3.2 Chip Tray Home Switch Replacement
163
ARP 3.3 Chip Level Emitter Replacement
164
ARP 3.4 Chip Level Receiver Replacement
164
ARP 3.5 Punch Motor Replacement
165
ARP 3.6 Punch Motor Belt Replacement (Timing Belt)
166
ARP 3.7 Clutch or Clutch Pulley Replacement
168
ARP 3.8 Punch Alignment Stepper Motor and Pulley Replacement, and Alignment Stepper Bracket Replacement
171
ARP 3.9 Steering Module Replacement
172
ARP 3.11 Alignment Carriage Sub Assembly Replacement
177
ARP 3.12 Steering Stepper Motor Replacement
180
ARP 3.13 Steering Motor Belt (65 Groove) Replacement
182
ARP 3.14 Steering Drive Roller Shaft Replacement
184
ARP 3.15 Steering Idler Panel Weldment Replacement
186
ARP 3.16 Steering Idler Roller Assembly Replacement
188
ARP 3.16.1 Steering Idler Roller Bearing Replacement
190
ARP 3.17 Steering Drive Panel Weldment Replacement
191
ARP 3.18 die Lock Plunger and Stripper Assembly Replacement
192
ARP 3.19 Punch Shaft Ball Bearing Replacement
193
ARP 3.20 die Stop Magnet Replacement
193
ARP 3.21 die Lock Handle Replacement
194
ARP 3.22 die Lock Shaft Replacement
195
ARP 3.23 die Rail Assembly and die Rail Springs Replacement
197
ARP 3.24 Alignment Sensor Bracket and Alignment Sensor Bottom Guide Replacement
199
ARP 3.25 Punch Module Mount Pin Replacement
201
ARP 3.26 Backgage Sensor Bracket Weldment and Backgage Sensor Lower Bracket Replacement
202
ARP 3.27 die Set Recognition Replacement
203
Power Supply
204
ARP 4.1 24V Power Supply Replacement
204
ARP 4.2 AC Filter Replacement
206
Electronics and Control
207
ARP 5.1 Main Control Board Replacement
207
ARP 5.2 Comm Board Replacement
209
ARP 5.3 Dieset Recognition Reader Board Replacement
210
Adjustments
211
ADJ 1.1 Door Latch Adjustment
211
ADJ 1.2 Diverter Solenoid Adjustment
212
ADJ 1.3 die Stop Magnet Adjustment
214
ADJ 1.4 Timing Belts Adjustment
215
ADJ 1.5 Punch Clutch Indexing
220
ADJ 1.6 Dieset Recognition Board Adjustment
224
ADJ 1.7 Idler Panel Magnetic Latches Adjustment
225
ADJ 1.8 Drive Panel Position Adjustment
226
Main Assembly
232
1.1. Final Assembly
232
1.2. Cabinet- Covers
233
Frame Assembly
234
2.1. Frame Assembly- Paper Path Panels
234
2.2. Frame Assembly- Front Side
235
2.3. Frame Assembly- Rear Side
236
2.4. Frame Assembly- Drive Rollers
237
2.5. Frame Assembly- Internal Parts
238
2.6. Frame Assembly- Motors and Motor Drivers
239
2.7. Frame Assembly- Sensors
240
2.8. Frame Assembly- Solenoids / Switches
241
Parts List
241
2.9. Frame Assembly- Belts
242
Paper Path
243
3.1. Paper Path- Entrance Drive Panel
243
3.2. Paper Path- Entrance Idler Panel
244
3.3. Paper Path- Acceleration Roller Idler
245
3.4. Paper Path- Exit Idler Panel
246
3.5. Paper Path- Upper Bypass Panel
247
3.6. Paper Path- Disengaging Roller Solenoid
248
Punch Module
249
4.2. Punch Module (Continued)
250
4.3. Punch Module- Motors/Sensors
251
4.4. Punch Module- Steering Module
252
Sub Assembly
253
4.6. Punch Module- Steering Module - Drive Panel Steering
254
4.7. Punch Module- Stepper Alignment Bracket
255
4.9. Punch Module- die Set Recognition Reader Board
257
PL 4.10. Punch Module- die Rail, Backgage, Align Sensors
258
PL 4.11. Punch Module- AC Motor
259
Die Sets
260
Electronics
261
6.2. Control Board Bracket Sub Assembly
262
6.3. Cable Part Number Index
263
Installation Kit Parts
266
Miscellaneous Parts
266
Part Number Index
267
General Procedures
275
User Interface
275
Settings
276
Information
276
User Interface Screen Map
277
GP 6.1 User Interface Procedure
278
Settings Procedure
278
GP 6.1.1 BACKGAGE SETTING Procedure
279
GP 6.1.2 ALIGNMENT SETTING Procedure
281
GP 6.1.3 CLEAR COVER Procedure
283
GP 6.1.4 LANGUAGE SETTINGS Procedure
285
UNITS Procedure
286
GP 6.1.7 INFORMATION Procedure
287
GP 6.1.8 die TYPE Procedure
287
GP 6.1.9 die CYCLES Procedure
287
GP 6.1.10 PUNCH CYCLES Procedure
290
GP 6.1.11 FIRMWARE Procedure
291
Service User Interface
292
Service Interface Screen Map
294
Main Screen
294
GP 6.2 Service User Interface Procedure
295
GP 6.2.1 PAPER SIZE Setting
296
GP 6.2.2 MAX BYPASS Setting
296
RUN MODE Setting
297
Gp 6.2.4 die Cycles
298
GP 6.2.5 SENSORS Check
299
Paper Size
299
Previous Menu
301
GP 6.2.6 SOLENOIDS Check
302
GP 6.2.7 MOTORS Check
303
GP 6.2.8 FUNCTION TESTS (Cycle Punch, Aligner Test, Fan Test)
304
GP 6.2.9 SKEW OFFSETS Adjustment
306
GP 6.2.10 ALIGN OFFSETS Adjustment
310
Gp 6.2.11 Log
312
GP 6.2.12 FIRMWARE UPGRADE Procedure
313
Firmware Upgrade
314
GP 6.3 Undock the Punch (Moving the Punch to Service Position)
315
GP 6.4 Dock the Punch (Moving the Punch to Operating Position)
315
Internal Inspection
316
Die Set Service
317
GP 6.7.1 die Set Life Expectancy
317
GP 6.7.2 die Set Components
317
GP 6.7.3 die Set Lubrication
318
GP 6.7.4 die Set Shoulder Bolts
319
GP 6.13 Door Latch Inspection
322
GP 6.14 Idler Roller and Idler Springs Inspection
323
GP 6.14.1 Idler Roller Cleaning
324
GP 6.14.2 Steering Idler Roller and Springs Inspection and Cleaning
325
GP 6.16 Panel Latch Inspection
327
GP 6.17 Optical Sensor Cleaning
330
Bypass Paper Path Inspection and Cleaning
331
GP 6.19 Punch Paper Path Inspection and Cleaning
332
General Information
340
GP 6.20 Punch Drive Cam Lubrication
348
GP 6.22 Solenoid Cleaning and Inspection
349
System Wiring
354
Communication Board
355
Installation Instructions
356
Required Parts
358
Docking Procedure
360

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