GBC StreamPunch Ultra User manual

GBC StreamPunch Ultra/Ultra MP 11-05-2018 Service Manual
Part Number: 7718591
Revision Number: A1
Issue Date: November 2018
GBC StreamPunch Ultra/Ultra MP
Service Manual

Service Manual 11-05-2018 GBC StreamPunch Ultra/Ultra MP
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GBC StreamPunch Ultra/Ultra MP 11-05-2018 Service Manual
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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. Punch Quality .....................................................3-1
4. Adjustment and Replacement Procedures......4-1
5. Parts List .............................................................5-1
6. General Procedures ...........................................6-1
7. Wiring Data .........................................................7-1
8. Installation ..........................................................8-1

Service Manual 11-05-2018 GBC StreamPunch Ultra/Ultra MP
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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
Acronyms................................................................................viii

GBC StreamPunch Ultra/Ultra MP 11-05-2018 Service Manual
v
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 Punch Quality
Section 4 Adjustments and Replacement Procedures
Section 5 Parts List
Section 6 General Procedures
Section 7 Wiring Data
Section 8 Installation Checklist
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
StreamPunch Ultra/Ultra MP. 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: Punch Quality
This section is used to diagnose punch quality defect problems.
Section 4: Adjustments and Repair Procedures (ARP)
This section contains all repair and adjustment procedures for the
machine. Repairs (ARPs) 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.

Service Manual 11-05-2018 GBC StreamPunch Ultra/Ultra MP
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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
StreamPunch Ultra/Ultra MP 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 StreamPunch Ultra/Ultra MP 11-05-2018 Service Manual
vii
Safety Devices
The GBC StreamPunch Ultra/Ultra MP has door interlock to prevent
personal injury when operating the machine.
When you open the Front Door, a Safety Interlock device automatically
disables the drive motors until you close the Front Door.
When the Front Door is open, the Operator Panel displays the “CLOSE
DOOR” message on the top line of the interface.
When you close the Front Door, the Operator Panel displays the
“READY” message on the top line of the interface.
CAUTION
Certain components in the GBC StreamPunch Ultra/Ultra MP are
susceptible to damage from electrostatic discharge. Observe all ESD
procedures to avoid component damage.
Operational Safety
Do not operate the GBC StreamPunch Ultra/Ultra MP with the interlocks
defeated.
Use care when a procedure in this Manual instructs you to “insert an
Interlock Cheater into the Punch Door interlock Switch SW1,” 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.
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.

Service Manual 11-05-2018 GBC StreamPunch Ultra/Ultra MP
viii
Important safeguards
♦Use StreamPunch Ultra/Ultra MP only for its intended purpose of
punching paper and covers according to the indicated specifications.
CAUTION: THE PRINTER ON/OFF SWITCH DOES NOT CUT
OFF POWER FROM THE PUNCH.
♦The Punch 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
Punch. It is provided for your safety.
♦Unplug the Punch before moving the machine or whenever the
machine is not in use for an extended period of time.
♦Do not operate the Punch 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 Operator Manual and Service Manual.
Acronyms
Acronyms are used in the parts list to provide information in a limited
amount of space. The following table lists the abbreviations used in this
manual:
Acronym Meaning
CBL Cable
DRV Motor Driver (Stepper Board)
F Fuse
FAN Fan
GND Ground
M Motor
P Plug
J Connector
PSU Power Supply
S Sensor
SW Switch
SOL Solenoid
UI User Interface

GBC StreamPunch Ultra/Ultra MP 11-05-2018 Service Manual
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Notes:

GBC StreamPunch Ultra/Ultra MP 02-03-2017 Service Call Procedures
1-1 Section Contents
1.Service Call Procedures
Section Contents
Service Call Procedures
Title Page
CALL FLOW.................................................1-2
INITIAL ACTION..........................................1-3
SYSTEM CHECKS......................................1-3
EVERY CALL ACTIVITIES..........................1-4
SCHEDULED MAINTENANCE ...................1-4
PREVENTATIVE MAINTENANCE..............1-4
StreamPunch Ultra/Ultra MP Maintenance
Schedule ...............................................1-5
Customer Maintenance.....................1-5
Periodic Maintenance .......................1-5
Periodic Replacement.......................1-6
HFSI.............................................................1-7
FINAL ACTION............................................1-7

Service Call Procedures 02-03-2017 GBC StreamPunch Ultra/Ultra MP
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 punch
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
repair of the problem. 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 punch
quality, the punch performance, and the
punch appearance are satisfactory. It will
also provide direction to help complete
administrative tasks.

GBC StreamPunch Ultra/Ultra MP 02-03-2017 Service Call Procedures
1-3
INITIAL 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. Do GP 6.1.9 PUNCH CYCLES to note down the total machine punch
cycles.
3. Do GP 6.1.8 DIE CYCLES Procedure to check the cycle life on the
Die Set installed in the StreamPunch Ultra/Ultra MP.
4. If any of the Die Set life cycles have exceeded 750,000 sheets
(cycles) go to Section 3 and check the Hole Quality.
DIE CYCLES
500,129
•If the Hole Quality is acceptable monitor the Hole Quality
frequently to ensure that the Hole Quality is okay.
•If the Hole Quality is not acceptable replace the Die Set.
5. Determine if the customer uses only one Die Set pattern (style) or if
they switch between different patterns.
6. Determine the last time the Die Set was lubricated. Perform GP 6.7.3
to lubricate die if necessary.
7. Determine the date of the last preventative maintenance performed
on the punch system. Perform Preventative Maintenance using the
StreamPunch Ultra/Ultra MP Maintenance Schedule on page 1-5 if
needed.
8. Vacuum all paper path, punch, dust box area of scrap/debris.
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 Punch Quality problem, go to 3.2 Initial Step in
Section 3.
•If there is a Fault Code, go to Section 2 Table of Contents. Locate
and perform the FAULT CODE RTP associated with the Fault
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 RTP associated with the Operator
Message.
•If there is No Fault Code or Operator Message associated with
the problem, go to Section 2 Table of Contents. Locate and
perform the OTHER FAULTS RTP which most closely matches
the problem described by the customer.
•If the problem is not repeatable, operate the StreamPunch
Ultra/Ultra MP 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 RTP for
those faults in Section 2 to check if the RTP relates to the
customer problem. If so, perform the RTP.
•If none of the above situations apply, go to EVERY CALL
ACTIVITIES.
2. Verify that the problem is corrected and go to EVERY CALL
ACTIVITIES.

Service Call Procedures 02-03-2017 GBC StreamPunch Ultra/Ultra MP
1-4
EVERY CALL ACTIVITIES
Purpose
List service activities required on every service call.
PROCEDURE
1. Perform GP 6.5 Operational Inspection.
2. Perform GP 6.6 Internal Inspection.
3. Perform GP 6.8 External Cleaning.
4. Perform GP 6.9 Internal Cleaning
5. Perform GP 6.10 Base Cleaning
6. Perform GP 6.11 Chip Bin Cleaning
7. Perform GP 6.12 Die Guide Cleaning
8. Perform GP 6.17 Optical Sensor Cleaning
SCHEDULED MAINTENANCE
PROCEDURE
1. Do GP 6.1.8 DIE CYCLES Procedure to check the cycle life on the
Die Set installed in the StreamPunch Ultra/Ultra MP.
2. See the StreamPunch Ultra/Ultra MP Maintenance Schedule on page
1-5.
PREVENTATIVE MAINTENANCE
Purpose
If operating properly, the StreamPunch Ultra/Ultra MP will punch the
same types of copy paper and cover materials handled by the printer and
run at the same speed.
Hole quality will vary between different grades of paper.
See the StreamPunch Ultra/Ultra MP Maintenance Schedule on page 1-5.

GBC StreamPunch Ultra/Ultra MP 02-03-2017 Service Call Procedures
1-5
StreamPunch Ultra/Ultra MP Maintenance Schedule
Note: cycles = sheets of paper punched, not impressions.
Customer Maintenance
Area/Unit Period See: Measures Remarks
Punch Die 100K Die cycles GP 6.7.3 Lubrication Oil the punch pins
Die set shoulder bolts 200k Die cycles GP 6.7.4 Inspect and lubricate Grease
Periodic Maintenance
Area/Unit
Period
See:
Measures
Remarks
Punch Drive Cams 5000K cycles GP 6.20 Inspect and lubricate
Punch Motor Belt 1,000K cycles GP 6.21 Inspect
Alignment Stepper Belt 1,000K cycles GP 6.21 Inspect
Steering Carriage Belt 1,000K cycles GP 6.21 Inspect
Steering Rollers 1,000K cycles GP 6.14 Inspect and clean Alcohol and Cloth
Punch Clutch 1,000K GP 6.24 Clean Cloth
Sensors S1 to S28 500K GP 6.17 Clean Air
Drive and Idler Rollers 1,000K cycles GP 6.14 & GP 6.15 Inspect and clean Alcohol & cloth
Solenoid Module 1,000K cycles GP 6.22 Inspect
Idler Panel Closing Magnet
Latches 1,000K cycles GP 6.16 Inspect
Acceleration Panel Latch 1,000K cycles GP 6.16 Inspect
Paper Path Drive Timing
Belts 1,000K cycles GP 6.21 Inspect and Adjust if necessary
Diverter Solenoid Assembly 1,000K cycles GP 6.25 Inspect
Die Set Recognition Board
Clips 1,000K cycles GP 6.26 Clean Cloth
Alignment Carriage Rails 500K Cycles GP 6.24 Inspect and Clean Air and Cloth
Die Lock Mechanism and
Die Rail Springs 1000K Cycles GP 6.27 Inspect
Die guide (rail) cleaning 500K cycles GP 6.12 Clean Vacuum
Paper path 1000K cycles GP 6.18 & GP 6.19 Inspect and clean Cloth

Service Call Procedures 02-03-2017 GBC StreamPunch Ultra/Ultra MP
1-6
Periodic Replacement
Area/Unit Part Number No. of pcs. Rough Standard Remarks
Die Set See PL 5-1 1 750K Cycles Replace as needed
Punch Module 7715710 (115V)
7715810 (230V) 1 15M Cycles Replacement
Solenoid module 7715223 6 5M Cycles Replacement

GBC StreamPunch Ultra/Ultra MP 02-03-2017 Service Call Procedures
1-7
HFSI
Replace the part if over threshold (See Pages 1-5 and 1-6).
Note down the DIE CYCLE counts (GP 6.1.8) and PUNCH CYCLE count
(GP 6.1.9) when performing HFSI.
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 paper jam free.
Purpose
Ensure acceptable punch quality, punch performance, and punch
appearance are satisfactory and to complete administrative tasks.
PROCEDURE
1. Install/close all covers and doors.
2. Inspect each Die Set visually and lubricate as needed. See GP 6.7,
Die Set Service
3. Use the customer’s primary Die Set pattern to run 200 simplex printed
test sheets through the punch mode and examine the output for clean
hole quality and even hole alignment.
4. Use the customer’s primary Die Set pattern to run 200 duplex printed
test sheets through the punch mode and examine the output for clean
hole quality and even hole alignment.
5. Use any of the customer’s secondary Die Set pattern to run 100
simplex printed test sheets through the punch mode and examine the
output for clean hole quality and even hole alignment.
6. Run 100 sheets simplex and 100 sheets duplex through the punch
bypass mode.
7. Clean out all paper chips (chad) and paper dust from the chip tray,
the bottom of the machine and from the floor around the bottom of the
machine. See GP 6.10 Base Cleaning.
8. Explain to the customer the service work that was performed and
ensure they are satisfied before you close the call.
Service Call Close
1. Record your service activities along with the Punch Cycle Count.

Service Call Procedures 02-03-2017 GBC StreamPunch Ultra/Ultra MP
1-8
Notes:

GBC StreamPunch Ultra/Ultra MP 11-05-2018 RTPS
2-1 Section Contents
2. Repair and Troubleshooting Procedures (RTPS)
Section Contents
Title Page
Introduction.......................................................................................... 2-3
Troubleshooting Start Guide ................................................................ 2-4
OPERATOR MESSAGES ..................................................................... 2-5
Top Row of Text................................................................................... 2-5
Bottom Row of Text.............................................................................. 2-5
Check Die............................................................................................. 2-6
Close Door ........................................................................................... 2-8
Chip Tray Out ....................................................................................... 2-9
Chip Tray Out message is not displayed when the Chip tray is out .... 2-9
Chip Tray Full ..................................................................................... 2-10
ERROR CODES .................................................................................. 2-11
ERROR E450 DIE TYPE/CODE INVALID ......................................... 2-11
ERROR E451 DIE ENCRYPTION ERROR .................................... 2-12
ERROR E452 INCOMPATIBLE DIE ............................................... 2-12
FAULT CODES ................................................................................... 2-13
Fault Code Text.................................................................................. 2-13
Fault Code Areas ............................................................................... 2-13
Fault Code and Jam Type.................................................................. 2-14
PAPER JAM J126 ......................................................................... 2-14
PAPER JAM J101 ......................................................................... 2-14
PAPER JAM J125 ......................................................................... 2-14
PAPER JAM J202 ......................................................................... 2-14
PAPER JAM J203 ......................................................................... 2-14
PAPER JAM J204 ......................................................................... 2-14
PAPER JAM J220 ......................................................................... 2-14
PAPER JAM J221 ......................................................................... 2-14
PAPER JAM J218 ......................................................................... 2-14
PAPER JAM J219 ......................................................................... 2-14
PAPER JAM J305 ......................................................................... 2-14
PAPER JAM J316 ......................................................................... 2-14
PAPER JAM J317 ......................................................................... 2-14
PAPER JAM J411 ......................................................................... 2-14
PAPER JAM J412 .........................................................................2-14
PAPER JAM J413 .........................................................................2-14
PAPER JAM J414 .........................................................................2-14
PAPER JAM J415 ......................................................................... 2-14
PAPER JAM J506 .........................................................................2-14
PAPER JAM J507 .........................................................................2-14
PAPER JAM J508 .........................................................................2-14
PAPER JAM J509 .........................................................................2-14
PAPER JAM J510 .........................................................................2-14
PAPER JAM J622 ......................................................................... 2-14
PAPER JAM J623 .........................................................................2-14
PAPER JAM J624 .........................................................................2-14
PAPER JAM J625 .........................................................................2-14
PAPER JAM J999 .........................................................................2-14
Jam Types ..........................................................................................2-15
1POWER FAULTS.......................................................................... 2-16
RTP 1.1 No AC Power....................................................................2-16
RTP 1.2No DC Power....................................................................2-18
RTP 1.3 Operator Panel Does Not Illuminate.................................2-19
RTP 1.4 Operator Panel Does Not Show Text ...............................2-20
RTP 1.5 Up, Down, Enter Keys Do Not Respond .......................... 2-21
2PAPER JAMS ...............................................................................2-22
RTP 2.1 Jam Type A ...................................................................... 2-22
RTP 2.2 Jam Type B ...................................................................... 2-23
RTP 2.3 Jam Type C ......................................................................2-24
RTP 2.4 Jam Type D ......................................................................2-26
RTP 2.5Jam Type E ...................................................................... 2-27
RTP 2.6 Jam Type F.......................................................................2-28
RTP 2.7 Multiple Sheets Jammed - Die Pins Partially Through the
Sheets ..............................................................................2-29
RTP 2.8 Checking Obstruction in Paper Path ................................2-30

GBC StreamPunch Ultra/Ultra MP 11-05-2018 RTPS
2-2
3SENSOR CHECKS ....................................................................... 2-33
RTP 3.1 Check Sensors S1, S2, S3, S4, S5, S22, S23, S24, S25, S26
......................................................................................... 2-33
Sensor Cables............................................................................... 2-35
RTP 3.2 Check Sensors S6 to S21 ................................................ 2-36
RTP 3.3 Checking Sensor S28 Align Home Sensor ...................... 2-41
4SOLENOID CHECKS ................................................................... 2-43
RTP 4.1 Check Solenoid SOL 1..................................................... 2-43
RTP 4.2 Check Solenoid SOL 2..................................................... 2-43
RTP 4.3 Check Solenoids SOL 3 to SOL 8.................................... 2-44
5MOTOR CHECKS......................................................................... 2-46
RTP 5.1 Checking Stepper Motors................................................. 2-46
6OTHER FAULTS........................................................................... 2-48
RTP 6.1 Die Set Will Not Slide In or Out Easily ............................. 2-48
RTP 6.2 Punch Overheats ............................................................. 2-48

GBC StreamPunch Ultra/Ultra MP 11-05-2018 RTPS
2-3
Introduction
This section contains the Repair and Troubleshooting Procedures (RTPs).
Organization
This section lists the Repair Analysis Procedure (RTP) for each Operator
Message and Fault Code. In some cases, one Repair Analysis 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 x.y) that refer to the pertinent page
in Section 5, Part List.