1. Check the punch frame mechanics. Make sure that the slides are tight and straight. Check the hydraulic cylinder mounting. Make sure it is attached tightly. Make sure the punch and die are tight and lined up with each other. Any mechanical wear or movement in the frame up/down assembly will cause inaccurate measurement.

2. Check the alignment of the encoder gear and the gear rack through entire length of frame movement. There should be a little slack (clearance) between the gear and the gear rack. The gear on the encoder should be able to turn slightly (very slightly). If, at one end there is slack and the other end there is not (tight), chances are that the shaft of the encoder is being side loaded. This will cause the bearing in the encoder to fail. If there is too much slack, the measurements will be inconsistent and inaccurate. Any mechanical wear or movement in the encoder, encoder gear, or encoder gear rack will cause inaccurate measurement.

3. Check that the punch frame moves fully up and down. If it does not, the machine will initialize the punch frame at the wrong position, causing incorrect measurement. Often dirt, grease, or punch slugs will keep the frame from moving fully up and down.

4. Check that the punch frame high and low speed up/down movement is correct. There are 2 flow controls to adjust the high speed up/down and 2 flow controls to adjust the low speed up/down.

5. Check all of the V-rolls in the machine base. All should be tight and lined up with each 5ther and lined up with the rest of the machine. Check the holddown wheels and/or clamps. Make sure they are tight and that they clamp the material evenly.

6. Enter the DIAGNOSTICS for the unit that is being checked. In the middle of the computer screen, the encoder count is displayed under the heading COUNTER. With the punch frame all the way down, note the encoder count number that is displayed. Move the punch frame up using the specified function key. The encoder count number will count up as the frame moves up. When it is fully up, note the encoder count number that is now displayed. As the punch frame is moved fully up and down, the encoder will count up and down to the same numbers every time. The encoder count numbers may vary by one or two counts due to the slack between the gear and gear rack. If there is more variance, see step B. If the number gradually increases or decreases, or does not change at all, eithere the encoder or the cable is bad. Swap the encoder in question with the encoder on the other punch frame to determine if the encoder or the cable is bad.