GBC FusionPunch II User manual

GBC FusionPunch II
With Stacker and Bypass
Service Manual
Revision: 4.0
December 17th, 2003
Part Number: 1722683

NOTE: Certain components in this
product are susceptible to damage from
electrostatic discharge. Observe all ESD
procedures to avoid component
damage.
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
represent or warrant that it will notify or provide to
such customer any future changes to this
documentation. Service by the customer of
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.
Prepared by:
GBC
© 2001 by GBC Corporation. All rights reserved.
GBC products mentioned in this publication are
registered trademarks of the GBC Corporation.

Table of Contents
GBC FusionPunch II Service Manual 12/2003
i
Table of Contents
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - ii
About this manual - - - - - - - - - - - - - - - - - - - - - ii
Organization - - - - - - - - - - - - - - - - - - - - - - - - - ii
How to use this manual - - - - - - - - - - - - - - - - - ii
Terminology and Symbols- - - - - - - - - - - - - - - - ii
Electrostatic Discharge- - - - - - - - - - - - - - - - - - ii
List of Abbreviations- - - - - - - - - - - - - - - - - - - - ii
1. Service Call Procedures - - - - - 1-1
Section Contents- - - - - - - - - - - - - - - - - -1-1
2. Status Indicator RAPs - - - - - - - 2-1
Section Contents- - - - - - - - - - - - - - - - - -2-1
3. Quality RAPs- - - - - - - - - - - - - - 3-1
Section Contents- - - - - - - - - - - - - - - - - -3-1
4. Repair/Adjustment- - - - - - - - - - 4-1
Section Contents- - - - - - - - - - - - - - - - - -4-1
5. Parts Lists- - - - - - - - - - - - - - - - 5-1
Section Contents- - - - - - - - - - - - - - - - - -5-1
6. General Procedures- - - - - - - - - 6-1
Section Contents- - - - - - - - - - - - - - - - - -6-1
7. Wiring Data- - - - - - - - - - - - - - - - -7-1
Section Contents- - - - - - - - - - - - - - - - - -7-1
8. Installation Instructions- - - - - -8-1
Section Contents- - - - - - - - - - - - - - - - - -8-1
9. FusionPunch II User Guide
Separate publication

GBC FusionPunch II Service Manual
Table of Contents 12/2003
ii
Introduction
About this manual
This manual is part of the multinational
documentation that is structured in a specified
GBC format.
Organization
The Fusion Punch and Stacker Service
Manual is the primary document used for
repairing and maintaining the products. The
manual contains this information divided into
the following sections:
Section 1 Service Call Procedures
This section is used to identify the first
audible or visual symptom for the problem.
The procedures will then direct you to a
RAP or identify a faulty component or
subassembly.
Section 2 Status Indicator RAPs
This section contains Repair Analysis
Procedures (RAPs). You will be directed
to this section to isolate a faulty
component or subassembly.
Section 3 Quality RAPs
This section contains Quality Repair
Analysis Procedures (RAPs). You will be
directed to this section if the defect is
related to Punch or Stacker quality.
Section 4 Repairs / Adjustments
This section contains the instructions for
removal, replacement, and adjustment of
the spared parts within the machine.
Section 5 Parts Lists
This section consists of illustrations and
part number lists. Any part that is spared is
illustrated. Common hardware is
shown as a letter callout
Section 6 General Procedures
This section contains general procedures,
product specifications, supplemental tools,
supplies and modification information.
This section also contains Host
Enablement procedures and Personality
Profiles for Host Printer to Finisher.
Section 7 Wiring Data
This section contains illustrations and lists
of the signals and connectors. The
illustrations show the power, ground, and
the control signal distribution. The lists
show the signals and pin assignments for
all connectors.
Section 8 Installation Instructions
This section contains the instructions for
installation of the equipment.
Section 9 FusionPunch II User Guide
The FusionPunch II User Guide is a
separate publication that describes
operation and maintenance of the
FusionPunch II.
How to use this manual
Start and end all service calls with the Service
Call Procedures, Section 1. Perform Initial
Actions and the System Check to identify a
symptom.
Follow the instructions provided within the
Service Call Procedures and proceed to the
appropriate section of the manual.
After the repair is complete, verify the repair
with the System Check.
Terminology and Symbols
The following are the terminology and symbols
that are used in this manual for
Warnings, Electrostatic Device or
general Cautions, and Notes.
Electrostatic Discharge
Certain components in this product are
susceptible to damage from electrostatic
discharge. Observe all ESD procedures to
avoid component damage.
WARNING
Improper operation may result in
injury to a person.
CAUTION
Improper operation may result in
machine damage.
NOTE: Hints or other information that
may assist the user.
List of Abbreviations
Acronym Definition
BLK Black
BLU Blue
BRN Brown
GRN Green
ORG\ORN Orange
WHT White
YEL Yellow

GBC FusionPunch II Service Manual 12/2003
1-1
1
1. Service Call Procedures
Section Contents
Technical Support Process - - - - - - - - - - -1-2
Partner Emergency
On-site Support Procedure - - - - - - - - - - -1-2
Parts Ordering Process- - - - - - - - - - - - - -1-3
GBC Emergency Parts
Ordering Procedure - - - - - - - - - - - - - - - -1-3
GBC Parts Replenishment
Ordering Procedure - - - - - - - - - - - - - - - -1-4
GBC Training Process - - - - - - - - - - - - - -1-5
Initial Actions - - - - - - - - - - - - - - - - - - - - -1-7
System Checks - - - - - - - - - - - - - - - - - - -1-8
Cleaning and Maintenance - - - - - - - - - - 1-18
Final Actions - - - - - - - - - - - - - - - - - - - - 1-19
Introduction
This chapter describes the tasks that a
service technician must complete when
responding to a problem at a customer site.
Collectively, these tasks are the Service
Call Procedure.
These procedures direct you to other
sections to diagnose and repair the
FusionPunch II. You should return to this
section to continue with the Service Call
Procedure.
Complete the procedures in this chapter in
the order given. By ignoring the sequence
of procedures, you may diagnose a
symptom incorrectly and cause the
customer undue frustration and expense.
Initial Actions are used to gather
information regarding the performance of
the machine and to prepare the product for
servicing.
System Checks are used to verify the
normal operation of the machine. In the Y/N
steps of the system checks, a Yes response
will lead you to the next step. A No
response will indicate the next step to
perform or will direct you to a RAP.
RAPs will provide the instructions to isolate
the faulty part or provide a list of suspect
parts, when isolation is not possible.
Subsystem maintenance contains routine
maintenance procedures.
Final Actions describe procedures you
carry out when completing the service call.
Electrostatic
Discharge
Certain components in this product are
susceptible to damage from electrostatic
discharge. Observe all ESD procedures to
avoid component damage.

GBC FusionPunch II Service Manual
Technical Support Process 12/2003
1-2
Technical Support Process
Technical Support
How to Call for Assistance.
Monday - Friday 9:00 AM to 5:00 PM
Central Time.
1. Xerox CSE contacts GBC National
Technical Specialist at 1-866-259-0101.
2. The GBC National Technical Specialist
responds with support, and fills out a Help
Desk Call Report Form, and logs
information into a database.
Weekends and After Hour Support
5:00 PM to 9:00 AM Central Time.
1. Xerox CSE contacts GBC National
Technical Specialist (Answering Service)
at 1-866-259-0101.
2. Answering Service contacts GBC National
Technical Specialist on call who responds
within 30 minutes.
3. The GBC National Technical Specialist
provides support, and fills out a Help Desk
Call Report Form, and logs information
into a database.
Partner Emergency On-site
Support Procedure
1. The GBC National Technical Specialist
works with Xerox CSE over the phone and
determines that the problem cannot be
resolved over the phone in a timely
manner.
2. The GBC National Technical Specialist
then asks Xerox CSE for the following:
a. CSE’s Service Manager’s name and
phone number.
b. CSE’s employee number.
c. A phone number to confirm travel
arrangements.
d. Customer's address, phone number,
and contact.
3. The GBC National Technical Specialist
makes decision to go out on-site Next
Flight Out (NFO), or sends the following:
a. A well trained, experienced GBC local
technician if available.
b. GBC National Technical Specialist
goes himself NFO if available.
c. If not available, asks another GBC
National Technical Specialists to go
on-site NFO.
4. The GBC National Technical Specialist
notifies Xerox Partnership SEM about the
Emergency On-site Request.
5. Once the GBC National Technical
Specialist has made arrangements for this
request as specified in Step 3, he then
calls the Xerox CSE back to confirm the
Travel Itinerary and to confirm that the
CSE responsible for the account during
the hours of GBC’s arrival to be present.
6. The GBC National Technical Specialist
notifies the Xerox CSE’s Service Manager
about the Emergency On-site Request.
Note: GBC can leave a voice mail or
make this call early the next morning.
7. The GBC National Technical Specialist
leaves a voice mail for the GBC Director of
Service Operations to notify him of the
Emergency On-site Request.
8. The GBC National Technical Specialist
goes to the customer’s site to resolve the
problem.
9. The GBC National Technical Specialist
fills out a trip report to be issued to Xerox
Partnership SEM and the GBC Director of
Service Operations.

Parts Ordering Process
GBC FusionPunch II Service Manual 12/2003
1-3
Parts Ordering Process
GBC Emergency Parts
Ordering Procedure
1. Xerox CSE faxes Emergency Parts Order
Form to 1-630-259-1724.
2. Fax machine pages GBC Material
Handler.
3. The GBC Material Handler picks the
parts, and places an order NextFlight Out
(NFO).
4. The GBC Material Handler returns phone
call to customer per Emergency Parts
Order Form, and also contacts GBC
National Technical Specialists via
voicemail to give shipping information and
Estimated Time of Arrival (ETA).
5. The GBC Material Handler contacts the
shipper and sends out the Emergency
Parts Order Next Flight Out (NFO).
G
ENERAL BINDING CORPORATION
Emergency Parts Order Form
Xerox
Fax To: 1-630-259-1724
Date: ___________________________ Work Order No.: _________________________________
Customer P.O.#: ___________________________ DSS Initials: _________________________________
Dealer Number: XEROX Ordered by: _________________________________
Model Number: ___________________________ Serial Number: _________________________________
Xerox Customer Service Engineer SHIP TO:
Company:
Address:
Customer Contact/ Phone Number City, State, ZIP:
Attn:
Ship VIA: Air
Part Number Qty Description
Special Instructions:

GBC FusionPunch II Service Manual
Parts Ordering Process 12/2003
1-4
Parts Ordering Process
GBC Parts Replenishment
Ordering Procedure
1. Xerox CSE faxes Parts Replenishment
Order Form to 1-630-259-1718.
2. Fax machine pages GBC Material
Handler.
3. The GBC Material Handler picks the parts,
and places an order per Replenishment
Fax requirements.
4. The GBC Material Handler returns phone
call to the customer per Replenishment
Fax, and also contacts GBC National
Technical Specialists via voicemail to give
shipping information and Estimated Time
of Arrival (ETA).
5. The GBC Material Handler contacts the
shipper and sends out the replenishment
parts order UPS Ground.
G
ENERAL BINDING CORPORATION
Parts Replenishment Order Form
Xerox
Fax To: 1-630-259-1718
Date: ___________________________ Work Order No.: _________________________________
Customer P.O.#: ___________________________ DSS Initials: _________________________________
Dealer Number: XEROX Ordered by: _________________________________
Model Number: ___________________________ Serial Number: _________________________________
Xerox Customer Service Engineer SHIP TO:
Company:
Address:
Customer Contact/ Phone Number City, State, ZIP:
Attn:
Ship VIA: UPS GROUND
Part Number Qty Description
Special Instructions:

GBC Training Process
GBC FusionPunch II Service Manual 12/2003
1-5
GBC Training Process
GBC Factory Product Training
for Xerox CSE’s
1. Xerox contacts GBC National Technical
Support at 1-866-259-0101, with the
names of CSE’s requiring training. GBC
requires thirty (30) days prior notice to
schedule training classes.
2. GBC National Technical Support will
arrange training schedule.
3. GBC National Technical Support calls
back Xerox with training dates and
accommodations.
4. Class size is limited to maximum of Six
(6) CSE’s, minimum of two (2), and is two
(2) days in length.
5. GBC National Technical Support will
maintain training records and send to
Xerox Partnership SEM upon completion
of training.

GBC FusionPunch II Service Manual
GBC Training Process 12/2003
1-6
Notes

Initial Actions
GBC FusionPunch II Service Manual 12/2003
1-7
Initial Actions
Description
Initial Actions are used to gather information
about equipment performance and to direct the
Customer Service Engineer (CSE) through the
call.
Procedure
1. Ask the customer to describe or
demonstrate the problem that causes the
service call, and the job being finished
when the problem occurred.
2. Inspect any rejected work for evidence of
defects.
3. Noteand record any errorsdisplayed on the
LCD.
4. Examine any customer maintenance
records for previous problems or activities
that may be related to this service call.
5. Go to System Checks.

GBC FusionPunch II Service Manual
System Checks 12/2003
1-8
System Checks
After you perform the Initial Actions, use the
procedures in this section to check the
operation of the equipment.
The System Check will help identify any
problems and refer you to the appropriate
RAP or REP.
After you have repaired any problems you
may have found, perform this system check
again, and then perform the Final Action
procedure.
Procedure
1. Ensure that both the Punch and the
Stacker(s) are plugged in and that the
Main Power Switch\Circuit Breakers for all
devices are switched on. Go to Step 2.
2. Observe the Punch Control Panel.
Check the LCD panel to see if there are
visible messages displayed, and if the
Backlight is lit.
The backlight is operating normally and
messages are visible on the LCD Panel.
YN
The LCD Panel is completely blank
(no backlight, no LCD Panel
messages).
YN
If the backlight is not lit, but the
LCD Panel is displaying
messages, go to RAP 1.3 +5
VDC Power RAP. If the
backlight is OK, but there are no
messages displayed, go to Step
2A.
Go to Step 2A.
Go to Step 3.
2A. Remove the rear covers of the
Punch and the Stacker(s). Refer to
the information in Table 1-1 to
evaluate the Punch and Stacker
LEDs for normal operation.
The LEDs are operating normally.
YN
Refer to Table 1-2 for instructions.
Go to RAP 2.1 Control Panel RAP.
3. Evaluate error messages on the
FusionPunch II Control Panel. Compare
any messages displayed to Table 1-3, and
follow table instructions to locate the
appropriate RAP. If no error messages
are present, go to Step 4.
Table 1-1 Punch and Stacker LEDs
LED/PWB Normal
Condition
LED 1 on
Little Star
Controller
On
LOA1 on
Punch I/O On when in Cycle up (55
sec delay)
andinOnline
Mode, after
Start is
pressed
LOA2 on
Punch I/O On
LOA3 on
Punch I/O On
LED 1 on
Punch
AC/DC Dist.
On
LED 1 on
Stacker 1 or
2 AC/DC
Dist.
On
LOB1 on
Stacker 1
I/O
Flashing
brightly
LOB3 on
Stacker 1
I/O
Flashing
brightly
LOB4 on
Stacker 1
I/O
Flashing
brightly
Table 1-2 LED Conditions
LED
Condition Go to RAP
All LEDs
extinguished RAP 1.1 AC Power to
the Punch,
and RAP 1.4
Punch +24
VDC Power.
Stacker 1 I/O
LEDs LOB1,
3 and 4
flashing
dimly, and
Stacker 1
AC/DC Dist.
LED 1 off, all
Punch LEDs
On.
RAP 1.5
Stacker +24
VDC Power
Stacker 2
AC/DC Dist.
LED 1 off, all
Stacker 1
and Punch
LEDs On.
RAP 1.5
Stacker +24
VDC Power

System Checks
GBC FusionPunch II Service Manual 12/2003
1-9
4. Evaluate Host Printer Error Messages.
a. Go tothe Host Printer User Interface.
Note any failure messages on the
screen. Compare them to the error
messages listed in Table 1-4.
b. Troubleshoot the Error Messages by
going to the RAP listed in Table 1-4.
c. If there are no Error Messages, go to
Step 5.
5. Run a Test Job
a. Open the top covers to the Punch and
Stacker(s) and bypass the interlocks.
Run a test job from the Host Printer
and watch the sheets as they are
punched and stacked. Refer to Table
1-5 for Punch/Stack Quality
problems.
For jams, either note the error
message associated with the jam, or
refer to Table 1-6 to locate the correct
RAP.
b. (Optional for Stackers with a Bypass)
Run several sheets through the
Bypass and into the downstream
device. Perform this step for each
Bypass-configured Stacker in the
system.
c. Place several sheets into the Single
Sheet Feeder to test the operation of
that assembly.
d. If the Test Job runs normally, go to
Step 6.
6. Run the Test Mode.
a. Open the Punch and Stacker Top
Covers. Bypass the Interlock
Switches.
b. Press the Diagnostics button until the
following message is displayed:
FOR SERVICE MENU
Enter Keycode
c. Enter the Diagnostics keycode
(1. Left Arrow, 2. Right Arrow, 3.
Down Arrow, 4. Up Arrow).
d. Press Stop/Reset.
e. Press the Online/Offline button until
the following message is displayed:
FUSION TEST MODE
Full Stop
When you press START in the
following step, the Punch and
Stacker will operate.
f. Press the START button. The Punch
and Stacker will operate.
g. Using the information in Table 1-7,
check the operation of the Punch and
Stacker. For problems with specific
components, use the information in
the table to locate the appropriate
RAP or ADJ to fix the problem.
h. Operate the Stacker Tray for each
Stacker in the system. While the
Stacker Tray Motor will activate
during the Test Mode, you should also
test it by pressing the Raise/Lower
Stacker button on the Control Panel.
When the motor is running, observe
the movement of the tray and the
condition of the Stacker Tray 90xl
Timing Belt (PL 5.1A). After driving
the tray down, press the Raise/Lower
Stacker button again to return the tray
to the home position.
7. Press the STOP/RESET to stop the test
mode.
8. Switch main power to the Punch off and
then on again to return to normal
operation.
WARNING

GBC FusionPunch II Service Manual
System Checks 12/2003
1-10
Table 1-3 FusionPunch II Control Panel Messages
FusionPunch II Message Meaning Operator Action Technician Action
Jam Entrance Sensor A sheet of paper blocks the Entrance Sensor.
The Entrance Sensor is dirty or is not
working correctly.
Remove the sheet of paper that blocks the Entrance
Sensor.
Use a dry cloth, a Q-tip or a can of air to clean the
Entrance Sensor and the Reflector.
Go to RAP 4.1 Document
Transport JAMs.
JamDocXportSensor1 A sheet of paper blocks the Jam Document
Transport Sensor1.
The Jam Document Transport Sensor1 is
dirty or is not working correctly.
Use a dry cloth, a Q-tip or a can of air to clean the
Document Transport Sensor 1 and the Reflector. Go to RAP 4.1 Document Transport JAMs.
JamDocXportSensor2 A sheet of paper blocks the Jam Document
Transport Sensor2.
The Jam Document Transport Sensor2 is
dirty or is not working correctly.
Remove the sheet of paper that blocks the Document
Transport Sensor 2.
Use a dry cloth, a Q-tip or a can of air to clean the
Document Transport Sensor 2 and the Reflector.
Go to RAP 4.1 Document
Transport JAMs.
Jam At Punch Sensor A sheet of paper blocks the Jam at Punch
Sensor.
The Jam at Punch Sensor is dirty or is not
working correctly.
Remove any paper from the Punch Sensor and press
Reset.
Use a dry cloth, a Q-tip or a can of air to clean the
Punch Sensor and the Reflector.
Go to RAP 4.1 Document
Transport JAMs.
Jam PunchExit Sensor A sheet of paper blocks the Punch Exit
Sensor.
The Jam Punch Exit Sensor is dirty or is not
working correctly.
Remove any paper from the Punch Exit Sensor and
press Reset.
Use a dry cloth, a Q-tip or a can of air to clean the
Punch Exit Sensor and the Reflector.
Switch on the main power to the Stacker.
For jams in the Document
Transport only, go to RAP 4.1
Document Transport JAMs.
For jams in the Stacker that
block the Punch Exit Sensor,
go to RAP 5.3 Stacker Jams.
If the job was to stack in
Stacker 1, but entered the
Stacker 1 Bypass instead and
jammed there, check LOB6
and LOB7 at
P/J22 on the Stacker 1 I/O
PWB. If these LEDs are lit,
go to RAP 3.2 and
troubleshoot a failure of the
Front Door Interlock for
Stacker 1.
If the job was NOT to stack in
Stacker 1 but still originates in
the Bypass and backs up into
the Punch, go to RAP 5.4
Stacker Bypass Jams.

System Checks
GBC FusionPunch II Service Manual 12/2003
1-11
Jam Bypass Sensor Paper has jammed at the Stacker 1 Bypass
Sensor Remove any paper from the Stacker Bypass Exit Sensor and press Reset.
Use a dry cloth, a Q-tip or a can of air to clean the
Punch Exit Sensor and the Reflector.
Switch on the main power to the Stacker.
If the job was to stack in
Stacker 2, but entered the
Stacker 2 Bypass instead and
jammed there, check LOB6
and LOB7 at P/J22 on the
Stacker 2 I/O PWB. If these
LEDs are lit, go to RAP 3.2
and troubleshoot a failure of
the Front Door Interlock for
Stacker 2.
For all other jams, go to RAP
5.4 Stacker Bypass Jams.
Jam Bypass2 Sensor Paper has jammed at the Stacker 2 Exit
Sensor Remove any paper from the Stacker Bypass Exit Sensor and press Reset.
Use a dry cloth, a Q-tip or a can of air to clean the
Punch Exit Sensor and the Reflector.
Switch on the main power to the Stacker.
For jams that originate in a
downstream device,
troubleshoot that failure first.
If the jam does not originate in
the downstream device, go to
RAP 5.4 Stacker Bypass
Jams.
Next Device Faulted The downstream device has an error, or the
Stacker Exit Sensor has failed. Call for service Check the downstream device for failure indications.
If there are no indications of
failure, go to RAP 5.5 Stacker
Exit Sensors.
Punch Covers Open TheCovers did not actuate one orbothofthe
IS4 and IS5 Cover Interlock Switches. Close the Punch Covers. Go to RAP 3.1 Punch Interlock Switches
Punch Mid Door Open The Middle Door did not actuate the IS2 Mid
Door Interlock Switch. Close the Punch Middle Door. Go to RAP 3.1 Punch Interlock Switches
Punch RightDoor Open The Right Door did not actuate the IS1 Right
Door Interlock Switch. Close the Punch Right Door. Go to RAP 3.1 Punch Interlock Switches
Punch Left Door Open The Left Door did not actuate the IS3 Left
Door Interlock Switch. Close the Punch Left Door. Go to RAP 3.1 Punch Interlock Switches
Please Home Stackers The Stacker Tray is not in the home position. Raise the Stacker Tray, then press Reset. Go to RAPs 5.1 Stacker Full,
Stacker Almost Full and
Stacker Upper Switches &
RAP 5.2 Stacker Tray
Direction
Stacker Running-Wait The Lower/Raise Stacker Switch has been
pressed and the Stacker Tray Motor is
running. Machine will not process any other
commands until motor stops.
Wait until Stacker Tray Motor has stopped running. N/A
Table 1-3 FusionPunch II Control Panel Messages (Continued)
FusionPunch II Message Meaning Operator Action Technician Action

GBC FusionPunch II Service Manual
System Checks 12/2003
1-12
Please Empty Stacker The Stacker is full.
The Stacker Tray was left in the down
position.
Lower the Stacker Tray, unload the paper, raise the
Tray, then press Reset. Go to RAPs 1.2 AC Power to the Stacker, RAP 5.1 Stacker
Full, Stacker Almost Full and
Stacker Upper Switches, and
RAP 5.2 Stacker Tray
Direction.
Stacker Direction?? The Stacker Tray is moving in the incorrect
direction. Press STOP. Press Raise/Lower Stacker #1 to lower the Stacker. Press Raise/Lower Stacker #1 again to
raise the Stacker. If error persists or returns, call for
service.
Go to RAP 5.1 Stacker Full,
Stacker Almost Full and
Stacker Upper Switches, and
RAP 5.2 Stacker Tray
Direction.
Stacker 1 Door Open
Note: This dialog may appear
with other interlock related
dialogs. If it occurs with
Stacker 1 Cover Open, Stacker
2 Door Open, and Stacker 2
Cover Open, ensure all covers
and doors are closed and see
the related error information
below in this table.
The Stacker Door did not actuate the Stacker
Door Interlock Switch. Close the Stacker Door. Remove the rear cover of the Stacker and observe LED
LOB1, LOB3 and LOB4 on
the Stacker I/O PWB. If they
are flashing dimly, go to RAP
1.5 Stacker +24 VDC Power.
If the LEDs are normal
(flashing brightly) go to RAP
3.2 Stacker Interlock
Switches.
Stacker 1 Cover Open
Note: This dialog may appear
with other interlock related
dialogs. If it occurs with
Stacker 1 Door Open, Stacker
2 Door Open, and Stacker 2
Cover Open, ensure all covers
and doors are closed and see
the related error information
below in this table.
The Stacker Cover did not actuate the
Stacker Cover Interlock Switch. Close the Stacker Cover Remove the rear cover of the Stacker and observe LED
LOB1, LOB3 and LOB4 on
the Stacker I/O PWB. If they
are flashing dimly, go to RAP
1.5 Stacker +24 VDC Power.
If the LEDs are normal
(flashing brightly) go to RAP
3.2 Stacker Interlock
Switches.
Table 1-3 FusionPunch II Control Panel Messages (Continued)
FusionPunch II Message Meaning Operator Action Technician Action

System Checks
GBC FusionPunch II Service Manual 12/2003
1-13
Stacker2 Door Open
Note: This dialog may appear
with other interlock related
dialogs.
If may occur with:
Stacker 1 Cover Open, Stacker
1 Door Open, and Stacker 2
Cover Open.
It may also occur with Stacker
2 Cover Open.
If either of these situations
occurs, ensure all covers and
doors are closed and see the
related error information below
in this table.
The Stacker 2 Door did not actuate the
Stacker 2 Door Interlock Switch. Close the Stacker 2 Door Go to RAP 3.2 Stacker Interlock Switches.
Stacker2 Cover Open
Note: This dialog may appear
with other interlock related
dialogs.
If may occur with:
Stacker 1 Cover Open, Stacker
1 Door Open, and Stacker 2
Door Open.
It may also occur with Stacker
2 Door Open.
If either of these situations
occurs, ensure all covers and
doors are closed and see the
related error information below
in this table.
The Stacker2 Cover did not actuate the
Stacker 2 Cover Interlock Switch. Close the Stacker 2 Cover Go to RAP 3.2 Stacker Interlock Switches.
Table 1-3 FusionPunch II Control Panel Messages (Continued)
FusionPunch II Message Meaning Operator Action Technician Action

GBC FusionPunch II Service Manual
System Checks 12/2003
1-14
Stacker 1 Cover Open
Stacker 1 Door Open
Stacker 2 Cover Open
Stacker 2 Door Open
or
Stacker 2 Cover Open
Stacker 2 Door Open
Failure of +24VDC to Stacker 1
or
Failure of +24VDC to Stacker 2
Call for Service Go to RAP 1.5 Stacker
+24VDC Power
Stacker Upper Switch?? The Stacker Upper Switch did not release
during an emptying operation. Go to RAPs 1.2 AC Power to the Stacker, and RAP 5.2
Stacker Tray Direction.
Table 1-3 FusionPunch II Control Panel Messages (Continued)
FusionPunch II Message Meaning Operator Action Technician Action

System Checks
GBC FusionPunch II Service Manual 12/2003
1-15
Table 1-4 Printer Control Panel Messages
Printer Message Meaning Operator Action Technician Action
Docutech 61XX displays:
Jam in area 20 and external
finisher. (Fault Code P12-400)
Indicates that the printer has lost
communications with the external device. Clear any jams, press Stop/Reset, resume the printer. Check device profiles are correctly set. Go to RAP 6.2 Printer Connectivity.
Go to RAP 4.2 Punch Jam
Sensors and troubleshoot a
failure with the PUNCH EXIT
SENSOR.
Docutech 61XX displays:
External Finisher Jam. (Fault
Code P12-401)
Indicates that a fault has occurred in the
external device. Clear any jams, press Stop/Reset, resume the printer. Check device profiles are correctly set. Ensure that there are no fault indications at the downstream
device.
If no faults are present on the
downstream device, go to
RAP 5.5 Stacker Bypass Exit
Sensors
Docutech 61XX displays:
Jam in area 20 and external
finisher. (Fault Code P12-403)
Indicates that the external device did not
respond within the specified time to a sheet
that the IOT sent it.
Clear any jams, press Stop/Reset, resume the printer.
Check device profiles are correctly set. Clear any jams, press Stop/ Reset, resume the printer.
Check device profiles are
correctly set.
If the failure continues to
occur, go to RAP 5.5 Stacker
Bypass Exit Sensors.
Docutech 135 displays:
Clear External Finisher to run
jobs to the Bypass Transport/
External Finisher Not Ready
The current job is faulted and requires a
reset.
The FusionPunch II is not on-line.
Click on the Printer Icon. Select reset if the reset option
is available.
Press Stop/Reset, then press Online/Offline to ensure
that the FusionPunch II is in online mode.
Go to RAP 6.2 Printer
Connectivity
Docutech 135, 61xx displays:
External Finisher Full
Xerox 4xxx Printer displays:
External Finisher Full
The Stacker is full and requires unloading. Unload the Stacker. Start the FusionPunch II in online
mode. Go to RAP 5.1 Stacker Full, Stacker Almost Full and
Stacker Upper Switches.
Docutech 135, 61xx displays:
Clear External Finisher to run
jobs to the Bypass Transport or
External Finisher Not Ready
Xerox 4xxx Printer displays:
External Finisher Not Ready
The FusionPunch II is not in online mode. Press Stop/Reset, then press Online/Offline to check
that the FusionPunch II is in online mode. Then, press
Start.
Go to RAP 6.2 Printer
Connectivity
Docutech 135, 61xx does not
recognize the Finisher.
Xerox 4xxx Printer does not
recognize the Finisher.
The Host Printer has no error message
displayed or has no External Finisher option. Check that the Profile is loaded in the Printer and set up correctly.
Contact your System Administrator to verify proper
Host Enablement.
Enable the Host Printer

GBC FusionPunch II Service Manual
System Checks 12/2003
1-16
.
Table 1-5 Punch/Stack Quality Checkout.
Punch/Stack Quality
Problem Technician Action
Sets do not offset. Go to Quality RAP 5.3
Trailing Edges of
documents are torn,
marked, or creased.
Go to Quality RAP 5.4
The document stack is
shingled Go to Quality RAP 5.5
Documents are not
punched Go to Quality RAP 5.6
Documents are punched in
the center of the sheet Go to Quality RAP 5.7
Table 1-6 Jam Locations
Jam Location Technician Action
Punch Document Transport Go to RAP 4.1 Document Transport Jams
Stacker (not in the Bypass) If there is no Bypass installed, go to RAP
5.3 Stacker Jams.
If there is a Bypass installed, and the jam is
in Stacker 2 that backs up into the Stacker
1 Bypass, check the LEDs on the Stacker 1
Exit Sensor. Normal conditions are; Green
LED - always lit, Red LED - lit when the
sensor is NOT BLOCKED, extinguished
when the sensor is BLOCKED. If these
conditions do not exist, go to RAP 5.5
Stacker Bypass Exit Sensors.
Stacker Bypass Go to RAP 5.4 Stacker Bypass Jams