GBC StreamWire User manual

GBC StreamWire 07/23/2020 Service Manual
GBC StreamWire
Service Manual
Part Number: 7716519
Revision Number: E1
Issue Date: July 2020

Service Manual 07/23/2020 GBC StreamWire
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Quick Start
Below is an excerpt from page 1-3. These steps should be performed at
the start of every service call and will direct you through the use of the
manual.
At the start of every service call, you should perform the following:
•If called for a problem, determine the exact nature of the
service complaint. Determine the paper type and quality,
especially as it relates to curl. Determine the size and color of
twin loop wire being used.
•Identify if any media changes correlate with the emergence of
the customer issue.
•Determine if the problem occurs with all element sizes or only
specific sizes. If multiple sizes have not been used, try running
the eWire using a different wire size.
•Do GP 6.2.7 to note the total machine bind and sheet cycles.
•If possible, run a bind cycle and evaluate the quality of the
bound book. Refer to Section 3 of this manual for additional
information regarding the book quality.
•Do GP 6.8 and GP 6.7 to replace the supply spool and re-
evaluate the performance using the new supply spool.
•Determine the date of the last preventative maintenance
performed on the system. Perform preventative maintenance
as indicated on page 1-5.
•Vacuum the paper path, element feeder, and book stacking
areas. Visually inspect the eWire and clear any scraps/debris.
•Save the system settings to a data file.
•Download a log file to USB. Note any error codes, especially if
they occur repeatedly.
SYSTEM CHECKS
Purpose
Direct repair activity for problems found in Initial Action.
PROCEDURE
1. Select the appropriate condition from the list below and perform
the directed service actions.
•Replace any obviously broken parts.
•If there is a Book Quality problem but no Fault Codes or other
obvious problems, go to Section 3.
•If there is a Fault Code, go to Section 2 Table of Contents.
Locate and perform the RAP associated with the code.
•If there is an Operator Message that will not clear, go to
Section 2 Table of Contents. Locate and perform the steps in
the OPERATOR MESSAGE RAP associated with the
Operator Message.
•If the problem is not repeatable, operate the eWire in the
same job conditions the customer used and recheck for a
problem in the categories listed here.
•If the problem is still not reproduced, examine the Machine
Service Log and note any repeating faults. Refer to the RAP
for those faults in Section 2 to check if the RAP relates to the
customer problem. If so, perform the RAP.
•If general problems occur that are not related to any fault
code, repeat the steps in install section.
•If the problem is not resolved after 2 hours, escalate to Canon
2nd level support.
•If none of the above situations apply, go to EVERY CALL
ACTIVITIES on page 1-4.
Verify that the problem is corrected and go to EVERY CALL ACTIVITIES
on page 1-4.

GBC StreamWire 07/23/2020 Service Manual
iii
Table of Contents
NOTICE
All service documentation is supplied to external customers for
informational purposes only. Service documentation is intended for use by
certified, product trained service personnel only. GBC does not warrant or
represent that such documentation is complete. GBC does not warrant or
represent that it will notify or provide to such customer any future changes
to this documentation. Service by the customer of the equipment, or
modules, components, or parts of such equipment may void any
otherwise applicable GBC warranties. If customer services such
equipment, modules, components, or parts thereof, Customer releases
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
claims which arise directly or indirectly from such service.
Changes are periodically made to this document. Changes, technical
inaccuracies, and typographic errors will be corrected in subsequent
editions.
Copyright Notice
GBC
ACCO Brands Inc.
Four Corporate Drive
Lake Zurich, IL 60047.
USA
© Copyright 2014 by ACCO Brands Inc. All Rights reserved.
No part of this document may be photocopied or reproduced by any
means, or translated to another language without prior written consent of
GBC
All brand names, trademarks and registered trademarks are the property
of their respective owners. Information contained within this document is
subject to change without notice.
GBC products mentioned in this publication are registered trademarks of
the ACCO Brands Corporation.
Title Page
Service Call Procedures
Introduction...............................................................iii
1. Service Call Procedures ....................................1-1
2. Repair and Troubleshooting Procedures ........2-1
3. Book Quality .......................................................3-1
4. Replacement and Adjustment Procedures......4-1
5. Parts List .............................................................5-1
6. General Procedures ...........................................6-1
7. Wiring Data .........................................................7-1
8. Installation Instructions.....................................8-1

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Introduction
Section Contents
Title Page
Table of Contents.........................................................................iii
Introduction ..................................................................................iv
Organization ............................................................................. v
How to Use This Documentation .......................................... v
Other Information .....................................................................vi
The Use of Caution, Warning, and Note statements............vi
Safety Devices ........................................................................vii
CAUTION ................................................................................vii
Operational Safety...................................................................vii
Important safeguards .............................................................viii

GBC StreamWire 07/23/2020 Service Manual
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Organization
This documentation is divided into eight sections. In addition to the
Introduction, this documentation contains the following sections.
Section 1 Service Call Procedures
Section 2 Repairs and Troubleshooting Procedures
Section 3 Book Quality
Section 4 Replacement and Adjustment Procedures
Section 5 Parts List
Section 6 General Procedures
Section 7 Wiring Data
Section 8 Installation Instructions
How to Use This Documentation
Introduction
This section provides the Service Representative with information
pertaining to the organization and use of this service documentation.
Section 1: Service Call Procedures
This section is used by the Service Representative as a structured
process for determining the type and sequence of actions that are
performed during a service call. The Service Call Procedures section is
designed to assist in the effective recognition of machine symptoms and
problems, as well as to provide instructions for the maintenance and
corrective actions that are required to return the machine to the full
operating condition
Section 1 of this service documentation is the entry level for all service
calls. The Service Representative should begin each service call with the
Initial Action Procedure found in Section 1.
The Service Call Procedures section is composed of five integral
elements: Initial Action, System Checks, Every Call Activities, Scheduled
Maintenance, and Final Action.
The maintenance and diagnostic activities in this section may direct the
Service Representative to perform additional service activities found
elsewhere in the documentation, such as RTPs, Replacement
Procedures, and Adjustment Procedures.
Section 2: Repairs and Troubleshooting Procedures
(RTP)
Section 2 of this documentation contains the Repair and Troubleshooting
Procedures (RTPs) necessary to repair all faults associated with eWire.
Service Representative will be referred to this section from some other
section of this documentation during the service call. When a machine
defect or fault has been resolved by using a RTP, the Service
Representative should immediately return to the point in the service call
from which Section 2 was entered. There are two types of RTPs found in
Section 2. The first type is a RTP that is associated with the display of an
error message in the RTP title. The second type is the Troubleshooting
RTP. Troubleshooting RTPs are diagnostic procedures that are designed
to address symptoms or problems that are not identified by, or
associated with, a displayed status or fault code.
Section 3: Book Quality
This section is used to diagnose book binding problems.
Section 4: Replacement and Adjustment Procedures
This section contains all repair and adjustment procedures for the
machine. Repairs (REPs) and adjustments (ADJs) are identified by the
use of a standard chain prefix number.
Section 5: Parts List
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.

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Section 6: General Procedures
This section contains procedures and information of a general nature
that apply to the machine. This section is divided into two basic parts:
General Procedures and General Information.
Section 7: Wiring Data
This section contains support information to assist in the electrical
diagnosis of machine problems and is a central location for electrical
wiring diagrams. This section is used in conjunction with other diagnostic
or maintenance procedures that are contained in other sections of the
service documentation.
Section 8: Installation
This section contains service information that supports the GBC
StreamWire Installation.
Other Information
The Use of Caution, Warning, and Note statements
Information relative to the completion of a task in a safe or thorough
manner will be supplied in the form of a Caution, a Warning, or a Note
statement. These statements are found throughout the service
documentation.
Cautions, Warnings, and Note statements appear before the steps to
which they apply. These statements should be read before continuing to
the next step in a procedure.
Caution - A Caution statement indicates an operating or maintenance
procedure, practice, or condition that, if not strictly observed, could result
in damage to, or destruction of, equipment.
Warning - A Warning statement indicates an operating or maintenance
procedure, practice, or condition that, if not strictly observed, could result
in personal injury or loss of life.
Note - A Note statement indicates an operating or maintenance problem,
practice, or condition that is necessary to accomplish a task efficiently.

GBC StreamWire 07/23/2020 Service Manual
vii
Safety Devices
The GBC eWire™ Pro has door interlocks to prevent personal injury
when operating the machine.
When you open a door, a Safety Interlock device automatically disables
the drive motors until you close the doors.
When a door is open, the Operator Interface Panel displays the “CLOSE
DOOR” message on the top line of the interface.
When you close all the doors, the Operator Interface Panel displays the
“READY” message on the top line of the interface.
CAUTION
Certain components in the GBC StreamWire are susceptible to damage
from electrostatic discharge. Observe all ESD procedures to avoid
component damage.
Operational Safety
Do not operate the GBC eWire™ with the interlocks defeated.
Use care when a procedure in this Manual instructs you to “insert an
Interlock Cheater” in order to test the operation of a component.
WARNING
Moving Parts, keep hands clear of nips and the belts when the
Interlock Cheater is inserted.
THE FOLLOWING PICTORIAL IS FOUND ON THE eWire™ Pro:
This safety symbol means that you might get
seriously hurt or killed if you open the product and
expose yourself to hazardous voltage. NEVER
remove the screwed on covers. ALWAYS refer
service requirements to qualified service personnel.
This safety symbol means that you may get cut if
you touch the knife positioned behind the cover it is
affixed to. Do not remove this cover or place fingers
behind it.

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viii
Important safeguards
♦Use the eWire™ only for its intended purpose of creating bound
books according to the indicated specifications.
♦Retain this Operation Instructions manual for future use.
CAUTION: THE PRINTER ON/OFF SWITCH DOES NOT CUT
OFF POWER FROM THE EWIRE.
CAUTION: THE EWIRE™ ON/OFF SWITCH DOES NOT CUT
OFF POWER FROM THE PRINTER.
♦The eWire™ must be connected to a supply voltage corresponding
to the electrical rating of the machine operation instructions (also
listed on the serial number label).
♦The grounding plug is a safety feature and will only fit into the proper
grounding-type power outlet. If you are unable to insert the plug into
an outlet, contact a qualified electrician to have a suitable outlet
installed.
♦Do not alter the plug on the end of the cordset (if provided) of the
eWire™. It is provided for your safety.
♦Unplug the eWire™ before moving the machine.
♦Do not operate the eWire™ if the machine has a damaged power
supply cord or plug. Do not operate the machine after any
malfunction. Do not operate the machine in case of liquid spills, or if
the machine has been damaged in any other way.
♦Do not overload electrical outlets beyond their capacity. To do so
may result in fire or electrical shock.
Do not open any panels other than those indicated by this Manual.
♦Pay particular attention to the WARNINGS and CAUTIONS listed in
the User Manual and Service Manual.

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ix
Notes:

GBC StreamWire 07/23/2020 Service Call Procedures
1-1
1. Service Call Procedures
Section Contents
Title Page
CALL FLOW ................................................1-2
INITIAL ACTION ..........................................1-3
SYSTEM CHECKS ......................................1-3
EVERY CALL ACTIVITIES ..........................1-4
SCHEDULED MAINTENANCE ...................1-4
eWIRE MAINTENANCE SCHEDULE .........1-5
Periodic Maintenance .......................1-5
Periodic Replacement.......................1-5
FINAL ACTION ............................................1-6

Service Call Procedures 07/23/2020 GBC StreamWire
1-2
CALL FLOW
INITIAL ACTION
This step is used to gather information
about the reason for the call, to determine
the machine condition, and to run a book
sample if possible.
SYSTEM CHECKS
This step is used to suggest a direction for
using the information obtained during Initial
Action. You can then repair and verify the
effectiveness of the repair. This step may
also provide information to assist in the
identification of new problems and suggest
actions to take to repair/resolve them.
FINAL ACTIONS
This step is used to ensure that the
machine performance and book quality are
satisfactory. It will also provide direction to
help complete administrative tasks.

GBC StreamWire 07/23/2020 Service Call Procedures
1-3
INITIAL ACTION
At the start of every service call, you should perform the following:
•If called for a problem, determine the exact nature of the service
complaint. Determine the paper type and quality, especially as it
relates to curl. Determine the size and color of twin loop wire being
used.
•Identify if any media changes correlate with the emergence of the
customer issue.
•Determine if the problem occurs with all element sizes or only
specific sizes. If multiple sizes have not been used, try running the
eWire using a different wire size.
•Do GP 6.2.7 to note the total machine bind and sheet cycles.
•If possible, run a bind cycle and evaluate the quality of the bound
book. Refer to Section 3 of this manual for additional information
regarding the book quality.
•Do GP 6.8 and GP 6.7 to replace the supply spool and re-evaluate
the performance using the new supply spool.
•Determine the date of the last preventative maintenance
performed on the system. Perform preventative maintenance as
indicated on page 1-5.
•Vacuum the paper path, element feeder, and book stacking areas.
Visually inspect the eWire and clear any scraps/debris.
•Save the system settings to a data file.
•Download a log file to USB. Note any error codes, especially if
they occur repeatedly.
SYSTEM CHECKS
Purpose
Direct repair activity for problems found in Initial Action.
PROCEDURE
•Select the appropriate condition from the list below and perform
the directed service actions.
•Replace any obviously broken parts.
•If there is a Book Quality problem but no Fault Codes or other
obvious problems, go to Section 3.
•If there is a Fault Code, go to Section 2 Table of Contents.
Locate and perform the RAP associated with the code.
•If there is an Operator Message that will not clear, go to
Section 2 Table of Contents. Locate and perform the steps in
the OPERATOR MESSAGE RAP associated with the
Operator Message.
•If the problem is not repeatable, operate the eWire in the
same job conditions the customer used and recheck for a
problem in the categories listed here.
•If the problem is still not reproduced, examine the Machine
Service Log and note any repeating faults. Refer to the RAP
for those faults in Section 2 to check if the RAP relates to the
customer problem. If so, perform the RAP.
•If general problems occur that are not related to any fault
code, repeat the steps in install section.
•If the problem is not resolved after 2 hours, escalate to Ricoh
2nd level support.
•If none of the above situations apply, go to EVERY CALL
ACTIVITIES.
•Verify that the problem is corrected and go to EVERY CALL
ACTIVITIES.

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1-4
EVERY CALL ACTIVITIES
Purpose
List service activities required on every service call.
PROCEDURE
•Perform GP 6.10 Internal Inspection.
•Perform GP 6.11 External Cleaning.
•Perform GP 6.12 Internal Cleaning
•Perform GP 6.13 Base Cleaning
•Perform GP 6.15 Optical Sensor Cleaning
SCHEDULED MAINTENANCE
PROCEDURE
•Check the number of Bind Cycles and Sheet Cycles in the eWire
Settings. Refer to GP 6.2.7.
•Refer to the eWire Maintenance Schedule on Page 1-5. Perform all
scheduled maintenance.
•Replace wear components as indicated in the Periodic Maintenance
section of this document.

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1-5
eWIRE MAINTENANCE SCHEDULE
Periodic Maintenance
Area/Unit Period Measures Remarks
Drag Finger and Closer Pusher
1M sheets
Inspect and Clean
Alcohol & Cloth, see GP 6.10
Stacker Module Green Belt 1M sheets Inspect and Clean Alcohol & Cloth, see GP 6.10
Bypass Transfer Idler Rollers 1M sheets Inspect and Clean Alcohol & Cloth, see GP 6.14.1
Deflector Module Idler Rollers
1M sheets
Inspect and Clean
Alcohol & Cloth, see GP 6.14.1
Steering Module Idler Rollers
1M sheets
Inspect and Clean
Alcohol & Cloth, see GP 6.10
Element Feeder Belt 1M sheets Inspect See GP 6.10
Element Detect Flapper Sensor 1M sheets Inspect and Clean,
Ensure Free Movement
Clean area with vacuum or compressed air. See GP 6.13
Element Alignment at Stack Position 1M sheets Inspect Perform ADJ 1.10
Book Drawer Belt
1M sheets
Inspect
See GP 6.17
Kick Downs 1M sheets Inspect See GP 6.10
Paper Path and Other Sensors 1M Sheets Inspect & Clean Anti-static wipes. Note
use an Anti-static cleaning wipe
(7718648 PL 5.30) If these are not available use a dry
cloth or canned air. Do not use alcohol or detergents. See
GP 6.15
Closer Transport Rail 1M sheets Clean and then Oil Wipe rails with alcohol & cloth and then rub a few drops of
light machine oil on each rail. See GP 3.19
Closer Chain 1M sheets Clean and then Grease Apply Grease and wipe away excess
Periodic Replacement
Area/Unit
Period
See:
Measures
Remarks
Knife/Anvil 50,000 books REP 3.14.3 Replacement PL 5.11
Stacker Module, Kick Downs 4M Sheets REP 4.7 Replacement PL 5.15
Vacuum Stacker 12M sheets REP 4.1 Replacement PL 5.14
Closer Jaw Plates 50,000 binds REP 6.5 Replacement PL 5.19
Element Feeder Belt 100,000 binds Rep 3.6 Replacement PL 5.8

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1-6
FINAL ACTION
This section explains the actions a technician should take at the
end of every service call. With each step, verify that the system
runs smoothly and jam free.
Purpose
Ensure machine performance and book quality are satisfactory
and complete administrative tasks.
Procedure
•Clear the Book Tray and install a Supply Spool of the size the
customer was using when the problem initially occurred.
•Install/close all covers and doors.
•Run the eWire using the same settings as the customer was
using when the problem occurred. If necessary, run a variety
of different paper and spool size configurations to capture
different configurations that may have been present during
the failure.
•Carefully monitor the machine during the test run and make a
note of any unusual observations. Listen for any unusual or
excessive noise produced during operation.
•Explain to the customer the service work that was performed
and ensure they are satisfied before you close the call.
Service Call Close
•Record your service activities along with the BIND and
SHEET counts.

GBC StreamWire 07/23/2020 RTPS
2-1
2. Repair & Troubleshooting Procedures (RTPS)
Section Contents Title Page
Section 1.01 Introduction................................................................. 2-3
Entry RTP............................................................................................. 2-3
Section 1.02 OPERATOR MESSAGES............................................ 2-4
a) Top Row of Text ....................................................................... 2-4
b) Bottom Row of Text .................................................................. 2-4
c) Book Tray Full........................................................................... 2-5
d) Close Tray ................................................................................ 2-6
e) Add Elements ........................................................................... 2-7
f) Close Door................................................................................ 2-7
g) Close Cover .............................................................................. 2-8
Section 1.03 FAULT CODES .......................................................... 2-10
a) Fault Code Text ...................................................................... 2-10
b) Fault Code Areas.................................................................... 2-10
c) Jam Code Classification ......................................................... 2-11
2POWER FAULTS.......................................................................... 2-13
RTP 2.1 No AC Power.................................................................... 2-13
RTP 2.2 No DC Power ................................................................... 2-15
RTP 2.3 Operator Panel Does Not Illuminate ................................ 2-17
RTP 2.4 Operator Panel Does Not Show Text............................... 2-18
RTP 2.5 Up, Down, Enter Keys Do Not Respond .......................... 2-19
RTP 2.6 Close Door, Tray, Cover Message When All Are Closed 2-19
3PAPER TRANSPORT JAM CODES- J1xx and J2xx ................. 2-20
RTP 3.1 J244- UNBOUND BOOK PRESENT IN COLLECTION TRAY
......................................................................................... 2-20
RTP 3.2 J260- NO LEAD EDGE AT SKEW SENSOR DETECTED2-20
RTP 3.3 Paper jam in Transport section ........................................ 2-21
RTP 3.4 Jammed sheets in the Stacker module............................ 2-26
4WIRE JAM CODES....................................................................... 2-27
RTP 4.1 J320- S20 SPOOL ELEMENT SLACK TIMEOUT ........... 2-27
RTP 4.2 J321- S21 LEAD EDGE DETECT TIMEOUT...................2-28
RTP 4.3 J322- S22 ELEMENT AT PYRAMID TIMEOUT...............2-29
RTP 4.4 J323- S23 KNIFE HOME TIMEOUT ................................2-30
RTP 4.5 J324- S24 PUSHOVER HOME TIMEOUT.......................2-30
RTP 4.6 J325- S25 FEED BELT HOME TIMEOUT .......................2-31
RTP 4.7 J332- S32 EXPAND T HOME TIMEOUT .........................2-32
RTP 4.8 J333- S33 EXPAND T OUT TIMEOUT ............................2-33
RTP 4.9 J334- FEED BELT JAM....................................................2-34
RTP 4.10 J350- SPOOL NEAR EMPTY...........................................2-35
RTP 4.11 J351- S32 & S33 BOTH BLOCKED.................................2-36
RTP 4.12 J361- RESIDUAL ELEMENT ERROR .............................2-36
RTP 4.13 J362- ELEMENT FAILED TO CUT ..................................2-37
RTP 4.14 J363- FEED BELT HOME STEPS TIMEOUT..................2-38
RTP 4.15 J364- M9 ELEMENT BACKUP STEPS TIMEOUT ..........2-39
RTP 4.16 J365- M9 MESH STEPS TIMEOUT .................................2-40
RTP 4.17 J366- ELEMENT AT PUSHOVER STEPS TIMEOUT .....2-41
RTP 4.18 J367- ELEMENT STEPS TIMEOUT ................................2-41
RTP 4.19 J368- PUSHOVER FWD ENCODER TIMEOUT..............2-42
5BIND JAM CODES .......................................................................2-43
RTP 5.1 J370- HOLDER AT S37 TIMEOUT ..................................2-43
RTP 5.2 J371- S38 HOLDER POSITION ELEMENT TIMEOUT ...2-44
RTP 5.3 J372- S39 DETECT AT REV GATE TIMEOUT ...............2-46
RTP 5.4 J373- S40 AT BOOK DROP POSITION TIMEOUT .........2-48
RTP 5.5 J374- S46 BOOK DROP TIMEOUT.................................2-49
RTP 5.6 J375- BOOK DROP POSITION TIMEOUT ......................2-51
RTP 5.7 J376- CLOSER AT HOLDER STEPS TIMEOUT.............2-51
RTP 5.8 J377- CLOSER CARRIAGE HOME TIMEOUT................2-51
RTP 5.9 J379- CLOSER JAWS HOME ENCODER TIMEOUT .....2-51
RTP 5.10 J380- CLOSER JAWS HOME TIMEOUT.........................2-52

GBC StreamWire 07/23/2020 RTPS
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RTP 5.11 J381- CLOSER STAGED TIMEOUT ............................... 2-53
RTP 5.12 J382- FULL CLOSE TIMEOUT........................................ 2-53
RTP 5.13 J383- FULL OPEN TIMEOUT .......................................... 2-54
RTP 5.14 J384- HOLDER AT CLOSER STEPS TIMEOUT............. 2-54
RTP 5.15 J385- HOLDER DETECT AT GATE TIMEOUT ............... 2-55
RTP 5.16 J386- HOLDER FULL RIGHT TIMEOUT......................... 2-57
RTP 5.17 J387- HOLDER HOME TIMEOUT ................................... 2-58
RTP 5.18 J388- HOLDER NOT HOME TIMEOUT .......................... 2-59
RTP 5.19 J389- HOLDER PAST HOME TIMEOUT......................... 2-59
RTP 5.20 J390- HOLDER ROTATE HORIZONTAL TIMEOUT ....... 2-60
RTP 5.21 J391- HOLDER ROTATE VERTICAL TIMEOUT............. 2-62
RTP 5.22 J392- HOLDER STACK POSITION STEPS TIMEOUT... 2-64
RTP 5.23 J393- HOLDER WAIT VERTICAL TIMEOUT .................. 2-64
RTP 5.24 J394- PARTIAL CLOSE TIMEOUT.................................. 2-65
RTP 5.25 J395- S28 MOTOR STEPS TIMEOUT ............................ 2-65
RTP 5.26 J396- CLOSER RE-HOME ENCODER TIMEOUT .......... 2-66
6BOOK DRAWER FAULT CODES................................................ 2-68
RTP 6.1J442- DRAWER FULL UP TIMEOUT .............................. 2-68
RTP 6.2 J443- DRAWER FULL DOWN TIMEOUT........................ 2-69
RTP 6.3 J445- BOOK DRAWER FULL .......................................... 2-70
RTP 6.4 J451- S42 & S43 BLOCKED AT SAME TIME ................. 2-70
RTP 6.5 J452- BOOK DRAWER OPENED DURING JOB ............ 2-71

GBC StreamWire 07/23/2020 RTPS
2-3
Section 1.01 Introduction
This section contains the Repair and Troubleshooting Procedures (RTPs).
Organization
This section lists the Repair and Troubleshooting Procedure (RTP) for
each Operator Message and Fault Code. In some cases, one Repair and
Troubleshooting Procedure may apply to several Fault Codes. In those
cases, subsequent Fault Codes include a cross reference to the pertinent
RTP.
To help you locate each component, the Repair and Troubleshooting
Procedures include part locators (PL 5.X) that refer to the pertinent page
in Section 5, Part List.
Entry RTP
Always do this RTP first.
Attempt to retrieve the number of Bind cycles and Sheet cycles (GP 6.2.7)
and note it down.
1. If the customer says that they have a book quality problem, go to
Section 3.
2. For the entire printing device- Power off, then power on (POPO).
Check that eWire runs properly in all modes.
eWire runs properly.
Y N
Go to Step 3.
Go to INITIAL ACTION in Section 1.
3. Check the top row of text on the Operator Interface to determine if
there is there an operator message.
There is an operator message on line 1.
Y N
Go to Step 4.
Go to the Table of Contents for Section 2 and locate the RTP for that
status message.
4. Check the top row of text on the Operator Interface to determine if
there is there an Error Code.
There is an Error Code on line 1.
Y N
Go to Step 5.
Go to the Table of Contents for Section 2 and locate the RTP for that
fault code.
5. Check the top row of text on the Operator Interface to determine if
there is there a Fault Code.
There is a Fault Code on line 1.
Y N
Go to Step 6.
Go to the Table of Contents for Section 2 and locate the RTP for that
fault code.
6. Is there a Power Fault (No AC Power, No DC Power, No power to
Control Board, Operator Panel Does Not Illuminate)?
There is a Power Fault.
Y N
Go to Step 7.
Go to the Table of Contents for Section 2 and locate the RTP for that
power fault.
7. Can the operator use the Operator Interface to operate the
equipment?
The operator can use the Operator Interface to operate the
equipment.
Y N
Check with the customer to determine what symptom they have.
Go to the Table of Contents for Section 2 and find the RTP that
most closely fits the customer’s description of the problem.
Go to INITIAL ACTION in Section 1.

GBC StreamWire 07/23/2020 RTPS
2-4
Section 1.02 OPERATOR MESSAGES
The Operator Panel displays status messages and fault codes on two rows of text.
READY
TO BIND
a) Top Row of Text
Message
Description
Action
BOOK TRAY FULL The Book tray is Full Empty the Book tray
CLOSE TRAY The Book tray is pulled out Insert the Book tray
READY The eWire is ready for Operation n/a
b) Bottom Row of Text
Message
Description
Action
ADD ELEMENTS Element spool is almost empty/ not present Replace the element spool with a new one.
CLOSE DOOR Door for Element feeder drawer is opened Insert the Element feeder drawer and close the door
CLOSE COVER Top cover is open Close the Top cover
TO BIND eWire is in Bind mode Use eWire in Bind mode

GBC StreamWire 07/23/2020 RTPS
2-5
c) Book Tray Full
The BOOK TRAY FULL message indicates that the book tray capacity
has been reached and the tray needs to be emptied.
1. Open the Book drawer by pulling the drawer out.
2. Remove all the bound books from the tray. Note that all the books
need to be removed to clear this message.
3. Re-insert the book drawer.
This clears the fault code.
Y N
Go to step 4.
Normal operation.
4. Do GP 6.4 to check Sensor 42 Sensor 43 & Sensor 45 Book drawer
Full. Remove any debris or obstructions.
This clears the fault code.
Y N
Go to step 5.
Normal operation.
5. Do GP 6.5.10 to check Motor 19 Drawer elevation motor
This clears the fault code.
Y N
Go to step 6.
Normal operation.
6. Inspect the pulley lift mechanism for the Book Drawer. Repair or
replace any damaged components.
This clears the fault code.
Y N
Go to step 7.
Normal operation.
7. Do GP 6.3.5 to re-flash the firmware.
This clears the fault code.
Y N
Go to step 8
Normal operation
8. Replace Control board “B” (REP 11.2)
This clears the fault code.
Y N
Escalate to second level.
Normal operation.