Canon Perfect Binder-C1 Operating and safety instructions

Sep 29 2009
Replacement Manual for Durability
Enhancement Parts
Finisher, Sorter, DeliveryTray
Perfect Binder-C1

Application
This 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.
Corrections
This 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.
Trademarks
The product names and company names used in this manual are the registered trademarks of the individual companies.
Copyright
This 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
Caution
Use of this manual should be strictly supervised to avoid disclosure of confidential information.

Introduction
Symbols Used
This 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 the
direction 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 in
supplying 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 microprocessors
used 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 the
DC 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 be
able 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- 1
2.1.1 Points to Note on Disassembly and Reassembly....................................................................................................2- 1
2.1.2 Removing from the Host Machine...........................................................................................................................2- 2
2.1.3 Removing the Front Covers (Left/Right) .................................................................................................................2- 3
2.1.4 Removing the Front Upper Cover............................................................................................................................2- 3
2.1.5 Removing the Rear Cover.......................................................................................................................................2- 4
2.1.6 Removing the Rear Upper Cover ............................................................................................................................2- 4
2.1.7 Removing the Left Upper Cover..............................................................................................................................2- 4
2.1.8 Removing the Inner Cover (Upper) .........................................................................................................................2- 4
2.1.9 Removing the Inner Cover (Lower) .........................................................................................................................2- 5
2.1.10 Drawing out the Cover Transport Assembly..........................................................................................................2- 5
2.1.11 Removing the Cover Horizontal Registration Unit .................................................................................................2- 6
2.1.12 Drawing out the Trimming Assembly.....................................................................................................................2- 8
2.1.13 Replacement parts in stacking tray assembly .......................................................................................................2- 9
2.1.14 Before replacing the SB flapper gear (15 million sheets) ......................................................................................2- 9
2.1.15 SB flapper gear (15 million sheets)........................................................................................................................2- 9
2.1.16 Before replacing the SB flapper unit (15 million sheets)......................................................................................2- 10
2.1.17 SB flapper unit (15 million sheets).......................................................................................................................2- 10
2.1.18 Before replacing the alignment rack (front)/alignment rack (rear) (15 million sheets) .........................................2- 11
2.1.19 Alignment rack (front)/Alignment rack (rear) (15 million sheets)..........................................................................2- 11
2.1.20 Alignment Motors (front/rear) (M4/M5) (15 million sheets) ..................................................................................2- 15
2.1.21 Replecement parts in cover transport assembly..................................................................................................2- 15
2.1.22 Before replacing the transport roller 1 (15 million sheets) ...................................................................................2- 15
2.1.23 Transport roller 1 (15 million sheets)...................................................................................................................2- 15
2.1.24 Before replacing the transport roller 2 (15 million sheets) ...................................................................................2- 16
2.1.25 Transport roller 2 (15 million sheets)...................................................................................................................2- 16
2.1.26 Before replacing the transport roller 3 (15 million sheets) ...................................................................................2- 16
2.1.27 Transport roller 3 (15 million sheets)...................................................................................................................2- 16
2.1.28 Before replacing the transport rollers 4/5 (15 million sheets) ..............................................................................2- 17
2.1.29 Transport rollers 4/5 (15 million sheets) ..............................................................................................................2- 17
2.1.30 Before replacing the transport driven roller 1 (Cover transport entrance) (15 million sheets) .............................2- 17
2.1.31 Transport driven roller 1 (Cover transport entrance) (15 million sheets) .............................................................2- 18
2.1.32 Before replacing the transport driven roller 1 (Cover transport exit) (15 million sheets)......................................2- 18
2.1.33 Transport driven roller 1 (Cover transport exit) (15 million sheets)......................................................................2- 18
2.1.34 Before replacing the transport driven roller 2 (Spine bending roller 2/3 unit) (15 million sheets) ........................2- 18
2.1.35 Transport driven roller 2 (Spine bending roller 2/3 unit) (15 million sheets) ........................................................2- 19
2.1.36 Before replacing the transport driven roller 2 (Spine bending unit (right)) (15 million sheets).............................2- 20
2.1.37 Transport driven roller 2 (Spine bending unit (right)) (15 million sheets).............................................................2- 20
2.1.38 Before replacing the transport driven roller 2 (Spine bending unit (left)) (15 million sheets)...............................2- 23
2.1.39 Transport driven roller 2 (Spine bending unit (left)) (15 million sheets)...............................................................2- 23
2.1.40 Before replacing the transport driven roller 2 (Delivery roller 1/2 unit) (15 million sheets)..................................2- 25
2.1.41 Transport driven roller 2 (Delivery roller 1/2 unit) (15 million sheets) ..................................................................2- 25
2.1.42 Before replacing the delivery roller 1/delivery roller 2 (15 million sheets)............................................................2- 26
2.1.43 Delivery roller 1/Delivery roller 2 (15 million sheets)............................................................................................2- 27
2.1.44 Before replacing the spine bending harness (right) (120,000 sets).....................................................................2- 28
2.1.45 Spine bending harness (right) (120,000 sets)......................................................................................................2- 28

Contents
2.1.46 Before replacing the spine bending harness (left) (240,000 sets)........................................................................2- 28
2.1.47 Spine bending harness (left) (240,000 sets)........................................................................................................2- 28
2.1.48 Replecement parts in trimming assembly............................................................................................................2- 30
2.1.49 Before replacing the sprocket shaft 1/sprocket/sprocket bearing (Left) (150,000 sets).......................................2- 30
2.1.50 Sprocket shaft 1/Sprocket/Sprocket bearing (Left) (150,000 sets) ......................................................................2- 30
2.1.51 Before replacing the sprocket shaft 1/sprocket/sprocket bearing (middle) (150,000 sets) ..................................2- 30
2.1.52 Sprocket shaft 1/Sprocket/Sprocket bearing (middle) (150,000 sets)..................................................................2- 30
2.1.53 Before replacing the sprocket shaft 2/sprocket/sprocket bearing (right) (150,000 sets)......................................2- 31
2.1.54 Sprocket shaft 2/Sprocket/Sprocket bearing (right) (150,000 sets) .....................................................................2- 31
2.1.55 Before replacing the sprocket bracket (150,000 sets)..........................................................................................2- 31
2.1.56 Sprocket bracket (150,000 sets)..........................................................................................................................2- 31
2.1.57 Replacement parts in book stacking assembly....................................................................................................2- 32
2.1.58 Before replacing the drawer connector (male) (20,000 times).............................................................................2- 32
2.1.59 Drawer connector (male) (20,000 times)..............................................................................................................2- 32
2.1.60 Before replacing the drawer connector (female) (20,000 times)..........................................................................2- 32
2.1.61 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 Parts
0024-2987
T-1-1
Category Parts Name Parts No. Q'ty Replacement Interval Remarks
Stacking tray assembly SB flapper Gear 4A3-2823-000 115,000,000 sheets
Stacking tray assembly SB flapper unit 4G3-1221-000 115,000,000 sheets
Stacking tray assembly Alignment rack (front) 4G3-2243-000 115,000,000 sheets
Stacking tray assembly Alignment rack (rear) 4G3-2244-000 115,000,000 sheets
Stacking tray assembly Alignment motor FH5-1040-000 215,000,000 sheets
Cover transport assembly Transport roller 1 4A3-3137-000 115,000,000 sheets
Cover transport assembly Transport roller 2 4A3-3134-000 115,000,000 sheets
Cover transport assembly Transport roller 3 4A3-3179-000 115,000,000 sheets
Cover transport assembly Transport roller 4 4A3-3237-000 115,000,000 sheets
Cover transport assembly Transport roller 5 4A3-3238-000 115,000,000 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 4A3-3216-000 115,000,000 sheets
Cover transport assembly Delivery roller 2 4A3-3135-000 115,000,000 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 1240,000 sets Bookbinding sets
Trimming assembly Sprocket bracket 4A3-2266-000 1150,000 sets Bookbinding sets
Trimming assembly Sprocket shaft 1 4A3-2288-000 2150,000 sets Bookbinding sets
- Sprocket shaft 1 (left) (1)
- Sprocket shaft 1 (middle) (1)
Trimming assembly Sprocket shaft 2 4A3-2286-000 1150,000 sets Bookbinding sets
Trimming assembly Sprocket 4S3-3099-000 3150,000 sets Bookbinding sets
- Sprocket (left) (1)
- Sprocket (middle) (1)
- Sprocket (right) (1)
Trimming assembly Sprocket bearing XG9-0581-000 3150,000 sets Bookbinding sets
- Sprocket bearing (left) (1)
- Sprocket bearing (middle) (1)
- Sprocket bearing (right) (1)
Book stacking assembly Drawer connector (male) 4H3-0223-000 120,000 times Tray opening and
closing frequency
Book stacking assembly Drawer connector (female) 4H3-0222-000 120,000 times Tray opening and
closing frequency

Chapter 2 Parts Replacement Procedure

Contents
Contents
2.1 Parts Replacement Procedure.........................................................................................................................................2-1
2.1.1 Points to Note on Disassembly and Reassembly......................................................................................................................... 2-1
2.1.2 Removing from the Host Machine............................................................................................................................................... 2-2
2.1.3 Removing the Front Covers (Left/Right) .................................................................................................................................... 2-3
2.1.4 Removing the Front Upper Cover................................................................................................................................................ 2-3
2.1.5 Removing the Rear Cover............................................................................................................................................................ 2-4
2.1.6 Removing the Rear Upper Cover................................................................................................................................................. 2-4
2.1.7 Removing the Left Upper Cover.................................................................................................................................................. 2-4
2.1.8 Removing the Inner Cover (Upper)............................................................................................................................................. 2-4
2.1.9 Removing the Inner Cover (Lower)............................................................................................................................................. 2-5
2.1.10 Drawing out the Cover Transport Assembly ............................................................................................................................. 2-5
2.1.11 Removing the Cover Horizontal Registration Unit ................................................................................................................... 2-6
2.1.12 Drawing out the Trimming Assembly ....................................................................................................................................... 2-8
2.1.13 Replacement parts in stacking tray assembly ............................................................................................................................ 2-9
2.1.14 Before replacing the SB flapper gear (15 million sheets).......................................................................................................... 2-9
2.1.15 SB flapper gear (15 million sheets) ........................................................................................................................................... 2-9
2.1.16 Before replacing the SB flapper unit (15 million sheets) ........................................................................................................ 2-10
2.1.17 SB flapper unit (15 million sheets).......................................................................................................................................... 2-10
2.1.18 Before replacing the alignment rack (front)/alignment rack (rear) (15 million sheets)........................................................... 2-11
2.1.19 Alignment rack (front)/Alignment rack (rear) (15 million sheets) .......................................................................................... 2-11
2.1.20 Alignment Motors (front/rear) (M4/M5) (15 million sheets) .................................................................................................. 2-15
2.1.21 Replecement parts in cover transport assembly....................................................................................................................... 2-15
2.1.22 Before replacing the transport roller 1 (15 million sheets)...................................................................................................... 2-15
2.1.23 Transport roller 1 (15 million sheets) ...................................................................................................................................... 2-15
2.1.24 Before replacing the transport roller 2 (15 million sheets)...................................................................................................... 2-16
2.1.25 Transport roller 2 (15 million sheets) ...................................................................................................................................... 2-16
2.1.26 Before replacing the transport roller 3 (15 million sheets)...................................................................................................... 2-16
2.1.27 Transport roller 3 (15 million sheets) ...................................................................................................................................... 2-16
2.1.28 Before replacing the transport rollers 4/5 (15 million sheets) ................................................................................................. 2-17
2.1.29 Transport rollers 4/5 (15 million sheets).................................................................................................................................. 2-17
2.1.30 Before replacing the transport driven roller 1 (Cover transport entrance) (15 million sheets)................................................ 2-17
2.1.31 Transport driven roller 1 (Cover transport entrance) (15 million sheets)................................................................................ 2-18
2.1.32 Before replacing the transport driven roller 1 (Cover transport exit) (15 million sheets)....................................................... 2-18
2.1.33 Transport driven roller 1 (Cover transport exit) (15 million sheets) ....................................................................................... 2-18
2.1.34 Before replacing the transport driven roller 2 (Spine bending roller 2/3 unit) (15 million sheets)......................................... 2-18
2.1.35 Transport driven roller 2 (Spine bending roller 2/3 unit) (15 million sheets) ......................................................................... 2-19
2.1.36 Before replacing the transport driven roller 2 (Spine bending unit (right)) (15 million sheets).............................................. 2-20
2.1.37 Transport driven roller 2 (Spine bending unit (right)) (15 million sheets).............................................................................. 2-20
2.1.38 Before replacing the transport driven roller 2 (Spine bending unit (left)) (15 million sheets)................................................ 2-23
2.1.39 Transport driven roller 2 (Spine bending unit (left)) (15 million sheets) ................................................................................ 2-23
2.1.40 Before replacing the transport driven roller 2 (Delivery roller 1/2 unit) (15 million sheets) .................................................. 2-25
2.1.41 Transport driven roller 2 (Delivery roller 1/2 unit) (15 million sheets) .................................................................................. 2-25
2.1.42 Before replacing the delivery roller 1/delivery roller 2 (15 million sheets) ............................................................................ 2-26
2.1.43 Delivery roller 1/Delivery roller 2 (15 million sheets)............................................................................................................ 2-27
2.1.44 Before replacing the spine bending harness (right) (120,000 sets).......................................................................................... 2-28
2.1.45 Spine bending harness (right) (120,000 sets)........................................................................................................................... 2-28
2.1.46 Before replacing the spine bending harness (left) (240,000 sets)............................................................................................ 2-28
2.1.47 Spine bending harness (left) (240,000 sets)............................................................................................................................. 2-28
2.1.48 Replecement parts in trimming assembly................................................................................................................................ 2-30
2.1.49 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).......................................................................................... 2-30
2.1.51 Before replacing the sprocket shaft 1/sprocket/sprocket bearing (middle) (150,000 sets)...................................................... 2-30
2.1.52 Sprocket shaft 1/Sprocket/Sprocket bearing (middle) (150,000 sets) ..................................................................................... 2-30
2.1.53 Before replacing the sprocket shaft 2/sprocket/sprocket bearing (right) (150,000 sets) ......................................................... 2-31
2.1.54 Sprocket shaft 2/Sprocket/Sprocket bearing (right) (150,000 sets)......................................................................................... 2-31
2.1.55 Before replacing the sprocket bracket (150,000 sets).............................................................................................................. 2-31
2.1.56 Sprocket bracket (150,000 sets)............................................................................................................................................... 2-31
2.1.57 Replacement parts in book stacking assembly......................................................................................................................... 2-32
2.1.58 Before replacing the drawer connector (male) (20,000 times)................................................................................................ 2-32
2.1.59 Drawer connector (male) (20,000 times)................................................................................................................................. 2-32
2.1.60 Before replacing the drawer connector (female) (20,000 times)............................................................................................. 2-32
2.1.61 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 Reassembly
0024-7278
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 Machine
0024-6639
1) Disconnect the signal cable [1] from the perfect binder.
F-2-1
2) 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-2-3
5) 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]