GBC Explorer 107 Manual

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GBC Explorer 107
Laminator
Instruction Manual

GBC Pro - Tech
4151 Anderson Road
DeForest, WI 53532
Revision : Ph: ( 608 ) 246 - 8844
Fx: ( 608 ) 246 - 8645
EXPLORER 107 OPERATION &
MAINTENANCE MANUAL
© December 1999 GBC Pro-Tech
Do not duplicate without written permission.
Partnumber:930-041
R NSON RO R
O R NS ON O R
C O N N
O ORC N RO
SS H S
RA R CON RO
ROR

Read me fileExplorer 107 Operation and Maintenance Manual
© GBC Pro - Tech December 1999
Read Me File . . . . . . . . .
The information in this publication is provided for reference and is believed to be
accurate and complete. GBC Pro - Tech is not liable for errors in this publication or for
incidental or consequential damage in connection with the furnishing or use of the information
in this publication, including, but not limited to, any implied warranty of fitness or merchant-
ability for any particular use.
GBC Pro - Tech reserves the right to make changes to this publication and to the prod-
ucts described in it without notice. All specifications and information concerning products are
subject to change without notice.
Reference in this publication to information or products protected by copyright or
patent does not convey any license under the rights of GBC Pro - Tech or others. GBC Pro -
Tech assumes no liability arising from infringements of patents or any other rights of third
parties.
This publication is copyrighted © 1999 by GBC Pro - Tech. All rights reserved. The
information contained in this publication is proprietary and may not be reproduced, stored,
transmitted, or transferred, in whole or in part, in any form without the prior and express
written permission of GBC Pro - Tech.
In the electronic version of this publication, the hand will change to a pointer finger
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Should you find an error within this publication or would like to make a suggestion,
please utilize the fax correspondence sheet following this read me file and fax it to the number
provided. Your comments and help will ensure up to date information. Thank you.

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© GBC Pro - Tech December 1999
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Read me fileExplorer 107 Operation and Maintenance Manual
© GBC Pro - Tech December 1999
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4151 Anderson Road
DeForest, WI 53532
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Re : Explorer 107 Operations and Maintenance Manual
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Page I
TableofContentsExplorer 107Operation and Maintenance Manual
© GBC Pro - Tech December 1999
Table of Contents
Section 1: Safety
1.1 Symbols .....................................................................................................1 - 1
1.2 Safety features ...........................................................................................1 - 1
1.3 Installation .................................................................................................1 - 3
1.4 Operations .................................................................................................1 - 8
1.5 Applications .............................................................................................1 - 13
1.6 Troubleshooting ......................................................................................1 - 17
1.7 Maintenance ............................................................................................1 - 18
1.8 Label Explanation ...................................................................................1 - 21
Figure 1.8.1 Label Location ....................................................1 - 22
Section 2: Warranty
2.1 Limited warranty information ...................................................................2 - 1
2.2 Exclusions to the warranty .......................................................................2 - 1

Page II
Table ofContents Explorer 107 Operation and Maintenance Manual
© GBC Pro - Tech December 1999
Section 3: Specifications
3.1 General .......................................................................................................3 -1
3.2 Consumables..............................................................................................3 - 1
3.3 Function .....................................................................................................3 - 2
3.4 Electrical ...................................................................................................3 - 2
3.5 Dimensions ................................................................................................3 - 3
Figure 3.5.1 Dimensions ..............................................................3 - 3
Section 4: Installation
4.1 Pre-installation check list ..........................................................................4 - 1
Figure 4.1.1 Plug ..........................................................................4 - 2
Figure 4.1.2 Suggested receptacle ...............................................4 - 2
Figure 4.1.3 Suggested floor layout .............................................4 - 3
4.2 Unpacking .................................................................................................4 - 4

Page III
TableofContentsExplorer 107Operation and Maintenance Manual
© GBC Pro - Tech December 1999
4.3 Shrink wrapped .........................................................................................4 - 4
4.4 Crated ........................................................................................................4 - 5
4.5 Safety check ..............................................................................................4 - 7
4.6 Control panel check ................................................................................4 - 10
4.7 Main roller handle ...................................................................................4 - 15
4.8 Pull roller handle .....................................................................................4 - 16
4.9 Lateral film adjustment ...........................................................................4 - 17
4.10 Film brake adjustment ..........................................................................4 - 18
4.11 Inline slitters ..........................................................................................4 - 19
4.12 Rear cut-off blade .................................................................................4 - 23
Section 5: Operations
5.1 Control panels ...........................................................................................5 - 1
5.1.1 Operations control panel .......................................................................5 - 1

Page IV
Table ofContents Explorer 107 Operation and Maintenance Manual
© GBC Pro - Tech December 1999
Figure 5.1.1 Operations control panel ........................................5 - 4
5.1.2 Temperature control panel .....................................................................5 - 5
Figure 5.1.2 Temperature control panel ......................................5 - 8
5.2 Emergency .................................................................................................5 - 9
5.3 Set up .......................................................................................................5 - 10
5.3.1 Power ....................................................................................................5 - 11
5.3.2 Film loading ..........................................................................................5 - 11
Figure 5.3.1 Film centering chart ..............................................5 - 14
5.3.3 Roller handles ......................................................................................5 - 15
5.3.4 Heating ................................................................................................5 - 16
5.4 Lateral film adjustmentt ..........................................................................5 - 18
5.5 Film brake adjustment ............................................................................5 - 20
5.6 Using inline slitters...................................................................................5 - 20
5.7 Rear cut-off blade ...................................................................................5 - 23

Page V
TableofContentsExplorer 107Operation and Maintenance Manual
© GBC Pro - Tech December 1999
5.8 Front safety shield .....................................................................................5 - 24
5.9 Pressure plate ..........................................................................................5 - 25
5.10 Feed table ..............................................................................................5 - 26
5.11 Feed guides ............................................................................................5 - 29
Section 6: Applications
6.1 Initial webbing ...........................................................................................6 - 1
6.2 New film to existing film ..........................................................................6 - 10
6.3 Unwebbing ...............................................................................................6 - 12
6.4 Parameter charts .......................................................................................6 - 13
Chart 6.4.1 Nap-Lam II ( SAE ) ..................................................6 - 14
Chart 6.4.2 Nap-Lam I ( SAE ) ...................................................6 - 14
Chart 6.4.3 Premium ( SAE ) ......................................................6 - 15

Page VI
Table ofContents Explorer 107 Operation and Maintenance Manual
© GBC Pro - Tech December 1999
Chart 6.4.4 Nap-Lam II ( Metric ) ..............................................6 - 15
Chart 6.4.5 Nap-Lam I ( Metric ) ................................................6 - 16
Chart 6.4.6 Premium ( Metric ) ...................................................6 - 16
Chart 6.4.7 Temperautre conversion chart ................................6 - 17
Section 7: Troubleshooting
7.1 Wave problems .........................................................................................7 - 1
7.2 Output problems .......................................................................................7 - 4
7.2.1 Problems/ Cause/ Hints...........................................................................7 - 4
7.3 Machine problems .....................................................................................7 - 5
7.3.1 Problem/ Hints ........................................................................................7 - 5
7.3.2 Clearing a jam .........................................................................................7 - 6
7.4 Glossary .....................................................................................................7 - 7

Page VII
TableofContentsExplorer 107Operation and Maintenance Manual
© GBC Pro - Tech December 1999
Section 8: Maintenance
8.1 Maintenance schedule ...............................................................................8 - 1
8.2 Cleaning the rollers ..................................................................................8 - 2
8.3 Clean the cabinets and covers ....................................................................8 - 7
8.4 Cleaning the control panels ........................................................................8 - 7

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Table ofContents Explorer 107 Operation and Maintenance Manual
© GBC Pro - Tech December 1999
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Page 1 - 1
Safety
Explorer 107 Operation and Maintenance Manual
© GBC Pro - Tech December 1999
Section 1 Safety
CAUTION
Do not attempt to operate your Falcon 160
laminator until you have read this section
carefully!
Your safety, as well as the safety of others, is
important to GBC Pro - Tech. This section contains
importantsafetyinformation.
Thefollowingsymbolsareusedthroughoutthis
manual to indicate Information,Caution, Warning,
DangerandElectricalShock conditions.
1.1 Symbols
INFORMATION
Indicates helpful information that should be
considered before, during, or after an
action, step or procedure is given.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, could result in minor
or moderate injury, or alerts against unsafe
practices or alerts against actions which
could damage the product.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in serious
injury.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, could result in death
or serious injury.
ELECTRICAL
SHOCK
Indicates an electrical shock situation which,
if not avoided, could result in serious
paralyzation of the body or death.
1.2 Safety features
TheExplorer107laminatorhasbeendesigned
withsafetyasaprimaryconsideration;however,youmust
become thoroughly familiar with the controls, proper
operation,properserviceproceduresand safetyfeatures
ofthelaminatorbeforeusingorservicingtheunit.

Page 1 - 2
Safety Explorer 107 Operation and Maintenance Manual
© GBC Pro - Tech December 1999
In addition, the heating components of the
Explorer107canreachtemperaturesof over 200oF
( 100oC ).
DANGER
At these temperatures there is a danger of
severe burn if the rolls are touched during
setup, operation or servicing.
INFORMATION
Only a qualified service technician should
perform any procedure requiring the
cabinet doors to be opened.
Thewordqualifiedisdefinedbelow;
Qualified;
•Any engineerthathasexperiencewithelectrical
and mechanical design of lamination equipment.The
engineersshouldbefullyawareofallaspectsofsafety
withregardstolaminationequipment.
•Anycommissioningorserviceengineermustbe
ofcompetentnature,trained and qualified toGBCPro-
Techstandardstofulfillthatjob.Thispersonwillhave
completedandpassedthefullservicetrainingcoursefrom
GBCPro-Tech.
•Any GBCTechnician, GBCSpecialist, and/or
GBCPro-TechTechnicianthathasbeenthroughtheGBC
Pro-Techservice trainingcourse.
An important feature of the Explorer 107
laminatorarethesafetylatchesandtheinterlocks.The
frontsafetyshieldandthefeedtablearebothequipped
withsafetylatches.Whenasafetylatchisnotinthelocked
position,themotor is disabled.RefertoFigure1.2.1
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
WARNING
Figure 1.2.1 Safety latches
RUR ON O
Safet
y
latches
Safety latches
Under the feed table

Page 1 - 3
Safety
Explorer 107 Operation and Maintenance Manual
© GBC Pro - Tech December 1999
The laminator is equipped with two
EMERGENCY STOPS ( E-STOP ).One is located
above the TEMPERATURE CONTROL panel and
thesecondislocatedabovemachine POWER.Referto
Figure1.2.2
Figure 1.2.2 Emergency stops
ARONRO
Emergency stops
To engage the EMERGENCYSTOPfeature,
press down. Either of these, when engaged, removes
powertothemotor.
Push down
Tocontinueoperation,both E-STOPSmustbe
intheupposition.ToresettheE-STOP, twist thebutton
1/4turnclockwise.
Rotate
INFORMATION
The laminator will operate only when
all safety latches are in the fully
latched position.
1.3 Installation
Thefollowingsymbolsarepositioned atvarious
points in Section4 Installation.
CAUTION
Failure to follow the pre-installation check
list can result in damage to the laminator.

Page 1 - 4
Safety Explorer 107 Operation and Maintenance Manual
© GBC Pro - Tech December 1999
WARNING
The operating environment must be free of
dust, flammable liquids and vapors. You can
be injured by inhaling chemical vapors.
WARNING
Vapor build up or stored flammable liquids
can cause a fire. Excessive dust can damage
the laminator.
CAUTION
Do not locate the laminator where air is
blowing directly on the machine. The air
flow can cool the rolls unevenly and result in
poor quality output.
WARNING
The Explorer 107 Laminator is a large and
heavy piece of equipment. It is necessary to
employ LICENSED RIGGERS ONLY to
move the laminator. The laminator is not
designed to be tipped up or sideways in any
way. Such action disturbs the exact
alignment of the rolling parts of the machine
and requires extensive realignment. You can
be crushed or seriously injured.
INFORMATION
ALL SHIPMENTS ARE EX-WORKS. At our
dock, title passes to the buyer. Please review
your insurance coverage prior to shipment,
as you are responsible for all subsequent
freight charges and risks.
INFORMATION
Before signing the Bill of Lading, you should
be sure to inspect the crate and / or pallet
for signs of damage or missing items; if
applicable, make note of this on the Bill of
Lading.
INFORMATION
Depending on the destination and customer
preference, the Falcon 160 may be shipped
in various ways. The laminator may arrive
shrink wrapped or in a plywood crate on a
skid. Please follow the unpacking procedure
that pertains to your method of shipment.
WARNING
The unpacking process requires at least two
people. You can be severely injured, crushed
or cause damage to the laminator.

Page 1 - 5
Safety
Explorer 107 Operation and Maintenance Manual
© GBC Pro - Tech December 1999
CAUTION
Do not use a knife or other sharp object to
remove the shrink wrap from around the
laminator. You can cause irreparable
damage to the rollers.
WARNING
Do not attempt to move the laminator across
anything other than a flat level surface
without trained and qualified riggers. You
can be crushed or seriously injured.
CAUTION
Do not allow the top to fall into the crate. It
can damage the laminator.
INFORMATION
Do not put packing screws on the floor.
They can cause problems when trying to roll
the laminator into position or you can
become injured if stepped on.
CAUTION
A second person must support the side
labeled 5 in Figure 4.4.1 It can fall and
damage the laminator or cause harm to you
and others.
GBC Pro-Tech's warranty does not cover
malfunction of the equipment due to
mishandling and / or tipping. GBC Pro-
Tech bears no responsibility for personal
injury or damage due to moving the
laminator improperly.
INFORMATION
About recycling: The crate components can
be reused for shipping the laminator again
or can be disassembled and the wood and
screws recycled. The shrink wrap is not
recyclable, so it must be discarded.
INFORMATION
WARNING
Do not wear ties, loose fitting clothes or
dangling jewelry while operating or
servicing the laminator. These items can get
caught in the nip and choke you or you can
be crushed or burned.

Page 1 - 6
Safety Explorer 107 Operation and Maintenance Manual
© GBC Pro - Tech December 1999
WARNING
If a safety feature is not functioning
properly, contact your local service
representative immediately
INFORMATION
When the laminator is first turned on, the
control panels display the default settings.
Default setting; Cooling Fan = Off, Motor
Speed = Off, Top Teflon Roller = 32
o
F, Nip
Rollers = 32
o
F, Bottom Teflon Roller = 32
o
F and Sub Heaters = 32
o
F.
INFORMATION
When any command is pressed ( with the
exception of Reverse ) on the Operations
Control Panel, a "beep" will sound. If the
command is held down, the panel will
continually "beep".
INFORMATION
Leave the motor speed adjust at 5 to
continue with the function check.
INFORMATION
Reverse speed can be controlled by
Speed Adjust.
INFORMATION
A second person is needed to assist with the
idler tension checks.
INFORMATION
Lower film tension idler: gray rubber
covered idler located below the lower
cooling fan assembly.
INFORMATION
Upper film tension idler: gray rubber
covered idler located above the upper
cooling fan assembly.