GBC AdvancedPunch Operating manual

Document # 7712571, Rev. C1 (23 08 2013)
AdvancedPunch
Technical Service Manual

Copyright Notice
GBC
300 Tower Parkway
Lincolnshire, IL 60069
USA
www.gbcconnect.com
© Copyright 2011 GBC. 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
respectiveowners.Informationcontained withinthisdocumentissubjecttochange
without notice.

Advanced Punch Service Manual © Copyright 2009 GBC. All rights reserved. i
Table of Contents
Preface P-1
Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-1
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-2
Setting the Right Expectations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-3
Product Positioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-3
Long Edge Feed (LEF) Only - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-3
Die Sets XC / Letter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-4
Die Sets XE / A4 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P-5
Section 1 Maintenance 1-1
Initial Service Action - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Paper Jam Service Action - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
Die Set Service - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Die Set Life Expectancy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Die Set Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Serviceable Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Die Set Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7
Die Set Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8
Hole Alignment Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
Inspection, Cleaning, and Lubrication - - - - - - - - - - - - - - - - - - - - - - - - 1-10
External Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11
Internal Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11
Operational Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11
Internal Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11
Base Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12
Chip Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Die Guide Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13
Door Latch Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14
Separating Punch From Printer - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14
Rear Cover Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14
Aligner Panel Inspection and Cleaning - - - - - - - - - - - - - - - - - - - - - 1-15
Aligner Idler Roller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
Aligner Green Drive Belt Maintenance . . . . . . . . . . . . . . . . . . . . . .1-18

ii © Copyright 2009 GBC. All rights reserved. Advanced Punch
Table of Contents
Back Gauge Solenoid Inspection and Cleaning - - - - - - - - - - - - - - - 1-19
Idler Roller Inspection and Cleaning - - - - - - - - - - - - - - - - - - - - - - - 1-20
Idler Roller Removal and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . .1-21
Non-Removable Idler Roller Cleaning . . . . . . . . . . . . . . . . . . . . . .1-22
Drive Roller Inspection and Cleaning - - - - - - - - - - - - - - - - - - - - - - 1-24
Aligner Latch Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-25
Optical Sensor Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-26
Bypass Paper Path Inspection and Cleaning - - - - - - - - - - - - - - - - - 1-28
Punch Paper Path Inspection and Cleaning - - - - - - - - - - - - - - - - - 1-29
Punch Drive Cam Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-30
Timing Belt Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-31
Final Service Action - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-32
Section 2 Fault Analysis Procedures 2-1
040-101 Fault Diagnosis: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
Initial Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
RAP AC Power - No Indication of Power - - - - - - - - - - - - - - - - - - - - - - - 2-3
Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
Initial Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
RAP DC Power - No Indication of 24V DC - - - - - - - - - - - - - - - - - - - - - 2-4
Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
Initial Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
RAP Paper Jams at Punch, Chad is Present in the Paper Path - - - - - - - 2-5
RAP Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
RAP Initial Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
RAP References - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
RAP Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
RAP Paper Jams at Punch, Chad is Not Present in the Paper Path - - - - 2-6
RAP Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
RAP Initial Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
RAP References - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
RAP Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
RAP Paper is Skewed Before It Gets to the Punch. - - - - - - - - - - - - - - - 2-7
RAP Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
RAP Initial Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
RAP References - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
RAP Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
Back Gauge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-10
Die Set - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-10

Advanced Punch Service Manual © Copyright 2009 GBC. All rights reserved. iii
Table of Contents
Section 3 Output Quality Analysis Procedures 3-1
RAP Hole Alignment Inspection Procedure - - - - - - - - - - - - - - - - - - - - - 3-1
RAP Hole Skew Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
RAP Hole Quality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
RAP Oil On Paper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
RAP Skuff Marks On Paper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
RAP Lead Edge Damage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
Section 4 Repair and Adjustment Procedures 4-1
Preparing the Advanced Punch for Service - - - - - - - - - - - - - - - - - - - - - 4-1
Separating the Punch From the Printer - - - - - - - - - - - - - - - - - - - - - - 4-1
Removing the Rear Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
Leveling And Aligning to the Printer - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
Door Latch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
Door Latch Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
Door Latch and Switch Replacement - - - - - - - - - - - - - - - - - - - - - - - 4-6
Bypass Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
Bypass Panel Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
Bypass Idler Roller Replacement - - - - - - - - - - - - - - - - - - - - - - - - - 4-13
Punch Idler Rollers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-15
Idler Roller Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-16
Aligner Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17
Aligner Idler Roller Replacement - - - - - - - - - - - - - - - - - - - - - - - - - 4-17
Aligner Panel Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-18
Aligner Drive Belt (Green Belt) Replacement - - - - - - - - - - - - - - - - - 4-20
Paper Entrance Side Green Drive Belt Replacement . . . . . . . . . . 4-21
Green Drive Belt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Entrance Aligner Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Paper Exit Side Green Drive Belt Replacement . . . . . . . . . . . . . . 4-27
Green Drive Belt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Aligner Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Energy Drive Roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-35
Back Gauge Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-36
Back Gauge Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-37
Back Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Solenoid Cleaning and Inspection - - - - - - - - - - - - - - - - - - - - - - - - 4-45
Solenoid Spring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Back Gauge Paddle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-47
Punch Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-48
Punch Module Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-49
Punch Drive Cam Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-54
Clutch Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-55
Punch Module Brake Replacement and Adjustment - - - - - - - - - - - - 4-60

iv © Copyright 2009 GBC. All rights reserved. Advanced Punch
Table of Contents
Punch Module Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . .4-60
Punch Module Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .4-62
Punch Module Motor Replacement - - - - - - - - - - - - - - - - - - - - - - - 4-63
Punch Module Motor Drive Belt Replacement . . . . . . . . . . . . . . . .4-65
Punch Module Drive Roller Cleaning and Replacement - - - - - - - - - 4-66
Belt Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-69
Hole Alignment Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-70
Replacement - ChipTray Microswitch - - - - - - - - - - - - - - - - - - - - - - - - 4-74
Sensor Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-75
Diverter Gate Solenoid Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - 4-80
Section 5 Parts List 5-1
Section 6 General Procedures 6-1
Component Control And Diagnostic Modes Entry and Exit Procedures - 6-2
Entering and Exiting Maintenance/Diagnostic Tools Mode - - - - - - - - 6-2
Component Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-2
NVM Read/Write - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-3
Adjustments and Feature Control General Procedures - - - - - - - - - - - - - 6-4
GBC AdvancedPunch Input Component Control - - - - - - - - - - - - - - - - - 6-5
GBC AdvancedPunch Output Component Control - - - - - - - - - - - - - - - - 6-6
GBC AdvancedPunch NVM Setting List - - - - - - - - - - - - - - - - - - - - - - - 6-7
GBC AdvancedPunch Fault Code List - - - - - - - - - - - - - - - - - - - - - - - - 6-8
Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-9
Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-9
Principle of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-10
Inputs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-10
Outputs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-11
Printer Communication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-11
Serial EEPROM Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-11
Stepper #1 Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-12
Punch Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-12
Stepper #2 Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-12
Paper Flow - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-13
Glossary of Terms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-14
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15
Section 7 Wiring and Electrical Data 7-1
Service Schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
AC Motors Punch / Transport - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-4
AC Filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Safety Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-6
Door Chiptray DS Switches / Inputs - - - - - - - - - - - - - - - - - - - - - - - - 7-7

Advanced Punch Service Manual © Copyright 2009 GBC. All rights reserved. v
Table of Contents
Communication Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
Boot Load - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
24 Volts Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10
Steppers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Overlay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12
Sensor Inputs Config- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
PCB Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-14
Section 8 Installation and Set Up 8-1
Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-2
Space Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10
Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11
Test Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11

Advanced Punch Service Manual © Copyright 2009 GBC. All rights reserved. P-1
Preface
1. Safety
These symbols are used in this documentation alert you to danger or important
information.
Warning: Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious Injury.
Warning: Risk of electrical shock. This warning statement indicates situations
where there is a risk of death by electric shock.
Caution: This notice indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be used to alert
against unsafe practices.
Ce
rtain components in this product are susceptible to damage from electrostatic
discharge. Observe all ESD procedures to avoid component damage.

P-2 © Copyright 2009 GBC. All rights reserved. Advanced Punch Service Manual
2. Introduction
This service manual is provided for use by an authorized service technician for the
repair and maintenance of the Advanced Punch.
The Advanced Punch is an innovative, labor saving solution for punching paper
in-line and includes the following design features:
•Maximum productivity saver with punching in-line at the speed of the printer!
Does not slow up or stop the print system.
•Quick-change die sets that are self-latching without tools or levers.
•Advanced Punch die sets are available in all of the most common hole
patterns and include an Identifying Label providing user with the hole pattern
and name.
•Convenient storage area for three extra Die Sets located above the sheet
bypass.
•Accurate hole punching with consistent alignment.
With each Advanced Punch, the customer receives a user manual. They are
encouraged to keep this manual for future reference. The information contained in
the user manual is also helpful to the service technician. Please refer to it for
detailed information regarding dies sets, operationor specifications. You will find a
copy of the User Guide at the end of section 8, Installation and Setup.

Preface
Advanced Punch Service Manual © Copyright 2009 GBC. All rights reserved. P-3
3. Setting the Right Expectations
The following excerpts are copied from sales and marketing literature. This
customer expectation information is helpful for the service technician.
3.1 Product Positioning
The Advanced Punch provides a flexible, cost effective punching solution for light
to medium level production oriented customers.
•Designed for customers that have the need to punch their documents at a
maximum of 60-70% of their overall workflow.
•Recommended punching limit to 200K sheets per month. (600k sheets in
bypass mode)
•Die Sets will decrease in performance over time based on the types of stocks
and weights that are being punched.
•The expected life of a dieset is 500K punches. However, if paper stock
punched is typically 20 lb. bond, then up to 2 million punches can be
achieved.
•Should be regarded as a long-term supply item.
3.2 Long Edge Feed (LEF) Only
The Advanced Punch is designed to punch LEF only. No exceptions. Attempting
to punch a sheet size other than LEF will cause a paper jam.
•Use a colored sheet insert (instead of the tab) in the job workflow for easier
tab insertion after the job has been run.

P-4 © Copyright 2009 GBC. All rights reserved. Advanced Punch Service Manual
3.3 Die Sets XC / Letter
AdvancedPunch
The AdvancedPunch uses a variety of easily interchangeable die
sets that allow you to punch documents in line for several different
binding styles. By selecting the appropriate die set, you can use your
AdvancedPunch to punch documents in any of the binding styles
indicated in Table 1.
4. PUNCHING PATTERNS
For Plastic Comb Binding choose from:
PB Plastic Bind; Hole Size: 8mm x 2.9mm (0.313" x 0.116") (LxW); Center-to-Center Hole Spacing: 14.3 mm (0.563")
For Twin Loop™ Binding choose from:
W3 Wire; Square; 3 Holes per inch; Hole Size: 4mm x 4mm (0.156" x 0.156") ( L x W); Center-to-Center Hole Spacing: 8.5 mm (0.333")
W2 Wire; Rectangle; 2 Holes per inch; Hole Size: 6.4mm x 5.4mm (0.250" x 0.214")(L xW); Center-to-Center Hole Spacing: 12.7 mm (0.500")
For Color Coil™ Binding choose from:
C4 Coil; Round; 4 Holes per inch; Hole Size: 4.4mm ( 0.174") Diameter; Center-to-Center Hole Spacing: 6.3mm (0.2475")
For Velo®Bind choose from:
VB Velobind®; Round; 1 Hole per inch Hole Size: 3.2mm ( 0.125") Diameter; Center-to-Center Hole Spacing: 25.4mm (1")
For Velo® Bind choose from:
For Looseleaf Binding choose from:
3 Ring Binder; U.S. (Standard Looseleaf Patterns); Hole Size: 8mm (0.316") Diameter
©2003 GBC, Northbrook Illinois - All rights reserved. Rev 10/02 R2 3/03 Graphics do not represent actual punch pattern dimensions or spacing.
119
132
121
441
11
1
3
1
For Proclick®Binding choose from:
W3 Proclick®; Rectangle; Hole Size: 4.9mm x 5.5mm; 0.196”x0.215”(LxW); Center-to-Center Hole Spacing:8.5mm(0.333”)
132
Xerox Part Number:
XEROX PB-19H 008R13066
XEROX C4-44H 008R13067
XEROX W2-21H-SQ 008R13068
XEROX W3-32H-SQ 008R13069
XEROX VB-11H 008R13070
XEROX PC-32H 008R13071
XEROX 3H 008R13072
GB

Preface
Advanced Punch Service Manual © Copyright 2009 GBC. All rights reserved. P-5
3.4 Die Sets XE / A4
AdvancedPunch
The AdvancedPunch uses a variety of easily interchangeable die
sets that allow you to punch documents in line for several different
binding styles. By selecting the appropriate die set, you can use your
AdvancedPunch to punch documents in any of the binding styles
indicated in Table 1.
4. PUNCHING PATTERNS
Xerox Part Number:
XEROX PB-20H, A4 498K19340
XEROX PB-21H, A4 498K19440
XEROX C4-47H, A4 498K19350
XEROX W2-23H-RND, A4 498K19360
XEROX W3-34H-RND, A4 498K19370
XEROX W2-23H-SQ, A4 498K19380
XEROX W3-34H-SQ, A4 498K19390
XEROX VB-12H, A4 498K19400
XEROX PC-34H, A4 498K19410
XEROX 2H-8mm, A4 498K19420
XEROX 4H-8mm, A4 498K19430
For Plastic Comb Binding:
PB Plastic Bind; Hole Size: 8mm x 3.2mm (0.315" x 0.126") (LxW); Centre-to-Centre Hole Spacing: 14.3mm (0.563")
21
1
For Twin Loop™ Binding:
W3 Wire; Round; 3 Holes per inch; Hole Size: 4mm (0.158") Diameter; Centre-to-Centre Hole Spacing: 8.5mm (0.335")
W2 Wire; Round; 2 Holes per inch; Hole Size: 6.5mm (0.256") Diameter; Centre-to-Centre Hole Spacing: 12.7mm (0.5")
For Loose-leaf Binding:
120
1
134
For Colour Coil™ Binding:
C4 Coil; Round; 4 Holes per inch; Hole Size: 4.5mm ( 0.177") Diameter; Centre-to-Centre Hole Spacing: 6.3mm (0.248")
For Velo®Binding:
23
VB Velo®Bind Round; 1 Hole per inch Hole Size: 3.2mm ( 0.126") Diameter; Centre-to-Centre Hole Spacing: 25.4mm (1")
21
1 4
W3 Wire; Square; Australia; 3 Holes per inch; Hole Size: 4mm x 4mm (0.158” x 0.158”) (L x W) Centre to Centre Hole Spacing:
8.5mm (0.335)”
W2 Wire; Square; Australia; 2 Holes per inch; Hole Size: 6.4mm x 5.5mm (0.252” x 0.217”) (L x W) Centre to Centre hole
spacing 12.7mm (0.5)
PB Plastic Bind; Australia Hole Size: 8mm x 3.2mm (0.315” x 0.126”)(LxW) Centre to Centre hole spacing: 14.3mm (0.563”)
4 Ring Binder; European (Standard Loose-leaf Patterns); Hole Size: 8mm (0.315") Diameter
2 Ring Binder; European (loose-leaf pattern), Hole Size: 8mm (0.315") Diameter
ProClick®A4 34-Hole Binding:
134
Graphics do not represent actual punch pattern dimensions or spacing.
Please note that each punching style listed above requires a
separate die set for the AdvancedPunch. The AdvancedPunch can
hold up to four Die Sets in it’s cabinet (one in the operating slot and
three in the storage area).
To purchase additional or replacement Die Sets, contact your
authorized sales representative.
You cannot use die sets for the AdvancedPunch..
You can confirm the attached die set in the printer/copier.
PC ProClick®; Rectangular; 3 holes per inch, Hole size: 5.5mm (0.217"H) x 5.0mm (0.197"W). Centre to Centre 8.5mm (0.335")
GB

Advanced Punch Service Manual © Copyright 2009 GBC. All rights reserved. 1-1
Section 1
Maintenance
This section contains service call initial action procedures, cleaning and
maintenance procedures, and service call final action procedures.
1.1 Initial Service Action
At the start of every service call, you should perform the following.
1. 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 and identify
if any media changes correlate with the emergence of the customer issue.
2. Estimate the cycle life on the Die Sets. Determine if any of the Die Set life
cycles have exceeded 500k sheets (cycles).
3. Determine if the customer uses only one Die Set pattern (style) or if they switch
between different patterns.
4. Determine the last time the Die Set was lubricated.
5. Determine the date of the last preventative maintenance performed on the
punch system.
6. Vacuum all paper path, punch, dust box area of scrap/debris.
7. Clean backgage solenoid per instructions given in section “Back Gauge
Solenoid Inspection and Cleaning” on page 1-19.

Section 1
1-2 © Copyright 2009 GBC. All rights reserved. Advanced Punch Service Manual
1.2 Paper Jam Service Action
To clear a paper jam, first press the Stop button on the printer and then check the
printer screen to see the area of the paper jam.
If the paper jam is in the printer or finisher only, follow the information on the
screen to clear the paper jam. If the screen shows a paper jam in the punch, follow
this sequence.
To clear a paper jam in the punch:
1. Open the punch cabinet door.
2. Ensure the Chip Bin is not overflowing.
3. Turn punch knob [1] anticlockwise until the punch is in its home position [2].
Figure 1.1 Setting the Punch to Its Home Position.
4. Open the Bypass panel cover [1] and check for obstructions in the Bypass [2].
5. Ensure the Entrance Guide is clear [3].
6. Ensure the Diverter is clear [4].
Figure 1.2 Clearing The Bypass.
[1]
[2]
[1]
[2]
[4]
[3]

Maintenance
Advanced Punch Service Manual © Copyright 2009 GBC. All rights reserved. 1-3
7. Open the entrance paper Aligner panel latch [1] and clear obstructions in the
Aligner.
8. Open the exit paper Aligner panel latch [2] and clear obstructions in each
Aligner.
Figure 1.3 Checking Paper Path Through the Punch.
[1]
[2]

Section 1
1-4 © Copyright 2009 GBC. All rights reserved. Advanced Punch Service Manual
9. Open the bottom U-channel by pressing the lever in [1] and lower the
U-channel [2] and clear the path.
Figure 1.4 Opening the Bottom U-Channel
10. When all the paper is cleared, close the U-channel, Aligner Panels, and
Bypass.
11. Shut the cabinet door.
12. Verify on the printer screen that the paper jam has been cleared. If not, repeat
the above steps.
13. Press the resume button on the printer. The printing operation should resume.
[1]
[2]

Maintenance
Advanced Punch Service Manual © Copyright 2009 GBC. All rights reserved. 1-5
1.3 Die Set Service
The Die Set assembly is not serviceable other than inspection and periodic
lubrication.
If a Die Set is at its end of life, it will tend to cause paper jam due to hanging chips.
This is a result of die plate wear, and not pin wear, which cannot be corrected.
When this occurs, the Die Set should be replaced with a new one.
1.3.1 Die Set Life Expectancy
The Advanced Punch Die Sets have a minimum life expectancy of 500K cycles
(sheets of paper punched). With periodic lubrication and optimum paper types, life
can exceed this number. Access GP6 #1 to read the counter for the GBC module.
Variables that affect life expectancy:
•Failure to follow the lubrication schedule or using the incorrect lubricant
•Variety and types of paper being punched
•Cover stocks being punched
•Length of the average job
•Other environmental conditions
1.3.2 Die Set Components
The Advanced Punch uses two types of Die Sets.
Table 1.1 Die Set Types
Type Description Bindery Style
No Felt Oiler Pad — 3H, 4H, 5H, 7H, VB (VeloBind)
Encircled Felt Oiler Pad Felt oiler pad surrounds the
punch pins
PB 19H, 20H and 21H
(Plastic Bind), PC 32H and
34H (Pro Click), C4 44H and
47H (Plastic Coil)

Section 1
1-6 © Copyright 2009 GBC. All rights reserved. Advanced Punch Service Manual
1.3.2.1 Serviceable Components
•Punch pins [1]
•Felt pad (on some Die Sets) [2]
Figure 1.5 Die Set Serviceable Components.
[2] [1]

Maintenance
Advanced Punch Service Manual © Copyright 2009 GBC. All rights reserved. 1-7
1.3.3 Die Set Inspection
Maintenance Schedule
Inspect every 500K cycles.
Replace as needed.
Procedure
Set the Die Set on a table and press the top plate straight down at both ends at
the same time [1] and look for a smooth operation. The top plate and pins should
retract fully when you release.
Figure 1.6 Check For Free Movement.
Reinstall the Die Set into the punch and run several sheets of the customer’s
paper through the punch. Inspect the holes.
•Holes should be clean and even with no tearing or frayed edges.
•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 “Idler Roller Inspection and Cleaning” on page 1-20.
[1]
[1]

Section 1
1-8 © Copyright 2009 GBC. All rights reserved. Advanced Punch Service Manual
1.3.4 Die Set Lubrication
Maintenance Schedule
Inspect every 500K cycles.
Lubricate Die Set pins every 50K cycles.
Procedure
Inspect the punch pins for signs of wear or mis-alignment. Periodic lubrication
extends the life of the Die Sets.
The customer or operator can perform this maintenance between technician
inspections.
Figure 1.7 Inspect Punch Pins.
To lubricate Die Set pins that do not have felt pads:
1. Depress the Die Set so that the pins protrude from the bottom plate.
2. Apply a drop of high quality machine oil to the end of each pin.
3. Wipe clean, leaving a light coat of oil on them.
To lubricate Die Set pins that have felt pads:
•Lubricate with a high quality machine oil.
•Apply oil lightly along the length of the pad [1], but do not over saturate.
•Do not use spray lubricants because they tend to dry up quickly and leave a
sticky residue.