GT 3250 GERBERcutter

SYSTEM SERVICE MANUAL

Copyright Ó 2001 by Gerber Technology, Inc. All rights reserved.

This document may not be reproduced by any means, in whole or in part, without the
written permission of the copyright owner.

This document is part of the proprietary articles furnished to document Gerber Technology’s
GT 3250 GERBERcutter® systems.

In consideration of the furnishing of the information contained in this document, the party to
whom it is given assumes its control and custody and agrees to the following:

1. The information contained herein is given in confidence and any part thereof shall not be
copied or reproduced without the written consent of Gerber Technology, Inc.

2. This document or the contents herein under no circumstances shall be used in the
manufacture or reproduction of the article shown and the delivery shall not constitute
any right or license to do so.

The information contained in this document is subject to change without notice.

Gerber Technology, Inc., its subsidiaries and affiliates shall not be liable for errors in this
documentation or for incidental or consequential damages in connection with furnishing, or
use of this material.
COMMAND, G (stylized logo), GERBER BRISTLE SQUARE, GERBERcutter,
GERBERmover, Knife Intelligence, and MARKAMATIC are registered trademarks of
Gerber Technology, Inc.
AccuMark, AccuPlot, Booster PAK, GERBERmarker, GERBERplanner, GERBERsaver,
GERBERspreader, IMPACT, MicroMark, and POWER Processor are trademarks of Gerber
Technology, Inc.
Windows NT is a registered trademark of Microsoft Corporation.
Adobe and Acrobat are registered trademarks of Adobe Systems Incorporated.
Other company names, brand names, and product names mentioned in this book are
recognized as trademarks or registered trademarks of their respective companies.

Gerber Technology, Inc.

24 Industrial Park Road West
Tolland, CT 06084 USA

Document Number: 87425000

9/01

i
ii
Contents Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Information You Need to Know 1
What Information is available . . . . . . . . . . . . . . . . . . . . . . . . . 1
Viewing Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Printing Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintenance Information 7
Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance Manager and Summary . . . . . . . . . . . . . . . . . . 10
Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reference Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Beam Maintenance 21
Beam Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Roundway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Flatway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cutter Head Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
X-axis Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Y-axis Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
BCP Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Remote-End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cutter Head Maintenance 35
Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
C-axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Knife Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Knife Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Presser Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Sharpener Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Grinding Pulley Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . 49
Grinding Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Elevator Roundways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Up/Down Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

GT 3250 System Service Manual Contents iii

 Drill Maintenance 57
Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Drill Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Drill Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Cutting Table Maintenance 65
Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Side Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Operator Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Take-On Ramp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
BRISTLE SQUARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Automatic Bristle Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Slats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Drive Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
C-200 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
MCC Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Table Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Electrical and Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Film Dispenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Resealer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Conveyorized Take Off Table . . . . . . . . . . . . . . . . . . . . . . . 97
Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Troubleshooting 101
Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Glossary 107
Appendix A - Vacuum Features 113

iv Contents GT 3250 System Service Manual

 Safety Precautions
Dangerous Procedure Warnings
Warnings precede potentially dangerous procedures throughout this manual.
Instructions contained in warnings must be followed. You also should employ
all other safety precautions that you deem necessary for safe operation of the
equipment in your operating environment.

WARNING! Failure to follow these safety precautions could result

in injury or death.

Do Not Perform Maintenance Alone

Do not perform any maintenance on the equipment unless another person that
can render first aid and resuscitation is present.

Live Circuits
High voltages exist inside the C-200 controller and vacuum and electrics
enclosures. There are no operator-serviceable parts in these enclosure(s).
Two power cables enter the primary vacuum/electric enclosure: a three-phase
cable for the vacuum generator system and a single-phase power cable for the
C-200 controller. Both power cables must be disconnected before it is safe for
trained, maintenance personnel to work within the enclosure. There must be a
main disconnect that meets local electrical codes for each power supply.

GT 3250 System Service Manual Safety Precautions v

 Turn Off Power Before Maintenance
To prevent accidental start-up while performing any maintenance, always turn
off power as directed in the Maintenance Information chapter of this manual.

Circuit breakers located outside of the C-200 controller and vacuum and electric
enclosures allow you to shut down power to the FEP (or PC), vacuum system,
C-200 cutter controller, servomotors, and conveyor. See the Maintenance
Information chapter for exact location(s).

Use circuit breaker 1 to turn power on or off to the controller, servomotors, and
conveyor as needed during normal operation of the GERBERcutter.

Circuit
Breaker
CB1

vi Safety Precautions GT 3250 System Service Manual

 Laser Origin Light
The origin light in the cutter head uses a laser light that points toward the cutting
surface. When viewed as intended (by looking at the dot projected on the
material to be cut), the laser should pose no hazard to operators. However, the
origin light is a Class IIIa laser product, with a peak power of 5 mW at a
wavelength of 670 nm. Never look straight into the light source of this laser
beam; doing so may cause temporary, or even permanent, damage to your eyes.
Direct, bright reflections from the laser may also be harmful. Remove all highly
reflective material (such as jewelry and mirrors) from the cutting surface before
turning on the origin light. Turn off the origin light before performing any
maintenance on the GERBERcutter.

WARNING! Use of controls or adjustments or performance of

procedures other than those specified herein may result
in hazardous radiation exposure.

Additional Precautions

Moving Machinery
Keep hands away from the Resealer and other moving machine parts to avoid
personal injury. Make sure there is no one else near the table when you are
operating the GERBERcutter.

Replacing Parts
Report any broken or missing parts to your Field Service representative. Because
of the danger of introducing additional hazards, do not install substitute parts or
perform any unauthorized modification of the equipment.

GT 3250 System Service Manual Safety Precautions vii

 Knife Blade
The knife blade is very sharp. Be extremely careful when working near the knife
blade.

Clothing
Loose-fitting clothing, dangling neck chains and ties, loose jewelry, and long
hair can be a hazard when working around machinery.

Compressed Air
Always use caution when using compressed air. Never use compressed air to
blow lint and dust off clothing or skin.

Lint
Avoid breathing in lint when changing the table and stack filters. Wear a mask
suitable for this purpose.

Equipment Training
Never attempt to operate this machinery unless you have received formal
training to do so.

Do Not Operate in an Explosive Atmosphere

Use extreme caution when handling flammable liquids such as cleaning solvents.
Do not operate the equipment in the presence of flammable gases or fumes.

Use Caution When Handling a CRT Monitor

The monitor on the operator console is a flat panel screen. On other cutters the
monitor may be a cathode ray tube (CRT). Breaking a CRT could cause it to
implode and scatter glass fragments at a high velocity. To prevent CRT
implosion, avoid rough handling or jarring of the equipment.

viii Safety Precautions GT 3250 System Service Manual

 Information You Need to Know
What information is available?
A GT 3250 GERBERcutter system includes hardware, electrical, and software
components. Documentation for operating and maintaining the GERBERcutter
is available on your computer or from CD in the form of online help for the
C-200MT software and in PDF format. This means that information is available
to you whenever you need it. The next sections explain:
· Where information can be found
· How to access and print this information
· How to get customer support

Where is it?

GT 3250 GERBERcutter System Service Manual

To locate specific information, see the following sections inside this manual.

· Safety Precautions – Read this section before you start cutting

· Maintenance Information – Safety warnings before beginning

maintenance; tools and lubricants; illustrated drawings of GT 3250
GERBERcutter.

· Maintenance Schedules – Maintenance Manager; schedules for

maintenance sorted both by cutter component and by interval between
required servicing.

· Beam Maintenance – Procedures for maintaining the beam.

· Cutter Head Maintenance – Procedures for maintaining the cutter head

and changing the knife.

· Drill Maintenance – Procedures for maintaining the drill.

· Cutting Table Maintenance – Procedures for maintaining components of

the table including cutting surface and some optional equipment.

· Troubleshooting – Where to find information about diagnostics, error

messages, and specific cutting applications.

GT 3250 System Service Manual Information You Need to Know 1

 · Glossary – Terms you need to know

· Appendix A – Description of the vacuum system and other vacuum

features.

C-200MT Online Help and Release Info

The C-200MT software program provides several ways to get help.

Note: Information in the C-200MT online help may be more current than in
the C-200MT Software User’s Guide.

To get help on a C-200MT function

1. Choose a C-200MT menu and use the pointing device or Down arrow
key to highlight the command.

2. Press the F1 key to display the appropriate Help topic.

To get help on a specific parameter

1. In Parameter Manager, highlight a parameter.

2. Press F1.

To view information for current release

1. From the Help menu, click Index.

2. Make sure the Contents page is displayed.

3. Then select the New Features for (current version number) or

Limitations topics.

2 Information You Need to Know GT 3250 System Service Manual

 Available Documentation on Desktop or CDs
Documentation for your GERBERcutter hardware and software is now delivered
in online format on CD. This means that specific information can be viewed on-
screen, searched for, and printed as you need it. Some documentation for your
cutter was installed on your computer during the C-200MT software installation
and is available by double-clicking the Gerber Documents icon on your
Windows desktop.

Additional documentation available on C-200MT software CD and/or

GERBERservice Documentation CD:
· GT Series GERBERcutters Getting Started Manual
· C-200MT Software User’s Guide
· GERBERcutter Application Manual
· NT Quick Reference Guide
· Service drawings
· Parts information

Note: Both CDs allow you to view and print information at

another PC. For hints on printing see a later section in this
chapter.

Viewing Documentation

To view documents from Windows desktop

1. In the C-200MT program, click on the middle button (marked by two

boxes) in the top left corner of the main cutter control screen. This does
not shut down the C-200MT program.

2. On the Windows desktop, double-click on the Gerber Documents icon.

3. Double-click on the icon for the PDF file you want to view. The reader
opens first and then the document displays.

4. From the reader’s tool bar, use the buttons marked with arrows to turn
pages. Click the button marked with binoculars to search for a specific
item.

GT 3250 System Service Manual Information You Need to Know 3

 To view documents from CD

1. Follow instructions on the CD or use Windows Explorer to locate the

PDF file you want to view.

2. Double-click on the file. The reader opens first and then the document
displays.

3. From the reader’s tool bar, use the buttons marked with arrows to turn
pages. Click the button marked with binoculars to search for a specific
item.

Acrobat Reader and PDF Format

GERBER Technology, Inc. now provides many documents and service
drawings in PDF format. A document in PDF format is displayed in Adobe
Acrobat Reader. If not already installed on your cutter, this viewer can be
installed from the C-200MT Software CD.

Printing Documentation
If you prefer to print out information and your cutter is not networked to a
printer, you can take the CD to another PC that does have access to a printer.
The Acrobat Reader must be installed on that PC.

To print from a PDF document

1. Follow the instructions for opening a PDF document from CD.

2. From the File menu, select Print. You can print one page or all pages.

4 Information You Need to Know GT 3250 System Service Manual

 Conventions
The following conventions are used throughout this manual:
· Bullets at the beginning of a section tell you what is covered in that
section. Bullets also list a group of related items.
Bold type highlights important information. In procedures, selections to make
with a pointing device or keyboard keys to press are bolded. In text, information
that you need to consider first is bolded.

Text that you need to type or message prompts look like this.

Note: Notes contain important or helpful information.

CAUTION: Cautions appear before procedures that could cause damage to

equipment if not performed correctly.

WARNING! Warnings tell you when you must follow a specific procedure
or practice to avoid personal injury or death.

GT 3250 System Service Manual Information You Need to Know 5

 Customer Support
If a problem still exists after troubleshooting, call Gerber Field Service
Engineering for assistance. In North America, call Customer Support
800-321-2448. Outside North America, call your local service office.

Have the following information ready when you call:

· GERBERcutter you are using
· Any special equipment or software you are using, such as the drill,
resealer, or bar code reader option
· Software packages you are using; include the software version numbers
· Equipment number, if available

6 Information You Need to Know GT 3250 System Service Manual

 Maintenance Information
About This Chapter
Proper maintenance is important because it improves cut quality and extends
the life of the system. This chapter provides information you need to know to
perform routine maintenance on your GT 3250 GERBERcutter. (It does not
cover highly-technical procedures or those requiring special skills. These are
best left to your Gerber qualified technician.) This chapter includes:

• Safety issues before maintenance

• Maintenance Manager
• Maintenance summary and schedules
• Reference drawings

Safety Precautions

WARNING! High voltages exist inside the C-200 controller.

There are no operator-serviceable parts inside the C-200 controller
enclosure. Only qualified personnel should perform maintenance.
Contact your service technician in case of a problem. Failure to
follow these instructions could cause injury or death.

WARNING! You may get seriously hurt if you do not turn off
the C-200 controller and vacuum generator when instructed. When
the C-200 controller is on, it applies power to the cutting table and
vacuum generator. Parts could move suddenly.

WARNING! The origin light on the cutter head employs a

Class IIIa laser product. Do not look along the axis of the laser
light without protective eyewear. Do not place reflective material
on the cutting table, as the reflection from the laser light may
cause injury. Be sure you unplug the cable connector on the origin
light before performing any maintenance on the system. Failure to
follow these warnings can cause injury.

GT 3250 System Service Manual Maintenance Information 7

 Circuit Breakers
The GT 3250 has three main circuit breakers on the cutting table. Circuit
breaker 1 provides power for the C-200 controller, servo motors, and
conveyor. It is located in the upper left corner of the electrics enclosures at
the take-off end. Use this circuit breaker to turn on the GT 3250.

C-200 CONTROLLER
ENCLOSURE

VACUUM ELECTRICS
ENCLOSURE

WARNING! Do not turn circuit breakers inside of the vacuum

electrics enclosure on or off. High voltages exist within this
enclosure and inside the controller board. Never perform any work
inside the vacuum electrics enclosure. There are no
operator-serviceable parts inside of this enclosure.

For information about the circuit breakers on your GERBERcutter, see the
chart below.

WARNING! Three-phase power for the vacuum generator and

single-phase power for the control unit both enter the C-200
controller. BOTH power cords must be disconnected for a safe
condition to exist within the C-200 enclosure. A single-switch main
disconnect for both of these power supplies must be provided
according to local electrical codes.

8 Maintenance Information GT 3250 System Service Manual

Ordering Spare Parts
If you find a broken or worn part while performing preventive maintenance,
see the Customer Support section in the Troubleshooting chapter. This
section tells how to order any spare parts you may need.

Tools Available
The following tables list some tools and lubricants that are available from
Gerber. For more complete information, contact your Gerber sales
representative.

Tool Gerber Part No.

belt tension kit 73705000
50-lb spring scale 945500252
belt deflection gauge 45412000
internal/external snap ring pliers 944291503
grease gun 944233101
metric combination wrench set 945500093
metric right-angle and ball combination hex key set 945500094
metric T-handle hex key set 945500089
oiler 653000000
socket wrench, 1/2" combo 944002506
Torx drive 73440000
vise grip 945500002

Lubricant Gerber Part No.

Mobil 1, 5w-30 synthetic oil 596118001
GSG-44 72395000
Cleaner 308010101
Loctite #222-21 120050216
Loctite #74756 120050209

GT 3250 System Service Manual Maintenance Information 9

Maintenance Manager
The C-200MT program provides this utility to monitor routine, preventive
maintenance procedures for your GERBERcutter. Maintenance Manager,
which is available in newer versions of C-200MT software, keeps track of all
routine maintenance and notifies you on-screen whenever a task, or
maintenance procedure, needs to be performed. These procedures correspond
to tasks in the Maintenance Manager. For availability, check with your
Gerber Field Service representative.

Information about individual tasks is also available on-screen, including the

steps required to perform the task. Once a maintenance procedure is
completed, clearing the status for that task resets information stored in the
database. Tracking continues automatically, without your attention being
required until Maintenance Manager notifies you.

For information on how to use this utility, refer to the C-200MT online help.
For safety precautions and corrective maintenance, use this manual.

Maintenance Summary
The table below summarizes where in this manual the preventive
maintenance procedures can be found. The maintenance schedules, which
begin on the next page, conveniently lists procedures in order of how often
they must be done.

Note: The reference figures beginning on page 15 can help you

find various parts on your GT 3250 GERBERcutter.

Maintenance Summary by Component

Major Assembly/
Page
Assembly Option
beam 21
cutter head 35
drill 57
cutting table 65
operator console 69
conveyor 71
air filters 83, 86
mast 88
film dispenser 90
resealer 92
CTOT 97

10 Maintenance Information GT 3250 System Service Manual

Maintenance Schedules
The following schedules list preventive procedures that should be performed:
each shift; daily; weekly; at six month intervals; as needed.

CAUTION Failure to perform routine maintenance, as indicated,

may result in damage to your GERBERcutter.

Maintenance Schedules

Major
Assembly Component Action Page
Assembly

Each Shift
C-200 electrics MCC air filter inspect 83
controller enclosure
cutter head drill drill bit inspect 62
and drill elevator N/A inspect 52
roundways
C-axis knife blade inspect 43
assembly
presser foot inspect 48
sharpener grinding pulley inspect 50
clean 51

Daily
cutting table racks N/A inspect 66
mast warning light N/A inspect 89
cutting table conveyor BRISTLE inspect 71
SQUARES
table air filter N/A inspect 86
resealer plastic film N/A inspect 93

GT 3250 System Service Manual Maintenance Information 11

 Maintenance Schedule (cont’d.)

Major
Assembly Component Action Page
Assembly

Weekly
beam beam N/A inspect 22
alignment
cables N/A inspect 32
cutter head N/A inspect 26
drive belt adjust 27
flatway N/A inspect 25
clean/lubricate 25
roundway N/A inspect 24
clean/lubricate 24
X-axis drive N/A inspect 28
belts
Y-axis drive N/A inspect 30
belts
cutter head C-axis C-axis inspect 37
and drill assembly assembly
C-axis drive inspect 38
belt
knife drive belts inspect 41
drill drive belt inspect 60
sharpener pulley drive belt inspect 49
cutting table conveyor slats inspect 76
mast power/air lines N/A inspect 88

6 Months
CTOT drive chain N/A lubricate 98
cutting table conveyor drive assembly lubricate 81
drive chains lubricate 82

12 Maintenance Information GT 3250 System Service Manual

 Maintenance Schedule (cont’d.)

Major
Assembly Component Action Page
Assembly

As Needed
beam beam N/A adjust 22
alignment
BCP cover N/A remove 33
install 33
remote-end N/A remove 34
cover install 34
X-axis drive N/A adjust 29
belts
Y-axis drive N/A adjust 31
belts
cutter head C-axis C-axis drive remove 38
and drill assembly belt install 39
adjust 40
knife blade remove 45
install 46
knife drive belts adjust 41
presser foot clean/lubricate 48
drill drill remove 58
install 59
drill bit remove 62
install 63
drive belt remove 60
install 61
adjust 61
elevator N/A clean/lubricate 52
roundways
front cover N/A remove 36
install 36
sharpener drive belt remove 49
install 49
grinding pulley remove 50
install 51
up/down stops inspect 53
adjust 55

GT 3250 System Service Manual Maintenance Information 13

 Major
Assembly Component Action Page
Assembly

As Needed (cont’d.)
C-200 electrics MCC air filter clean 84
controller enclosure
cutting table conveyor BRISTLE clean 72
SQUARES rearrange 74
racks N/A clean 66
side panels N/A remove 68
install 68
clean 68
table air filter N/A clean 87
take-on ramp N/A remove 70
install 70
film plastic film roll N/A remove 90
dispenser
install 91
operator monitor/ N/A clean 69
console keyboard
resealer plastic film N/A remove 93
install 94

14 Maintenance Information GT 3250 System Service Manual

Reference Drawings
The following drawings can be used before performing maintenance to find
various parts of your GT 3250 GERBERcutter.

OPERATOR
CONSOLE ROLL BAR STATUS LIGHTS FILM DISPENSER

CUTTER HEAD

BEAM
BEAM CONTROL
PANEL

CONVEYOR

FILTER
RACK TABLE MOTION
ACCESS
CONTROLS
DOOR
SIDE PANELS
Operator Side from Take-on End

MAST
STATUS LIGHTS
FILM DISPENSER CUTTER HEAD
BEAM BEAM CONTROL
EXHAUST STACK PANEL

CONVEYOR

CTOT

SIDE PANELS
CB1 CONTROLLER AND VACUUM
CB8
ELECTRICS ENCLOSURES
CB2

Remote Side from Take-off End

GT 3250 System Service Manual Maintenance Information 15

 MONITOR

PC

OPERATOR
CONTROL
PANEL
KEYBOARD

SWING ARM

Operator Console

Y-AXIS CABLE

CUTTER HEAD
BEAM CONTROL
PANEL COVER

BEAM

X-AXIS CABLE

Y-AXIS DRIVE
BELT

FLATWAY

ROUNDWAY

Cutter Head and Beam

16 Maintenance Information GT 3250 System Service Manual

 SPIDER

KNIFE DRIVE
KNIFE DRIVE BELT TRAIN

KNIFE DRIVE
MOTOR

LASER ORIGIN
LIGHT SWITCH

C-AXIS DRIVE BELT

KNIFE BLADE

ELEVATOR
ROUNDWAY

PRESSER FOOT
ORIGIN LIGHT

GRINDING PULLEY

GRINDING PULLEY
DRIVE BELT

Cutter Head

GT 3250 System Service Manual Maintenance Information 17

 DRIVE BELT

EJECTOR ROD

DRILL BIT

Drill Assembly

18 Maintenance Information GT 3250 System Service Manual

 FILTER
ACCESS
DOOR

Access to Table Air Filters

GT 3250 System Service Manual Maintenance Information 19

 CABLE
SUPPORT

EXHAUST STACK

MAST

WARNING LIGHT
AIR PRESSURE
REGULATOR

Mast and Exhaust Stack

20 Maintenance Information GT 3250 System Service Manual

 Preventive Maintenance
About This Chapter
Proper maintenance is important because it improves cut quality and extends
the life of the system. This chapter describes routine maintenance on your
GERBERcutter. Preventive maintenance tasks include inspecting, cleaning,
and lubricating moving parts such as gears and bearings.

If routine maintenance indicates the need to perform corrective maintenance

procedures, alignments, or adjustments, these are best referred to a Gerber
qualified technician (someone who has attended a training class for
GERBERcutter operation and maintenance).

Beam Maintenance
The beam, shown below, carries the cutter head on a roundway and a
flatway. Electric motors drive the beam along racks on the cutting table and
move the cutter head along the beam. The combined motions of the beam
and cutter head let the knife cut complex patterns.

Y-AXIS CABLE

CUTTER HEAD
BEAM CONTROL
PANEL COVER

BEAM

X-AXIS CABLE

Y-AXIS DRIVE
BELT

FLATWAY

ROUNDWAY

Cutter Head and Beam

GT 3250 System Service Manual Preventive Maintenance 21

Beam Maintenance / Beam Alignment

Beam Alignment 3. Loosen the collar clamp on the right end

torque tube. This lets the right end of
Inspect the beam move freely.
1. Turn on the C-200 controller.
a. Insert the appropriate hex key into
2. Run the C-200MT program. the access hole just in front of the
E-stop button.
3. Place a piece of paper, 1.5 m by 1.5 m
(60 in. by 60 in.) on the conveyor b. Insert the hex key into the screw on
surface. the collar clamp. You may need to
move the beam forward or backward
4. Run the Beam Square Test (see the so that the collar clamp screw is in
C-200MT Software User’s Guide or the correct position.
C-200MT online help). If the beam is c. Loosen the collar clamp screw by
not square, adjust the beam alignment. turning it counterclockwise.
5. Exit the C-200MT program. d. Remove the hex key from the access
hole.
6. Turn off the C-200 controller.

Adjust

NOTE: Only adjust the beam alignment if the HEX KEY

beam is not square.

1. Turn off the C-200 controller.

2. Remove the remote end cover

(page 34).

RACK
COLLAR CLAMP TORQUE
TUBE

22 Preventive Maintenance GT 3250 System Service Manual

 Beam Maintenance / Beam Alignment

NOTE: You must turn on the C-200 b. If the -Y end of the beam leads the
controller to turn on the beam’s drive +Y end, move the right end of the
motors. When these motors are on,
they stop the left side of the beam
beam forward towards the take-off
from moving. This lets you move end of the table.
only the right side of the beam for
beam alignment. 7. Tighten the collar clamp screw with the
T-handled hex key.
4. Turn on the C-200 controller.
8. Run the Beam square test (see the
5. Run the C-200MT program. C-200MT Software User’s Guide or
C-200MT online help).
6. Align the beam by moving the right side
of the beam. The right side of the beam 9. If the beam is not square, repeat steps 4
rides on the right-side rack. To align the through 7 until the beam is square.
beam, move it only a few teeth in either
direction. 10. Install the remote end cover
(page 34).
a. If the +Y end of the beam leads the
-Y end, move the right end of the
beam back towards the take-on end
of the table.

OR
HEX KEY

RACK
TORQUE TUBE
COLLAR CLAMP

GT 3250 System Service Manual Preventive Maintenance 23

Beam Maintenance / Roundway

Roundway Clean/Lubricate
The roundway is one of two components 1. Turn off the C-200 controller.
(the other is the flatway) that support and
guide the cutter head as it travels along the 2. Wipe the roundway with a clean shop
beam. The roundway is a round shaft that rag and a small amount of synthetic oil.
runs the length of the beam. The roundway This cleans and lubricates the roundway.
must be clean, lightly lubricated, and free of
scratches so the cutter head can move freely. CAUTION: Excess oil is thrown onto fabric
and damages it. Use as little oil
as possible. It is better to
Inspect lubricate lightly and more
frequently than it is to apply one
1. Turn off the C-200 controller. heavy coat.

2. Inspect the roundway for dirt and built- 3. Turn on the C-200 controller.
up lint. Clean and lubricate the
roundway, if needed.

3. Inspect the roundway for scratches,

nicks, and gouges. These defects can
damage the roundway bearings in the
cutter head. If you find any of these
defects, have this repaired or replaced
by a Gerber qualified technician.

4. Turn on the C-200 controller.

ROUNDWAY

24 Preventive Maintenance GT 3250 System Service Manual

 Beam Maintenance / Flatway

Flatway Clean/Lubricate
The flatway is one of two components 1. Turn off the C-200 controller.
(the other is the roundway) that support and
guide the cutter head as it travels along the 2. Wipe the flatway with a clean shop rag
beam. The flatway is a flat plate that runs the and a small amount of synthetic oil.
length of the beam. The flatway must be kept This cleans and lubricates the flatway.
clean, lightly lubricated, and free of scratches
so the cutter head can move freely. CAUTION: Excess oil is thrown onto fabric
and damages it. Use as little oil
as possible. It is better to
Inspect lubricate lightly and more
frequently than it is to apply
1. Turn off the C-200 controller. one heavy coat.

2. Inspect the flatway for dirt and built-up 3. Turn on the C-200 controller.
lint. Clean and lubricate the flatway, if
needed.

3. Inspect the flatway for scratches, nicks,

and gouges. These defects can damage
the flatway bearings in the cutter head.
If you find any of these defects, have
this repaired or replaced by a Gerber
qualified technician.

4. Turn on the C-200 controller.

FLATWAY

GT 3250 System Service Manual Preventive Maintenance 25

Beam Maintenance / Cutter Head Drive Belt

Cutter Head Drive Belt d. Put a small piece of paper between

The cutter head drive belt moves the cutter the belt tensioner and flatway.
head along the beam. The drive belt must be The belt tensioner should hold the
properly tensioned and free of defects to en- paper against the flatway.
sure accurate cutting. e. Attach a spring scale, 0-23 kg
(0-50 lb.) to the belt tensioner.
Inspect f. Pull the spring scale until the paper
1. Inspect the drive belt for nicks, cuts, falls from between the flatway and
gouges, or fraying. belt tensioner. The spring scale
should read 3.63 to 4.54 kg
a. Turn on the C-200 controller. (8 to 10 lb.).
b. Slew the cutter head so you can see g. If tension is incorrect, adjust the
the entire drive belt. cutter head drive belt tension.
c. If you see any of these defects, have
3. Remove the belt tensioner.
it replaced by a Gerber qualified
technician.
4. Install the remote-end cover
(page 34).
2. Check drive belt tension.

a. Remove the remote-end cover

(page 34).
b. Using the slew keys, position the
cutter head at X=127 cm,
Y=127 cm (X= 50 in., Y=50 in.).
c. Place the belt tensioner on the drive
belt halfway between the belt
clamping plate and the belt pulley
on the console side of cutter.

SPRING SCALE

DRIVE BELT

SHEET OF PAPER
BELT TENSIONER

26 Preventive Maintenance GT 3250 System Service Manual

 Beam Maintenance / Cutter Head Drive Belt

Adjust c. If the drive belt rides up on one edge

1. Adjust drive belt tension: of the pulley, adjust the adjusting
screw closest to that edge.
a. Turn the adjustment screws d. Repeat until the belt tracks properly.
clockwise to increase tension.
b. Turn the adjustment screws 3. Repeat steps 1 and 2 until the cutter
counterclockwise to decrease head drive belt tracks properly and has
tension. correct tension.
c. Check belt tension. 4. Install the remote-end cover
d. Repeat steps a, b, and c until tension (page 34).
is correct.

2. Check drive belt tracking.

a. Remove the belt tensioner.

b. Slew the cutter head back and forth
along the beam several times.

ADJUSTMENT
SCREWS
DRIVE BELT

GT 3250 System Service Manual Preventive Maintenance 27

Beam Maintenance / X-axis Drive Belts

X-axis Drive Belts Inspect

The three X-axis drive belts let electric mo- 1. Turn off the C-200 controller.
tors in the beam turn the gears and pulleys
that move the beam along the cutting table. 2. Remove the BCP cover (page 33).
Each drive belt must be in good condition for
the beam to move properly. 3. Inspect the primary and secondary drive
belts for nicks, cuts, gouges, glazing, or
fraying. If you see any of these defects,
Required Tools and Supplies
have them repaired or replaced by a
Item Gerber P/N Gerber qualified technician.
6-in. adjustable wrench 944002510
4. Install the BCP cover (page 33).
belt deflection gauge 045412000

metric right-angle hex key set 945500079 5. Turn on the C-200 controller.
screw eye, 4 mm 854501265

split collar 324500026

spring scale, 0 - 23 kg (0 - 50 lb.) 945500252

PRIMARY DRIVE
BELTS
SECONDARY
DRIVE BELT

28 Preventive Maintenance GT 3250 System Service Manual

 Beam Maintenance / X-axis Drive Belts

Adjust d. Tighten the three retaining screws

1. Turn off the C-200 controller. for the intermediate idler shaft.

2. Remove the BCP cover (page 33). 6. Adjust primary belt tension.

3. Loosen the eight retaining screws for a. Thread a 4 mm screw eye into one
the X-axis servo motors. of the adjusting brackets.
b. Hook the spring scale, 0-23 kg (0-50
4. Loosen the three retaining screws for lb.), to the screw eye.
the intermediate idler shaft.
c. Pull on the spring scale until it reads
5. Adjust secondary belt tension. 9 to 10 kg (20 to 22 lb.).
d. While keeping proper tension,
a. Set the belt deflection gauge to
tighten the four retaining screws for
measure a deflection of 5 to 7 mm
the X-axis servo motor.
(0.20 to 0.30 in.) at 6.8 to 9.1 kg (15
to 20 lb.). e. Repeat steps a through d for the
other X-axis servo motor.
b. Measure secondary belt deflection at
the point shown below.
7. Install the BCP cover (page 33).
c. If the belt tension is incorrect, use an
adjustable wrench to turn the 8. Turn on the C-200 controller.
intermediate idler shaft until the
secondary belt is tensioned correctly.
INTERMEDIATE
DRIVE SHAFT X-AXIS SERVO MOTOR
RETAINING DRIVE SHAFT
SCREW

MEASURE BELT
DEFLECTION HERE 9 to 10 kg
(20 to 22 lb.)

PRIMARY DRIVE BELTS

SCREW EYE

X-AXIS SERVO MOTOR

SECONDARY DRIVE SHAFT
DRIVE BELT
RETAINING SCREW

GT 3250 System Service Manual Preventive Maintenance 29

Beam Maintenance / Y-axis Drive Belts

Y-axis Drive Belts Inspect

Three Y-axis drive belts, driven by electric 1. Turn off the C-200 controller.
motors in the beam, turn the gears, pulleys,
and drive belt that move the cutter head along 2. Remove the BCP cover (page 33).
the beam. Each drive belt must be in good
condition for the beam to move properly. 3. Inspect the primary and secondary drive
belts for nicks, cuts, gouges, glazing, or
fraying. If you see any of these defects,
Required Tools and Supplies
have them replaced by a Gerber
Item Gerber P/N qualified technician.
6-in. adjustable wrench 944002510
4. Install the BCP cover (page 33).
belt deflection gauge 045412000

metric right-angle hex key set 945500079 5. Turn on the C-200 controller.
screw eye, 4 mm 854501265

split collar 324500026

spring scale, 0 - 23 kg (0 - 50 lb.) 945500252

Y-axis belt tensioning tool 073551000

PRIMARY DRIVE
BELTS

SECONDARY
DRIVE BELT

30 Preventive Maintenance GT 3250 System Service Manual

 Beam Maintenance / Y-axis Drive Belts

Adjust NOTE: If necessary, you can also use the

Y-axis motor belt tensioner for this
1. Turn off the C-200 controller. procedure. See step 7.

2. Remove the BCP cover (page 33). a. Thread a 4 mm screw eye into the
adjusting bracket.
3. Loosen the eight retaining screws for
the Y-axis servo motors. b. Hook the spring scale to the screw eye.
c. Pull on the spring scale until it reads
4. Loosen the three retaining screws for 9 to 10 kg (20 to 22 lb.).
the intermediate idler shaft.
d. While keeping proper tension,
5. Adjust secondary belt tension. tighten the four retaining screws for
the X-axis servomotor.
a. Set the belt deflection gauge to
e. Tighten the four retaining screws for
measure a deflection of 5 to 7 mm
the Y-axis servomotor.
(0.20 to 0.30 in.) at 6.8 to 9.1 kg (15
to 20 lb.).
7. Adjust tension of the primary belt 2
b. Measure secondary belt deflection at using the Y-axis motor belt tensioner.
the point shown below.
a. Hook the belt tensioner to the
c. If the belt tension is incorrect, use an servomotor drive shaft.
adjustable wrench to turn the
intermediate idler shaft until the b. Apply tension 9 to 10 kg (20 to 22 lb.)
secondary belt is tensioned correctly. to the Y-axis servomotor pulley.
d. Tighten the three retaining screws c. Repeat steps 6d and 6e.
for the intermediate idler shaft.
8. Install the BCP cover (page 33).
6. Adjust tension of the primary belt 1
using the spring scale. 9. Turn on the C-200 controller.

RETAINING SCREW

Y-AXIS SERVO
INTERMEDIATE MOTOR DRIVE SHAFT
DRIVE SHAFT
PRIMARY BELT 2

MEASURE BELT
DEFLECTION HERE

9 to 10 kg
(20 to 22 lb.)

PRIMARY BELT 1

SECONDARY DRIVE BELT

GT 3250 System Service Manual Preventive Maintenance 31

 Beam Maintenance / Cables

Cables 5. Inspect the cables for fraying or breaks

The cables provide power and cutting com- and the armor for broken links. If you see
mands for the cutter head and beam. They are any of these defects, have them repaired
protected with plastic link armor. or replaced by a technician.

6. Install side panel 2 (page 68).

Inspect
1. Move the beam to the take-off end of 7. Turn on the C-200 controller.
the cutting table.

2. Remove side panel 2 (page 68).

3. Move the beam to the take-on end of the

cutting table.

4. Turn off the C-200 controller.

Y-AXIS CABLE
X-AXIS
CABLE

32 Preventive Maintenance GT 3250 System Service Manual

 Beam Maintenance / BCP Cover

BCP Cover Install

The beam control panel (BCP) cover encloses 1. Slide the BCP cover straight down over
the moving parts and electronics inside the the beam control panel. Be careful not
BCP. to pinch any wires or tubing.

2. Install the four screws that retain the

Required Tools and Supplies
BCP cover.
Item Gerber P/N
metric right-angle hex key set 945500079 3. Turn on the C-200 controller.

Remove
1. Turn off the C-200 controller.

2. Remove the four screws that retain the

BCP cover.

3. Lift the BCP cover straight up to

remove it.

BCP COVER

GT 3250 System Service Manual Preventive Maintenance 33

Beam Maintenance / Remote-End Cover

Remote-End Cover Install

This cover encloses the moving parts and 1. Slide the remote-end cover straight
electrical components on the remote-end of down over the beam control panel.
the beam. Be careful not to pinch any wires.

2. Install the two screws that retain the

Required Tools and Supplies
remote-end cover.
Item Gerber P/N
metric right-angle hex key set 945500079 3. Turn on the C-200 controller.

Remove
1. Turn off the C-200 controller.

2. Remove the two screws that retain the

remote-end cover.

3. Remove the remote-end cover by lifting

it straight up.

RETAINING SCREWS

REMOTE-END
COVER

34 Preventive Maintenance GT 3250 System Service Manual

Cutter Head Maintenance
The cutter head contains the knife and does the actual cutting of material.
It moves across the cutting table on the beam.

SPIDER

KNIFE DRIVE
TRAIN

KNIFE DRIVE BELT

KNIFE DRIVE
MOTOR

LASER ORIGIN
LIGHT SWITCH

C-AXIS DRIVE BELT

KNIFE BLADE

ELEVATOR
ROUNDWAY

PRESSER FOOT
GRINDING PULLEY
DRIVE BELT ORIGIN LIGHT

GRINDING PULLEY

Cutter Head

GT 3250 System Service Manual Preventive Maintenance 35

Cutter Head Maintenance / Front Cover

Front Cover Install

The cutter head cover is made of two parts: 1. While holding the D-ring up, lower the
the front cover and the back cover. The front front cover onto the hinge pins.
cover encloses most of the cutter head.
It protects the cutter head from damage and 2. Release the D-ring.
the operator from injury.
3. Turn on the C-200 controller.
Remove
1. Turn off the C-200 controller.

2. Release the latch by raising the D-ring.

3. While holding the D-ring up, lift the

front cover off the hinge pins.

D-RING

BACK COVER
FRONT COVER

HINGE PINS

36 Preventive Maintenance GT 3250 System Service Manual

 Cutter Head Maintenance / C-axis Assembly

C-axis Assembly 3. Manually turn the C-axis assembly

The C-axis assembly is a major assembly in several times to the right and left.
the cutter head. It contains the knife drive It should turn freely without binding
train which drives the knife and turns, so the or noise.
knife blade can cut corners, notches, curves,
and other complex shapes. Drive belts con- 4. If you find any defects, have the
nect the knife drive train to the C-axis drive assembly repaired or replaced by a
motor and knife drive motor. Gerber qualified technician.

5. Install the cutter head front cover

Inspect (page 36).
1. Turn off the C-200 controller.
6. Turn on the C-200 controller.
2. Remove the cutter head front cover
(page 36).

C-AXIS
ASSEMBLY

GT 3250 System Service Manual Preventive Maintenance 37

Cutter Head Maintenance / C-axis Assembly

C-Axis Drive Belt. The C-axis drive belt links 5. Install the cutter head front cover
the C-axis motor and the C-axis assembly. The (page 36).
drive belt must be in good condition and prop-
erly tensioned for accurate cutting. 6. Turn on the C-200 controller.

Required Tools and Supplies Remove

Item Gerber P/N 1. Turn off the C-200 controller.
C-axis drive belt 065181000
2. Remove the cutter head front cover
metric right-angle hex key set 945500079 (page 36).
screw eye, 4 mm 854501265
3. Remove the drill, if your cutter has one
spring scale, 0 - 23 kg (0 - 50 lb) 945500252
(page 58).

Inspect 4. Loosen the four retaining screws for the

C-axis motor.
1. Turn off the C-200 controller.
5. Loosen the C-axis belt adjusting screw.
2. Remove the cutter head front cover
(page 36).
6. Slide the C-axis motor toward the
C-axis assembly.
3. Inspect the drive belt for nicks, cuts,
and gouges. If you see any of these
7. Slip the C-axis drive belt off the pulley
defects, have it replaced by a Gerber
that is on the C-axis motor.
qualified technician.
8. Slide the drive belt down the C-axis
4. Visually inspect the belt for proper
assembly, under the presser foot bowl,
tensioning. Adjust it, if necessary.
and out of the cutter head.

C-AXIS DRIVE
C-AXIS BELT
MOTOR

ADJUSTING
SCREW

ADJUSTING
BRACKET

C-AXIS
RETAINING ASSEMBLY
SCREW

38 Preventive Maintenance GT 3250 System Service Manual

 Cutter Head Maintenance / C-axis Assembly

Install 8. Remove the 4 mm screw eye from the

1. Slide the drive belt over the presser foot adjusting bracket.
bowl and up the C-axis assembly.
9. Install the adjusting screw into the
2. Slip the drive belt onto the pulleys on adjusting bracket.
the C-axis motor and C-axis assembly.
10. Tighten the adjusting screw by hand
3. Remove the C-axis adjusting screw until it is snug.
from the adjusting bracket.
11. Install the drill, if your cutter has one
4. Install a 4 mm screw eye into the (page 59).
adjusting bracket.
12. Install the cutter head front cover
5. Hook the spring scale to the screw eye. (page 36).

6. Pull on the spring scale until it reads 13. Turn on the C-200 controller.
9 to 10 kg (20 to 22 lb).

7. While keeping proper tension on the

spring scale, tighten the four screws that
retain the C-axis motor.

C-AXIS MOTOR

ADJUSTING
BRACKET C-AXIS DRIVE
BELT

9 to 10 kg
(20 to 22 lb)

4 MM SCREW EYE

RETAINING
SCREW

GT 3250 System Service Manual Preventive Maintenance 39

Cutter Head Maintenance / C-axis Assembly

Adjust 9. While keeping proper tension on the

1. Turn off the C-200 controller. spring scale, tighten the four screws that
retain the C-axis motor.
2. Remove the cutter head front cover
(page 36). 10. Remove the 4 mm screw eye from the
adjusting bracket.
3. Remove the drill, if your cutter has one
(page 58). 11. Install the adjusting screw into the
adjusting bracket.
4. Remove the C-axis adjusting screw
from the adjusting bracket. 12. Tighten the adjusting screw by hand
until it is snug.
5. Install a 4 mm screw eye into the
adjusting bracket. 13. Install the drill, if your cutter has one
(page 59).
6. Loosen the four screws that retain the
C-axis motor. 14. Install the cutter head front cover
(page 36).
7. Hook the spring scale to the screw eye.
15. Turn on the C-200 controller.
8. Pull on the spring scale until it reads
9 to 10 kg (20 to 22 lb).

C-AXIS MOTOR

ADJUSTING
BRACKET C-AXIS DRIVE
BELT

9 to 10 kg
(20 to 22 lb)

4 MM SCREW EYE

RETAINING
SCREW

40 Preventive Maintenance GT 3250 System Service Manual

 Cutter Head Maintenance / Knife Drive Belts

Knife Drive Belts 3. Check both knife drive belts for cracks,
The two knife drive belts connect the knife nicks, cuts, and glazing.
drive motor to the knife crankshaft through a
series of pulleys. As the knife drive motor 4. If you see any of these defects, have
turns, the drive belts transfer motion to the them replaced by a Gerber qualified
knife crankshaft. The drive belts must be in technician.
good condition and properly tensioned to get
the best cutting performance. 5. Install the cutter head front cover
(page 36).

Required Tools and Supplies 6. Turn on the C-200 controller.

Item Gerber P/N
knife drive belt 1 180500104 Adjust

knife drive belt 2 180500105 1. Turn off the C-200 controller.

metric right-angle hex key set 945500079
2. Remove the cutter front head cover
screw eye, 4 mm 854501265 (page 36).
spring scale, 0 - 23 kg (0 - 50 lb) 945500252
CAUTION: Drive belts 1 and 2 must be
standard right-angle hex key set 945500051 adjusted together in the proper
sequence. Doing otherwise can
damage the belts and bearings.
Inspect
1. Turn off the C-200 controller. 3. Loosen the adjusting screw for the drive
belt 2 at least six turns.
2. Remove the cutter head front cover
(page 36).

DRIVE BELT 1 INTERMEDIATE

PULLEY
PULLEY ADJUSTING SCREW
(DRIVE BELT 2)

RETAINING
SCREW

DRIVE BELT 2

KNIFE DRIVE
MOTOR
PULLEY

GT 3250 System Service Manual Preventive Maintenance 41

Cutter Head Maintenance / Knife Drive Belts

4. Loosen the four screws that retain the 7. Adjust drive belt 2 for equal belt slip
knife drive motor. with drive belt 1.

5. Slide the knife drive motor toward the a. Insert a Philips screw driver into the
C-axis assembly to loosen drive belt 1. hole in the C-axis assembly. This
keeps the crank shaft from turning.
6. Adjust drive belt 1.
b. Tighten drive belt 2 adjusting screw
a. Thread a 4 mm screw eye into one slightly.
of the adjusting brackets. c. Turn the knife drive motor pulley by
b. Hook the spring scale to the screw hand.
eye. d. Repeat steps b and c until belt 1 just
c. Pull on the spring scale until it reads begins to slip on the knife drive
13.5 to 16 kg (30 to 35 lb). motor pulley.

d. While keeping proper tension on the e. Loosen drive belt 2 adjusting screw
spring scale, tighten the four slightly.
retaining screws for the knife drive
8. Install the cutter head front cover
motor.
(page 36).

9. Turn on the C-200 controller.

DRIVE BELT 1
13.5 to 16 kg ADJUSTING SCREW
(30 to 35 lb) (DRIVE BELT 2)
INTERMEDIATE
PULLEY PULLEY

SCREW EYE

ADJUSTING
BRACKET

KNIFE DRIVE
MOTOR

PULLEY
DRIVE BELT 2

42 Preventive Maintenance GT 3250 System Service Manual

 Cutter Head Maintenance / Knife Blade

Knife Blade 5. Check the knife blade for proper

The knife blade cuts material. It must be sharpening.
sharp and within wear limits to cut properly.
a. Use a black felt-tip marker to color
both sides of the knife blade black.
WARNING! The knife blade is very sharp.
Handle the knife blade carefully. Never hold b. Turn on the C-200 controller.
the knife blade by its sharp end.
c. Run the C-200MT program.
Required Tools and Supplies d. Press F8 to sharpen the knife blade.
Item Gerber P/N
Sharpen each side of the knife blade
five or six times.
knife blade (low ply) 073335000
e. Exit the C-200MT program.
knife blade (chisel tip) 073387000
metric T-handle hex key set 945500089
f. Turn off the C-200 controller.

screwdriver set 944211601 g. Inspect both sides of the knife blade.

The pattern of ink on the knife blade
shows where the knife blade was
Inspect sharpened.
1. Turn off the C-200 controller.
NOTE: If the knife blade is sharpened
2. Remove the cutter head front cover correctly, the grinding wheel
(page 36). removes ink from the leading edge to
a width of no less than 1⁄8 inch.
3. Check the knife blade for excessive
wear. 6. Adjust the knife blade sharpen angle
(page 44) if:
4. If the leading edge of the knife blade is
damaged or is not straight, replace the a. the leading edge of the knife blade is
knife blade (page 4-40). not sharpened.
b. a width of less than 1⁄8 inches is
sharpened.

OK UNACCEPTABLE

OK UNACCEPTABLE

7. Install the cutter head front cover

(page 36).

8. Turn on the C-200 controller.

GT 3250 System Service Manual Preventive Maintenance 43

Cutter Head Maintenance / Knife Blade

Adjust 6. Check the knife blade for proper

1. Turn on the C-200 controller. sharpening.

2. Run the C-200MT program. a. Use a black felt-tip marker to color

both sides of the knife blade black.
3. Initialize the system. b. Sharpen each side of the knife blade
five or six times.
4. From the Diagnostics menu, select
Sharpen Angle (see the C-200MT online c. Inspect both sides of the knife blade.
help). The pattern of ink on the knife blade
shows where the knife blade was
5. Adjust the sharpen angle for each sharpened.
sharpen position if:
7. Repeat steps 4 through 6 until both
a. The sharpener does not sharpen the sides of the knife blade sharpen
leading edge of the knife blade. correctly.

UNACCEPTABLE SHARPEN ANGLE

OR

b. The sharpener sharpens less than a

1⁄ -inch wide area of the leading
8
edge.

1⁄ -IN. 1⁄ -IN.
8 8

ACCEPTABLE SHARPEN ANGLE

8. Exit the C-200MT program.

9. Turn off the C-200 controller.

UNACCEPTABLE SHARPEN ANGLE

44 Preventive Maintenance GT 3250 System Service Manual

 Cutter Head Maintenance / Knife Blade

Remove 5. Remove the clevis.

1. Turn off the C-200 controller.
a. Insert a Phillips screwdriver into the
2. Remove the cutter head front cover hole in the C-axis assembly. This
(page 36). keeps the crankshaft from turning.
b. Remove the clevis mounting screw.
3. Set the clevis at either top dead center
or bottom dead center. Either position
removes tension from the knife blade.

WARNING! Do not place your hand

under the presser foot when you loosen the
knife blade mounting screw.

4. Remove the knife blade retaining screw.

The knife blade drops to the cutting
surface.

c. Remove the clevis from the

COUNTER- crankshaft.
WEIGHT

CLEVIS

RETAINING
SCREW

NOTE: The clevis mounts on its

crankshaft with the T-shaped
clevis counterweight and knife
blade retaining screw towards the
back of the C-axis.

GT 3250 System Service Manual Preventive Maintenance 45

Cutter Head Maintenance / Knife Blade

6. Rotate the counterweight until it is Install

horizontal and to the left of the knife 1. Make sure the counterweight is
axis. horizontal to the cutting surface and to
the left of the knife axis.
WARNING! The knife blade is very sharp.
Handle it carefully.
CAUTION: You must align the sharp edge
of the knife correctly at zero (0)
degrees. If you do not, the knife
7. Carefully lift the knife blade until the will not cut fabric correctly.
shank of the knife blade appears below
the counterweight. 2. With the sharp edge toward the beam,
slide the knife blade down, through
8. Grasp the shank of the knife blade and center of the spider. Let the knife drop
push the knife blade up and to the left of to the cutting surface.
the clevis crankshaft.
WARNING! Never hold the knife blade
9. Push the knife up, through the center of by the sharp end. The knife is very sharp
the spider. The top of the knife blade and can cause serious injury.
will appear at the top center of the
spider before the sharp edge of the knife
blade is at the counterweight.

10. Pull the knife blade from the center of

the spider.

46 Preventive Maintenance GT 3250 System Service Manual

 Cutter Head Maintenance / Knife Blade

3. Install the clevis. 4. Lift the knife blade.

a. Slide the clevis onto the crankshaft. 5. Align the hole in the knife with the
knife-retaining screw holes in the clevis.
CAUTION: There is only one correct way to
install the clevis. Install the CAUTION: Only tighten the knife retaining
clevis onto the crankshaft so screw until it is snug. Do not
that the knife retaining screw is overtighten the knife retaining
as close as possible to the screw. If you overtighten the
counterweight. Failure to do so knife retaining screw, it may
can cause inaccurate cutting. break.

6. Install the knife retaining screw.

b. Insert a Phillips screwdriver into

the hole on the C-axis. This keeps
the crankshaft from turning.
c. Install the clevis mounting screw.

7. Install the cutter head front cover

(page 36).

CAUTION: To allow proper initializing, you

must move the cutter head away
from the limit switches in the X
and Y-axes.

8. Turn on the C-200 controller.

GT 3250 System Service Manual Preventive Maintenance 47

Cutter Head Maintenance / Presser Foot

Presser Foot c. If you notice any binding, have the

The presser foot flattens the top of the lay as assembly repaired or replaced by a
the knife blade cuts it. Gerber qualified technician.
d. At the operator console, restore the
Required Tools and Supplies presser foot bowl pressure to its
original level.
Item Gerber P/N
clean shop rag N/A 6. Install the cutter head front cover
SAE 10 non-detergent oil N/A (page 36).

7. Turn on the C-200 controller.

Inspect
1. Turn off the C-200 controller. Clean/Lubricate

2. Remove the cutter head front cover. 1. Turn off the C-200 controller.

3. Check the presser foot shafts for dirt 2. Remove the cutter head front cover
and debris. Clean them if needed. (page 36).

4. Check the shafts for bends, nicks, and 3. Wipe the shafts with a lightly-oiled shop
gouges. If you find any of these defects, rag. This cleans and lubricates the shafts
have them repaired or replaced by a at the same time.
Gerber qualified technician.
CAUTION: Excess oil is thrown onto fabric
and damages it. Use as little oil
5. Check the presser foot for binding. as possible. It is better to
lubricate lightly and more
a. At the operator console, decrease the frequently, than to apply one
presser foot bowl pressure to 0 heavy coat.
kgf/cm2 (0 psi).
4. Install the cutter head cover
b. Slide the presser foot straight up. (page 36).
It should move smoothly without
binding. Binding indicates a 5. Turn on the C-200 controller.
problem with the shafts and/or
alignment of the lower blade guide.

PRESSER FOOT
SHAFT

PRESSER
FOOT

48 Preventive Maintenance GT 3250 System Service Manual

 Cutter Head Maintenance / Sharpener Assembly

Sharpener Assembly Remove

The knife blade must be sharp to cut properly. 1. Turn off the C-200 controller.

Grinding Pulley Drive Belt

2. Remove the cutter head front cover
(page 36).
The drive belt connects the sharpener motor
to the grinding pulley. It must be in good con- 3. Remove the drill, if your cutter has this
dition for the sharpener to work properly. option (page 58).

Required Tools and Supplies CAUTION: Oil and grease damage the drive
belt and cause it to slip. Keep
Item Gerber P/N the drive belt clean while
grinding pulley drive belt 496500075 handling it.
(O-ring)
4. Gently stretch the drive belt off the drive
metric T-handle hex key set 945500089
pulley and slip it off the grinding pulley.
metric right-angle hex key set 945500079

Install
Inspect 1. Slip the drive belt onto the grinding pulley.
1. Turn off the C-200 controller.
2. Gently stretch the drive belt over the
2. Remove the cutter head front cover drive pulley.
(page 36).
3. Install the drill (page 59).
3. Check the drive belt for nicks and cuts.
Replace it if you find any of these defects. 4. Install the cutter head front cover
(page 36).
4. Install the cutter head front cover
(page 36). 5. Turn on the C-200 controller.

5. Turn on the C-200 controller.

DRIVE BELT SCREWS

(O-RING)

GRINDING PULLEY DRIVE PULLEY

GT 3250 System Service Manual Preventive Maintenance 49

Cutter Head Maintenance / Sharpener Assembly

Grinding Pulley 3. Inspect the grinding pulley for missing

The grinding pulley is a grit-covered metal grit, debris, and chips. Replace or clean
wheel that sharpens the knife blade. Grinding the grinding pulley, as needed.
pulley condition affects sharpening which, in
turn, affects cutting performance. 4. Install the cutter head front cover
(page 36).
Required Tools and Supplies 5. Turn on the C-200 controller.
Item Gerber P/N
grinding pulley 50/60 grit 071659004 Remove
grinding pulley 60/80 grit 071659003 1. Turn off the C-200 controller.
grinding pulley 80/100 grit 071659002
2. Remove the cutter head front cover
grinding pulley 100/120 grit 071659001 (page 36).
grinding pulley 140/170 grit 071659005
3. Remove the drive belt (page 49).
Locktite safety solvent 308010101
metric right-angle hex key set 945500079 4. Remove the retainer from the grinding
metric T-handle hex key set 945500089 pulley support.
small brass brush N/A 5. Slide the grinding pulley support out of
the pivot arm.
Inspect
1. Turn off the C-200 controller. NOTE: If you are cleaning, not replacing, the
grinding pulley, skip steps 6 and 7.

2. Remove the cutter head front cover

(page 36).

DRIVE BELT
RETAINER (O-RING)

GRINDING
PULLEY

GRINDING PULLEY SUPPORT

PIVOT ARM

50 Preventive Maintenance GT 3250 System Service Manual

 Cutter Head Maintenance / Sharpener Assembly

6. Remove the retaining screws and slide Install

the grinding pulley out of the grinding
NOTE: If you are installing a cleaned
wheel support. grinding wheel, skip step 1.

7. Remove and save the washers, bearings, 1. Install the washers, bearings, and spacer
and spacer. in the grinding pulley.

Clean 2. Slide the grinding pulley into the

grinding wheel support.
1. Spray the grinding pulley thoroughly
with safety solvent. 3. Slide the grinding pulley support into
the pivot arm.
2. Using a stiff, brass brush, scrub the
grinding pulley until you remove all 4. Install the plastic retainer on the
deposits. grinding pulley support.
3. Air dry the grinding pulley until all 5. Install the drive belt (page 49).
solvent is gone.
6. Install the cutter head front cover
4. Install the grinding pulley. (page 36).

7. Turn on the C-200 controller.

FLAT WASHER
BEARING RETAINING
SCREW

LOCK WASHER

GRINDING
PULLEY
PLASTIC
RETAINER

GRINDING PULLEY
SUPPORT
SPACER

GT 3250 System Service Manual Preventive Maintenance 51

Cutter Head Maintenance / Elevator Roundways

Elevator Roundways 5. Install the cutter head front cover

The elevator roundways are two round shafts (page 36).
on which the elevator rides up and down. As
the elevator moves, it plunges and raises the 6. Turn on the C-200 controller.
knife.
Clean/Lubricate
Required Tools and Supplies 1. Turn off the C-200 controller.
Item Gerber P/N
2. Remove the cutter head front cover
clean shop rag N/A (page 36).
SAE 10 non-detergent oil N/A
3. Wipe the cutter head roundways with a
lightly-oiled shop rag. This cleans and
Inspect lubricates them at the same time.
1. Turn off the C-200 controller.
CAUTION: Excess oil is thrown onto fabric
2. Remove the cutter head front cover and damages it. Use as little oil
(page 36). as possible. It is better to
lubricate lightly and more
frequently than to apply one
3. Inspect the roundways for dirt and lint heavy coat.
build-up. Clean and lubricate them, if
necessary. 4. Install the cutter head front cover
(page 36).
4. Inspect the roundways for scratches,
nicks, and gouges. These defects show 5. Turn on the C-200 controller.
problems with the roundway bearings.
If you have any of these problems, have
them repaired or replaced by a Gerber
qualified technician.

ROUNDWAYS

52 Preventive Maintenance GT 3250 System Service Manual

 Cutter Head Maintenance / Up/Down Stops

Up/Down Stops 5. You must check the knife penetration at

The up/down stops control the depth of knife five points on the cutting surface. Move
cuts. If the down stop is set low, the knife the cutter head to test point 1 on the work
cuts off the bristles in the BRISTLE surface. Test points 1 through 4 are about
SQUARES. If the down stop is set high, the 30.5 cm (1 ft) from each corner. Test
knife does not cut bottom plies cleanly. point 5 is at the center of the work
Improper setting of the up stop causes poor surface.
sharpening.

Required Tools and Supplies

1 2
Item Gerber P/N
metric combination wrench set 945500093 5
screwdriver set 944211601
4 3

Inspect
1. Turn on the C-200 controller.

2. Remove the cutter head cover

(page 36). 6. Plunge the knife and presser foot bowl in
the following manner:
3. Turn the crankshaft until the clevis is at
top dead center (TDC). a. Turn the TOOL switch on the BCP
to AUTO.
TDC
b. From the Diagnostics menu, select
Input Output Test (DG23) (see the
C-200MT Software User’s Guide or
CLEVIS
C-200MT online help).
The monitor displays the DG 23
menu.

4. Cover the work surface with paper and

plastic film.

GT 3250 System Service Manual Preventive Maintenance 53

Cutter Head Maintenance / Up/Down Stops

c. Use the arrow keys to highlight c. The pencil line should be positioned
Vacuum Enbl. as shown by the dashed line in the
figure below.
d. Hold down the CTRL key on your
keyboard and press the SPACE bar.
CHISEL TIP LOW PLY
This turns on table vacuum. KNIFE KNIFE

e. Use the arrow keys to highlight

Knife Sol.

f. Hold down the CTRL key on your

keyboard and press the SPACE bar.
This plunges the knife and the
presser foot bowl. Note that the
number in the KNIFE SOL line
changes from 1 to 0.

NOTE: Make a note of the air pressure

reading on the presser foot air gauge
at the operator console. You will
TOP OF
need to reset the regulator to that BRISTLE
pressure when you are through with
this procedure. d. Turn on air to the presser foot bowl
by returning pressure at the
g. Turn off air to the presser foot bowl
regulator at the operator console.
by releasing pressure at the regulator
Do this by turning the regulator
on the operator console. Do this by
clockwise.
turning the regulator
counterclockwise. You can now
8. Repeat steps 6 through 7 for test points
manually raise the presser foot bowl
2 through 5. If needed, adjust the down
to see the knife.
stop.
7. Check the down stop setting in the
9. On the BCP, press VAC to turn off table
following manner:
vacuum.
a. With a pencil, mark the knife at the
10. Press Esc to exit the DG 23 menu.
point it enters the plastic sealer.
b. At the operator console, hold down
the CTRL key on your keyboard
and press the SPACE bar. The knife
rises.

54 Preventive Maintenance GT 3250 System Service Manual

 Cutter Head Maintenance / Up/Down Stops

11. Check the up stop setting. Adjust

If you find while checking the up and down
a. Position the clevis at top dead center. stops (page 53) that you need to adjust them,
b. Check the knife blade. The tip of the follow this procedure:
knife blade should be level with the
bottom of the grinding pulley. CAUTION: Too much penetration damages
the work surface, too little keeps
pieces from being cut completely.

NOTE: Because of tolerances, bristle

GRINDING PULLEY penetration usually cannot be set to
the same value for each test point.
However, all test points must be
within the proper range.

1. Adjust the down stop:

a. Loosen the lock nut on the adjusting

screw by turning it counterclockwise.

c. Adjust the up stop, if necessary. LOCKNUT

ADJUSTING
12. Exit the C-200MT program. SCREW

13. Turn off the C-200 controller.

14. Install the cutter head cover

(page 36).

GT 3250 System Service Manual Preventive Maintenance 55

Cutter Head Maintenance / Up/Down Stops

b. Turn the adjusting screw clockwise d. Inspect the up/down stop settings
to decrease bristle penetration or (page 53).
counterclockwise to increase it.
e. Tighten the lock nut by turning it
c. Inspect the up/down stop settings clockwise.
(page 53).
f. Repeat steps a through e until the up
d. Tighten the lock nut by turning it stop is set correctly.
clockwise.
g. Install the drill (page 59).
e. Repeat steps a through d until bristle
penetration is set correctly. 3. Install the cutter head cover
(page 36).
2. Adjust the up stop.
4. Turn off the C-200 controller.
a. Remove the drill (page 58).
b. Loosen the lock nut on the adjusting
screw by turning it counterclockwise.
c. Turn the adjusting screw clockwise
to lower the up stop setting or
counterclockwise to raise the up
stop setting.

ADJUSTING
SCREW
LOCKNUT

56 Preventive Maintenance GT 3250 System Service Manual

Drill Maintenance
The drill option attaches to the cutter head. It lets the GT 3250 automatically
make drill hole marks as it cuts the material.

DRIVE BELT

EJECTOR ROD

DRILL BIT

Drill Assembly

GT 3250 System Service Manual Preventive Maintenance 57

Drill Maintenance / Drill

Drill 4. Disconnect the drill up/down air lines.

5. Disconnect the drill motor air line.

Required Tools and Supplies
Item Gerber P/N
6. Disconnect the drill limit switch wires
at the connector.
metric right-angle hex key set 945500079
7. Remove screw 1.
Remove
8. Remove screws 2 and 3 from both sides
1. Turn off the C-200 controller. of the drill mounting bracket.
2. Turn off air supply to the drill at the air 9. Remove the drill and mounting bracket
pressure gauge on the mast. assembly.
3. Remove the cutter head front cover
(page 36).

DRILL UP/DOWN
AIR LINES

CONNECTOR

SCREW 3

SCREW 2

DRILL MOTOR
AIR LINE

SCREW 1

58 Preventive Maintenance GT 3250 System Service Manual

 Drill Maintenance /

Install 5. Connect the drill motor air line.

1. Line up the screw holes in the drill
mounting bracket and cutter head 6. Connect the drill up/down air lines.
casting.
7. Install the cutter head front cover
2. Install screws 2 and 3 on both sides of (page 36).
the drill mounting bracket.
8. Turn on air to the drill at the air pressure
3. Install screw 1. gauge on the mast. Set the pressure to
5.6 - 7.0 kgf/cm2 (80-100 psi).
4. Connect the drill limit switch wires at
the connector. 9. Turn on the C-200 controller.

DRILL UP/DOWN
AIR LINES

CONNECTOR

SCREW 3

SCREW 2

DRILL MOTOR
AIR LINE

SCREW 1

GT 3250 System Service Manual Preventive Maintenance 59

Drill Maintenance / Drill Drive Belt

Drill Drive Belt 5. Install the cutter head front cover

The drive belt connects the drill to the drill (page 36).
motor.
6. Turn on the C-200 controller.
Required Tools and Supplies
Remove
Item Gerber P/N
1. Turn off the C-200 controller.
drill drive belt 180500117
metric right-angle hex key set 945500079 2. Remove the cutter head front cover
(page 36).
pliers 944003903
3. Remove the drill bit (page 62).
Inspect
4. Remove the ejector rod.
1. Turn off the C-200 controller.
5. Remove the retaining washer from the
2. Remove the cutter head front cover drive pulley.
(page 36).
6. Loosen the adjusting screws and slide
3. Check the drive belt for glazing, cuts, and the drill motor toward the drill.
nicks. Replace it, if necessary.
7. Slide the drive belt off the pulleys.
4. Check the drive belt for proper tension.
Adjust it, if necessary.

EJECTOR
ROD

MOUNTING
SCREWS

RETAINING
WASHER
DRIVE BELT DRILL BIT

60 Preventive Maintenance GT 3250 System Service Manual

 Drill Maintenance / Drill Drive Belt

Install Adjust
1. Slide the drive belt onto the pulleys. 1. Turn off the C-200 controller.

2. Install the retaining washer on the drive 2. Remove the cutter head front cover
pulley. (page 36).

3. Adjust the drive belt tension. 3. Loosen the mounting screws.

4. Install the ejector rod. 4. Slide the drill motor toward the drill to
loosen the drive belt.
5. Install the drill bit (page 63).
OR
6. Install the cutter head front cover
(page 36). Slide the drill motor away from the drill
to tighten the drive belt.
7. Turn on the C-200 controller.
5. Tighten the mounting screws.

6. Install the cutter head front cover

(page 36).

7. Turn on the C-200 controller.

EJECTOR
ROD

MOUNTING
SCREWS

RETAINING
WASHER
DRIVE BELT DRILL BIT

GT 3250 System Service Manual Preventive Maintenance 61

Drill Maintenance / Drill Bit

Drill Bit 4. Install the cutter head front cover

The drill bit is the part of the drill that cuts (page 36).
holes in the material. Drill bits are available
in a variety of sizes and types. 5. Turn on the C-200 controller.

Required Tools and Supplies Remove

Item Gerber P/N 1. Turn off the C-200 controller.
drill bits, ejector rods, collets see table
2. Remove the cutter head front cover
standard combination wrench 944002401 (page 36).
set
3. Hold the flats on the drive shaft with a
Inspect wrench.
1. Turn off the C-200 controller.
4. Using another open-end wrench, loosen
2. Remove the cutter head front cover the chuck.
(page 36).
5. While holding the drill bit with one
3. Check the cutting surface of the drill bit hand, use the other hand to remove the
for nicks, burrs, and dullness. If chuck and collet.
necessary, replace the drill bit.

EJECTOR
ROD

DRIVE
SHAFT

COLLET

CHUCK

DRILL BIT

62 Preventive Maintenance GT 3250 System Service Manual

 Drill Maintenance / Drill Bit

Install 5. Tighten the chuck finger-tight.

1. If you are installing a new drill bit, use
the table to select the matching ejector 6. Use an open-end wrench to tighten the
rod and collet. chuck 1⁄4 turn more.

2. Install the ejector rod, if necessary. CAUTION: To allow proper initializing, you
must move the cutter head away
a. Remove the old ejector rod by from the limit switches in the X
and Y-axes.
turning it counterclockwise.
b. Install the new ejector rod by 7. Install the cutter head front cover
turning it clockwise. (page 36).

3. Slide the drill bit straight up into the 8. Turn on the C-200 controller.
drill until it stops.

4. Slide the collet and chuck into place

over the drill bit.

Drill bits
Dimension Ejector rod Collet
Type Gerber P/N
(mm/inch)
1.2 / 0.046 solid 044330000 N/A 067064001
1.6 / 0.062 solid 044330001 N/A 067064002
2.0 / 0.078 groove point 030595003 N/A 067064003
2.4 / 0.093 half round 030595002 N/A 945500098
2.4 / 0.093 hollow 024351001 066638005 945500098
3.2 / 0.125 half round 030595001 N/A 945500098
3.2 / 0.125 hollow 024351002 066638006 945500096
4.0 / 0.156 hollow 024351003 066638007 945500096
4.8 / 0.187 hollow 024351004 066638008 945500095
6.4 / 0.250 hollow 067915001 066638008 945500095
7.9 / 0.312 hollow 067915002 066638008 945500097
9.5 / 0.375 hollow 067915003 066638009 945500097

GT 3250 System Service Manual Preventive Maintenance 63

Drill Maintenance / Drill Bit

64 Preventive Maintenance GT 3250 System Service Manual

Cutting Table Maintenance
The cutting table provides a work surface for cutting material. Its major
assemblies include the beam, cutter head, conveyor, vacuum generator, and
C-200 controller.

OPERATOR
CONSOLE ROLL BAR STATUS LIGHTS FILM DISPENSER

CUTTER HEAD

BEAM
BEAM CONTROL
PANEL

CONVEYOR

FILTER
RACK TABLE MOTION
ACCESS
CONTROLS
DOOR
SIDE PANELS
Operator Side from Take-on End

MAST
STATUS LIGHTS
FILM DISPENSER CUTTER HEAD
BEAM BEAM CONTROL
EXHAUST STACK PANEL

CONVEYOR

CTOT

SIDE PANELS
CB1 CONTROLLER AND VACUUM
CB8
ELECTRICS ENCLOSURES
CB2

Remote Side from Take-off End

GT 3250 System Service Manual Preventive Maintenance 65

Cutting Table Maintenance / Racks

Racks Clean
The racks are two, toothed tracks that run the 1. Turn off the C-200 controller.
length of the cutting table. Motors and gears in
the beam drive the beam along the racks. 2. Clean the racks with a paint brush and
The beam cannot travel smoothly, if the racks rag.
are dirty.
CAUTION: Do not lubricate the racks.
Grease and oil cause lint to
Required Tools and Supplies build up rapidly on the racks,
make cleaning more difficult,
Item Gerber P/N
and get thrown or rubbed into
clean shop rag N/A fabric.

paint brush N/A 3. Turn on the C-200 controller.

Inspect
1. Turn off the C-200 controller.

2. Inspect the racks for built-up lint and

dirt. Clean them, if necessary.

3. Turn on the C-200 controller.

RACK

66 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Side Covers

Side Covers There are two side panels on the operator side
The design of the side covers on your of the cutter (1 and 2 below).
GERBERcutter provides additional protec-
tion of your investment in the cutting room There are two major side panels on the
environment. If a maintenance procedure remote side of the cutter (3 and 4 below). An
requires removal of a side cover, follow the additional small panel (5 below) is located at
procedure on the next page. the exhaust stack and mast.

5
4

GT 3250 System Service Manual Preventive Maintenance 67

Cutting Table Maintenance / Side Covers

Install
Required Tools and Supplies
1. With the help of an assistant, lift the
Item Gerber P/N
cover into position at the side of the
mild detergent N/A cutter.
soft cloth N/A
2. Replace and tighten the bolts.

Remove
Clean
1. Use a socket wrench to remove the bolts
1. Wipe side covers with a soft cloth
located along the bottom flange of each
dampened in water and mild detergent.
side cover that needs to be removed.

Note: If removing the side cover near the

stack, first remove the small stack
side cover.

2. With the help of an assistant, lift the

cover away from the cutter.

68 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Operator Console

Operator Console Clean

The operator console runs the entire GT 1. Clean the screen with an anti-static
3250. It includes a PC, monitor, keyboard glass cleaner and a clean, soft cloth.
and trackball.
Keyboard and Trackball
Monitor The keyboard is a device with keys, like those
The monitor is a television-like device that lets on a typewriter, that lets you enter data and
you communicate with the GT 3250. communicate with the operator console. The
It displays the commands you enter and the trackball allows you to make selections on the
messages the operator console sends. screen and communicate with the C-200MT
program.
Required Tools and Supplies
Item Gerber P/N Inspect
1. Inspect the keyboard and trackball for
anti-static glass cleaner N/A
dirt buildup. Clean these surfaces, if
mild detergent N/A needed.
clean, soft cloth N/A
Clean
Inspect 1. Clean the keyboard and trackball with
1. Inspect the screen for dust and smudges. clean, soft cloth dampened with water
Clean the screen, if needed. and detergent.

MONITOR

TRACKBALL
KEYBOARD

GT 3250 System Service Manual Preventive Maintenance 69

Cutting Table Maintenance / Take-On Ramp

Take-On Ramp Install

The take-on ramp is a smooth, flat piece of 1. Place the take-on ramp onto the cutting
stainless steel at the take-on end of the cutting table. Make sure you align the screw
table. This lets you easily load material for cut- holes on the ramp with those on the
ting onto the conveyor. cutting table.

2. Install the screws that fasten the take-on

Required Tools and Supplies
ramp to the cutting table.
Item Gerber P/N
metric T-handle hex key set 945500089 3. Turn on the C-200 controller.

Remove
1. Turn off the C-200 controller.

2. Remove the screws that fasten the

take-on ramp to the cutting table.

3. Lift the take-on ramp off the cutting

table.

SCREW

TAKE-ON
RAMP

70 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Conveyor

Conveyor Inspect
The conveyor is a moving work surface for cut- 1. Turn on the C-200 controller.
ting material. Proper cleaning and lubrication
are vital for maintaining cut quality. 2. Run the C-200MT program.

NOTE: You must run the C-200MT program

BRISTLE SQUARES so you can jog the conveyor.
The BRISTLE SQUARES form the con- Jogging moves hidden parts of the
veyor’s work surface. They are plastic conveyor into view.
squares with bristles on the top side and a
perforated base on the bottom. The BRISTLE 3. Inspect the BRISTLE SQUARES for
SQUARES are installed in aluminum slats lint, broken bristles, and other cutting
linked by the conveyor chain to form the debris. Clean them, as needed
conveyor. BRISTLE SQUARES last longer if (page 72).
you clean and rearrange them regularly.
Rearrange means to move the BRISTLE 4. Inspect the BRISTLE SQUARES for
SQUARES to different places within each signs of uneven wear, such as scarring
slat to spread wear evenly. or creasing of the bristle. Rearrange
them, if necessary (page 74).

Required Tools and Supplies

Item Gerber P/N
blue 4-inch BRISTLE SQUARE 096386001 BARRIER STRIP
BRISTLE
white 4-inch BRISTLE 096386002 SQUARE
SQUARE
SLAT
metric T-handle hex keys 945500089
shop vacuum cleaner N/A
slotted screwdriver 944211601
table air filter 460500110

GT 3250 System Service Manual Preventive Maintenance 71

Cutting Table Maintenance / BRISTLE SQUARES

Clean 5. Turn on the C-200 controller.

The optional automatic bristle cleaner or
optional manual bristle cleaner are each 6. Run the C-200MT program.
designed to clean the BRISTLE SQUARES
on your GT 3250. 7. Initialize the cutting table.

8. Turn on table vacuum. (Press F9 on the

1. Inspect the table air filters. Clean them,
operator console or turn the VAC switch
if necessary (page 86).
on the BCP to ON.)
2. If your system does not have the
9. Move the the cleaning nozzle over the
optional automatic bristle cleaner,
work surface to clean the BRISTLE
connect the 14-ft vacuum hose to the
SQUARES.
vacuum port.
10. Jog the conveyor as needed to clean all
OR
the BRISTLE SQUARES.
3. If your system has the optional 11. When you finish, turn off table vacuum.
automatic bristle cleaner, connect the
14-ft vacuum hose to the lower 12. Inspect the table air filters. Clean them,
vacuum port. if necessary (page 86).

NOTE: There is only one port on systems 13. Disconnect the 14-ft vacuum hose from
that do not have an optional the port.
automatic bristle cleaner. It is the
same as the lower port on the
automatic systems. It leads to the
14. Remove the cleaning nozzle from the
vacuum generator and produces 14-ft hose.
suction.
15. Exit the C-200MT program.
4. Install the cleaning nozzle onto the 14-ft
vacuum hose. 16. Turn off the C-200 controller.

14-FT VACUUM HOSE CLEANING NOZZLE

VACUUM PORTS
CUTTING TABLE

72 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Automatic Bristle Cleaner

Automatic Bristle Cleaner 7. From the Utilities menu, select Bristle

Cleaner (see C-200MT Software User’s
NOTE: Some systems with the automatic
BRISTLE cleaner use an external Guide or C-200MT online help).
canister to collect debris. You can
replace this canister with the new air The Bristle Cleaner dialog box displays.
filters (Gerber P/N 460500110) and
the 30-in. vacuum hose (Gerber P/N 8. If desired, click to select one or more of
548500111).
the Upon Completion options. Click the
Start button.
1. Inspect the air filters. Clean them, if
necessary (page 86).
9. When finished, click OK or press
ENTER.
2. Connect the 30-in. vacuum hose
between both vacuum ports. This routes
10. Turn off table vacuum, if this option
vacuum from the vacuum generator to
was not selected in step 8.
the automatic bristle cleaner.
11. Inspect the table air filters. Clean them,
3. Turn on the C-200 controller.
if necessary (page 86).
4. Run the C-200MT program.
12. Remove the 30-inch vacuum hose.
5. Initialize the cutting table.
13. Exit the C-200MT program, if not
selected in step 8.
6. At the operator console, press F9 to turn
on the vacuum generator.
14. Turn off the C-200 controller.

PORTS

CUTTING TABLE
30-IN. VACUUM
HOSE

GT 3250 System Service Manual Preventive Maintenance 73

Cutting Table Maintenance / Automatic Bristle Cleaner

Rearrange WARNING! Turn off the C-200 controller

before removing any BRISTLE squares. This
Rearrange the BRISTLE SQUARES to en-
prevents the conveyor from being jogged
sure even wear. accidentally. Failure to do this may cause
severe injury to yourself and/or damage to
NOTE: Move the BRISTLE SQUARES with the equipment.
the most wear to the area of the slat
that gets the least wear. 6. Turn off the C-200 controller.

1. Turn on the C-200 controller. NOTE: Remove the BRISTLE SQUARE at the
left end of the slat first.
2. Run the C-200MT program.
7. First remove the BRISTLE SQUARE
NOTE: You must run the C-200MT program from the left end of the slat.
so you can jog the conveyor.
Jogging moves hidden parts of the a. Insert the tip of a slotted screwdriver
conveyor into view. between the slat and the BRISTLE
SQUARE.
3. Remove the take-on ramp (page 70).
b. Work the BRISTLE SQUARE loose
4. Choose one slat to work on. by rotating the tip of the screwdriver.
c. When the BRISTLE SQUARE is
5. Jog the conveyor until the slat that you
loose, pull it away from the slat.
want to work on is 1⁄3 the way around
the end of the conveyor. You need a
space between the slat you want to work
on and the neighboring slats.

BRISTLE SQUARE

74 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Automatic Bristle Cleaner

8. Loosen the bristle block stop. The 10. Determine where you want to install
bristle block stop is located under the each BRISTLE SQUARE.
BRISTLE SQUARE at the left end of
the slat. NOTE: Make sure you move the BRISTLE
SQUARES with the most wear to a
BRISTLE
BLOCK STOP part of the slat that gets the least
wear.

11. In one slat, install all the BRISTLE

SQUARES to the right of the bristle
block stop.

a. Align each BRISTLE SQUARE

horizontally on the slat.
b. There are four clips on the back of
the BRISTLE SQUARE that fit into
two slots on the slat. Push the
9. Remove additional BRISTLE BRISTLE SQUARE firmly onto the
SQUARES from the same slat. slat with the palm of your hand. This
sets the BRISTLE SQUARE in the
a. Slide the BRISTLE SQUARES slat.
along the slat so there is a space next c. Push down on each corner of the
to the one that you want to BRISTLE SQUARE to make sure
remove. that each of the four clips is secure.
b. Insert the blade of a screwdriver
under the BRISTLE SQUARE. NOTE: When the BRISTLE SQUARES are
installed correctly, they will be flat
c. Use the screwdriver as a lever to pry and flush with the rest of the
the BRISTLE SQUARE out of the BRISTLE SQUARES on the work
slat. surface.

d. Repeat steps a through c for each 12. Tighten the bristle block stop.
BRISTLE SQUARE that you want
to remove. a. Slide the bristle block stop towards
the take-on end until it stops.
BRISTLE SQUARE b. Tighten the bristle block stop.

13. Install the bristle block at the left end of

the slat.

14. Repeat steps 11 through 13 until you

have installed BRISTLE SQUARES in
all of the slats

GT 3250 System Service Manual Preventive Maintenance 75

Cutting Table Maintenance / Slats

Slats 4. Stand at the take-on end of the cutting

The slats are aluminum trays that hold the table. From here, you can see the edges
BRISTLE SQUARES. The slats are linked of the slats as they come from under the
by the conveyor chain to form the conveyor. table.
Each slat has several seals that must be kept
in good condition to maintain vacuum during 5. Inspect the slat edges for:
cutting. These seals are the barrier strip,
• loose, torn, or crushed foam blocks
tongue, and groove.
• loose or torn barrier strips
Required Tools and Supplies
Item Gerber P/N • dented, gouged, or bent tongue
3⁄8-in. drive socket set (metric) 945500090
• dented, gouged, or bent groove
3⁄8-in. drive socket set (metric) 945500092
6. If you see any of these defects, mark the
slotted screwdriver 944211601
problem slat with a piece of masking
tape. This will help identify
Inspect the problem slat later.
1. Remove the take-on ramp (page 70).
7. Jog the conveyor so the next set of
2. Turn on the C-200 controller. edges comes into view.

3. Run the C-200MT program. 8. Repeat steps 4 through 7 until you have
checked all of the slats. If you find any
defects, repair or replace the part(s)
NOTE: You must run the C-200MT program
so you can jog the conveyor. causing the problem.
Jogging moves hidden parts of the
conveyor into view. 9. Turn off the C-200 controller.

10. Install the take-on ramp (page 70).

BRISTLE SQUARE
BARRIER
STRIP

SLAT

TONGUE
GROOVE

76 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Slats

Remove 5. Jog the conveyor until the slat that you

CAUTION: Do not jog the table if more than want to work on is 1⁄3 the way around
three adjacent slats are the end of the conveyor. You need a
removed. If you need to jog the space between the slat you want to work
table, install every other slat and
torque the mounting bolts to 677
on and the neighboring slats.
Nmm (6 in.lbs). Failure to install
every other slat may damage WARNING! Turn off the C-200 controller
the conveyor and conveyor before removing any BRISTLE SQUARES or
chain. slats. This prevents the conveyor from being
jogged accidentally. Failure to turn off the
C-200 controller may cause severe injury to
yourself and/or damage to the equipment.
1. Remove the take-on ramp (page 70).
6. Exit the C-200MT program.
2. Turn on the C-200 controller.

3. Run the C-200MT program.

4. Choose the slat that you want to remove.

SLAT MOUNTING BOLTS

ENDCAP
SLAT

PRECISION
SPACER

CONVEYOR CHAIN

GT 3250 System Service Manual Preventive Maintenance 77

Cutting Table Maintenance / Slats

7. Turn off the C-200 controller. NOTE: Some systems use precision spacers
to position the slats. On some of
8. Remove the BRISTLE SQUARE from these systems, the precision spacers
are between the conveyor and the
each end of the slat (page 74). bottom of the end cap. On other
systems, precision spacers are
9. Remove the two slat mounting bolts between the bottom of the slat and
from each end of the slat. The slat the endcap.
mounting bolts fasten the slat and the
endcap to the conveyor chain. 10. Lift the slat from the cutting table.

CAUTION: Look for precision spacers that 11. Lift the end caps from the table.
have become loose. If you find
any, save them and reinstall
them when you install the slat.
Failure to install precision
spacers in the correct place can
damage the conveyor and/or
cause inaccurate cutting.

SLAT MOUNTING BOLTS

ENDCAP
SLAT

PRECISION
SPACER

CONVEYOR CHAIN

78 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Slats

Slats 7. Replace precision spacers (if any) that

(Cont’d.) were dislodged when you removed
the slat.

Install CAUTION: Never install a slat without its

CAUTION: Do not jog the table if more than precision spacers. Never install
three adjacent slats are damaged precision spacers.
removed. If you need to jog the Failure to install the correct
table, install every other slat and precision spacers in the correct
torque the mounting bolts to place can damage the conveyor
677Nmm (6 in.lbs). Failure to and/or cause inaccurate cutting.
install every other slat may If you lose or find damaged
damage the conveyor and precision spacers, have them
conveyor chain. replaced by a Gerber qualified
technician.
1. Turn on the C-200 controller.
NOTE: Some systems use precision spacers
2. Run the C-200MT program. to position the slats. On some of
these systems, the precision spacers
are between the conveyor and the
3. Choose the place where you want to bottom of the end cap. On other
install a slat. systems, precision spacers are
between the bottom of slat and the
4. Jog the conveyor until the place for the endcap.
slat is 1⁄3 the way around the end of the
conveyor. 8. Put the endcap with the slotted bolt
holes on the conveyor at the left side of
5. Exit the C-200MT program. the table.

6. Turn off the C-200 controller. 9. Put the endcap with the round bolt holes
on the conveyor at the right side of the
WARNING! Turn off the C-200 controller table.
before installing any slats. This prevents the
conveyor from being jogged accidentally. 10. Align the bolt holes in the endcaps with
Failure to turn off the C-200 controller may the bolt holes in the conveyor.
cause severe injury to yourself and/or dam-
age to the equipment.
11. Put the slat onto the endcaps. Align the
bolt holes in the slat with those in the
endcaps and conveyor.
SLAT MOUNTING BOLTS

ENDCAP
SLAT

PRECISION
SPACER

CONVEYOR CHAIN

GT 3250 System Service Manual Preventive Maintenance 79

Cutting Table Maintenance / Slats

12. Put the four slat mounting bolts into the 22. Turn on the C-200 controller.
bolt holes. Each bolt should go through
bolt holes in the slat, end cap, and 23. Run the C-200MT program.
conveyor chains.
24. Advance the conveyor to expose other
13. With your hand, turn each bolt slats that need to be tightened.
clockwise to thread it part of the way
into its bolt hole. 25. Exit the C-200MT program.

14. Gently push the left end cap towards the 26. Turn off the C-200 controller.
middle of the slat until it is aligned with
neighboring end caps. 27. Repeat steps 21 through 26 until you
have tightened all the slats.
15. With a torque wrench, tighten each slat
mounting bolt to 677 Nmm (6 in.lbs). 28. Turn on the C-200 controller.

16. Repeat steps 1 through 15 for each slat 29. Run the C-200MT program.
that you need to install.
30. Slowly jog the conveyor through two
17. Jog the conveyor through two complete revolutions and make sure that all
revolutions. endcaps and slats align.

18. Exit the C-200MT program. CAUTION: If any slats or endcaps are
misaligned, you must remove
and reinstall them. Failure to do
19. Turn off the C-200 controller. so can damage the conveyor
and/or cause inaccurate cutting.
20. On all exposed slats, torque all slat
mounting bolts to between 17.6 and 31. Exit the C-200MT program.
20.3 Nm (13 and 15 ft.lbs).
32. Turn off the C-200 controller.
21. Install BRISTLE SQUARES in both
ends of the slat (page 74). 33. Install the take-on ramp (page 70).

SLAT MOUNTING BOLTS

ENDCAP
SLAT
PRECISION
SPACER

CONVEYOR CHAIN

80 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Drive Assembly

Drive Assembly 3. Check the oil level in the gearbox.

The drive assembly turns the conveyor. It is
at the take-off end on the operator side of the a. Remove the fill plug. The oil should
cutting table. be up to the bottom of the fill hole.
b. If necessary, fill the gearbox with
Required Tools and Supplies SAE 90 weight oil.
Item Gerber P/N c. Install the fill plug.
grease gun 944233101
4. Install side covers 3 and 4
shop rag N/A (page 68).
SAE 90 transmission oil N/A
5. Turn on the C-200 controller.

Lubricate
1. Turn off the C-200 controller.

2. Remove side covers 3 and 4

(page 68).

DRIVE ASSEMBLY

FILL PLUG

GT 3250 System Service Manual Preventive Maintenance 81

Cutting Table Maintenance / Drive Chains

Drive Chains 3. Find the drive chains.

The slats are bolted to two drive chains to
form the conveyor. One drive chain runs 4. Using the shop rag, clean lint and other
under each side of the conveyor. The drive debris from the chain.
chain on the operator side connects the
conveyor to the drive assembly. 5. Lubricate the chain lightly with
multipurpose grease.

Required Tools and Supplies CAUTION: To avoid damage to material,

Item Gerber P/N do not over grease. Moving
equipment throws excess
grease gun 944233101 lubricant.
multipurpose grease 596500005
6. Install all side panels (page 68).
shop rag N/A
7. Turn on the C-200 controller.
Lubricate
1. Turn off the C-200 controller.

2. Remove all side panels (page 68).

DRIVE CHAIN

82 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / MCC Air Filter

C-200 Controller Inspect

WARNING! Before working in the C-200
controller electrics enclosure, turn off the
The C-200 controller is the command C-200 controller by using circuit breaker 1.
center of the GT 3250. Using C-200MT This turns off power to the controller elec-
trics enclosure. Failure to turn off the C-200
software, the C-200 controller tells the controller may result in injury or death and
system how to cut material. The C-200 con- damage to the C-200 controller.
troller has two parts: the Front End Processor
(FEP) and the Motion Control Computer 1. Turn off the C-200 controller.
(MCC). The FEP, or PC, is located in the op-
erator console. The MCC is located in the 2. Open the C-200 controller electrics
C-200 controller electrics enclosure. enclosure.

WARNING! Do not open or work in the

vacuum electrics enclosure which is located
MCC Air Filter to the left of the C-200 controller enclosure.
Circuit breaker 1 does not turn off all power
to the vacuum electrics enclosure. High volt-
The MCC is cooled by air that flows through ages exist inside this enclosure. These volt-
a filter and into the controller electrics enclo- ages can cause injury and death.
sure. You must keep this filter clean and free
from lint. If this filter is clogged, air flow 3. Inspect the filter for built-up lint. Clean
over the MCC is reduced and the MCC may it, if necessary.
overheat.
4. Close the controller electrics enclosure.
Required Tools and Supplies 5. Turn on the C-200 controller.
Item Gerber P/N
MCC air filter 460500106
shop vacuum cleaner N/A

MCC AIR FILTER

GT 3250 System Service Manual Preventive Maintenance 83

Cutting Table Maintenance / MCC Air Filter

Clean 3. Inspect the filter for built-up lint. Clean

WARNING! Before working in the C-200 it, if necessary.
controller electrics enclosure, turn off the
C-200 controller by using circuit breaker 1. 4. Remove the dirty MCC air filter:
This turns off power to the controller elec-
trics enclosure. Failure to turn off the C-200 a. Slide the filter up.
controller may result in injury or death and
damage to the C-200 controller. b. Pull the bottom of the filter out of its
bracket.
1. Turn off the C-200 controller.
c. Slide the filter down to remove it
2. Open the C-200 controller electrics completely from the bracket.
enclosure.
5. Vacuum the filter to remove any lint.
WARNING! Do not open or work in the
vacuum electrics enclosure which is located MCC AIR FILTER
to the left of the C-200 controller enclosure.
Circuit breaker 1 does not turn off all power
to the vacuum electrics enclosure. High
voltages exist inside this enclosure. These
voltages can cause injury and death.

MCC AIR FILTER

NOTE: If the filter is so plugged that you

cannot clean it effectively, install a
new filter.

84 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / MCC Air Filter

6. Install the clean MCC air filter. 7. Close the controller electrics enclosure.

a. Slide the filter up into the top of its 8. Turn on the C-200 controller.
bracket.
b. Put the bottom of the filter flat
against the side of the controller MCC AIR FILTER
electrics enclosure.
c. Slide the filter down to seat it
completely in the bracket.

MCC AIR FILTER

GT 3250 System Service Manual Preventive Maintenance 85

Cutting Table Maintenance / Table Air Filter

Table Air Filter Inspect

GT 3250 GERBERcutters have two 1. Turn off the C-200 controller.
high-efficiency air filters to improve air flow.
If they get clogged, air pressure drops. The 2. Pull the filter access door down and
manual and optional automatic bristle clean- then lift out.
ers also use these filters to collect debris.
3. Remove the filters by sliding them out.
Required Tools and Supplies 4. Inspect the filters and compartment for
Item Gerber P/N built-up lint. Clean them, if necessary.
air filter 460500110
5. Install the filters by sliding them into
shop vacuum cleaner N/A the compartment until they stop.

WARNING! Avoid breathing lint from the 6. Replace and close the filter access door.
filters. Wear a mask suitable for this purpose.
7. Turn on the C-200 controller.

FILTER ACCESS
DOOR

86 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Table Air Filter

Clean NOTE: The filter may become so plugged

that you cannot clean it effectively.
1. Turn off the C-200 controller. If this happens, install a new filter.

2. Pull the filter access door down and 5. Vacuum inside of the filter compartment
then lift out. to remove lint.
3. Remove the filters by sliding them 6. Install the filters by sliding them into
straight out. the compartment until they stop.
CAUTION: Never use the optional manual 7. Replace and close the filter access door.
bristle cleaner to vacuum the air
filters. The optional manual
bristle cleaner uses these filters 8. Turn on the C-200 controller.
to collect debris.

4. Vacuum both filters to remove heavy

lint.

GT 3250 System Service Manual Preventive Maintenance 87

Cutting Table Maintenance / Mast

Mast Inspect
The mast is a metal pole mounted on the right 1. Turn off the C-200 controller.
side of the cutting table. It provides a conven-
ient attachment point for the cutting table’s elec- 2. Check the electrical and compressed air
trical and compressed air lines. On traveling lines where they enter the mast. They
tables, the mast houses a warning light that should be free of cuts, tears, and chafing.
flashes when the cutting table moves.
3. If you see any of these defects, have
them repaired or replaced by a Gerber
Electrical and Air Lines qualified technician.
These lines provide the GT 3250 with power
and compressed air. On traveling tables, you 4. Turn on the C-200 controller.
should check them regularly for wear.

Required Tools and Supplies

Item Gerber P/N
stool or short ladder N/A

MAST

88 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Warning Light

Warning Light NOTE: Traveling tables do not move unless

the C-200MT program is running.
The warning light is a safety device which
flashes to let you know that a traveling table 3. At the take-on end of the cutter, use the
is moving. TABLE MOVE control to move the
table a short distance in FORWARD.
Required Tools and Supplies The warning light should flash.
Item Gerber P/N
4. Using the TABLE MOVE control, move
stool or short ladder N/A the table a short distance in REVERSE.
The warning light should flash.
Inspect
5. If the warning light does not flash, have
1. Turn on the C-200 controller. it repaired by a Gerber qualified
technician.
2. Run the C-200MT program.

WARNING
LIGHT

GT 3250 System Service Manual Preventive Maintenance 89

Cutting Table Maintenance / Film Dispenser

Film Dispenser WARNING! You will need the

The film dispenser holds a roll of plastic assistance of one person for this procedure.
Failure to do this may cause severe injury to
film. You use the plastic to seal the lay for yourself and/or damage the equipment.
proper vacuum during cutting.

Remove
Plastic Film Roll
1. With an assistant, lift the mandrel
The roll holds the plastic film. Replace it
assembly and film roll off the roll
when the film is used up.
supports.

Required Tools and Supplies 2. Loosen the clamp screw on the left flange.
Item Gerber P/N
3. Slide the flange off the assembly.
plastic film roll 644500120
metric T-handle hex keys 945500089 4. Slide the roll off the mandrel assembly.

PLASTIC
FILM ROLL
CLAMP FLANGE
SCREW
COLLARS

ROLL
SUPPORT

MANDREL
ASSEMBLY

DANCER BAR

LEFT SIDE RIGHT SIDE

90 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Film Dispenser

Install WARNING! Improper installation may

1. Slide the roll onto the mandrel cause the mandrel to slide out of the roll
supports. This could injure people or dam-
assembly. age equipment.

NOTE: Make sure the leading edge of the 5. Thread the film through the dispenser.
film faces the take-off end of the
table.

2. Slide the left flange onto the mandrel

assembly.

3. Tighten the clamp screw on the flange.

4. Lower the mandrel assembly onto the

supports. The collars must fit either side
of the idlers on the right side of the
table.

FILM PATH

TAKE-ON END TAKE-OFF END

GT 3250 System Service Manual Preventive Maintenance 91

Cutting Table Maintenance / Resealer

Resealer Plastic Film

The optional resealer attaches to the take-off The plastic film reseals the cut part of the lay
end of the cutting table and the beam. It as the GT 3250 processes a cut file.
stretches a sheet of plastic film over the work
surface during cutting. This plastic film covers Required Tools and Supplies
and reseals the cut part of the lay to maintain
vacuum. Item Gerber P/N
crescent wrench N/A
The plastic film is attached to two spring- plastic film 644500021
loaded rollers, the table and beam rollers, that
each work like a window shade. When the metric right-angle hex key set 945500079
beam moves toward the take-on end, the roll- two-sided tape N/A
ers let out plastic film. When the beam moves
toward the take-off end, the rollers take up
the plastic film.

BEAM ROLLER

TABLE
ROLLER
PLASTIC FILM

92 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Resealer

Inspect Remove
1. Turn on the C-200 controller. 1. Turn on the C-200 controller.

2. Run the C-200MT program. 2. Run the C-200MT program.

3. Manually slew the beam to the take-on 3. Manually slew the beam to the take-off
end of the cutting table. This unrolls the end of the cutting table. This rolls the
plastic film on the resealer. plastic film onto the beam and table
rollers.
4. Inspect the plastic film for tears, cracks,
cuts, and brittle areas. Replace the 4. Exit the C-200MT program.
plastic film, if necessary.
5. Turn off the C-200 controller.
5. Exit the C-200MT program.
6. At the table roller, shown below, unlock
6. Turn off the C-200 controller. the left shaft. This lets the rubber spring
unwind inside the roller.

a. Loosen the set screw in the side of

the clamp.
b. The rubber spring unwinds. At the
same time, the beam roller takes up
some of the plastic film on the table
roller.

7. Unroll the plastic film from the table

roller.

ROLL BAR
OPERATOR SIDE

TABLE ROLLER

SET
SCREW TWO-SIDED
TAPE

GT 3250 System Service Manual Preventive Maintenance 93

Cutting Table Maintenance / Resealer

8. At the table roller, peel off the end of 11. Unroll the plastic film from the beam
the plastic film. It is fastened with roller.
two-sided tape. Remove any adhesive
remaining on the roller. 12. Peel the end of the plastic film off the
beam roller. It is fastened with
9. At the beam roller, shown below, use a two-sided tape. Remove any adhesive
pencil to draw a line on the trailing arm remaining on the roller.
that marks the position of the beam
roller.

10. Remove the beam roller from the

trailing arms.

a. Remove the snap ring on the end of

each trailing arm. TWO-SIDED
TAPE
b. Remove the outermost screw on the
right side of the beam roller.
Install
c. Loosen the clamp-release on the left
side the beam roller. NOTE: This procedure requires assistance
from a second person.
d. Slide the beam roller off the trailing
arms. 1. At the table roller, fasten one end of the
plastic film to newly installed two-sided
tape.

2. At the beam roller, fasten the other end

CLAMP
CLAMP-RELEASE of the plastic film to newly installed
two-sided tape.

3. Roll half the plastic film onto the table

roller and half onto the beam roller.

TRAILING
ARM

SNAP RING

94 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Resealer

4. Tension the beam roller. c. Slide the beam roller onto the
trailing arms.
a. Have an assistant hold the beam
roller and right shaft so they cannot d. Install the snap rings on the left and
right trailing arms.
turn.
e. Slide the beam roller to align it with
b. Wind the left shaft counterclockwise
the pencil mark on the trailing arm.
14 turns. This tensions the rubber
spring. f. Install and tighten the outermost
screw on the right side of the beam
roller.
14 TURNS g. Tighten the left clamp on the beam
roller.

CLAMP
CLAMP-RELEASE

TRAILING
ARM

SNAP RING

GT 3250 System Service Manual Preventive Maintenance 95

Cutting Table Maintenance / Resealer

5. Tension the table roller.

a. Have an assistant hold the beam

roller and the table roller to keep
them from moving.
b. Use a crescent wrench to wind the
left shaft clockwise 14 turns. This
tensions the rubber spring.
c. Tighten the set screw on the left
clamp.
d. Release the beam and table rollers.

6. Turn on the C-200 controller. 14 TURNS

NOTE: These are initial settings that will

need to be adjusted during use. If the
plastic film tends to accumulate on
the take-off roller, increase the
number of turns on both rollers

96 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Conveyorized Take Off Table

Conveyorized Take Off Table WARNING! The CTOT is heavy. Use two
The optional conveyorized take off table or three people to open the CTOT. Failure to
use the necessary number of people may
(CTOT) attaches to the take-off end of the cause injury.
cutting table. The CTOT helps you more
easily and quickly move material from the 3. Lift the take-off end of the CTOT.
cutting table.
4. Hold the CTOT open.
Required Tools and Supplies
5. Lift the CTOT props into place. The
Item Gerber P/N
CTOT props are two hinged metal
metric combination wrench set 945500093 pieces that hold open the CTOT.
metric T-handle hex key set 945500089
6. Lift the the vacuum assembly cover.
multipurpose grease 596500005
shop rag N/A 7. Attach the hooks to hold open the
vacuum assembly cover.
Open
1. Turn off the C-200 controller.

2. Remove the take-off ramp by removing

the mounting screw(s). CTOT

CTOT PROP
AND HOOK

TAKE-OFF
RAMP

MOUNTING
SCREW(S) VACUUM
COVER
DOOR

GT 3250 System Service Manual Preventive Maintenance 97

Cutting Table Maintenance / Drive Chain

Close Drive Chain

WARNING! The CTOT is heavy. Use two A drive chain, driven by an electric motor,
or three people to close the CTOT. Failure to turns the CTOT. The drive chain is located on
use the necessary number of people may the right side of the CTOT when viewed from
cause injury.
the take-off end of the cutter.
1. Remove the hooks from the vacuum
assembly cover and lower the cover. Lubricate
1. Turn off the C-200 controller.
2. Lift up the CTOT and hold it open.
2. Remove the take-off ramp by removing
3. Lower the CTOT props. The CTOT the two mounting screws.
props are two hinged metal pieces that
hold open the CTOT. 3. Open the CTOT (page 97).
4. Lower the CTOT. CAUTION: To avoid damage to material,
do not use too much grease.
5. Install the take-off ramp by installing Moving equipment throws
the two mounting screws. excess lubricant.

6. Turn on the C-200 controller. 4. Lubricate the drive chain lightly with
multipurpose grease.

DRIVE
CHAIN

98 Preventive Maintenance GT 3250 System Service Manual

 Cutting Table Maintenance / Drive Chain

WARNING! Make sure that personnel CAUTION: To avoid damage to material,

maintain a safe distance from the CTOT and do not use too much grease.
the GERBERcutter while the power is on and Moving equipment throws
the CTOT is moving. Failure to do so can excess lubricant.
result in injury.
8. Lubricate the drive chain lightly with
5. Turn on the C-200 controller. multipurpose grease.

6. Move the CTOT conveyor through 9. Install the take-off ramp by installing
one-half a revolution. the two mounting screws.

7. Turn off the C-200 controller. 10. Turn on the C-200 controller.

GT 3250 System Service Manual Preventive Maintenance 99

Cutting Table Maintenance / Drive Chain

100 Preventive Maintenance GT 3250 System Service Manual

 Troubleshooting
The C-200MT cutter control software provides the following features to assist
you in troubleshooting your GERBERcutter.
· Error messages
· Diagnostics
Additional troubleshooting tools available on CD-ROM:
· GERBERservice Parts lists
· GERBERcutter Application Manual
This chapter briefly explains these features and tells where to find specific
information.

Customer Support
If a problem still exists after troubleshooting, call Gerber Field Service
Engineering for assistance. In North America, call Customer Support
800-321-2448. Outside North America, call your local service office.

Have the following information ready when you call:

· GERBERcutter you are using
· Any special equipment or software you are using, such as the drill,
resealer, or bar code reader option
· Software packages you are using; include the software version numbers
· Equipment number, if available

GT 3250 System Service Manual Troubleshooting 101

 Error Messages
The GERBERcutter displays an error message dialog box when it detects an
error condition. The system numbers these error messages for easy reference.
The first digit of the error number defines the error class. The error classes range
from 1 to 4, with class 1 being the least severe. PreProcessor error messages do
not have an error number.

Error Message Type Error Number Range

Class 1 FEP 1000-1999

Class 1 MCC 1000-1999
Class 2 2000-2999
Class 3 3000-3999
Class 4 4600

For a complete list of errors and solutions, refer to the C-200MT online help.

Diagnostics
Diagnostics are provided in the C-200MT program. These are tools that can be
used by the person in your company who is a Gerber qualified technician to
ensure cutter performance. Diagnostics used for routine maintenance include:
· Input Output Test (DG23)
· KI Calibration (DG 20)
· C Home to System Zero
· Heel to Heel Cut Test
· Beam Square Cut Test
· Knife Offset Setup Cut Test

Note: For detailed information about diagnostics, refer to the C-200MT

Software User’s Guide or C-200MT online help.

102 Troubleshooting GT 3250 System Service Manual

 Service Parts
The GERBERservice CD-ROM provides the latest parts information for your
GERBERcutter. Assembly drawings in exploded view are each provided with an
index that identifies names and part numbers. Drawings are grouped by
GERBERcutter model. Categories within each type are Head, Beam, Electrical,
and Installation. There is also a listing for all GERBERcutters of consumables
(spare parts), such as drill bits, knife blades, and belts.

For easy access, information is stored in Adobe Acrobat PDF format on the CD.
Features in the Adobe Acrobat reader include:
· Zoom for enlarging drawings
· Search for finding a part by name or number
· Print for printing out assembly drawings or part number lists
Refer to the installation instructions that come with the CD when installing the
Parts documentation and the Adobe Acrobat reader.

Applications
Flexibility within the C-200MT program allows you to set up your
GERBERcutter based on differences in patterns, materials, and types of
manufacture. When your GERBERcutter was first installed, your Field Service
representative or trainer customized setup files for your manufacturing needs at
that time. To achieve optimal cutting performance for a different application
you should:
· Prepare the cut file data for automated cutting. Consider fabric, size of
the pieces, and cutting sequence. See Data Preparation on page 104.
· Select the most appropriate preset setup available in the C-200MT
program. Your selection should be based on fabric hardness, porosity,
tendency to fuse, and ply height. Refer to the C-200MT Software User’s
Guide or C-200MT online help.
· Customize vacuum settings, knife sharpening, and motion control
parameters for this setup. See page 105.
Automated cutting concepts are explained briefly on the next page. For detailed
applications information, refer to the CAM Applications Manual, which is
available on the C-200MT software and GERBERservice CDs.

GT 3250 System Service Manual Troubleshooting 103

 Automated Cutting Concepts
The GERBERcutter is an efficient, computer-aided manufacturing (CAM)
system. Computer aided design (CAD) systems provide instructions in a cut file
to control the cutting system. The GERBERcutter executes those commands.
Parameters in the C-200MT program determine exactly how those commands
are executed.

To improve cutting results consider the following concepts.

Data Preparation
Preparation of data for a GERBERcutter differs from hand cutting in that special
consideration must be given to the pattern pieces and the material being cut. An
operator cutting by hand intuitively compensates for a different fabric or tattered
corners on a pattern piece.

Because the GERBERcutter simply follows CAD instructions, the pattern

maker, digitizer, and marker maker must give consideration to some of the
things mentioned below. Remember, automated cut quality is directly related to
the CAD instructions.

Pattern Pieces — Before pattern pieces are digitized and stored, it is a good idea
to answer the following questions based on the cutting results desired.
· Are slit, V, or both notch types going to be used?
· Is it permissible to miter corners?
· Is there an added buffer on the pattern template to compensate for hand
cutting inaccuracy? If so, is it still needed?
If existing pattern pieces are torn, wrinkled, or frayed, redefine them. Make sure
corners are accurate, crisp, and clean with straight lines and smooth curves.

Digitizing — Always define an accurate grain line. If the grain line is off in
rectangular pieces, the parts will not nest with true common lines.

Marker Making — The marker maker should consider the placement of large
and small pieces. See Vacuum Hold Down on page 105.

104 Troubleshooting GT 3250 System Service Manual

 Vacuum Hold Down
The GERBERcutter relies upon a vacuum system to compress and stabilize the
material to be cut. The size of cut pieces, material porosity, and cutting sequence
affect the performance of the cutting system. You can customize a setup by
changing parameters in the Vacuum Systems category.

Regularly scheduled maintenance of the vacuum system ensures optimum

mechanical performance of the GERBERcutter. For more about Vacuum System
features, see Appendix A.

Knife Sharpening
Material content (i.e. natural or synthetic fibers, coatings, etc.) and ply heights
determine knife sharpening requirements. You can customize a setup by
changing parameters in the Sharpen Parameters category. Refer to the C-200MT
Software User’s Guide or C-200MT online help.

Regularly scheduled maintenance of the sharpener assembly ensures optimum

mechanical performance of the GERBERcutter. See page 49.

Motion Control
Quality requirements, material, and type of manufacture must be considered
when optimizing the performance of the GERBERcutter.

The C-200MT program has a built-in knowledge base and is flexible enough to
meet the needs of Aerospace, Apparel, Automotive, Furniture and many other
industrial applications. For example: if cutting tubular goods, you may want to
use the Clipping Window or Centerline Origin features. If cutting narrow
markers, Marker Stacking may speed throughput. Refer to the C-200MT
Software User’s Guide or C-200MT online help.

GT 3250 System Service Manual Troubleshooting 105

106 Troubleshooting GT 3250 System Service Manual
 Glossary
axis
An imaginary line used to describe movement and location on the cutting table. The GERBERcutter
utilizes three axes: X (parallel to table length), Y (parallel to table width), and C (knife direction).
beam
A support and carrier for the cutter head as it moves across the width and up/down the length of
the table.
beam control panel (BCP)
A terminal at the cutting table that lets you control cutter head and beam assembly activities. The
computer that processes input from the beam control panel is called the BCC.
For specific controls available on the BCP for your cutter, refer to the Operator Controls section of the
Getting Started Manual or Operator’s Manual for your cutter.
bite
A section of a marker that (a) fits on the cutting table and (b) can be cut at one time. Bite feeding
matches cutter head movement with conveyor movement. This permits automatic cutting of a long
spread of material. The spread is cut in sections that fit on the cutting table surface. Each section is
called a bite.
BRISTLE SQUARES
Squares of molded bristle that install into conveyor slats or into a fixed grid. They form a work surface
for cutting material.
C-axis
An imaginary, straight line that the knife rotates about.
Cutter Information Database (CIDB)
An optional C-200MT utility that uses a database to track time relative to cutter operation and to report
this information.
command
Request to perform a function. The request can be entered at a terminal, such as the BCP at the cutting
table or FEP or PC at the operator console. Also, an item you can choose in a C-200MT menu in order
to use a feature in the C-200MT program.
conveyor
Moving work surface made from slats and covered with Gerber BRISTLE SQUARES.
CTOT
The Conveyorized Take-off Table (CTOT) is a device for moving cut pieces off the cutting table
surface. The CTOT is made of plastic links, that move in synch with the conveyor.

GT 3250 System Service Manual Glossary 107

cut file
Computer data file with directions on how particular pieces should be cut from a spread of material by a
GERBERcutter. Also, see marker.
data
Information stored on a disk.
default
A setting that is programmed into the computer at the factory or set by Field Service when the cutter is
first installed. This is used until you, or your supervisor, choose to override it and select another setting.
disk or disc
Medium used for storage of computer data. GERBERcutter systems can use 3.5-inch disks and CD-
ROM discs.
disk drive
A device that lets a computer read and write data on a disk. Your cutter has a hard drive, a 3.5-inch disk
drive, and a CD-ROM disc drive.
drill
An optional unit for making drill holes that attaches to the cutter head.
dry haul
The distance traveled with the knife out of the material.
dry run
To execute a cut file without plunging the knife or drill into the material.
EStop
Red button that can be pressed during an emergency to immediately stop all GERBERcutter motion.
Also, a yellow paddle on the beam that when bumped stops all GERBERcutter motion.
feed rate dial/slider
Control used to set the desired cut speed.
front end processor (FEP)
A computer (PC) in the operator console that relays your commands, cut file data, and setup file data to
the Motion Control Computer (MCC) for processing.
hard disk drive
A device that holds the software that runs the GERBERcutter. A hard disk drive uses rigid metal disks
to store large amounts of data.
You need to manage your hard disk so it does not become too full and disorganized. For information on
managing files on the hard disk, see File Manager in the C-200MT online help for cut file management
or refer to documentation for AccuMark Explorer or Windows NT for data management.

108 Glossary GT 3250 System Service Manual

hardware
Physical elements of a computer, such as the monitor and keyboard.
heel cut
Cut made by the heel of the knife. The heel is the thickest edge (following edge) of the knife blade.
home
Cutting table's (X0,Y0) coordinates.
initialize
To set the cutting table's (X0,Y0) coordinate after downloading the C-200MT software. The system
uses this coordinate as a reference when processing a marker.
Knife Intelligence
Knife IntelligenceÒ (KI) is a GERBERcutter feature that:
· Senses deflection of the knife (lateral force) caused by cutting difficult materials or high ply spreads
· Changes knife angle to compensate for this deflection
Note: KI is not applicable for S-3200, GT 3250, and GTxL GERBERcutter systems.
job queue
A job queue contains multiple markers or cut files to be cut sequentially. Each marker and its
corresponding setup file is called a job. Refer to Queue Manager in the C-200MT online help.
lay
One or more layers of material spread on the cutting table surface for cutting. May also be called a
spread.
limit switch
Sensors that restrict beam travel across and down the length of the cutting table.
marker
A layout of pieces on a spread that provides cutting instructions. This can be created in a grading/
marking system such as AccuMark or MicroMark.
mast
A tower available with lateral drive GERBERcutter systems that holds the overhead power cables, shop
air hoses, and houses a flashing warning light and alarm to alert others when the cutting table is moving.
An exhaust stack for the vacuum system may also be located on the mast.
motion control computer (MCC)
A computer, or controller board, that responds to instructions sent from the front end processor, or PC,
to control cutting table, beam, and head motion.
network
A set of computers connected together. For example, a GERBERcutter may be networked to a CAD
grading and marking system.

GT 3250 System Service Manual Glossary 109

offset
A condition when one item’s location differs relative to another item. For example: stripe and plaid
lines on fabric are offset by a certain distance.
operator console
The location on the GERBERcutter where the C-200MT program is accessed and marker processing is
initiated. The operator console includes a monitor, keyboard, and computer with a hard drive, disk
drive, and CD-ROM disc drive. See also Front End Processor FEP.
OpStop
A command in a cut file that causes the cutter to stop processing while the operator checks matching
points and slews the cutting head as necessary.
origin
The “start” position (X0,Y0) of a marker on the table. This is set at the corner of the marker closest to
the take-off end on the side of the cutting table where the operator console is located.
parameter
A setting defined in the setup file.
Path Intelligence
Path Intelligence (PI) completely or partially controls cut speed using built-in application knowledge
and by measuring one or more of the following:
· Knife sharpness
· Vacuum level
· XY force
Use commands in the Diagnostics/ Path Intelligence menu to ensure that the GERBERcutter is running
properly.
program
A set of instructions that allows a computer to interact with people or equipment. The programs that
direct a computer are called software.
remote side
The side of the cutter opposite of the beam control panel.
right side
The right side of the cutting table as seen from the take-on end. For cutters with the RSO option, the
beam control panel is located on this side of the cutter.
servo motor
An electric motor used to move the beam along the X-axis or the cutter head along the beam in the
Y-axis of the cutting table.
setup
A setup is a file containing parameters that enable or disable various features, options, and modes
depending on such considerations as ply height, material characteristics, or marker width.

110 Glossary GT 3250 System Service Manual

software
Set of computer programs used to run the GERBERcutter and communicate with you. These include
the C-200MT program and Windows NT.
spread
One or more layers of material spread on the cutting table surface for cutting. May also be called a lay.
stack
A pipe, mounted vertically, that vents vacuum exhaust away from the GERBERcutter. This is usually
mounted on the mast.
take-off end
The end of the cutting table where cut pieces and scrap material leaves after being cut.
take-on end
The end of the cutting table where material spread for cutting is loaded on from the spreading table.
utility
A program that helps you operate the cutter, such as Queue Manager, Preprocessor, or View Marker.
X-axis
A horizontal reference line in a coordinate system. For the GERBERcutter, the X-axis runs the length of
the table from the take-on end to the take-off end.
Y-axis
A vertical reference line in a coordinate system. For the GERBERcutter, the Y-axis runs the width of
the table from the left side to the right side.
zone (vacuum)
An area of the cutting table separated from other areas. Baffles divide a cutting table with this feature
into five or six zones. Vacuum can be applied to one or more zones at a time depending on parameter
settings.

GT 3250 System Service Manual Glossary 111

112 Glossary GT 3250 System Service Manual
Appendix A
Vacuum Features
This chapter describes each of the three optional vacuum features for the
GT 3250 GERBERcutter. For more information on using these features refer
to the C-200MT Software User’s Guide or the C-200MT online help.

How Vacuum Works

The vacuum generator plays a critical part in the cutting process. It makes a
vacuum that holds the material firmly on the work surface during cutting.
The vacuum generator is under the take-off end of the cutting table. The vac-
uum generator draws air through the BRISTLE SQUARES and down
through the conveyor slats. The air goes through a manifold and a filter, into
the vacuum generator, and out the silencer in the exhaust stack (see below).

SLAT WITH EXHAUST STACK

BRISTLE SQUARES

CUTTER HEAD SILENCER

BUTTERFLY

VACUUM
GENERATOR
FILTER MANIFOLD

DUCT

GT 3250 STANDARD-LENGTH

GT 3250 System Service Manual Appendix A - Vacuum Features 113

 There are three available GT 3250 GERBERcutter vacuum features that let
you control where and when vacuum is applied. You can use one, two, or all
of these features, in various combinations. If more than one feature is turned
on, they act interrelatedly.

To use these vacuum features, turn on the option and set up certain parame-
ters in the setup (configuration) file. You can temporarily enable/disable two
of the features. The table below summarizes this information.

See GT Series GERBERcutters Getting Started Manual for information

about setups, parameters, and Parameter Manager.

Note: Information in the following sections is generic. For more

information on specific cutting applications, see the
GERBERcutter Application Manual available on the Gerber
Service CD.

GT 3250 Vacuum Features

Feature Name What It Controls Category/Parameters

Vacuum Zoning Where vacuum is Vacuum System
(optional) applied
Energy Saving Mode When vacuum is Options & Modes/
applied Energy Saving Mode
Time Until ESM
Cut Path Intelligence Feedrate if vacuum is Path Intelligence
Vacuum Feature at caution level
(optional)

114 Appendix A - Vacuum Features GT 3250 System Service Manual

Vacuum Zoning
The optional vacuum zoning feature improves cut quality and lowers power
use. This feature applies vacuum where it is needed most ---- the area being
cut. In zoned vacuum, the cutting table is divided into five zones (six zones
on optional long tables). Each zone receives vacuum from a duct that can be
opened or closed automatically with a butterfly valve. Each butterfly valve is
closed unless the cutter head is in its zone. When the cutter head enters a
zone, the butterfly valve opens, applying vacuum to the area being cut.

CUTTER HEAD

BUTTERFLY

VACUUM
GENERATOR

DUCT

GT 3250 STANDARD-LENGTH

Cutting Table Air Flow with Vacuum Zoning

If you turn off (disable) vacuum zoning, the GT 3250 applies vacuum to the
entire cutting table surface. You may want to disable vacuum zoning if you
need consistent vacuum to prevent slippage. For example, you may want to
disable zoning when cutting high-ply spreads of slippery material.

The GT 3250 applies vacuum in one to three zones at a time: the zone in
which the cutter head is currently cutting and one or two ‘‘look-ahead’’ zones.
The purpose of the look-ahead zones is to ensure consistent vacuum during
cutting.

The GT 3250 calculates look-ahead zones in several different ways.

The example on the next page illustrates these methods.

GT 3250 System Service Manual Appendix A - Vacuum Features 115

 Look-Ahead Zones. When the GT 3250 looks at the marker and sees
that the cutter head will be in the next zone within a certain period of time
(about 0.25 seconds), the GT 3250 applies vacuum to that zone. For example
shown below, when the system cuts Piece 2, it will turn on vacuum to both
Zones 1 and 2.

When the GT 3250 looks at the marker and sees that the cutter will be
zigzagging between the same two zones, it will apply vacuum to both zones
instead of continually turning them on and off. Again in the example, when
the system is cutting Piece 5, it will apply vacuum to both Zones 1 and 2.

When the cutter head is cutting a piece close to the next zone, it will apply
vacuum to that zone. It does this even though it will not be moving into the
next zone. Again in the example, when the system is cutting Piece 8, it will
apply vacuum to both Zones 2 and 3 even though the cutter head will not cut
in Zone 3.

Marker with Look-Ahead Zones

116 Appendix A - Vacuum Features GT 3250 System Service Manual

Energy Saving Mode
The energy saving mode (ESM) greatly reduces table vacuum when the
GT 3250 is idle for a certain period of time. The system displays a warning
message on the operator screen thirty seconds before ESM goes into effect.

ESM reduces energy consumption in two ways. First, since ESM

automatically sets vacuum requirements, the operator does not need to
remember when to lower vacuum to the table. Secondly, ESM reduces
vacuum without turning off the vacuum generator. Instead, it opens and
closes the vacuum zone valves. This method uses less energy than turning
the motor on and off.

ESM goes into effect when these three conditions are met:

• the vacuum generator is on

• no marker is being processed
• the beam, head, and conveyor are idle for a certain period of time
(defined in Parameter Manager)

Low Vacuum Messages

The GT 3250 has two messages which indicate vacuum is too low for cutting:

• The Vacuum Low Caution message warns you that vacuum is

dangerously low. If you have Cut Path Intelligence (CPI) low vacuum
feature turned on when the vacuum is at caution level, the feedrate for
the marker slows by a configurable amount. If this CPI feature is not
turned on, you must either increase vacuum or stop cutting.
• The Vacuum Low Error message causes the cutter to stop cutting
until proper vacuum is resumed.

Cut Path Intelligence Vacuum Feature

The optional Cut Path Intelligence (CPI) vacuum feature slows the feedrate
for your marker if table vacuum is at caution level. To use this feature,
you must first set the Vacuum Low Caution Level parameter using
Parameter Manager.

GT 3250 System Service Manual Appendix A - Vacuum Features 117

118 Appendix A - Vacuum Features GT 3250 System Service Manual
Index
cutting table, 65
A racks, 66 O
side covers, 67
Air Filters operator console, 69
table air filter, 86
table, 86
MCC, 83
D P
parts
B diagnostics, 102
spare 9, 103
drill, 57
beam, 21 plastic film
drill bit, 62
alignment, 22 film dispenser, 90
drill drive belt, 60
BCP cover, 33 resealer, 92
maintenance, 58
cables, 32 presser foot, 48
cutter head drive belt, 26 pulley, 50
flatway, 25 E
remote-end cover, 34
roundway, 24 elevator roundways, 52 R
X-axis drive belts, 28 error messages, 102
racks, 66
Y-axis drive belts, 30 roundway
bristle cleaner, 73 beam, 24
F
BRISTLE SQUARES, 71 elevator, 52
cleaning, 72 film dispenser, 90 resealer, 92
maintenance, 74 flatway, 25

S
C G
safety precautions, v, 7
cables, 32 grinding pulley, 50 schedules, 11
C-200 controller, 83 See Also Sharpener Assembly servomotors, 29, 31
MCC air filter, 83 sharpener assembly, 49
C-axis drive belt, 49
assembly, 37 K pulley, 50
drive belt, 38 keyboard, 69 side covers, 67
circuit breakers, vi, 8 knife blade, 43 maintenance, 68
conveyor, 71 bristle penetration, 54 slats, 76
BRISTLE SQUARES, 71 maintenance, 43 stops (up/down), 53
drive assembly, 37 knife drive belt, 41
drive chains, 82 knife sharpening, 103
slats, 76 T
Covers
table
BCP, 33 L air filter, 86
front head, 36
lubricants, 9 See Also Cutting Table
remote-end, 34
take-on ramp, 70
side, 68
tools, 9
CTOT M trackball, 69
maintenance, 97
Maintenance Manager, 10 troubleshooting, 101
drive chain, 98
customer support, 6, 101 maintenance schedules, 11
mast, 88
cutter head, 35
electrical and air lines, 88
U
cover, 36
elevator roundways, 52 warning light, 89 up/down stops, 53
knife drive belts, 41 MCC air filter, 83
monitor, 69
motion control computer, 83

Gerber Technology, Inc. Index 119

V
vacuum 105, 113

W
warning light, 89

X
X-axis drive belt, 28

Y
Y-axis drive belt, 30

120 Index Gerber Technology, Inc.

U.S.A./CANADA INTERNATIONAL EUROPE
Gerber Technology, Inc. Gerber Technology, Inc. Gerber Technology N.V./S.A.
WORLD HEADQUARTERS INTERNATIONAL DIVISION Excelsiorlaan 55
P.O. Box 769 P.O. Box 769 B-1930 Zaventem, BELGIUM
24 Industrial Park Road West 24 Industrial Park Road West TEL: (32) (2) 716 03 11
Tolland, Connecticut 06084 USA Tolland, Connecticut 06084 USA FAX: (32) (2) 716 03 22
TEL: (860) 871-8082 TEL: (860) 871-8082
FAX: (860) 871-6007 FAX: (860) 872-6007

Document Number: 87425000

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