Perfect Binder-C1 Durability Enhancement Parts Replacement ...downloads.canon.com/imagepress/Perfect_Binder-C1_DEP_PRM_Rev0_092909.pdfReplacement Manual for Durability Enhancement

Sep 29 2009

Replacement Manual for Durability Enhancement Parts

Finisher, Sorter, DeliveryTrayPerfect Binder-C1

ApplicationThis manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and repair

of products. This manual covers all localities where the products are sold. For this reason, there may be information in this

manual that does not apply to your locality.

CorrectionsThis manual may contain technical inaccuracies or typographical errors due to improvements or changes in products. When

changes occur in applicable products or in the contents of this manual, Canon will release technical information as the need

arises. In the event of major changes in the contents of this manual over a long or short period, Canon will issue a new edition

of this manual.

The following paragraph does not apply to any countries where such provisions are inconsistent with local law.

TrademarksThe product names and company names used in this manual are the registered trademarks of the individual companies.

CopyrightThis manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied, reproduced or

translated into another language, in whole or in part, without the written consent of Canon Inc.

COPYRIGHT © 2001 CANON INC.Printed in Japan

CautionUse of this manual should be strictly supervised to avoid disclosure of confidential information.

Introduction

Symbols UsedThis documentation uses the following symbols to indicate special information:

Symbol Description

Indicates an item of a non-specific nature, possibly classified as Note, Caution, or Warning.

Indicates an item requiring care to avoid electric shocks.

Indicates an item requiring care to avoid combustion (fire).

Indicates an item prohibiting disassembly to avoid electric shocks or problems.

Indicates an item requiring disconnection of the power plug from the electric outlet.

Indicates an item intended to provide notes assisting the understanding of the topic in question.

Indicates an item of reference assisting the understanding of the topic in question.

Provides a description of a service mode.

Provides a description of the nature of an error indication.

Memo

REF.

Introduction

The following rules apply throughout this Service Manual:1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical and mechanical systems with refer-

ence to the timing of operation.In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol , the arrow indicates thedirection of the electric signal.The expression "turn on the power" means flipping on the power switch, closing the front door, and closing the delivery unit door, which results insupplying the machine with power.

2. In the digital circuits, '1'is used to indicate that the voltage level of a given signal is "High", while '0' is used to indicate "Low".(The voltage value, how-ever, differs from circuit to circuit.) In addition, the asterisk (*) as in "DRMD*" indicates that the DRMD signal goes on when '0'.In practically all cases, the internal mechanisms of a microprocessor cannot be checked in the field. Therefore, the operations of the microprocessorsused in the machines are not discussed: they are explained in terms of from sensors to the input of the DC controller PCB and from the output of theDC controller PCB to the loads.

The descriptions in this Service Manual are subject to change without notice for product improvement or other purposes, and major changes will be com-municated in the form of Service Information bulletins.All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant Service Information bulletins and beable to identify and isolate faults in the machine."

Contents

Contents

Chapter 1 Replacement Parts

1.1 List of Replacement Parts .......................................................................................................................... 1-1

Chapter 2 Parts Replacement Procedure

2.1 Parts Replacement Procedure ...................................................................................................................2- 12.1.1 Points to Note on Disassembly and Reassembly....................................................................................................2- 12.1.2 Removing from the Host Machine ...........................................................................................................................2- 22.1.3 Removing the Front Covers (Left/Right) .................................................................................................................2- 32.1.4 Removing the Front Upper Cover............................................................................................................................2- 32.1.5 Removing the Rear Cover .......................................................................................................................................2- 42.1.6 Removing the Rear Upper Cover ............................................................................................................................2- 42.1.7 Removing the Left Upper Cover ..............................................................................................................................2- 42.1.8 Removing the Inner Cover (Upper) .........................................................................................................................2- 42.1.9 Removing the Inner Cover (Lower) .........................................................................................................................2- 52.1.10 Drawing out the Cover Transport Assembly ..........................................................................................................2- 52.1.11 Removing the Cover Horizontal Registration Unit .................................................................................................2- 62.1.12 Drawing out the Trimming Assembly ..................................................................................................................... 2- 82.1.13 Replacement parts in stacking tray assembly ....................................................................................................... 2- 92.1.14 Before replacing the SB flapper gear (15 million sheets) ......................................................................................2- 92.1.15 SB flapper gear (15 million sheets)........................................................................................................................2- 92.1.16 Before replacing the SB flapper unit (15 million sheets) ......................................................................................2- 102.1.17 SB flapper unit (15 million sheets) .......................................................................................................................2- 102.1.18 Before replacing the alignment rack (front)/alignment rack (rear) (15 million sheets) .........................................2- 112.1.19 Alignment rack (front)/Alignment rack (rear) (15 million sheets)..........................................................................2- 112.1.20 Alignment Motors (front/rear) (M4/M5) (15 million sheets) ..................................................................................2- 152.1.21 Replecement parts in cover transport assembly..................................................................................................2- 152.1.22 Before replacing the transport roller 1 (15 million sheets) ...................................................................................2- 152.1.23 Transport roller 1 (15 million sheets) ................................................................................................................... 2- 152.1.24 Before replacing the transport roller 2 (15 million sheets) ...................................................................................2- 162.1.25 Transport roller 2 (15 million sheets) ................................................................................................................... 2- 162.1.26 Before replacing the transport roller 3 (15 million sheets) ...................................................................................2- 162.1.27 Transport roller 3 (15 million sheets) ................................................................................................................... 2- 162.1.28 Before replacing the transport rollers 4/5 (15 million sheets) ..............................................................................2- 172.1.29 Transport rollers 4/5 (15 million sheets) ..............................................................................................................2- 172.1.30 Before replacing the transport driven roller 1 (Cover transport entrance) (15 million sheets) .............................2- 172.1.31 Transport driven roller 1 (Cover transport entrance) (15 million sheets) .............................................................2- 182.1.32 Before replacing the transport driven roller 1 (Cover transport exit) (15 million sheets)......................................2- 182.1.33 Transport driven roller 1 (Cover transport exit) (15 million sheets)......................................................................2- 182.1.34 Before replacing the transport driven roller 2 (Spine bending roller 2/3 unit) (15 million sheets) ........................2- 182.1.35 Transport driven roller 2 (Spine bending roller 2/3 unit) (15 million sheets) ........................................................2- 192.1.36 Before replacing the transport driven roller 2 (Spine bending unit (right)) (15 million sheets) .............................2- 202.1.37 Transport driven roller 2 (Spine bending unit (right)) (15 million sheets).............................................................2- 202.1.38 Before replacing the transport driven roller 2 (Spine bending unit (left)) (15 million sheets) ............................... 2- 232.1.39 Transport driven roller 2 (Spine bending unit (left)) (15 million sheets) ...............................................................2- 232.1.40 Before replacing the transport driven roller 2 (Delivery roller 1/2 unit) (15 million sheets) ..................................2- 252.1.41 Transport driven roller 2 (Delivery roller 1/2 unit) (15 million sheets) ..................................................................2- 252.1.42 Before replacing the delivery roller 1/delivery roller 2 (15 million sheets)............................................................2- 262.1.43 Delivery roller 1/Delivery roller 2 (15 million sheets)............................................................................................2- 272.1.44 Before replacing the spine bending harness (right) (120,000 sets) .....................................................................2- 282.1.45 Spine bending harness (right) (120,000 sets)......................................................................................................2- 28

Contents

2.1.46 Before replacing the spine bending harness (left) (240,000 sets)........................................................................2- 282.1.47 Spine bending harness (left) (240,000 sets) ........................................................................................................2- 282.1.48 Replecement parts in trimming assembly ............................................................................................................2- 302.1.49 Before replacing the sprocket shaft 1/sprocket/sprocket bearing (Left) (150,000 sets) .......................................2- 302.1.50 Sprocket shaft 1/Sprocket/Sprocket bearing (Left) (150,000 sets) ......................................................................2- 302.1.51 Before replacing the sprocket shaft 1/sprocket/sprocket bearing (middle) (150,000 sets) ..................................2- 302.1.52 Sprocket shaft 1/Sprocket/Sprocket bearing (middle) (150,000 sets)..................................................................2- 302.1.53 Before replacing the sprocket shaft 2/sprocket/sprocket bearing (right) (150,000 sets) ......................................2- 312.1.54 Sprocket shaft 2/Sprocket/Sprocket bearing (right) (150,000 sets) .....................................................................2- 312.1.55 Before replacing the sprocket bracket (150,000 sets)..........................................................................................2- 312.1.56 Sprocket bracket (150,000 sets) ..........................................................................................................................2- 312.1.57 Replacement parts in book stacking assembly ....................................................................................................2- 322.1.58 Before replacing the drawer connector (male) (20,000 times) .............................................................................2- 322.1.59 Drawer connector (male) (20,000 times)..............................................................................................................2- 322.1.60 Before replacing the drawer connector (female) (20,000 times) ..........................................................................2- 322.1.61 Drawer connector (female) (20,000 times)...........................................................................................................2- 32

Chapter 1 Replacement Parts

Contents

Contents

1.1 List of Replacement Parts ..............................................................................................................................................1-1

1.1 List of Replacement Parts0024-2987

T-1-1

Category Parts Name Parts No. Q'ty Replacement Interval Remarks

Stacking tray assembly SB flapper Gear 4A3-2823-000 1 15,000,000 sheets

Stacking tray assembly SB flapper unit 4G3-1221-000 1 15,000,000 sheets

Stacking tray assembly Alignment rack (front) 4G3-2243-000 1 15,000,000 sheets

Stacking tray assembly Alignment rack (rear) 4G3-2244-000 1 15,000,000 sheets

Stacking tray assembly Alignment motor FH5-1040-000 2 15,000,000 sheets

Cover transport assembly Transport roller 1 4A3-3137-000 1 15,000,000 sheets





Cover transport assembly Transport driven roller 1 FC5-3670-000 12 15,000,000 sheets

- Transport driven roller 1 (Cover transport entrance) (4)

- Transport driven roller 1 (Cover transport exit) (8)

Cover transport assembly Transport driven roller 2 4S3-6114-000 16 15,000,000 sheets

- Transport driven roller 2 (Spine bending roller 2/3 unit) (4)

- Transport driven roller 2 (Spine bending unit (right)) (4)

- Transport driven roller 2 (Spine bending unit (left)) (4)

- Transport driven roller 2 (Delivery roller 1/2 unit) (4)

Cover transport assembly Delivery roller 1 4A3-3216-000 1 15,000,000 sheets

Cover transport assembly Delivery roller 24A3-3135-000

115,000,000 sheets

Cover transport assembly Spine bending harness (right)4H3-0362-000

1120,000 sets

Bookbinding sets

Cover transport assembly Spine bending harness (left) 4H3-0360-000 1 240,000 sets Bookbinding sets

Trimming assembly Sprocket bracket 4A3-2266-000 1 150,000 sets Bookbinding sets

Trimming assembly Sprocket shaft 1 4A3-2288-000 2 150,000 sets Bookbinding sets

- Sprocket shaft 1 (left) (1)

- Sprocket shaft 1 (middle) (1)

Trimming assembly Sprocket shaft 2 4A3-2286-000 1 150,000 sets Bookbinding sets

Trimming assembly Sprocket 4S3-3099-000 3 150,000 sets Bookbinding sets

- Sprocket (left) (1)

- Sprocket (middle) (1)

- Sprocket (right) (1)

Trimming assembly Sprocket bearing XG9-0581-000 3 150,000 sets Bookbinding sets

- Sprocket bearing (left) (1)

- Sprocket bearing (middle) (1)

- Sprocket bearing (right) (1)

Book stacking assembly Drawer connector (male) 4H3-0223-000 1 20,000 times Tray opening and closing frequency

Book stacking assembly Drawer connector (female) 4H3-0222-000 1 20,000 times Tray opening and closing frequency

Chapter 2 Parts Replacement Procedure

Contents

Contents

2.1 Parts Replacement Procedure.........................................................................................................................................2-12.1.1 Points to Note on Disassembly and Reassembly ......................................................................................................................... 2-12.1.2 Removing from the Host Machine............................................................................................................................................... 2-22.1.3 Removing the Front Covers (Left/Right) .................................................................................................................................... 2-32.1.4 Removing the Front Upper Cover................................................................................................................................................ 2-32.1.5 Removing the Rear Cover............................................................................................................................................................ 2-42.1.6 Removing the Rear Upper Cover................................................................................................................................................. 2-42.1.7 Removing the Left Upper Cover.................................................................................................................................................. 2-42.1.8 Removing the Inner Cover (Upper) ............................................................................................................................................. 2-42.1.9 Removing the Inner Cover (Lower)............................................................................................................................................. 2-52.1.10 Drawing out the Cover Transport Assembly ............................................................................................................................. 2-52.1.11 Removing the Cover Horizontal Registration Unit ................................................................................................................... 2-62.1.12 Drawing out the Trimming Assembly ....................................................................................................................................... 2-82.1.13 Replacement parts in stacking tray assembly ............................................................................................................................ 2-92.1.14 Before replacing the SB flapper gear (15 million sheets).......................................................................................................... 2-92.1.15 SB flapper gear (15 million sheets) ........................................................................................................................................... 2-92.1.16 Before replacing the SB flapper unit (15 million sheets) ........................................................................................................ 2-102.1.17 SB flapper unit (15 million sheets) .......................................................................................................................................... 2-102.1.18 Before replacing the alignment rack (front)/alignment rack (rear) (15 million sheets)........................................................... 2-112.1.19 Alignment rack (front)/Alignment rack (rear) (15 million sheets) .......................................................................................... 2-112.1.20 Alignment Motors (front/rear) (M4/M5) (15 million sheets) .................................................................................................. 2-152.1.21 Replecement parts in cover transport assembly....................................................................................................................... 2-152.1.22 Before replacing the transport roller 1 (15 million sheets) ...................................................................................................... 2-152.1.23 Transport roller 1 (15 million sheets) ...................................................................................................................................... 2-152.1.24 Before replacing the transport roller 2 (15 million sheets) ...................................................................................................... 2-162.1.25 Transport roller 2 (15 million sheets) ...................................................................................................................................... 2-162.1.26 Before replacing the transport roller 3 (15 million sheets) ...................................................................................................... 2-162.1.27 Transport roller 3 (15 million sheets) ...................................................................................................................................... 2-162.1.28 Before replacing the transport rollers 4/5 (15 million sheets) ................................................................................................. 2-172.1.29 Transport rollers 4/5 (15 million sheets).................................................................................................................................. 2-172.1.30 Before replacing the transport driven roller 1 (Cover transport entrance) (15 million sheets)................................................ 2-172.1.31 Transport driven roller 1 (Cover transport entrance) (15 million sheets) ................................................................................ 2-182.1.32 Before replacing the transport driven roller 1 (Cover transport exit) (15 million sheets) ....................................................... 2-182.1.33 Transport driven roller 1 (Cover transport exit) (15 million sheets) ....................................................................................... 2-182.1.34 Before replacing the transport driven roller 2 (Spine bending roller 2/3 unit) (15 million sheets) ......................................... 2-182.1.35 Transport driven roller 2 (Spine bending roller 2/3 unit) (15 million sheets) ......................................................................... 2-192.1.36 Before replacing the transport driven roller 2 (Spine bending unit (right)) (15 million sheets).............................................. 2-202.1.37 Transport driven roller 2 (Spine bending unit (right)) (15 million sheets) .............................................................................. 2-202.1.38 Before replacing the transport driven roller 2 (Spine bending unit (left)) (15 million sheets) ................................................ 2-232.1.39 Transport driven roller 2 (Spine bending unit (left)) (15 million sheets) ................................................................................ 2-232.1.40 Before replacing the transport driven roller 2 (Delivery roller 1/2 unit) (15 million sheets) .................................................. 2-252.1.41 Transport driven roller 2 (Delivery roller 1/2 unit) (15 million sheets) .................................................................................. 2-252.1.42 Before replacing the delivery roller 1/delivery roller 2 (15 million sheets) ............................................................................ 2-262.1.43 Delivery roller 1/Delivery roller 2 (15 million sheets) ............................................................................................................ 2-272.1.44 Before replacing the spine bending harness (right) (120,000 sets).......................................................................................... 2-282.1.45 Spine bending harness (right) (120,000 sets)........................................................................................................................... 2-282.1.46 Before replacing the spine bending harness (left) (240,000 sets) ............................................................................................ 2-282.1.47 Spine bending harness (left) (240,000 sets) ............................................................................................................................. 2-282.1.48 Replecement parts in trimming assembly ................................................................................................................................ 2-302.1.49 Before replacing the sprocket shaft 1/sprocket/sprocket bearing (Left) (150,000 sets) .......................................................... 2-30

Contents

2.1.50 Sprocket shaft 1/Sprocket/Sprocket bearing (Left) (150,000 sets) .......................................................................................... 2-302.1.51 Before replacing the sprocket shaft 1/sprocket/sprocket bearing (middle) (150,000 sets)...................................................... 2-302.1.52 Sprocket shaft 1/Sprocket/Sprocket bearing (middle) (150,000 sets) ..................................................................................... 2-302.1.53 Before replacing the sprocket shaft 2/sprocket/sprocket bearing (right) (150,000 sets) ......................................................... 2-312.1.54 Sprocket shaft 2/Sprocket/Sprocket bearing (right) (150,000 sets) ......................................................................................... 2-312.1.55 Before replacing the sprocket bracket (150,000 sets) .............................................................................................................. 2-312.1.56 Sprocket bracket (150,000 sets) ............................................................................................................................................... 2-312.1.57 Replacement parts in book stacking assembly......................................................................................................................... 2-322.1.58 Before replacing the drawer connector (male) (20,000 times) ................................................................................................ 2-322.1.59 Drawer connector (male) (20,000 times) ................................................................................................................................. 2-322.1.60 Before replacing the drawer connector (female) (20,000 times) ............................................................................................. 2-322.1.61 Drawer connector (female) (20,000 times).............................................................................................................................. 2-32

Chapter 2

2-1

2.1 Parts Replacement Procedure

2.1.1 Points to Note on Disassembly and Reassembly0024-7278

Before starting disassembly/reassembly work, turn off the main switch and unplug the power cord from the wall outlet, unless you are otherwise prompted to keep the unit running for servicing purposes.

CAUTION:- To keep the machine running in service mode, be sure to do so with the trimming assembly stowed inside.

- Before drawing out the trimming unit, move the trimming blade rearward in the service mode ( ) except when replacing the trimming blade.- To perform reassembly, reverse the disassembly procedures, unless otherwise noted.

SW1 SW2

Chapter 2

2-2

2.1.2 Removing from the Host Machine0024-6639

1) Disconnect the signal cable [1] from the perfect binder.

F-2-12) Remove the rear cover.3) Remove the shunt cable [1].

- 2 screws [2]

F-2-2

4) Turn the two nuts [1] in the direction of the arrow to lift up the stoppers.

F-2-35) Remove the two screws [1] and lift up the the main switch panel [2] after

sliding it to the rear side. Remove the connector [3], the reusable band [4],and then remove the main switch panel.

F-2-4

[1]

[2]

[1]

[1]

[2]

[3]

[1]

Chapter 2

2-3

6) Remove the screw [1] and move the power switch assembly [2] out of theway.

F-2-57) Remove the fixing brackets [1] (one at the front and the other at the back).

- Each 2 screws [2]

F-2-6

8) Remove the scerws [1] and turn up the locking claws [2], then separate theperfect binder from the host machine.

F-2-7

2.1.3 Removing the Front Covers (Left/Right) 0024-2989

1) Open the front covers (left/right).2) While holding the front cover (left) [1] with one hand and pressing the

black lever [2] with the other hand, pull the hinge [3] in the direction ofthe arrow to remove it. After removing the upper and lower hinges, re-move the front cover (left) [1].

3) Remove the front cover (right) [4] in the same manner as above.

F-2-8

2.1.4 Removing the Front Upper Cover0024-6641

1) Open the top cover.

[1]

[2]

[1][2]

[2]

[1]

[4]

[2][3]

[1]

Chapter 2

2-4

2) Remove the front cover [1] of the stacking assembly.- 3 screws [2]

F-2-93) Pull out the glue supply port [1]. Loosen the three screws [2] and remove

the one screw [3], then remove the upper front cover [4].

F-2-10

2.1.5 Removing the Rear Cover0024-6642

1) Remove the rear cover [1].- 6 screws [2]

F-2-11

2.1.6 Removing the Rear Upper Cover0024-6643

1) Remove the rear upper cover [1].- 6 screws [2]

F-2-12

2.1.7 Removing the Left Upper Cover0024-6644

1) Open the inserter and top cover.2) Remove the front cover [1] of the stacking assembly.

- 3 screws [2]

F-2-13

[1]

[2]

[3][2] [4] [1]

[1]

[2]

[4]

[3] [4]

[1]

[2]

Chapter 2

2-5

3) Remove the left upper cover [1].- 4 screws [2]

F-2-14

2.1.8 Removing the Inner Cover (Upper)0024-6645

1) Remove the front covers (left/right).2) Raise the jam removal lever, and then remove the upper inner cover [1].

- 6 screws [2]

F-2-15

2.1.9 Removing the Inner Cover (Lower)0024-6647

1) Remove the front covers (left/right).2) Draw out the waste paper unit.3) Release the book stacking assembly lock, and then draw out the book

stacking assembly.

4) Remove the jam removal knob [1]. With the three jam removal levers [2]released, remove the inner cover (lower) [3].- 7 screws [4]

F-2-16

2.1.10 Drawing out the Cover Transport Assembly0024-6839

1) Remove the rear cover.2) Remove the eleven connectors [1], and then remove one screw [2].

F-2-173) Go around to the front of the machine, and remove the front covers (left/

right).4) Remove the inner cover (lower).5) Remove the fixing bracket [1].

- 2 screws [2]

F-2-18

[2][1]

[2]

[2]

[2][1]

[2]

MEMO:The inner cover (lower) [3] must be removed with it lifted to prevent the stopper [5] from being caught on the surrounding parts.

[4]

[2]

[3]

[4]

[1][5][2] [2]

[1] [2] [1]

[1][2]

Chapter 2

2-6

6) Remove the four screws [1], loosen the four screws [2], and then draw outthe cover transport assembly [3].

F-2-19

2.1.11 Removing the Cover Horizontal Registration Unit0024-6856

1) Draw out the cover transport assembly.2) Remove the E-ring [1] and bearing [2].

F-2-20

3) Push the roller [1] backward, pull out the bearing [2] backward, releasethe roller pulley [3] from the belt, and then remove the roller.

F-2-214) Remove the transport roller 1 unit [1].

- 2 screws [2]

F-2-225) Remove the resin retaining ring [1].

F-2-23

[1]

[2]

[3]

[1]

[2]

[2][1]

[3][2][1]

[1]

[2]

[1]

Chapter 2

2-7

6) Remove the guide plate by shifting it in the sequence shown in the figure.6-1) Shift the guide plate forward, and then pull it out of the hole [2] in

the rear panel of the transport assembly.6-2) Shift the guide plate backward to insert its shaft in the hole [3] in the

rear panel of the transport assembly, and then remove the guideplate shaft from the front panel of the transport assembly.

6-3) Shift the guide plate forward again to remove it.

F-2-247) Remove the front cover interlock unit [1].

- 3 screws [2]

F-2-25

8) Remove the roller unit mount [1].- Each one screw [3]

F-2-269) Mark off the position of the positioning plate [1], and then remove the po-

sitioning plate.

F-2-2710) Remove the reinforcement plate [1]. Release the motor harness [3] from

the wire saddle [2], and then disconnect the connector [4] from the coverhorizontal registration motor.- 3 screws [5]

F-2-28

[2]

[3]

[1]

[2]

CAUTION:When reinstalling the horizontal registration unit, align it with the mark-off line.

[1]

[2]

[1]

[2]

[2][4]

[3]

[5]

[1]

Chapter 2

2-8

11) Release the harness from the wire saddle [1], disconnect the three con-nectors [2], and then remove the cover horizontal registration unit.

F-2-29

2.1.12 Drawing out the Trimming Assembly0024-6868

1) Insert the blade of a small-size screwdriver, and then turn it in the direc-tion of the arrow to unlock the stacking assembly.

F-2-302) Go around to the front of the machine, and then remove the front covers

(left/right). 3) Draw out the stacking assembly.4) Draw out the waste paper basket.5) Remove the inner cover (lower).6) Turn on the right front cover switch [1] and left front cover switch [2] by

inserting the service tool or the like.

F-2-317) Plug the power cord in the wall outlet.8) Remove the service PCB cover [1].

- Screw [2]

F-2-329) Turn on the SW1-1[1] on the service PCB and set the machine in service

mode.

F-2-3310) Turn on the Power switch.

CAUTION:Before drawing out the trimming unit, move the trimming blade rearward in

the service mode ( ) following the below procedure except when replacing the trimming blade.

[1]

[2]

[1]

[1]

SW1 SW2

CAUTION:To keep the machine running in service mode, be sure to do so with the trimming assembly stored inside.

[1][2]

[2]

[1]

LED1

PSW1

1

PSW2 PSW3

LED2 LED3

1 2 3 4 5 6 7 8

2 3

SW1

SW2

4

[1]

Chapter 2

2-9

11) Turn on SW2-2, SW2-3, and SW2-7 [1] on the service PCB and pressthe push switch PSW1 [2].

F-2-3412) Check that the trimming blade [1], pressing plate [2], and stack rotation

assembly [3] operate and that the trimming blade moves to the safe posi-tion.

13) Remove the fixing bracket [1].- 2 screws [2]

F-2-3514) Remove the four screws [1] securing the trimming assembly, and then

draw out the trimming assembly [2].

F-2-36

2.1.13 Replacement parts in stacking tray assembly0024-6650

T-2-1

2.1.14 Before replacing the SB flapper gear (15 million sheets)

0024-6653

1) Remove the top cover.2) Remove the front upper cover. (page 2-3)Reference[Removing the

Front Upper Cover]3) Remove the rear upper cover. (page 2-4)Reference[Removing the Rear

Upper Cover]

2.1.15 SB flapper gear (15 million sheets)0024-6657

1) Remove the frame upper cover [1].- 4 screws [2]

F-2-372) Remove the top cover switch [1].

- 2 screws [2]

F-2-38

CAUTION:Pressing the push switch PSW1 operates the trimming blade, pressing plate, and stack rotation assembly. Be careful not to have your hand and clothes caught in them.

No. Parts Name Q'ty

[1] SB flapper Gear 1

[2] SB flapper unit 1

LED1

PSW1

1

PSW2 PSW3

LED2 LED3

1 2 3 4 5 6 7 8

2 3

SW1

SW2

4

[2]

[1]

[1][2]

[1]

[1]

[2]

[3] Alignment rack (front) 1

[4] Alignment rack (rear) 1

[5] Alignment motor 2

No. Parts Name Q'ty

[2]

[1]

[1]

[2]

Chapter 2

2-10

3) Remove the top cover mount [1].- 5 screws [2]

F-2-394) Release the harness from the three wire saddles [1], and then remove the

six connectors [2].

F-2-405) Remove the switch-back flapper motor assembly.

- 2 screws [2]

F-2-41

6) Remove the SB flapper gear [2].- E-ring [1]- Straight pin [3]

F-2-42

F-2-43

2.1.16 Before replacing the SB flapper unit (15 million sheets)

0024-6836



Upper Cover]4) Remove the SB flapper gear. (page 2-9)Reference[SB flapper gear (15

million sheets)]

[2] [2]

[1]

[2]

[1] [2]

[2]

[1] [2]

[2]

CAUTION:While reassembling, attach the SB flapper gear so that the sensor flag of the gear is positioned downwards when the flapper hangs down.

[1] [2] [3]

Chapter 2

2-11

2.1.17 SB flapper unit (15 million sheets)0024-6837

1) Remove the SB flapper unit [1].- E-rings [2] 2 pcs.- Bushings [3] 2 pcs.

F-2-44

2.1.18 Before replacing the alignment rack (front)/alignment rack (rear) (15 million sheets)

0024-6658



Upper Cover]4) Remove the rear cover. (page 2-4)Reference[Removing the Rear Cover]5) Remove the left upper cover. (page 2-4)Reference[Removing the Left

Upper Cover]

2.1.19 Alignment rack (front)/Alignment rack (rear) (15 million sheets)

0024-6674

1) Remove the harness cover [1].- 2 screws [2]

F-2-452) Go around to the back of the machine, and then remove the top cover and

rear upper cover.

3) Remove the E-ring [1], flange [2], belt [3], pulley [4], and parallel pin [5].

F-2-464) Remove the E-ring [1] and bearing [2].

F-2-475) Disconnect the two connectors [1].

F-2-48

[2][1] [3]

[3] [2]

[2][1]

CAUTION:Be careful not to drop parts into the machine.

CAUTION:Be careful not to drop parts into the machine.

[1]

[2]

[3]

[4]

[5]

[2][1]

[1]

Chapter 2

2-12

6) Turn the knob [1] to lower the stacking tray to the lower limit.

F-2-497) Go around to the front of the machine, and then remove the E-ring [1],

bearing [2], and signature delivery roller [3].

F-2-50

8) Open the transport guide [1]. Remove the signature delivery assembly [2].- 4 screws [3]

F-2-51

[1]

[2]

[3]

[1]

[2]

[1]

[3]

[3]

Chapter 2

2-13

F-2-529) Remove the frame upper cover [1].

- 4 screws [2]

F-2-53

10) Remove the top cover switch [1].- 2 screws [2]

F-2-5411) Remove the top cover mount [1].

- 5 screws [2]

F-2-5512) Release the harness from the three wire saddles [1], and then remove the

six connectors [2].

F-2-56

CAUTION:1. After removal of the signature delivery assembly, the drive belt [4] remains on the motor shaft in the back. Be careful not to drop this belt into the machine.2. When reinstalling the signature delivery assembly, be sure to hang the drive belt on the motor shaft and the pulley [5] of the signature delivery assembly. It will be easy to reinstall the signature delivery assembly if the trail edge retaining motor (M3) is removed before reinstalling it.

[4]

[5]

[2]

[1]

[1]

[2]

[2] [2]

[1]

[2]

[1] [2]

[2]

Chapter 2

2-14

13) Remove the switch-back flapper motor assembly.- 2 screws [2]

F-2-5714) Remove the alignment assembly top cover [1].

- 4 screws [2]

F-2-5815) Remove the E-ring [1], flange [2], belt [3], pulley [4], and parallel pin

[5].

F-2-59

16) Remove the E-ring [1] and bearing [2].

F-2-6017) Remove the stacking upper unit [1].

- 4 screws [2]

F-2-61

F-2-62

[1] [2]

[2]

[2][1][2]

[4][3] [5][1] [2]

CAUTION:Be careful not to drop the rear belt [3] into the machine.

[2][1]

[2] [1]

[2]

[3]

Chapter 2

2-15

18) Remove the Alignment rack (front) [1] and the Alignment rack (rear) [2].- Each 2 screws [3]

F-2-63

2.1.20 Alignment Motors (front/rear) (M4/M5) (15 million sheets)

0024-6682

1) Open the top cover.2) Remove the alignment assembly top cover [1].

- 4 screws [2]

F-2-643) Remove the alignment motors (front) [1] and (rear) [2].

- Each one connector [3]- Each 2 screws [4]

F-2-65

2.1.21 Replecement parts in cover transport assembly0024-6684

T-2-2

2.1.22 Before replacing the transport roller 1 (15 million sheets)

0024-6687

1) Remove the rear cover. (page 2-4)Reference[Removing the Rear Cover]2) Draw out the cover transport assembly. (page 2-5)Reference[Drawing

out the Cover Transport Assembly]

2.1.23 Transport roller 1 (15 million sheets)0024-6840

1) Remove the E-ring [1] and bearing [2].

F-2-66

[1]

[2]

[3]

[3]

[2][1][2]

[4][3][4]

[1] [2]

[3]

No. Parts Name Q'ty

[1] Transport roller 1 1





[6] Transport driven roller 1 12

- Transport driven roller 1 (Cover transport entrance) (4)

- Transport driven roller 1 (Cover transport exit) (8)

[7] Transport driven roller 2 16

- Transport driven roller 2 (Spine bending roller 2/3 unit) (4)

- Transport driven roller 2 (Spine bending unit (right)) (4)

- Transport driven roller 2 (Spine bending unit (left)) (4)

- Transport driven roller 2 (Delivery roller 1/2 unit) (4)

[8] Delivery roller 1 1

[9] Delivery roller 2 1

[10] Spine bending harness (right) 1

[11] Spine bending harness (left) 1

[2][1]

Chapter 2

2-16

2) Push the roller [1] backward, pull out the bearing [2] backward, releasethe roller pulley [3] from the belt, and then remove the roller.

F-2-67


0024-6841




1) Remove the roller release lever shaft [1].- Resin retaining ring [2]- Bushing [3]

F-2-68

2) Remove the resin retaining ring [1], idle gear [2] and E-ring [3].

F-2-693) Pull out the bearing [1] towards front. Remove the E-ring [2] and slide the

gear [3] towards rear, and then remove the straight pin [4].

F-2-704) Open the transport roller 2/3 unit and remove the E-ring [1], flange [2],

timing belt [3] and pulley [4], and then remove the transport roller 2 [5]after shifting it towards rear.

F-2-71


0024-6843



[3][2][1]

[1]

[3]

[2]

[3]

[2]

[1]

[2]

[1]

[4]

[3]

[3][4][2]

[1]

[5]

Chapter 2

2-17


1) Remove the 2 E-rings [1]. Open the transport roller 2/3 unit, shift thetransport roller 3 [3] towards rear, release the timing belt [4] and then re-move the transport roller 3.

F-2-72

2.1.28 Before replacing the transport rollers 4/5 (15 million sheets)

0024-6845



2.1.29 Transport rollers 4/5 (15 million sheets)0024-6846

1) Remove each 2 E-rings at the front and rear sides. Remove the transportroller 4 and transport roller 5 after shifting them towards rear.

F-2-73

2.1.30 Before replacing the transport driven roller 1 (Cover transport entrance) (15 million sheets)

0024-6847



[1] [4]

[1]

[3]

[3]

[4]

[2]

[1]

Chapter 2

2-18

2.1.31 Transport driven roller 1 (Cover transport entrance) (15 million sheets)

0024-6848

1) Remove the springs [1] to remove the transport driven roller 1 [2].

F-2-74

F-2-75

2.1.32 Before replacing the transport driven roller 1 (Cover transport exit) (15 million sheets)

0024-6857



2.1.33 Transport driven roller 1 (Cover transport exit) (15 million sheets)

0024-6850

1) Remove the springs [1] to remove the transport driven roller 1 [2].

F-2-76

F-2-77

2.1.34 Before replacing the transport driven roller 2 (Spine bending roller 2/3 unit) (15 million sheets)

0024-6849


out the Cover Transport Assembly]3) Remove the cover horizontal registration unit. (page 2-6)Reference[Re-

moving the Cover Horizontal Registration Unit]

NOTE:There is a groove on the roller shaft to slide the slit of the roller shaft mount. Remove and install the transport driven roller sliding the groove.

[1][2]

[1]


[1]

[2]

[1]

Chapter 2

2-19

2.1.35 Transport driven roller 2 (Spine bending roller 2/3 unit) (15 million sheets)

0024-6854

1) Open the transport roller 2/3 unit [1].

F-2-782) Remove the harness protection cover [1].

- Screw [2]

F-2-793) Remove the two connectors [1], and then release the harness from the two

edge saddles [2].

F-2-80

4) Remove the transport roller unit 2/3 [1].- 4 screws [2]

F-2-81

F-2-82

[1]

[1]

[2]

[1]

[2]

CAUTION:Install the spine bending unit so the locking arm [3] on the back of the transport roller 2/3 unit will fit into the hole [4] in the spine bending unit. If you have difficulty precisely locating the spine bending unit, turn the spine bending drive pulley [5] by a hand to move the spine bending unit.

[1][2]

[2]

[5] [4]

[3]

Chapter 2

2-20

5) Remove the arm springs [1] and shaft spring [2], and then take out thetransport driven roller 2.

F-2-83

F-2-84

2.1.36 Before replacing the transport driven roller 2 (Spine bending unit (right)) (15 million sheets)

0024-6858




2.1.37 Transport driven roller 2 (Spine bending unit (right)) (15 million sheets)

0024-6859


F-2-852) Remove the harness protection cover [1].

- Screw [2]

F-2-863) Remove the two connectors [1], and then release the harness from the two

edge saddles [2].

F-2-87


[1]

[2]

[1]

[1]

[1]

[2]

[1]

[2]

Chapter 2

2-21

4) Remove the transport roller unit 2/3 [1].- 4 screws [2]

F-2-88

F-2-89

5) Remove the reuse band [1], free the harness [2] from the four wire saddles[3], and then pull out the connector [4].

F-2-906) With the transport roller (4/5) unit [1] moved to the left side, remove the

spine bending plate (right) [2].- 2 scerws [3]

F-2-91

CAUTION:Install the spine bending unit so the locking arm [3] on the back of the transport roller 2/3 unit will fit into the hole [4] in the spine bending unit. If you have difficulty precisely locating the spine bending unit, turn the spine bending drive pulley [5] by a hand to move the spine bending unit.

[1][2]

[2]

[5] [4]

[3]

[1]

[3][3]

[4]

[3]

[2]

[3]

[2]

[1]

Chapter 2

2-22

7) Opening the transport roller 2/3 unit [1], remove two screws [2].

F-2-928) Turn the spine bending drive pulley [1] by a hand to move the spine bend-

ing unit (right) [2] fully to the right side.

F-2-939) Lift up the spine bending unit (right) [1] in the arrow direction to remove

it.

F-2-94

F-2-9510) Remove the 3 screws [1] to detach the rack mount [2].

F-2-9611) Remove the arm springs [1] and the shaft spring [2] to detach the trans-

port driven roller 2.

F-2-97

[2][1]

[1]

[2]

[1]

CAUTION:Install the spine bending unit (right) [1] to keep it in parallel with the transport roller 2/3 unit [2].

[2]

[1]

[1]

[2]

[2]

[1]

Chapter 2

2-23

F-2-98

2.1.38 Before replacing the transport driven roller 2 (Spine bending unit (left)) (15 million sheets)

0024-6861



2.1.39 Transport driven roller 2 (Spine bending unit (left)) (15 million sheets)

0024-6860


F-2-992) Remove the connector cover [1].

- Screw [2]

F-2-100

3) Remove the connector [1] and the three screws [2] in the rear side.

F-2-1014) Remove the three scerws [1], and then remove the delivery roller 1/2 unit

[2].

F-2-102


[1]

[1]

[2][1]

[1]

[2] [2]

[1][2]

Chapter 2

2-24

F-2-1035) Pull out the connector [1], remove the reuse band [2], and free the sensor

harness [4] from the edge saddle [3].

F-2-104

6) Turn the spine bending drive pulley [1] by a hand to move the spine bend-ing unit (left) [2] towards the left side. Remove the four screws [3], andthen remove the spine bending unit (left).

F-2-1057) Remove the rack mount [1].

- Support plate [2]- 5 Screws [3]

F-2-106

CAUTION:When reinstalling the delivery roller 1/2 unit, position it with the pressure arms [4] on its reverse side in the holes [5] of the spine unit. If it is difficult to position the delivery roller 1/2 unit, turn the spine drive pulley [6] manually to move the spine unit.

[4]

[5] [6]

[1] [3] [3] [4][2]

CAUTION:Install the spine bending unit (left) [2] to keep it in parallel with the transport roller 4/5 unit [4].

[1]

[2] [3]

[3]

[4]

[2]

[1]

[3]

[3]

[3]

[3]

Chapter 2

2-25

8) Remove the arm springs [1] and the shaft spring [2] to detach the transportdriven roller 2.

F-2-107

F-2-108

2.1.40 Before replacing the transport driven roller 2 (Delivery roller 1/2 unit) (15 million sheets)

0024-6871



2.1.41 Transport driven roller 2 (Delivery roller 1/2 unit) (15 million sheets)

0024-6872


F-2-109

2) Remove the connector cover [1].- Screw [2]

F-2-1103) Remove the connector [1] and the three screws [2] in the rear side.


[2].

F-2-112


[2]

[1]

[1]

[1]

[2][1]

[1]

[2] [2]

[1][2]

Chapter 2

2-26

F-2-113

5) Remove the arm springs [1] and the shaft spring [2] to detach the transportdriven roller 2.

F-2-114

F-2-115

2.1.42 Before replacing the delivery roller 1/delivery roller 2 (15 million sheets)

0024-6852




[4]

[5] [6]


[1]

[2]

[1]

Chapter 2

2-27

2.1.43 Delivery roller 1/Delivery roller 2 (15 million sheets)0024-6853


F-2-1162) Remove the connector cover [1].

- Screw [2]


F-2-118

4) Remove the three scerws [1], and then remove the delivery roller 1/2 unit[2].

F-2-119

F-2-120

[1]

[2][1]

[1]

[2] [2]


[1][2]

[4]

[5] [6]

Chapter 2

2-28

5) Remove the E-ring [1] and the bearing [2].

F-2-1216) Remove the 2 screws [1] to detach the guide mount [2]. Take out the de-

livery roller 1 [4] and the delivery roller 2 [5] after releasing the gear fromthe belt [3].

F-2-122

2.1.44 Before replacing the spine bending harness (right) (120,000 sets)

0024-6862




2.1.45 Spine bending harness (right) (120,000 sets)0024-6863

1) Remove the reuse band [1] and release the spine bending harness (right)[2] from the 4 wire saddles [3]. Disconnect the 2 connectors [4] and thenremove the spine bending harness (right).

F-2-123

2.1.46 Before replacing the spine bending harness (left) (240,000 sets)

0024-6864



2.1.47 Spine bending harness (left) (240,000 sets)0024-6866


F-2-124

[1]

[1]

[2]

[2]

[1]

[4]

[2]

[3]

[5]

[1]

[3][3]

[4]

[3]

[2] [4]

[1]

Chapter 2

2-29

2) Remove the connector cover [1].- Screw [2]



[2].

F-2-127

F-2-1285) Disconnect the 2 connectors [1], remove the reuse band [2] and free the

harness from the edge saddles and wire saddles, and then take out thespine bending harness (left) [3].

F-2-129

[2][1]

[1]

[2] [2]

[1][2]


[4]

[5] [6]

[1] [3][2] [1]

Chapter 2

2-30

2.1.48 Replecement parts in trimming assembly0024-6867

T-2-3

2.1.49 Before replacing the sprocket shaft 1/sprocket/sprocket bearing (Left) (150,000 sets)

0024-6869

1) Draw out the trimming assembly. (page 2-8)Reference[Drawing out theTrimming Assembly]

2.1.50 Sprocket shaft 1/Sprocket/Sprocket bearing (Left) (150,000 sets)

0024-6870

1) Unhook the two springs [1] to release the tension of the chain.

F-2-1302) Release the harness from the edge saddle [1] and remove the seven screws

[2], then turn the chain guide to the arrow direction.

F-2-131

3) Release the harness from the 2 edge saddles [1] and the wire saddle [2],and remove the 7 screws [3]. Then turn the chain guide to the arrow di-rection.

F-2-1324) Release the support portion [1] of the wire saddle to free the harness. After

removing the 2 E-rings [2], remove the sprocket shaft 1 [3], sprocket [4],sprocket bearing [5] and bushing [6].

F-2-133

2.1.51 Before replacing the sprocket shaft 1/sprocket/sprocket bearing (middle) (150,000 sets)

0024-6873


2) Remove the sprocket shaft 1/sprocket/sprocket bearing (left). (page 2-30)Reference[Sprocket shaft 1/Sprocket/Sprocket bearing (Left)(150,000 sets)]

No. Parts Name Q'ty

[1] Sprocket bracket 1

[2] Sprocket shaft 1 2

- Sprocket shaft 1 (left) (1)

- Sprocket shaft 1 (middle) (1)

[3] Sprocket shaft 2 1

[4] Sprocket 3

- Sprocket (left) (1)

- Sprocket (middle) (1)

- Sprocket (right) (1)

[5] Sprocket bearing 3

- Sprocket bearing (left) (1)

- Sprocket bearing (middle) (1)

- Sprocket bearing (right) (1)

[1]

[1]

[2]

[2]

[1]

[3]

[3]

[2]

[2]

[1]

[6]

[5]

[4]

[3]

[2]

[2]

Chapter 2

2-31

2.1.52 Sprocket shaft 1/Sprocket/Sprocket bearing (middle) (150,000 sets)

0024-6874

1) Remove the E-ring [1], sprocket shaft 1 [2], sprocket [3], sprocket bearing[4] and bushing [5].

F-2-134

2.1.53 Before replacing the sprocket shaft 2/sprocket/sprocket bearing (right) (150,000 sets)

0024-6875



3) Remove the sprocket shaft 1/sprocket/sprocket bearing (middle). (page2-31)Reference[Sprocket shaft 1/Sprocket/Sprocket bearing (middle)(150,000 sets)]

2.1.54 Sprocket shaft 2/Sprocket/Sprocket bearing (right) (150,000 sets)

0024-6876

1) Remove the E-ring [1], sprocket shaft 2 [2], sprocket [3], sprocket bearing[4] and bushing [5].

F-2-135

2.1.55 Before replacing the sprocket bracket (150,000 sets)

0024-6877



3) Remove the sprocket shaft 1/sprocket/sprocket bearing (middle). (page2-31)Reference[Sprocket shaft 1/Sprocket/Sprocket bearing (middle)(150,000 sets)]

4) Remove the sprocket shaft 2/sprocket/sprocket bearing (right). (page 2-31)Reference[Sprocket shaft 2/Sprocket/Sprocket bearing (right)(150,000 sets)]

2.1.56 Sprocket bracket (150,000 sets)0024-6878

1) Remove the sprocket bracket [1].

F-2-136

[1]

[1]

[5]

[4]

[3]

[2]

[1]

[1]

[5]

[4]

[3]

[2]

[1]

Chapter 2

2-32

2.1.57 Replacement parts in book stacking assembly0024-6879

T-2-4

2.1.58 Before replacing the drawer connector (male) (20,000 times)

0024-6880

1) Unlock the stacking tray lock, and the draw out the stacking tray assem-bly.

2.1.59 Drawer connector (male) (20,000 times)0024-6882

1) Remove the two screws [1] from the left rail.

F-2-1373) Remove the three screws [1] from the right rail, and then remove the

stacking tray assembly [2].

F-2-138

3) Remove the drawer connector (male) [1].- 2 stepped screws [2]- 2 springs [3]- 2 spacer nuts [4]- 2 connectors [5]

F-2-139

2.1.60 Before replacing the drawer connector (female) (20,000 times)

0024-6883

1) Unlock the stacking tray lock, and the draw out the stacking tray assem-bly.

2) Remove the rear cover. (page 2-4)Reference[Removing the Rear Cover]

2.1.61 Drawer connector (female) (20,000 times)0024-6884

1) Remove the connector, and then remove the power supply unit 2 [1].- 2 screws [2]

F-2-140

No. Parts Name Q'ty

[1] Drawer connector (male) 1

[2] Drawer connector (female) 1

CAUTION:During the work, hold the stacking tray assembly so that it does not fall down.

[1]

[1]

[2]

[2]

[1]

[3]

[3]

[4]

[5]

[4]

[2]

[2]

[1]

2) Remove the drawer connector (female) [1].- 2 screws [2]- Wire saddle [3]- 2 cnnnectors [4]

F-2-141

[1]

[4]

[3]

[2]

Sep 29 2009

Documents

Perfect Binder-C1 Durability Enhancement Parts Replacement ...downloads.canon.com/imagepress/Perfect_Binder-C1_DEP_PRM_Rev0_092909.pdfReplacement Manual for Durability Enhancement