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Troubleshooting Guide
Perfect Binder-
A1/B1/C1/D1/E1
July 16, 2019
Canon U.S.A., Inc.

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Table of Contents

   Related Manuals for Canon Perfect Binder A1

   Summary of Contents for Canon Perfect Binder A1

  • Page 1 Troubleshooting Guide Perfect Binder- A1/B1/C1/D1/E1 July 16, 2019 Canon U.S.A., Inc.
  • Page 2 [Regarding Troubleshooting Guide] Please be advised of the release of Troubleshooting Guide for Perfect Binder. Troubleshooting Guide is a booklet compiled from FAQs issued by Canon Inc. [Additional case(s)] • 1FA5 Jam code due to wear of the roller in the signature delivery assembly(Perfect Binder-C1)
  • Page 3: Table Of Contents

    Contents Image Faults......................3 Marks on image caused by friction due to mini gripper edge (Perfect Binder- B1/D1/E1)....3 Marks on image caused by friction due to mini gripper edge (Perfect Binder-C1)......9 Malfunction......................15 The spread glue amount is unstable due to conducting inappropriate procedure to adjust the glue amount(Perfect Binder_A1 / Perfect Binder_C1)..............
  • Page 4 Alarm Code....................... 251 A warning message may be displayed and stay on even if the waste paper box is housed. Caused by the detection sensor bracket deformed.(PerfectBinder-A1,PerfectBinder-C1)..251 A warning message may be displayed and stay on even if the waste paper box is housed. Caused by the detection sensor bracket deformed.(PerfectBinder-B1/PerfectBinder-D1/ PerfectBinder-E1)........................
  • Page 5: Image Faults

    Image Faults Marks on image caused by friction due to mini gripper edge (Perfect Binder- B1/D1/E1) [Symptom] The marks caused by friction [A] may appear on the first and last pages of glued stacked of sheets during printing. [Reference] This symptom remarkably occurs on glossy paper such as coated paper. [Cause] The stuck of sheets loaded on the height tray assembly is fed by sub gripper assembly and then transferred to the main gripper assembly.
  • Page 6 4) Remove the service PCB cover. • 1 screw 5) Turn on SW1-2 and SW2-8 on the service PCB and set the machine in service mode. [CAUTION] To keep the machine running in service mode, be sure to do so with the trimming assembly stowed inside. 6) Plug the power cord in the wall outlet.
  • Page 7 10) Turn on the power switch. 11) Turn on SW2-1 and -3 on the service PCB and then press the push switch PSW1 3 (three) times to stop the mini gripper at the vertical position. 12) Turn off the main switch and unplug the power cord from the wall outlet. 13) Remove the filter case unit.
  • Page 8 [CAUTION] When attaching the glue transport stay, hang the cut part of the stay to the projection of the glue supply entrance. 15) Stand behind the machine to face the back side and then remove screws [2] fixing the mini grippers [1]. •...
  • Page 9 18) Remove the connector [2] being the right side of mini gripper [1] on your right and then remove the screw [3] to disconnect the ground wire [4]. • 1 screw 19) Lift up (in the direction of the black arrow) left and right mini grippers to remove the 2 (two) mini grippers from the pins [1]. The following photo shows the state that 1 (one) mini gripper [2] has been taken from the back side of machine.
  • Page 10 21) Reassemble the parts in the reverse order from Step 13). [Attention] Make sure that the position of unit [1] being the side of mini gripper is correct and then put the mini gripper. Photo [A] shows upside-down position of the unit on the side of mini gripper. Photo [B] shows the correct position. [Service parts] Part Number Description...
  • Page 11: Marks On Image Caused By Friction Due To Mini Gripper Edge (perfect Binder-c1)

    Copier B/W | imagePRESS 1135/1125/1110 Series | Marks on image caused by friction due to mini gripper edge (Perfect Binder-C1) [Symptom] The marks caused by friction [A] may appear on the first and last pages of glued stacked of sheets during printing. [Reference] This symptom remarkably occurs on glossy paper such as coated paper.
  • Page 12 4) Remove the service PCB cover. • 1 screw 5) Turn on SW1-2 and SW2-8 on the service PCB and set the machine in service mode. [CAUTION] To keep the machine running in service mode, be sure to do so with the trimming assembly stowed inside. 6) Plug the power cord in the wall outlet.
  • Page 13 10) Turn on the power switch. 11) Turn on SW2-1 and -3 on the service PCB and then press the push switch PSW1 3 (three) times to stop the mini gripper at the vertical position. 12) Turn off the main switch and unplug the power cord from the wall outlet. 13) Remove the filter case unit.
  • Page 14 [CAUTION] When attaching the glue transport stay, hang the cut part of the stay to the projection of the glue supply entrance. 15) Stand behind the machine to face the back side and then remove screws [2] fixing the mini grippers [1]. •...
  • Page 15 18) Remove the connector [2] being the right side of mini gripper [1] on your right and then remove the screw [3] to disconnect the ground wire [4]. • 1 screw 19) Lift up (in the direction of the black arrow) left and right mini grippers to remove the 2 (two) mini grippers from the pins [1]. The following photo shows the state that 1 (one) mini gripper [2] has been taken from the back side of machine.
  • Page 16 21) Reassemble the parts in the reverse order from Step 13). [Attention] Make sure that the position of unit [1] being the side of mini gripper is correct and then put the mini gripper. Photo [A] shows upside-down position of the unit on the side of mini gripper. Photo [B] shows the correct position. [Service parts] Part Number Description...
  • Page 17: Malfunction

    Malfunction Copier B/W | imagePRESS 1135/1125/1110 Series | The spread glue amount is unstable due to conducting inappropriate procedure to adjust the glue amount(Perfect Binder_A1 / Perfect Binder_C1) [Symptom] State of glue application to output products (book) is unstable even if spreading amount of glue has been adjusted. [Cause] It was reported in field that the spread amount of glue was unstable even after adjusting the spread amount of glue of Perfect Binder.
  • Page 18 - The screws firmly fixed with adhesive on the rear side of the device Remove the mount and confirm the screws [4] shown in the photo below: <Information lacked in the technical materials> B) Adjusting the spread glue amount in service mode and [Fine adjustment of spread amount of glue in perfect binding] in user mode.
  • Page 19 For instance, GLU-AMT3 adjustment value is to be applied when a booklet is produced whose thickness of stack of sheets (Signature) is between 3.5 and 6.4mm (when the thickness of paper is 0.1mm, approximate 35 to 64 sheets). At this time, if the number of the sheets is between 35 and 50, the parameter of [1 to 50 sheets] setting button in user mode also becomes effective, and if the number of the sheets is between 51 and 64, the parameter of [51 to 100 sheets] setting button in user mode also becomes effective.
  • Page 20 If the paper is not curled, go to the step 2). If the paper is curled, perform curl correction following the procedure below: [Reference] The tolerance of curl on the paper [1] that is delivered from copier host machine should be 10mm or less in regard to the height [a] of the curl, and the length of curl [b] should be 50mm or more.
  • Page 21 3) Check the GLUING parameter of service mode of the device and enter an adjustment value for correction Check the setting value of Service Mode of the device> SORTER> Adjust> GLUING When the service mode setting parameter is different from the label parameter, enter the label parameter checked in the step 2). 4) Check the stack registration guide Check if any glue particle is attached on the stack registration guide [a], and make sure to clean if glue particles are attached.
  • Page 22 Refer to the following table for details. Location Condition Description Lack of glue at spine/ glue come off spine Hollows are formed in the glue applied to spine. Otherwise glue is applied but not adhered to the cover. Side glue come off The cover easily comes off due to the scanty amount of side glue.
  • Page 23 Refer to the following table for details. Location Condition Description Spine glue is pushed and spread over in Due to an excessive amount of glue, the glue spreads over the sides (or a side) of the folded a T (L) letter shape spine cover.
  • Page 24 If glue is applied in this condition, the stack goes sagged and registration adjustment is not performed correctly, and this leads to [Slanted spine glue] [E] or [Imbalance of side glue] [F]. In this case, execute the curl correction in the step 1) and perform again from the step 5). After performing the step 5), if the [Slanted spine glue] or [Imbalance of side glue] is resolved but the side glue amount is still excessive, then perform b) Spine glue is pushed and spread over in a T (L) letter shape or an excessive amount of glue.
  • Page 25 [Caution] Be sure that the specified value of the curved spine is R1.5[mm] or less at the corner of the book when a cover of 128g/m2, horizontal grain paper [1] is used. 7) Print out a sample booklet of stack again Print out a book as same as in the step 5) and check the condition of the glue application.
  • Page 26 If the glue amount has become appropriate, adjustment of glue amount to the book of GLU-AMT1 stack thickness between 0 and 1.4mm is completed. Go to the step 8). 8) Print out a sample booklet of stack thickness 1.5 to 25.0mm As same as GLU-AMT1, go to Service mode>...
  • Page 27: The Spread Glue Amount Is Unstable Due To Conducting Inappropriate Procedure To Adjust The Glue Amount(perfect Binder_b1)

    Copier Color | imagePRESS C7011/C7010/C6011/C6010 Series | The spread glue amount is unstable due to conducting inappropriate procedure to adjust the glue amount(Perfect Binder_B1) [Symptom] State of glue application to output products (book) is unstable even if spreading amount of glue has been adjusted. [Cause] It was reported in field that the spread amount of glue was unstable even after adjusting the spread amount of glue of Perfect Binder.
  • Page 28 - The screws firmly fixed with adhesive on the rear side of the device Remove the mount and confirm the screws [4] shown in the photo below: <Information lacked in the technical materials> B) Adjusting the spread glue amount in service mode and [Fine adjustment of spread amount of glue in perfect binding] in user mode.
  • Page 29 For instance, GLU-AMT3 adjustment value is to be applied when a booklet is produced whose thickness of stack of sheets (Signature) is between 3.5 and 6.4mm (when the thickness of paper is 0.1mm, approximate 35 to 64 sheets). At this time, if the number of the sheets is between 35 and 50, the parameter of [1 to 50 sheets] setting button in user mode also becomes effective, and if the number of the sheets is between 51 and 64, the parameter of [51 to 100 sheets] setting button in user mode also becomes effective.
  • Page 30 If the paper is not curled, go to the step 2). If the paper is curled, perform curl correction following the procedure below: [Reference] The tolerance of curl on the paper [1] that is delivered from copier host machine should be 10mm or less in regard to the height [a] of the curl, and the length of curl [b] should be 50mm or more.
  • Page 31 3) Check the GLUING parameter of service mode of the device and enter an adjustment value for correction Check the setting value of Service Mode of the device> SORTER> Adjust> GLUING When the service mode setting parameter is different from the label parameter, enter the label parameter checked in the step 2). 4) Check the stack registration guide Check if any glue particle is attached on the stack registration guide [a], and make sure to clean if glue particles are attached.
  • Page 32 Refer to the following table for details. Location Condition Description Lack of glue at spine/ glue come off spine Hollows are formed in the glue applied to spine. Otherwise glue is applied but not adhered to the cover. Side glue come off The cover easily comes off due to the scanty amount of side glue.
  • Page 33 Refer to the following table for details. Location Condition Description Spine glue is pushed and spread over in Due to an excessive amount of glue, the glue spreads over the sides (or a side) of the folded a T (L) letter shape spine cover.
  • Page 34 If glue is applied in this condition, the stack goes sagged and registration adjustment is not performed correctly, and this leads to [Slanted spine glue] [E] or [Imbalance of side glue] [F]. In this case, execute the curl correction in the step 1) and perform again from the step 5). After performing the step 5), if the [Slanted spine glue] or [Imbalance of side glue] is resolved but the side glue amount is still excessive, then perform b) Spine glue is pushed and spread over in a T (L) letter shape or an excessive amount of glue.
  • Page 35 [Caution] Be sure that the specified value of the curved spine is R1.5[mm] or less at the corner of the book when a cover of 128g/m2, horizontal grain paper [1] is used. 7) Print out a sample booklet of stack again Print out a book as same as in the step 5) and check the condition of the glue application.
  • Page 36 If the glue amount has become appropriate, adjustment of glue amount to the book of GLU-AMT1 stack thickness between 0 and 1.4mm is completed. Go to the step 8). 8) Print out a sample booklet of stack thickness 1.5 to 25.0mm As same as GLU-AMT1, go to Service mode>...
  • Page 37: Lines Occurring On The Trimming Side Of The Books Due To The Nicked Trimming Blade (perfect Binder_a1 / Perfect Binder_c1)

    Copier B/W | iR7105/7095/7086 Series | Copier B/W | imagePRESS 1135/1125/1110 Series | Lines occurring on the trimming side of the books due to the nicked trimming blade (Perfect Binder_A1 / Perfect Binder_C1) [Symptom] In the machines prior to the Countermeasure cut-in serial number in factory described below lines may occur on the trimming side of the books.
  • Page 38 [Service work] If the above-mentioned symptom occurs, check the trimming blade. If the trimming blade is found to be nicked, prepare the new cutter unit (4Y8-3057-000), the reinforcement kit (4Y8-3099-000) and the super lube grease (FY9-6005-000). And replace the trimming blade and attach the reinforcement kit by following the procedures.
  • Page 39 1-5) Draw out the stacking tray assembly. 1-6) Draw out the waste paper basket. 1-7) Release the book stacking assembly lock, and then draw out the book stacking assembly. 1-8) Remove the jam removal knob. With the three jam removal levers released, remove the inner cover (lower). - 9 screws [Note] The inner cover (lower) must be removed with it lifted to prevent the stopper from being caught on the surrounding parts.
  • Page 40 1-10) Plug the power cord in the wall outlet. 1-11) Remove the service PCB cover. - 1 screw 1-12) Turn on the SW1-1 on the service PCB and set the machine in service mode. [Caution] To keep the machine running in service mode, be sure to do so with the trimming assembly stowed inside.
  • Page 41 1-13) Turn on the power switch. 1-14) Turn on SW2-2, SW2-3, and SW2-7 on the service PCB and press the push switch PSW1. [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.
  • Page 42 1-17) Draw out the trimming assembly. - 4 screws 2) Removing the Stack Rotation Assembly 2-1) Move to the right side of the trimming assembly, remove the three connectors and two reuse bands, and then release the harness from the edge saddle and wire saddle. - 3 connectors - 2 reuse bands - 1 edge saddle...
  • Page 43 2-2) Remove the drive assembly support plate. - 4 screws 2-3) Move to the right side of the trimming assembly, remove the screw retaining the earth wire. Remove the reuse band, release the harness from the wire saddle, and then disconnect the three connectors. - 1 screw - 1 reuse band - 5 wire saddles...
  • Page 44 2-4) Move to the front side of the trimming assembly, remove the sensor connector and reuse band, and then release the two wire saddle and one edge saddle. - 1 connector - 1 reuse band - 1 wire saddle - 1 edge saddle 2-5) Remove the stack rotation assembly by holding it left and right stays.
  • Page 45 3) Attaching the reinforcement kit 3-1) Check the contents of the kit. - UPPER PRESS RAIL [1] 2 pcs - LOWER PRESS RAIL [2] 2 pcs - FRONT PRESS SUPPORT GUIDE [3] 1 pcs - REAR PRESS SUPPORT GUIDE [4] 1 pcs - SPACER [5] 2 pcs - M3×8 Screw [6] 8 pcs - M4×8 Screw [7] 4 pcs...
  • Page 46 3-3) Remove the 4 screws [1] on the front side of the trimming assembly and remove the press rail [2]. -Screw x4 3-4) Remove the 6 screws [1]. -Screw x6...
  • Page 47 3-5) Apply the grease as much as a grain of rice (20mg) to the section [a] of the front press support guide [1] / the rear press support guide [2] respectively. 3-6) Press the spacer [2] forcefully into the front press support guide [1] to insert between the frame.
  • Page 48 3-7) Attach the 6 screws that were removed in the step 3-4). 3-8) Attach the press rail [2], that was removed in the step 3-3), with the 4 screws [1].
  • Page 49 3-9) Fix the lower press rail [1] in the kit with the 2 screws. The figure below shows the front side of the trimming assembly in the direction from an arrow. 3-10) Fix the upper press rail [1] in the kit with the 2 screws. [Note] Press the upper press rail softly from above and tighten the screw.
  • Page 50 3-11) Fix the upper press rail [1] /the lower press rail [2] with the 2 screws included in the kit. 3-12) Perform the rear side in the same manner by following the steps from 3-3) to 3-11). [Service parts] Part Number Description 4Y8-3057-000 CUTTER UNIT...
  • Page 51 Part Number Description [Countermeasure cut-in serial numbers in factory] Model Serial number Perfect Binder_A1 US No implemented due to production discontinuance. Perfect Binder_A1 EU/O No implemented due to production discontinuance. Perfect Binder_C1 US EGX20509 Perfect Binder_C1 EU/O EGZ20531...
  • Page 52: Lines Occurring On The Trimming Side Of The Books Due To The Nicked Trimming Blade (perfect Binder_b1 / Perfect Binder_d1)

    Lines occurring on the trimming side of the books due to the nicked trimming blade (Perfect Binder_B1 / Perfect Binder_D1) [Symptom] In the machines prior to the Countermeasure cut-in serial number in factory described below lines may occur on the trimming side of the books.
  • Page 53 [Service work] If the above-mentioned symptom occurs, check the trimming blade. If the trimming blade is found to be nicked, prepare the new cutter unit (4Y8-3057-000), the reinforcement kit (4Y8-3099-000) and the super lube grease (FY9-6005-000). And replace the trimming blade and attach the reinforcement kit by following the procedures.
  • Page 54 1-5) Draw out the stacking tray assembly. 1-6) Draw out the waste paper basket. 1-7) Release the book stacking assembly lock, and then draw out the book stacking assembly. 1-8) Remove the jam removal knob. With the three jam removal levers released, remove the inner cover (lower). - 9 screws [Note] The inner cover (lower) must be removed with it lifted to prevent the stopper from being caught on the surrounding parts.
  • Page 55 1-10) Plug the power cord in the wall outlet. 1-11) Remove the service PCB cover. - 1 screw 1-12) Turn on the SW1-1 on the service PCB and set the machine in service mode. [Caution] To keep the machine running in service mode, be sure to do so with the trimming assembly stowed inside.
  • Page 56 1-13) Turn on the power switch. 1-14) Turn on SW2-2, SW2-3, and SW2-7 on the service PCB and press the push switch PSW1. [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.
  • Page 57 1-17) Draw out the trimming assembly. - 4 screws 2) Removing the Stack Rotation Assembly 2-1) Move to the right side of the trimming assembly, remove the three connectors and two reuse bands, and then release the harness from the edge saddle and wire saddle. - 3 connectors - 2 reuse bands - 1 edge saddle...
  • Page 58 2-2) Remove the drive assembly support plate. - 4 screws 2-3) Move to the right side of the trimming assembly, remove the screw retaining the earth wire. Remove the reuse band, release the harness from the wire saddle, and then disconnect the three connectors. - 1 screw - 1 reuse band - 5 wire saddles...
  • Page 59 2-4) Move to the front side of the trimming assembly, remove the sensor connector and reuse band, and then release the two wire saddle and one edge saddle. - 1 connector - 1 reuse band - 1 wire saddle - 1 edge saddle 2-5) Remove the stack rotation assembly by holding it left and right stays.
  • Page 60 3) Attaching the reinforcement kit 3-1) Check the contents of the kit. - UPPER PRESS RAIL [1] 2 pcs - LOWER PRESS RAIL [2] 2 pcs - FRONT PRESS SUPPORT GUIDE [3] 1 pcs - REAR PRESS SUPPORT GUIDE [4] 1 pcs - SPACER [5] 2 pcs - M3×8 Screw [6] 8 pcs - M4×8 Screw [7] 4 pcs...
  • Page 61 3-3) Remove the 4 screws [1] on the front side of the trimming assembly and remove the press rail [2]. -Screw x4 3-4) Remove the 6 screws [1]. -Screw x6...
  • Page 62 3-5) Apply the grease as much as a grain of rice (20mg) to the section [a] of the front press support guide [1] / the rear press support guide [2] respectively. 3-6) Press the spacer [2] forcefully into the front press support guide [1] to insert between the frame.
  • Page 63 3-7) Attach the 6 screws that were removed in the step 3-4). 3-8) Attach the press rail [2], that was removed in the step 3-3), with the 4 screws [1].
  • Page 64 3-9) Fix the lower press rail [1] in the kit with the 2 screws. The figure below shows the front side of the trimming assembly in the direction from an arrow. 3-10) Fix the upper press rail [1] in the kit with the 2 screws. [Note] Press the upper press rail softly from above and tighten the screw.
  • Page 65 3-11) Fix the upper press rail [1] /the lower press rail [2] with the 2 screws included in the kit. 3-12) Perform the rear side in the same manner by following the steps from 3-3) to 3-11). [Service parts] Part Number Description 4Y8-3057-000 CUTTER UNIT...
  • Page 66 Part Number Description [Countermeasure cut-in serial numbers in factory] Model Serial number Perfect Binder_B1 US CVZ00183 Perfect Binder_B1 EU/O GZK00067 Perfect Binder_D1 US QWS00034 Perfect Binder_D1 EU/O QWT00047...
  • Page 67: Jam (delivery Options)

    Jam (Delivery options) 1FA5 Jam code due to wear of the roller in the signature delivery assembly(Perfect Binder-C1) [Symptom/Question] 1FA5 jam may occur during booklet printing using Perfect Binder-C1 that has been used over time. - 1FA5: Different media length Jam [Cause] The above symptom occurs when the roller [2] touching the signature delivery roller [1] in the signature delivery assembly wears out causing the paper feeding force to be insufficient.
  • Page 68: Error Code

    Error Code Copier B/W | imagePRESS 1135/1125/1110 Series | E5B5-xx16 due to damage on the mount portions of Dust Buffer Unit.(Perfect Binder-A1,Perfect Binder-C1) [Symptom] During operation of making booklets, E5B5-xx16 error may occur. - E5B5-xx16 : The waste paper is present error in Perfect Binder. [Cause] The mount portions [1] of the Dust Buffer Unit may be damaged due to low strength, and the Dust Buffer Unit cannot operate properly.
  • Page 69 2) Remove the Rear Cover. - Screw x6 3) Removing Inner Cover (Lower) 3-1) Pull out the Waste Basket, and take out the Waste Paper Box. 3-2) Release the lock of the Book Stacking Assembly, and pull out the Book Stacking Assembly. 3-3) Pull the jam clear knob.
  • Page 70 4) Removing Waste Paper Buffer Drive Unit (i.e. Dust Buffer Drive Assembly) 4-1) Remove the Stack Buffer Tray Motor Unit. - Connector x1 - Screw x2 4-2) Lower the Waste Paper Buffer Drive Unit - Screw x2 4-3) Remove the Waste Paper Buffer Drive Unit. - Connector x4...
  • Page 71 CAUTION: To install the Waste Paper Buffer Drive Unit, align the 2 bosses with the boss holes, and the positioning pins with the positioning holes. 5) Removing Dust Buffer Unit 5-1) Remove the 2 screws. 5-2) Remove the fixing plate in the Trimming Assembly. - Screw x2...
  • Page 72 5-3) Pull out the Trimming Assembly. - Screw x4 CAUTION: Before pulling out the Trimming Assembly, be sure to check that the Trimming Blade is at the REAR side. If the Trimming Blade is at the front side, move the Trimming Blade to the rear side by following the Service Manual. 6) Open the Controller Mount.
  • Page 73 7) Remove the reuse bands and the wire saddle, and pull out the connector. Remove the 2 rail guides. - Reuse band x2 - Wire saddle x1 - Connector x1 - Screw x2 - Rail guide x2 <For Perfect Binder-A1/B1/C1> <For Perfect Binder-D1>...
  • Page 74 <For Perfect Binder-D1> 9) Remove the sensors, cables, etc., from the Dust Buffer Unit, and install them to the new type Dust Buffer Unit. CAUTION: The cables in the Dust Buffer Unit are different between Perfect Binder-A1/B1/C1 and Perfect Binder-D1. Be careful of how to install the cables.
  • Page 75 [Countermeasure cut-in serial numbers in factory] Perfect Binder-A1 US : Not implemented due to production discontinuance Perfect Binder-A1 EU/O : Not implemented due to production discontinuance Perfect Binder-B1 US : CVZ00171 Perfect Binder-B1 EU/O : GZK00062 Perfect Binder-C1 US : EGX20503 Perfect Binder-C1 EU/O : EGZ20523 Perfect Binder-D1 US : QWS00001 Perfect Binder-D1 EU/O : QWT00001...
  • Page 76: E5b5-xx16 Due To Damage On The Mount Portions Of Dust Buffer Unit.(perfect Binder-b1,perfect Binder-d1)

    E5B5-xx16 due to damage on the mount portions of Dust Buffer Unit.(Perfect Binder-B1,Perfect Binder-D1) [Symptom] During operation of making booklets, E5B5-xx16 error may occur. - E5B5-xx16 : The waste paper is present error in Perfect Binder. [Cause] The mount portions [1] of the Dust Buffer Unit may be damaged due to low strength, and the Dust Buffer Unit cannot operate properly.
  • Page 77 2) Remove the Rear Cover. - Screw x6 3) Removing Inner Cover (Lower) 3-1) Pull out the Waste Basket, and take out the Waste Paper Box. 3-2) Release the lock of the Book Stacking Assembly, and pull out the Book Stacking Assembly. 3-3) Pull the jam clear knob.
  • Page 78 4) Removing Waste Paper Buffer Drive Unit (i.e. Dust Buffer Drive Assembly) 4-1) Remove the Stack Buffer Tray Motor Unit. - Connector x1 - Screw x2 4-2) Lower the Waste Paper Buffer Drive Unit - Screw x2 4-3) Remove the Waste Paper Buffer Drive Unit. - Connector x4...
  • Page 79 [Caution] To install the Waste Paper Buffer Drive Unit, align the 2 bosses with the boss holes, and the positioning pins with the positioning holes. 5) Removing Dust Buffer Unit 5-1) Remove the 2 screws. 5-2) Remove the fixing plate in the Trimming Assembly. - Screw x2...
  • Page 80 5-3) Pull out the Trimming Assembly. - Screw x4 [Caution] Before pulling out the Trimming Assembly, be sure to check that the Trimming Blade is at the REAR side. If the Trimming Blade is at the front side, move the Trimming Blade to the rear side by following the Service Manual. 6) Open the Controller Mount.
  • Page 81 - Reuse band x2 - Wire saddle x1 - Connector x1 - Screw x2 - Rail guide x2 <For Perfect Binder-A1/B1/C1> <For Perfect Binder-D1> 8) Move the Dust Buffer Unit in the direction indicated by the arrow to release the hook of the Dust Buffer Unit from the rail. Then remove the Dust Buffer Unit.
  • Page 82 <For Perfect Binder-D1> 9) Remove the sensors, cables, etc., from the Dust Buffer Unit, and install them to the new type Dust Buffer Unit. [Caution] The cables in the Dust Buffer Unit are different between Perfect Binder-A1/B1/C1 and Perfect Binder-D1. Be careful of how to install the cables.
  • Page 83 Perfect Binder-B1 US : CVZ00171 Perfect Binder-B1 EU/O : GZK00062 Perfect Binder-C1 US : EGX20503 Perfect Binder-C1 EU/O : EGZ20523 Perfect Binder-D1 US : QWS00001 Perfect Binder-D1 EU/O : QWT00001...
  • Page 84: E5b5-xx16 Due To Fractured Hook Arm In The Waste Paper Case Assembly.(perfect Binder-a1,perfect Binder-c1)

    Copier B/W | imagePRESS 1135/1125/1110 Series | E5B5-xx16 due to fractured hook arm in the waste paper case assembly.(Perfect Binder-A1,Perfect Binder-C1) [Symptom] E5B5-xx16 error may occur during bookbinding operation. - E5B5-xx16 error: Waste detection error of Perfect binder [Cause] The Hook arm of the shutter unit gets fractured and trim waste processing operation does not run properly. As a result, the symptom occurs.
  • Page 85 1-4) Pull the Waste paper unit. Remove the Waste paper box. 1-5) Release the lock of the Book stacking assembly and pull the Book stacking assembly. 1-6) Remove the Jam removal knob, and remove the Inner cover (Lower) with the 3 Jam removal levers released. - 9 screws NOTE: To remove the Inner cover (Lower), lift it so that the stopper is not stuck.
  • Page 86 NOTE: In conjunction with the movement of the Shutter [1] in the direction of arrow, the Dust buffer [2] coordinates. (below figure [A]) If the Shutter [1] is moved further in the direction of arrow, the Dust buffer [2] moves away from the Shutter (below figure [B]). Refer to the service manual for detail of the operation of the Shutter.
  • Page 87 2) Replace the Hook arm. 2-1) Remove the rear cover. - 6 screws 2-2) Remove the front cover [1] in the Waste paper case assembly. - 4 screws...
  • Page 88 2-3) Remove the front cover of the Book stacking assembly. - 4 screws 2-4) Remove the 2 screws from the left rail in the Book stacking assembly. - 2 screws...
  • Page 89 2-5) Remove the 3 screws from the right rail to remove the Stacking tray assembly. CAUTION: Perform the work supporting the Stacking tray assembly with a hand not to drop it. 2-6) Remove the right front cover and the Handing off lower cover. - 2 screws - 4 screws...
  • Page 90 2-7) Remove the metal plate and the frame. - 3 screws - 16 screws CAUTION: Some screws are hidden behind the levers. Remove the screws holding the levers. 2-8) Remove the fixing bracket of the trimming assembly. - 2 screws...
  • Page 91 2-9) Remove the screws fixing the Trimming assembly. - 4 screws CAUTION: Be sure to confirm that the Trimming blade is evacuated to a safe position before pulling it out. If the Trimming blade is not evacuated to a safe position, evacuate the Trimming blade to a safe position following to the service manual. 2-10) Removal of the Power supply mount Go to the step 2-11-1) for Perfect Binder-D1 as it has the Stack cooling fan (stack rotation assembly).
  • Page 92 2-11-2) Remove the 4 screws from the cooling fan assembly. 2-11-3) Remove the 1 connector and the 1 reuse band. 2-11-4) Open the PCB mount. - 13 connectors - 2 ribbon cables - 2 ribbon cable holders - 2 screws...
  • Page 93 2-11-5) Pull the Trimming assembly out. 2-11-6 ) Remove the Cooling fan unit. - 1 connector - 2 Reuse bands 2-11-7) Close the PCB mount. - 2 screws 2-11-8) Disconnect the 1 connector [1] of the Cutter controller PCB. NOTE: The connector can easily be located by following the cable from the Power supply PCB mount to the PCB mount.
  • Page 94 2-11-9) Disconnect the 4 connectors [1] of the Slave controller PCB. CAUTION: The connector can easily be located by following the cable from the Power supply PCB mount to the PCB mount. 2-11-10) Disconnect the 5 connectors [1] of the Master controller PCB. NOTE: The connector can easily be located by following the cable from the Power supply PCB mount to the PCB mount.
  • Page 95 2-11-11) Disconnect the 1 connector [2] at the lower-left corner of the PCB mount [1]. 2-11-12) Disconnect the 1 connector [1] of the Relay PCB (option controller).
  • Page 96 2-11-13) Remove the 7 screws [1] to remove the Power supply PCB mount [2]. 2-12) Rotate the gear of the Waste paper buffer drive unit counterclockwise and move the Stack buffer tray to the upper limit.
  • Page 97 2-13) Disconnect the Sensor connector seen from the Book stacking assembly side. 2-14) Remove the Stack tray sensor unit from the Waste paper unit. - 2 screws CAUTION: Match the notches on the Sensor mount to the plate guides to mount it.
  • Page 98 2-15) Remove the frame [1]. - 2 screws 2-16) Remove the Stack buffer tray motor unit. - 2 screws - 1 connector...
  • Page 99 2-17) Lower the Waste paper buffer drive unit. - 2 screws 2-18) Remove the Waste paper buffer drive unit. - 4 connectors CAUTION: To mount the Buffer drive unit, fit the 2 bosses to the boss holes and the positioning pin to the positioning hole.
  • Page 100 2-19) Remove the 2 screws fixing the Waste paper buffer unit. 2-20) Go to the back of the machine and open the Controller PCB mount. - 2 screws 2-21) Release the reuse bands, the wire saddle and disconnect the connector from the back of the machine. Then remove the 2 rail guides.
  • Page 101 <For Perfect Binder-D1> 2-22) From the back of the machine, move the Waste paper buffer in the direction of arrow to release the claw of the Waste paper buffer unit and remove the Waste paper buffer unit. <For Perfect Binder-A1/B1/C1> <For Perfect Binder-D1>...
  • Page 102 CAUTION: To close the Waste paper unit after mounting, rotate the Buffer drive pulley [1] to align the position of the Full detection lever with the notch [3] on the Waste basket so that the Full detection lever [2] of the Waste paper buffer unit and the Waste basket do not come in contact each other.
  • Page 103 2-24) Remove the e-ring [1]. CAUTION: Do not misplace the e-ring [1]. 2-25) Remove the Tray guide unit from the link [1].
  • Page 104 2-26) Remove the 1 screw [1] to remove the Fixing bracket [2]. Then move the Tray guide unit [3]in the direction of arrow to remove it. CAUTION: When removing the Fixing bracket, pay attention not to drop the torsion spring [4] inside the machine. 2-27) Remove the Tension spring [1] hooked on the Shutter with a pair of needle nose pliers or the like (by one side only).
  • Page 105 2-28) Remove the 2 screws [1] of the Dust catcher unit. 2-29) Move to in front of the machine and remove the 2 screws [1] and the metal plate [2] of the shutter.
  • Page 106 2-30) Remove the tension spring [1] on the front in the same manner as the step 2-27) (by one side only). 2-31) Remove the 2 screws [1] on the front side of the Dust catcher unit.
  • Page 107 2-32) Move to the back of the machine, remove the 2 screws [1] on the side face of the Dust catcher unit to remove the Dust catcher. NOTE: If the Dust catcher unit [1] and the metal plate [2] are brought together with the screw [3] by tightening the screw halfway, it facilitates mounting the Dust catcher unit.
  • Page 108 2-33) Remove the 4 screws and remove the metal plate unit. 2-34) Remove the 4 screws [1] fixing the Shutter unit. Then, pull the Shutter unit in the direction of arrow. 2-35) Pull the Shutter unit [1] from the left side of the machine. The below photo shows the appearance of the machine from its back to its left side.
  • Page 109 2-36) Remove the e-ring [1] from the Shutter unit and replace the Hook arm [2] with the new type Hook arm. CAUTION: Do not misplace the e-ring [1] or the torsion spring [3]. 2-37) Reassemble the parts in the reverse order from the step 2-35). 2-38) Perform the check of fracture of the Hook arm in the step 1) to verify all is fine.
  • Page 110: E5b5-xx16 Due To Fractured Hook Arm In The Waste Paper Case Assembly.(perfect Binder-b1,perfect Binder-d1)

    E5B5-xx16 due to fractured hook arm in the waste paper case assembly.(Perfect Binder-B1,Perfect Binder-D1) [Symptom] E5B5-xx16 error may occur during bookbinding operation. - E5B5-xx16 error: Waste detection error of Perfect binder [Cause] The Hook arm of the shutter unit gets fractured and trim waste processing operation does not run properly. As a result, the symptom occurs.
  • Page 111 1-4) Pull the Waste paper unit. Remove the Waste paper box. 1-5) Release the lock of the Book stacking assembly and pull the Book stacking assembly. 1-6) Remove the Jam removal knob, and remove the Inner cover (Lower) with the 3 Jam removal levers released. - 9 screws [Note]: To remove the Inner cover (Lower), lift it so that the stopper is not stuck.
  • Page 112 [Note]: In conjunction with the movement of the Shutter [1] in the direction of arrow, the Dust buffer [2] coordinates. (below figure [A]) If the Shutter [1] is moved further in the direction of arrow, the Dust buffer [2] moves away from the Shutter (below figure [B]). Refer to the service manual for detail of the operation of the Shutter.
  • Page 113 2) Replace the Hook arm. 2-1) Remove the rear cover. - 6 screws 2-2) Remove the front cover [1] in the Waste paper case assembly. - 4 screws...
  • Page 114 2-3) Remove the front cover of the Book stacking assembly. - 4 screws 2-4) Remove the 2 screws from the left rail in the Book stacking assembly. - 2 screws...
  • Page 115 2-5) Remove the 3 screws from the right rail to remove the Stacking tray assembly. [CAUTION]: Perform the work supporting the Stacking tray assembly with a hand not to drop it. 2-6) Remove the right front cover and the Handing off lower cover. - 2 screws - 4 screws 2-7) Remove the metal plate and the frame.
  • Page 116 - 16 screws [CAUTION] Some screws are hidden behind the levers. Remove the screws holding the levers. 2-8) Remove the fixing bracket of the trimming assembly. - 2 screws 2-9) Remove the screws fixing the Trimming assembly. - 4 screws [CAUTION]: Be sure to confirm that the Trimming blade is evacuated to a safe position before pulling it out.
  • Page 117 2-10) Removal of the Power supply mount Go to the step 2-11-1) for Perfect Binder-D1 as it has the Stack cooling fan (stack rotation assembly). Go to the step 2-11-8) for Perfect Binder-A1/B1/C1 as they do not have the Stack cooling fan (stack rotation assembly). 2-11-1) Remove the Power supply assembly 1.
  • Page 118 2-11-4) Open the PCB mount. - 13 connectors - 2 ribbon cables - 2 ribbon cable holders - 2 screws 2-11-5) Pull the Trimming assembly out. 2-11-6 ) Remove the Cooling fan unit. - 1 connector - 2 Reuse bands 2-11-7) Close the PCB mount.
  • Page 119 2-11-8) Disconnect the 1 connector [1] of the Cutter controller PCB. [Note] The connector can easily be located by following the cable from the Power supply PCB mount to the PCB mount. 2-11-9) Disconnect the 4 connectors [1] of the Slave controller PCB. [Note] The connector can easily be located by following the cable from the Power supply PCB mount to the PCB mount.
  • Page 120 2-11-10) Disconnect the 5 connectors [1] of the Master controller PCB. [Note] The connector can easily be located by following the cable from the Power supply PCB mount to the PCB mount. 2-11-11) Disconnect the 1 connector [2] at the lower-left corner of the PCB mount [1].
  • Page 121 2-11-12) Disconnect the 1 connector [1] of the Relay PCB (option controller). 2-11-13) Remove the 7 screws [1] to remove the Power supply PCB mount [2].
  • Page 122 2-12) Rotate the gear of the Waste paper buffer drive unit counterclockwise and move the Stack buffer tray to the upper limit. 2-13) Disconnect the Sensor connector seen from the Book stacking assembly side. 2-14) Remove the Stack tray sensor unit from the Waste paper unit. - 2 screws...
  • Page 123 [CAUTION]: Match the notches on the Sensor mount to the plate guides to mount it. 2-15) Remove the frame [1]. - 2 screws...
  • Page 124 2-16) Remove the Stack buffer tray motor unit. - 2 screws - 1 connector 2-17) Lower the Waste paper buffer drive unit. - 2 screws 2-18) Remove the Waste paper buffer drive unit. - 4 connectors...
  • Page 125 [CAUTION]: To mount the Buffer drive unit, fit the 2 bosses to the boss holes and the positioning pin to the positioning hole. 2-19) Remove the 2 screws fixing the Waste paper buffer unit. 2-20) Go to the back of the machine and open the Controller PCB mount. - 2 screws...
  • Page 126 2-21) Release the reuse bands, the wire saddle and disconnect the connector from the back of the machine. Then remove the 2 rail guides. - 2 reuse bands - 1 wire saddle - 1 connector - 2 screws - 2 rail guides <For Perfect Binder-A1/B1/C1>...
  • Page 127 <For Perfect Binder-D1> [CAUTION]: To close the Waste paper unit after mounting, rotate the Buffer drive pulley [1] to align the position of the Full detection lever with the notch [3] on the Waste basket so that the Full detection lever [2] of the Waste paper buffer unit and the Waste basket do not come in contact each other.
  • Page 128 2-23) Push down the metal plate from the back of the machine and lift the Tray guide unit in the direction of arrow. 2-24) Remove the e-ring [1]. [CAUTION]: Do not misplace the e-ring [1].
  • Page 129 2-25) Remove the Tray guide unit from the link [1]. 2-26) Remove the 1 screw [1] to remove the Fixing bracket [2]. Then move the Tray guide unit [3]in the direction of arrow to remove it. [CAUTION]: When removing the Fixing bracket, pay attention not to drop the torsion spring [4] inside the machine.
  • Page 130 2-27) Remove the Tension spring [1] hooked on the Shutter with a pair of needle nose pliers or the like (by one side only). 2-28) Remove the 2 screws [1] of the Dust catcher unit.
  • Page 131 2-29) Move to in front of the machine and remove the 2 screws [1] and the metal plate [2] of the shutter. 2-30) Remove the tension spring [1] on the front in the same manner as the step 2-27) (by one side only).
  • Page 132 2-31) Remove the 2 screws [1] on the front side of the Dust catcher unit. 2-32) Move to the back of the machine, remove the 2 screws [1] on the side face of the Dust catcher unit to remove the Dust catcher.
  • Page 133 [Note]: If the Dust catcher unit [1] and the metal plate [2] are brought together with the screw [3] by tightening the screw halfway, it facilitates mounting the Dust catcher unit. 2-33) Remove the 4 screws and remove the metal plate unit.
  • Page 134 2-34) Remove the 4 screws [1] fixing the Shutter unit. Then, pull the Shutter unit in the direction of arrow. 2-35) Pull the Shutter unit [1] from the left side of the machine. The below photo shows the appearance of the machine from its back to its left side.
  • Page 135 2-36) Remove the e-ring [1] from the Shutter unit and replace the Hook arm [2] with the new type Hook arm. [CAUTION]: Do not misplace the e-ring [1] or the torsion spring [3]. 2-37) Reassemble the parts in the reverse order from the step 2-35). 2-38) Perform the check of fracture of the Hook arm in the step 1) to verify all is fine.
  • Page 136: E5b5-xx16 Due To Sliding Failure Of The Waste Stopper In The Waste Paper Case Assembly(perfect Binder-a1,perfect Binder-c1 )

    Copier B/W | imagePRESS 1135/1125/1110 Series | E5B5-xx16 due to sliding failure of the waste stopper in the waste paper case assembly(Perfect Binder-A1,Perfect Binder-C1 ) [Symptom] E5B5-xx16 error may occur during bookbinding operation. - E5B5-xx16 error: Waste detection error of Perfect binder [Cause] Waste paper [1], generated upon trimming, normally falls into the waste paper buffer [2].
  • Page 137 1-3) Remove the front cover (Right) in the same manner. 1-4) Pull the Waste paper unit. Remove the Waste paper box. 1-5) Release the lock of the Book stacking assembly and pull the Book stacking assembly. 1-6) Remove the jam removal knob, and remove the inner cover (Lower) with the 3 jam removal levers released. - 9 screws NOTE: To remove the inner cover (Lower), lift it so that the stopper is not stuck.
  • Page 138 Turning the pulley in the counterclockwise direction moves the Waste stopper [1] in the direction indicated by the arrow. Keep tuning the pulley until the flanges [2] come to the positions indicated in the figure below. 1-10) Put a hand into the area where the Waste paper unit is housed. Hold the center edge [2] of the Waste stopper [1], and move it in the direction indicated by the arrow.
  • Page 139 2-1) Remove the rear cover. - 6 screws 2-2) Remove the Waste paper buffer drive unit 2-2-1) Remove the stack buffer tray motor unit. - 2 screws - 1 connector 2-2-2) Lower the Waste paper buffer drive unit. - 2 screws 2-2-3) Remove the Waste paper buffer drive unit.
  • Page 140 CAUTION: To mount the buffer drive unit, fit the 2 bosses to the boss holes and the positioning pin to the positioning hole. 2-3) Remove the Waste paper buffer unit. 2-3-1) Remove the 2 screws fixing the Waste paper buffer unit. 2-3-2) Remove the fixing plate in the Trimming Assembly.
  • Page 141 2-3-3) Pull out the Trimming Assembly. - Screw x4 CAUTION: Before pulling out the Trimming Assembly, be sure to check that the Trimming Blade is at the REAR side. If the Trimming Blade is at the front side, move the Trimming Blade to the rear side by following the Service Manual. 2-3-4) Open the Controller PCB Mount.
  • Page 142 2-3-5) Release the reuse bands, the wire saddle and disconnect the connector from the back of the machine. Then remove the 2 rail guides. - 2 reuse bands - 1 wire saddle - 1 connector - 2 screws - 2 rail guides <For Perfect Binder-A1/C1>...
  • Page 143 2-4) Remove the Dust stopper unit. Then install the new type Dust stopper unit. 2-5) Reassemble the parts in the reverse order from step 2-4) 2-6) Check sliding failure in step 1) to see whether the sliding performance has improved. [Countermeasure cut-in serial numbers in factory] Perfect Binder-A1 US WVL00010 Perfect Binder-A1 EU MVM00072...
  • Page 144: E5b5-xx16 Due To Sliding Failure Of The Waste Stopper In The Waste Paper Case Assembly(perfect Binder-b1,perfect Binder-d1 )

    E5B5-xx16 due to sliding failure of the waste stopper in the waste paper case assembly(Perfect Binder-B1,Perfect Binder-D1 ) [Symptom] E5B5-xx16 error may occur during bookbinding operation. - E5B5-xx16 error: Waste detection error of Perfect binder [Cause] Waste paper [1], generated upon trimming, normally falls into the waste paper buffer [2]. In some cases, the waste paper [1] may go into the space [4] between the waste paper buffer and the waste stopper [3].
  • Page 145 1-3) Remove the front cover (Right) in the same manner. 1-4) Pull the Waste paper unit. Remove the Waste paper box. 1-5) Release the lock of the Book stacking assembly and pull the Book stacking assembly. 1-6) Remove the jam removal knob, and remove the inner cover (Lower) with the 3 jam removal levers released. - 9 screws [Note]: To remove the inner cover (Lower), lift it so that the stopper is not stuck.
  • Page 146 Turning the pulley in the counterclockwise direction moves the Waste stopper [1] in the direction indicated by the arrow. Keep tuning the pulley until the flanges [2] come to the positions indicated in the figure below. 1-10) Put a hand into the area where the Waste paper unit is housed. Hold the center edge [2] of the Waste stopper [1], and move it in the direction indicated by the arrow.
  • Page 147 2-1) Remove the rear cover. - 6 screws 2-2) Remove the Waste paper buffer drive unit 2-2-1) Remove the stack buffer tray motor unit. - 2 screws - 1 connector 2-2-2) Lower the Waste paper buffer drive unit. - 2 screws 2-2-3) Remove the Waste paper buffer drive unit.
  • Page 148 [CAUTION]: To mount the buffer drive unit, fit the 2 bosses to the boss holes and the positioning pin to the positioning hole. 2-3) Remove the Waste paper buffer unit. 2-3-1) Remove the 2 screws fixing the Waste paper buffer unit. 2-3-2) Remove the fixing plate in the Trimming Assembly.
  • Page 149 2-3-3) Pull out the Trimming Assembly. - Screw x4 [Caution] Before pulling out the Trimming Assembly, be sure to check that the Trimming Blade is at the REAR side. If the Trimming Blade is at the front side, move the Trimming Blade to the rear side by following the Service Manual. 2-3-4) Open the Controller PCB Mount.
  • Page 150 2-3-5) Release the reuse bands, the wire saddle and disconnect the connector from the back of the machine. Then remove the 2 rail guides. - 2 reuse bands - 1 wire saddle - 1 connector - 2 screws - 2 rail guides <For Perfect Binder-B1>...
  • Page 151 <For Perfect Binder-D1> 2-4) Remove the Dust stopper unit. Then install the new type Dust stopper unit. 2-5) Reassemble the parts in the reverse order from step 2-4) 2-6) Check sliding failure in step 1) to see whether the sliding performance has improved. [Countermeasure cut-in serial numbers in factory] Perfect Binder-B1 US CVZ00172 Perfect Binder-B1 EU GZK00064...
  • Page 152: E5b5-xx07/ E5b5-xx13 Errors May Occur Due To Front Cover Of Booklet May Be Stained And Rotation Sheet May Peel Off.(perfect Binder_a1 / Perfect Binder_c1)

    Copier B/W | imagePRESS 1135/1125/1110 Series | Copier B/W | iR7105/7095/7086 Series | E5B5-xx07/ E5B5-xx13 errors may occur due to front cover of booklet may be stained and rotation sheet may peel off.(Perfect Binder_A1 / Perfect Binder_C1) [Symptom] In the machines prior to the Countermeasure cut-in serial number in factory described below Front cover of booklet may be stained [1] when bookbinding outputting.
  • Page 153 [Service work] Prepare 2 sheets of the rotation sheet, and c heck the condition of the stack rotation assembly. When the rotation sheet is peeling, re-stick the new type rotation sheet following the steps below. Clean the surface to be stuck with lint-free paper moistened with alcohol before the sticking.
  • Page 154 5) Pull out the trim waste unit. 6) Release the lock of stacker to pull it out. 7) Remove the Jam removal knob, and remove the Inner cover (Lower) with the 3 Jam removal levers released. - 9 screws [ Caution] To remove the Inner cover (Lower), lift it so that the stopper is not stuck.
  • Page 155 9) Remove the service mode PCB cover. - 1 screw 10) Turn ON the SW1-1 on the service mode PCB and set the main body to service mode. [ Caution] Make sure the trimming assembly is stowed inside of main body when operating the machine in service mode.
  • Page 156 11) Turn on the power supply switch. 12) Turn on SW2-2, SW2-3 and SW2-7 on the service mode PCB and press the push switch PSW1. [ Caution] Pressing the push switch PSW1 activates the trimming blade, the pressing plate and the stack rotation assembly. Be careful not to have your hand or clothes caught by them.
  • Page 157 16) Remove 4 screws fixing the trim section to pull out the section. - 4 screws 17) Ensure that the stack rotation unit stays at the upper limit. If it is not, turn the knob to raise the stack rotation unit to the upper limit.
  • Page 158 19) Reassemble the parts in reverse order from step 17). [Service parts] Part Number Description 4A3-2317-000 Rotation Sheet 4A3-2317-010 Rotation Sheet [Countermeasure cut-in serial numbers in factory] Model Serial number PERFECT BINDER-A1 JPN TGV : No implemented due to production discontinuance. PERFECT BINDER-A1 JPN MVL00005 PERFECT BINDER-A1 USA...
  • Page 159: Rotation Sheet May Peel Off.(perfect Binder_b1 / Perfect Binder_d1 / Perfect Binder_e1)

    E5B5-xx07/ E5B5-xx13 errors may occur due to front cover of booklet may be stained and rotation sheet may peel off.(Perfect Binder_B1 / Perfect Binder_D1 / Perfect Binder_E1) [Symptom] In the machines prior to the Countermeasure cut-in serial number in factory described below Front cover of booklet may be stained [1] when bookbinding outputting.
  • Page 160 [Service work] Prepare 2 sheets of the rotation sheet, and c heck the condition of the stack rotation assembly. When the rotation sheet is peeling, re-stick the new type rotation sheet following the steps below. Clean the surface to be stuck with lint-free paper moistened with alcohol before the sticking.
  • Page 161 8) Turn on the front right cover switch and the front left cover switch by inserting the service tool or the like. 9) Remove the service mode PCB cover. - 1 screw 10) Turn ON the SW1-1 on the service mode PCB and set the main body to service mode.
  • Page 162 [ Caution] Make sure the trimming assembly is stowed inside of main body when operating the machine in service mode. 11) Turn on the power supply switch. 12) Turn on SW2-2, SW2-3 and SW2-7 on the service mode PCB and press the push switch PSW1. [ Caution] Pressing the push switch PSW1 activates the trimming blade, the pressing plate and the stack rotation assembly.
  • Page 163 - 2 screws 16) Remove 4 screws fixing the trim section to pull out the section. - 4 screws 17) Ensure that the stack rotation unit stays at the upper limit. If it is not, turn the knob to raise the stack rotation unit to the upper limit.
  • Page 164 19) Reassemble the parts in reverse order from step 17). [Service parts] Part Number Description 4A3-2317-000 Rotation Sheet 4A3-2317-010 Rotation Sheet [Countermeasure cut-in serial numbers in factory] Model Serial number PERFECT BINDER-B1 JP CVY00032 PERFECT BINDER-B1 USA CVZ00092 PERFECT BINDER-B1 EU/O CWA00081 PERFECT BINDER-D1 JP QWR00001...
  • Page 165: Error E5b5-xx16 Due To The Deformation Of Shutter For Waste Paper Case Assembly (perfect Binder_a1 / Perfect Binder_c1)

    Copier B/W | imagePRESS 1135/1125/1110 Series | Error E5B5-xx16 due to the deformation of shutter for waste paper case assembly (Perfect Binder_A1 / Perfect Binder_C1) [Symptom] Error E5B5-xx16 may occur at the time of bookbinding printing. - Error E5B5-xx16 : Waste paper detection error for Perfect Binder [Cause] Normally, waste paper [1] generated at the time of trimming goes into the waste paper buffer [2].
  • Page 166 2) Replacement of shutter 2-1) Open the front covers (left/light). 2-2) While holding the front cover (left) with one hand and pressing the black lever with the other hand, pull the hinge in the direction of the arrow to remove it. After removing the upper and lower hinges, remove the front cover (left). 2-3) Remove the front cover (right) in the same manner as above.
  • Page 167 2-5) Pull out the waste paper unit to remove the waste paper box. 2-6) Release the lock of book stacking assembly and pull it out. 2-7) Remove the jam clear knob to remove inner cover (lower) releasing 3 jam removal levers. - 9 screws [Caution] Lift up the inner cover (lower) when it is removed, because its stopper is caught.
  • Page 168 2-9) Remove the front cover for stacking assembly. - 4 screws 2-10) Remove 2 screws from the left rail of book stacking assembly. - 2 screws...
  • Page 169 2-11) Remove 3 screws from the right rail and demount the book stacking tray assembly. - 3 screws [Note] Hold the book stacking tray assembly with hand during the operation not to drop it. 2-12) Remove the right front cover. - 2 screws 2-13) Remove the transfer lower cover.
  • Page 170 2-14) Remove the metal plate. - 3 screws 2-15) Detach the frame. - 16 screws [Caution] There are screws behind the lever. Move the lever up to remove the screws. 2-16) Remove the fixing bracket for trimming assembly. - 2 screws 2-17) Remove the fixing screws for trimming assembly.
  • Page 171 2-18) Desassembly of power supply mount. Perfect Binder-D1 has a stack cooling fan (Stack Rotation Assembly). Proceed to step 2-18-1). Perfect Binder-A1/B1/C1 do not have a stack cooling fan (Stack Rotation Assembly). Proceed to step 2-18-8). 2-18-1) Detach the power supply unit 1. - 2 connectors - 4 screws 2-18-2) Remove 4 screws of the cooling fan unit.
  • Page 172 2-18-4) Open the mount. - 13 connectors - 2 flexible cables - 2 flexible cable retainers - 2 screws 2-18-5) Face the front of the machine to pull out the trimming assembly. 2-18-6) Take out the cooling fan unit. - 1 connector - 2 reuse bands 2-18-7) Close the mount.
  • Page 173 2-18-8) Remove the connector [1] of the cutter controller PCB. [Reference]The position of connector can be found easily by following the harness from the power supply mount to the mount. 2-18-9) Remove 4 connectors [1] on the slave controller PCB. [Reference]The position of connectors can be found easily by following the harness from the power supply mount to the mount.
  • Page 174 2-18-10) Remove 5 connectors [1] on the master controller PCB. [Reference] The position of connector can be found easily by following the harness from the power supply mount to the mount. 2-18-11) Remove 1 connector [2] located at the bottom left of mount [1].
  • Page 175 2-18-12) Remove 1 connector [1] on the mount (option controller). 2-18-13) Remove 7 screws [1] and then detach the power supply mount [2].
  • Page 176 2-19) Turn the gear for the waste paper buffer drive assembly counterclockwise to move the stack buffer tray up to the upper limit position. 2-20) Pull off the sensor connector which can be seen from the stacking assembly side. 2-21) Detach the stacking tray sensor unit from the waste paper unit side. - 2 screws...
  • Page 177 [Note] When the stacking tray sensor unit is reinstalled, align the cutouts of the sensor mounting plate with plate guide. 2-22) Remove the frame [1]. - 2 screws...
  • Page 178 2-23) Detach the stacking buffer tray motor Unit. - 2 screwss 2-24) Take down the waste paper buffer drive unit. - 2 screws 2-25) Remove the waste paper buffer drive unit. - 4 connectors...
  • Page 179 [Note]When the waste paper buffer drive unit is reinstalled, fit the two bosses to the holes and the positioning pin to the positioning hole. 2-26) Remove 2 fixing screws of the waste paper buffer unit. 2-27) Face to back side of machine to open the controller mount. - 2 screws...
  • Page 180 2-28) Release the reuse band and the wire saddle to pull off the connector. Then remove 2 rail guides. - 2 reuse bands - 1 wire saddle - 1 connector - 2 screws - 2 rail guides << for A1/B1/C1 >> <<...
  • Page 181 << for D1 >> [Note] When closing the waste paper unit after the reinstalling, align the position of waste full detection lever of the waste paper buffer unit with the cutouts of waste paper basket by turning the waste paper buffer drive pulley, so that the detection lever will not come in contact with the waste paper basket.
  • Page 182 2-30) From the back side of the machine, press down the metal plate in the allow direction to lift up tray guide assembly in the direction of arrow. 2-31) Remove the E-ring [1].
  • Page 183 2-32) Remove the tray guide assembly [2] from link [1]. 2-33) Remove 1 screw [1] to remove fixing bracket [2]. Then shift the tray guide assembly [3] in the allow direction to remove it. [Caution] When the fixing bracket is removed, be careful not to drop the torsion spring [4] inside of machine.
  • Page 184 2-34) Unhook the tension spring [1] hooked the shutter with long-nose pliers. (Only one side of the spring) 2-35) Remove 2 screws [1] on the back side of dust catch unit.
  • Page 185 2-36) Face to the front side of machine to remove 2 screws [1] and then remove the metal plate [2] of shutter assembly. 2-37) As with step 2-34), unhook the front side of the torsion spring. (Only one side of the spring)
  • Page 186 2-38) Remove 2 screws [1] of the front side of dust catch unit. 2-39) Face to the back side of machine to remove 2 screws [1] located the side of dust catch unit and then detach the dust catch unit.
  • Page 187 [Note]Tighten the screw [3] halfway tentatively to tack dust catch unit [1] and the metal plate [2], so that the dust catch unit can be attached easily. 2-40) Remove 4 screws to demount the metal plate unit.
  • Page 188 2-41) Remove 4 screws fixing shutter unit and pull out the shutter unit in the direction of the arrow. 2-42) Pull out the shutter unit [1] from the left side of the machine. The following photo showing the left side of machine is taken from the back side of it.
  • Page 189 2-43) Take off the sheet [1] from shutter Unit. 2-44) Remove accessory components of the shutter [1] and then attach them to the new type shutter (FL0-0749-000).
  • Page 190 [Note] When the magnet [1] is attached, it shall be fixed in a state of that it is interspaced 1.5 mm from shutter. 2-45) Stick the new type sheet (4A3-2553-000) [1] to the new type shutter unit. [Note] As for the sticking position of the sheet, align the corners of the sheet [1] with the corners of the metal plate [2] for longitudinal direction and stick the sheet without protruding from the metal plate for lateral position.
  • Page 191 2-46) Assemble the parts in the reverse order from step 2-42). 3) Operation check with operation test mode. (Operation check for the waste paper buffer and dust catch unit) [Note]Remove the front cover (left/right) and the inner cover (lower) to check the inside of machine visually during the operation test.
  • Page 192 3-2) Set the SW1-2 [1] and SW2-2, -3, -5 [2] of service PCB to ON and turn on the power supply SW and then press PSW 1 [3]. The waste paper buffer [4] moves in the direction of arrow to the drop position of the waste paper. 3-3)Return the trimming assembly to the original position and turn on the power supply switch and then set the SW1-2 [1] and SW2-2, -3, -5 [2] of service PCB to ON and press PSW 1 [3].
  • Page 193 3-4) Press PSW1 to shift the dust catch assembly to the locked position. Confirm that the hook arm of dust catch assembly is locked in this state. Photo [A] shows normal state that the assembly is locked. Photo [B] shows unlocked state. 3-5) Press PSW1 to shift the waste paper buffer to the drop position of the waste paper.
  • Page 194: Error E5b5-xx16 Due To The Deformation Of Shutter For Waste Paper Case Assembly (perfect Binder_b1 / Perfect Binder_d1)

    Error E5B5-xx16 due to the deformation of shutter for waste paper case assembly (Perfect Binder_B1 / Perfect Binder_D1) [Symptom] Error E5B5-xx16 may occur at the time of bookbinding printing. - Error E5B5-xx16 : Waste paper detection error for Perfect Binder [Cause] Normally, waste paper [1] generated at the time of trimming goes into the waste paper buffer [2].
  • Page 195 2) Replacement of shutter 2-1) Open the front covers (left/light). 2-2) While holding the front cover (left) with one hand and pressing the black lever with the other hand, pull the hinge in the direction of the arrow to remove it. After removing the upper and lower hinges, remove the front cover (left). 2-3) Remove the front cover (right) in the same manner as above.
  • Page 196 2-5) Pull out the waste paper unit to remove the waste paper box. 2-6) Release the lock of book stacking assembly and pull it out. 2-7) Remove the jam clear knob to remove inner cover (lower) releasing 3 jam removal levers. - 9 screws [Caution] Lift up the inner cover (lower) when it is removed, because its stopper is caught.
  • Page 197 2-9) Remove the front cover for stacking assembly. - 4 screws 2-10) Remove 2 screws from the left rail of book stacking assembly. - 2 screws...
  • Page 198 2-11) Remove 3 screws from the right rail and demount the book stacking tray assembly. - 3 screws [Note] Hold the book stacking tray assembly with hand during the operation not to drop it. 2-12) Remove the right front cover. - 2 screws 2-13) Remove the transfer lower cover.
  • Page 199 2-14) Remove the metal plate. - 3 screws 2-15) Detach the frame. - 16 screws [Caution] There are screws behind the lever. Move the lever up to remove the screws. 2-16) Remove the fixing bracket for trimming assembly. - 2 screws 2-17) Remove the fixing screws for trimming assembly.
  • Page 200 2-18) Desassembly of power supply mount. Perfect Binder-D1 has a stack cooling fan (Stack Rotation Assembly). Proceed to step 2-18-1). Perfect Binder-A1/B1/C1 do not have a stack cooling fan (Stack Rotation Assembly). Proceed to step 2-18-8). 2-18-1) Detach the power supply unit 1. - 2 connectors - 4 screws 2-18-2) Remove 4 screws of the cooling fan unit.
  • Page 201 2-18-4) Open the mount. - 13 connectors - 2 flexible cables - 2 flexible cable retainers - 2 screws 2-18-5) Face the front of the machine to pull out the trimming assembly. 2-18-6) Take out the cooling fan unit. - 1 connector - 2 reuse bands 2-18-7) Close the mount.
  • Page 202 2-18-8) Remove the connector [1] of the cutter controller PCB. [Reference]The position of connector can be found easily by following the harness from the power supply mount to the mount. 2-18-9) Remove 4 connectors [1] on the slave controller PCB. [Reference]The position of connectors can be found easily by following the harness from the power supply mount to the mount.
  • Page 203 2-18-10) Remove 5 connectors [1] on the master controller PCB. [Reference] The position of connector can be found easily by following the harness from the power supply mount to the mount. 2-18-11) Remove 1 connector [2] located at the bottom left of mount [1].
  • Page 204 2-18-12) Remove 1 connector [1] on the mount (option controller). 2-18-13) Remove 7 screws [1] and then detach the power supply mount [2].
  • Page 205 2-19) Turn the gear for the waste paper buffer drive assembly counterclockwise to move the stack buffer tray up to the upper limit position. 2-20) Pull off the sensor connector which can be seen from the stacking assembly side. 2-21) Detach the stacking tray sensor unit from the waste paper unit side. - 2 screws...
  • Page 206 [Note] When the stacking tray sensor unit is reinstalled, align the cutouts of the sensor mounting plate with plate guide. 2-22) Remove the frame [1]. - 2 screws...
  • Page 207 2-23) Detach the stacking buffer tray motor Unit. - 2 screwss 2-24) Take down the waste paper buffer drive unit. - 2 screwss 2-25) Remove the waste paper buffer drive unit. - 4 connectors...
  • Page 208 [Note]When the waste paper buffer drive unit is reinstalled, fit the two bosses to the holes and the positioning pin to the positioning hole. 2-26) Remove 2 fixing screws of the waste paper buffer unit. 2-27) Face to back side of machine to open the controller mount. - 2 screws...
  • Page 209 2-28) Release the reuse band and the wire saddle to pull off the connector. Then remove 2 rail guides. - 2 reuse bands - 1 wire saddle - 1 connector - 2 screws - 2 rail guides << for A1/B1/C1 >> <<...
  • Page 210 << for D1 >> [Note] When closing the waste paper unit after the reinstalling, align the position of waste full detection lever of the waste paper buffer unit with the cutouts of waste paper basket by turning the waste paper buffer drive pulley, so that the detection lever will not come in contact with the waste paper basket.
  • Page 211 2-30) From the back side of the machine, press down the metal plate in the allow direction to lift up tray guide assembly in the direction of arrow. 2-31) Remove the E-ring [1].
  • Page 212 2-32) Remove the tray guide assembly [2] from link [1]. 2-33) Remove 1 screw [1] to remove fixing bracket [2]. Then shift the tray guide assembly [3] in the allow direction to remove it. [Caution] When the fixing bracket is removed, be careful not to drop the torsion spring [4] inside of machine.
  • Page 213 2-34) Unhook the tension spring [1] hooked the shutter with long-nose pliers. (Only one side of the spring) 2-35) Remove 2 screws [1] on the back side of dust catch unit.
  • Page 214 2-36) Face to the front side of machine to remove 2 screws [1] and then remove the metal plate [2] of shutter assembly. 2-37) As with step 2-34), unhook the front side of the torsion spring. (Only one side of the spring)
  • Page 215 2-38) Remove 2 screws [1] of the front side of dust catch unit. 2-39) Face to the back side of machine to remove 2 screws [1] located the side of dust catch unit and then detach the dust catch unit.
  • Page 216 [Note]Tighten the screw [3] halfway tentatively to tack dust catch unit [1] and the metal plate [2], so that the dust catch unit can be attached easily. 2-40) Remove 4 screws to demount the metal plate unit.
  • Page 217 2-41) Remove 4 screws fixing shutter unit and pull out the shutter unit in the direction of the arrow. 2-42) Pull out the shutter unit [1] from the left side of the machine. The following photo showing the left side of machine is taken from the back side of it.
  • Page 218 2-43) Take off the sheet [1] from shutter Unit. 2-44) Remove accessory components of the shutter [1] and then attach them to the new type shutter (FL0-0749-000).
  • Page 219 [Note] When the magnet [1] is attached, it shall be fixed in a state of that it is interspaced 1.5 mm from shutter. 2-45) Stick the new type sheet (4A3-2553-000) [1] to the new type shutter unit. [Note] As for the sticking position of the sheet, align the corners of the sheet [1] with the corners of the metal plate [2] for longitudinal direction and stick the sheet without protruding from the metal plate for lateral position.
  • Page 220 2-46) Assemble the parts in the reverse order from step 2-42). 3) Operation check with operation test mode. (Operation check for the waste paper buffer and dust catch unit) [Note]Remove the front cover (left/right) and the inner cover (lower) to check the inside of machine visually during the operation test.
  • Page 221 3-2) Set the SW1-2 [1] and SW2-2, -3, -5 [2] of service PCB to ON and turn on the power supply SW and then press PSW 1 [3]. The waste paper buffer [4] moves in the direction of arrow to the drop position of the waste paper. 3-3)Return the trimming assembly to the original position and turn on the power supply switch and then set the SW1-2 [1] and SW2-2, -3, -5 [2] of service PCB to ON and press PSW 1 [3].
  • Page 222 3-4) Press PSW1 to shift the dust catch assembly to the locked position. Confirm that the hook arm of dust catch assembly is locked in this state. Photo [A] shows normal state that the assembly is locked. Photo [B] shows unlocked state. 3-5) Press PSW1 to shift the waste paper buffer to the drop position of the waste paper.
  • Page 223: Measures When E5aa-000x, E5aa-800x Or The Trimming Assembly Breakage Occurs (perfect Binder-b1/d1)

    Measures when E5AA-000x, E5AA-800x or the trimming assembly breakage occurs (Perfect Binder-B1/D1) [Symptom] E5AA-000x, E5AA-800x or the trimming assembly breakage may occur in the booklet mode. - E5AA-000x : Error in Cutter Motor (M35) of Perfect Binder (x=1,2,3,4,5,6,7) - E5AA-800x : Error in Cutter Motor (M35) of Perfect Binder (x=1,2,3,4,5,6) [Cause] If the trimming blade continues to be used after it exceeds the expected service life of 40,000 cutting times, or if the drive torque at the time of trimming is raised due to the paper type, the above-mentioned errors occur.
  • Page 224 [Service work] If the above-mentioned symptom occurs, pull out the trimming assembly to check the broken sections. Replace the parts corresponding to the broken sections. The replacing parts are all the service parts used only for the service work. -If the bracket bent part of the trimming drive assembly or the press ball screw breaks, prepare a new-type cutter drive assembly (4Y3-0037-010) with its strength increased, and go to A) Replacing the cutter drive assembly.
  • Page 225 1) Check the contents of the cutter drive assembly (4Y3-0037-010). - Cutter drive assembly [1] 1pc - Reinforcement bracket [2] 1pc - Button head bolt (M4×10) [3] 5pcs - Flanged pan head screw (M4×8) [4] 4pcs 2) Referring to Service Manual, remove the stack rotation assembly. 3) Remove the 5 screws [2], and remove the 2 fixing sheet metal [1] on the both sides of the trimming assembly.
  • Page 226 5) Remove the 1 screw [1], and remove the cable arm [2] from the trimming assembly. 6) Remove the 6 screws [1], and remove the trimming assembly. [Reference] Marking the screw holes where the screws were attached with a permanent marker etc. will be helpful to find the place to attach them later.
  • Page 227 [Caution] - When removing the trimming assembly, make sure that 2 people hold the circled sections indicated below. - If the removed trimming assembly is placed on the floor, do not place it directly on the floor. Due to the protrusion part on the lower side of the trimming assembly, placing it directly on the floor may result in breakage.
  • Page 228 7) Disconnect the 2 connectors [1] and remove the cables from the 4 wire saddles [2] and the 2 edge saddles [3]. 8) Remove the 2 screws [1] that fix the drive assembly.
  • Page 229 9) Reverse the trimming assembly. 10) Remove the 2 screws [1] and remove the sheet metal part [2].
  • Page 230 11) Remove the 10 screws [1][2] in total, and remove the rear stay [2]. [Reference] When attaching the rear stay [2] later, the 8 screws [1] out of the removed 10 screws [1][2] are reused, and the remaining 2 screws [2] are replaced by the 2 button head bolts (M4x10) inside the kit. 12) Remove the screw [1] that fixes the cutter drive assembly.
  • Page 231 13) Remove the 5 screws [1] that fix the cutter drive assembly. 14) Remove the 3 screws [1] that fix the cutter drive assembly. [Reference] When attaching the cutter drive assembly later, screws removed in this step are not used but the 3 flanged pan head screws (M4x8) in the kit are used.
  • Page 232 15) Remove the 3 screws [1] that fix the cutter drive assembly. [Reference] When attaching the cutter drive assembly later, screws removed in this step are not used but the 3 button head bolts (M4x10) in the kit are used. 16) Remove the cutter drive assembly.
  • Page 233 17) Remove the 1 screw [1] from the removed cutter drive assembly, and remove the reinforcement bracket [2]. If the cutter drive assembly has no reinforcement bracket, go to the next step. 18) Attach the reinforcement bracket that was removed in the step 17) to the new cutter drive assembly inside the cutter drive assembly.
  • Page 234 20) Turn the knob [1] of the cutter motor of the new drive assembly with fingers to adjust the stop position of the press ball screw to be the same distance as measured in the step 19). [Note] Be sure to adjust the stop position of the press ball screw. Otherwise, the new drive assembly may not be attached. 21) Attach the trimming assembly to the main unit by reversing the steps from 16).
  • Page 235 2) Remove the 10 screws [2][3][4] in total from the lower side of the trimming assembly, and remove the rear stay [1]. [Reference] Some machines do not have the 2 screws [4], which depends on the time of production. 3) Attach the new rear stay inside the rear stay kit. When attaching the new rear stay [1], the 6 screws [2] and the 2 screws [3] that were removed in the step 2) are reused.
  • Page 236 3) Set the reinforcement plate [1] inside the reinforcement plate kit to fit the positioning pin [2] on the lower side of the trimming assembly. [Reference] Check that the positioning pin [2] fits the hole of reinforcement plate [1] for sure. 4) Insert the 1 screw with captive washer (M3x6) [1] inside the reinforcement plate kit from the lower side [a] into the screw hole [b] on the reinforcement plate attached in the step 3).
  • Page 237 [Reference] If the screw lock agent is left in the screw holes, remove it by using the tapping screw etc. 6) Attach the trimming assembly to the main unit. [Service parts] Part Number Description Q'ty Fig.No. 4Y3-0037-000 CUTTER DRIVE ASSEMBLY 1->0 4Y3-0037-010 CUTTER DRIVE ASSEMBLY...
  • Page 238: Measures When E5aa-000x, E5aa-800x Or The Trimming Assembly Breakage Occurs (perfect Binder-c1)

    Copier B/W | imagePRESS 1135/1125/1110 Series | Measures when E5AA-000x, E5AA-800x or the trimming assembly breakage occurs (Perfect Binder-C1) [Symptom] E5AA-000x, E5AA-800x or the trimming assembly breakage may occur in the booklet mode. - E5AA-000x : Error in Cutter Motor (M35) of Perfect Binder (x=1,2,3,4,5,6,7) - E5AA-800x : Error in Cutter Motor (M35) of Perfect Binder (x=1,2,3,4,5,6) [Cause] If the trimming blade continues to be used after it exceeds the expected service life of 40,000 cutting times, or if the drive torque...
  • Page 239 [Service work] If the above-mentioned symptom occurs, pull out the trimming assembly to check the broken sections. Replace the parts corresponding to the broken sections. The replacing parts are all the service parts used only for the service work. -If the bracket bent part of the trimming drive assembly or the press ball screw breaks, prepare a new-type cutter drive assembly (4Y3-0037-010) with its strength increased, and go to A) Replacing the cutter drive assembly.
  • Page 240 - Reinforcement bracket [2] 1pc - Button head bolt (M4×10) [3] 5pcs - Flanged pan head screw (M4×8) [4] 4pcs 2) Referring to Service Manual, remove the stack rotation assembly. 3) Remove the 5 screws [2], and remove the 2 fixing sheet metal [1] on the both sides of the trimming assembly. [Reference] Marking the screw holes where the screws were attached with a permanent marker etc.
  • Page 241 5) Remove the 1 screw [1], and remove the cable arm [2] from the trimming assembly. 6) Remove the 6 screws [1], and remove the trimming assembly. [Reference] Marking the screw holes where the screws were attached with a permanent marker etc. will be helpful to find the place to attach them later.
  • Page 242 [Caution] - When removing the trimming assembly, make sure that 2 people hold the circled sections indicated below. - If the removed trimming assembly is placed on the floor, do not place it directly on the floor. Due to the protrusion part on the lower side of the trimming assembly, placing it directly on the floor may result in breakage.
  • Page 243 7) Disconnect the 2 connectors [1] and remove the cables from the 4 wire saddles [2] and the 2 edge saddles [3]. 8) Remove the 2 screws [1] that fix the drive assembly.
  • Page 244 9) Reverse the trimming assembly. 10) Remove the 2 screws [1] and remove the sheet metal part [2].
  • Page 245 11) Remove the 10 screws [1][2] in total, and remove the rear stay [2]. [Reference] When attaching the rear stay [2] later, the 8 screws [1] out of the removed 10 screws [1][2] are reused, and the remaining 2 screws [2] are replaced by the 2 button head bolts (M4x10) inside the kit. 12) Remove the screw [1] that fixes the cutter drive assembly.
  • Page 246 13) Remove the 5 screws [1] that fix the cutter drive assembly. 14) Remove the 3 screws [1] that fix the cutter drive assembly. [Reference] When attaching the cutter drive assembly later, screws removed in this step are not used but the 3 flanged pan head screws (M4x8) in the kit are used.
  • Page 247 15) Remove the 3 screws [1] that fix the cutter drive assembly. [Reference] When attaching the cutter drive assembly later, screws removed in this step are not used but the 3 button head bolts (M4x10) in the kit are used. 16) Remove the cutter drive assembly.
  • Page 248 17) Remove the 1 screw [1] from the removed cutter drive assembly, and remove the reinforcement bracket [2]. If the cutter drive assembly has no reinforcement bracket, go to the next step. 18) Attach the reinforcement bracket that was removed in the step 17) to the new cutter drive assembly inside the cutter drive assembly.
  • Page 249 20) Turn the knob [1] of the cutter motor of the new drive assembly with fingers to adjust the stop position of the press ball screw to be the same distance as measured in the step 19). [Note] Be sure to adjust the stop position of the press ball screw. Otherwise, the new drive assembly may not be attached. 21) Attach the trimming assembly to the main unit by reversing the steps from 16).
  • Page 250 2) Remove the 10 screws [2][3][4] in total from the lower side of the trimming assembly, and remove the rear stay [1]. [Reference] Some machines do not have the 2 screws [4], which depends on the time of production. 3) Attach the new rear stay inside the rear stay kit. When attaching the new rear stay [1], the 6 screws [2] and the 2 screws [3] that were removed in the step 2) are reused.
  • Page 251 3) Set the reinforcement plate [1] inside the reinforcement plate kit to fit the positioning pin [2] on the lower side of the trimming assembly. [Reference] Check that the positioning pin [2] fits the hole of reinforcement plate [1] for sure. 4) Insert the 1 screw with captive washer (M3x6) [1] inside the reinforcement plate kit from the lower side [a] into the screw hole [b] on the reinforcement plate attached in the step 3).
  • Page 252 [Reference] If the screw lock agent is left in the screw holes, remove it by using the tapping screw etc. 6) Attach the trimming assembly to the main unit. [Service parts] Part Number Description Q'ty Fig.No. 4Y3-0037-000 CUTTER DRIVE ASSEMBLY 1->0 4Y3-0037-010 CUTTER DRIVE ASSEMBLY...
  • Page 253 Alarm Code Copier B/W | imagePRESS 1135/1125/1110 Series | Copier B/W | iR7105/7095/7086 Series | A warning message may be displayed and stay on even if the waste paper box is housed. Caused by the detection sensor bracket deformed.(PerfectBinder-A1,PerfectBinder-C1) [Symptom] A warning message "The trim waste unit of the Perfect Binder is pulled out."...
  • Page 254 2) Remove the rear cover. - 6 screws 3) Remove the inner cover (Lower) 3-1) Pull the Waste paper unit. Remove the Waste paper box. 3-2) Release the lock of the Book stacking assembly and pull the Book stacking assembly. 3-3) Remove the jam removal knob, and remove the inner cover (Lower) with the 3 jam removal levers released.
  • Page 255 [Note]: To remove the inner cover (Lower), lift it so that the stopper is not stuck. 4) Removal of the power supply mount For the Perfect Binder-D1, go to the step 4-1) as it has the stack cooling fan (stack rotation assembly). For the Perfect Binder-A1/B1/C1, go to the step 4-7) as they do not have the stack cooling fan (stack rotation assembly).
  • Page 256 4-3) Disconnect the 1 connector and release the cable from the 1 reuse band. 4-4) Open the Controller PCB Mount. - 13 connectors - 2 ribbon cables - 2 ribbon cable holders - 2 screws 4-5) Pull the Trimming assembly out. 4-6) Remove the Cooling fan unit.
  • Page 257 4-7) Disconnect the 1 connector [1] of the Cutter controller PCB. [Note] The connector can easily be located by following the cable from the Power supply PCB mount to the PCB mount. 4-8) Disconnect the 4 connectors [1] of the Slave controller PCB. [Note] The connector can easily be located by following the cable from the Power supply PCB mount to the PCB mount.
  • Page 258 4-9) Disconnect the 5 connectors [1] of the Master controller PCB. [Note] The connector can easily be located by following the cable from the Power supply PCB mount to the PCB mount. 4-10) Disconnect the 1 connector [2] at the lower-left corner of the PCB mount [1].
  • Page 259 4-11) Disconnect the 1 connector [1] of the Relay PCB (option controller). 4-12) Remove the 7 screws [1] to remove the Power supply PCB mount [2].
  • Page 260 5) Replacement of the detection sensor bracket 5-1) Move to in front of the machine, remove the 2 screws [1] and the metal plate [2]. 5-2) Rotate the gear of the Waste paper buffer drive unit counterclockwise and move the Stack buffer tray to the upper limit.
  • Page 261 5-3) Disconnect the Sensor connector[1], release cable [2] from 5 wire saddles [3]. 5-4) Move to at the back of the machine, release the cable [1] from the edge saddle [2] and the reuse band [3].
  • Page 262 5-5) Release the cable [1] from the edge saddle [2] and the wire saddle [3]. 5-6) Disconnect the sensor connector [4] and release the cable from the detection sensor bracket [5]. 5-7) Remove the 2 screws [1] and the detection sensor bracket [2]. The photo shows the detection sensor bracket viewed from the left side.
  • Page 263 5-8) Attach the sensor and the sensor flag those were attached on the detection sensor bracket to the new type detection sensor bracket (FE4-9766-000). 6) Reassemble the parts in reverse order from the step 5-7).
  • Page 264 A warning message may be displayed and stay on even if the waste paper box is housed. Caused by the detection sensor bracket deformed.(PerfectBinder-B1/PerfectBinder-D1/ PerfectBinder-E1) [Symptom] A warning message "The trim waste unit of the Perfect Binder is pulled out." may be displayed and stay on even if the waste paper box is housed.
  • Page 265 2) Remove the rear cover. - 6 screws 3) Remove the inner cover (Lower) 3-1) Pull the Waste paper unit. Remove the Waste paper box. 3-2) Release the lock of the Book stacking assembly and pull the Book stacking assembly. 3-3) Remove the jam removal knob, and remove the inner cover (Lower) with the 3 jam removal levers released.
  • Page 266 [Note]: To remove the inner cover (Lower), lift it so that the stopper is not stuck. 4) Removal of the power supply mount For the Perfect Binder-D1, go to the step 4-1) as it has the stack cooling fan (stack rotation assembly). For the Perfect Binder-A1/B1/C1, go to the step 4-7) as they do not have the stack cooling fan (stack rotation assembly).
  • Page 267 4-3) Disconnect the 1 connector and release the cable from the 1 reuse band. 4-4) Open the Controller PCB Mount. - 13 connectors - 2 ribbon cables - 2 ribbon cable holders - 2 screws 4-5) Pull the Trimming assembly out. 4-6) Remove the Cooling fan unit.
  • Page 268 4-7) Disconnect the 1 connector [1] of the Cutter controller PCB. [Note] The connector can easily be located by following the cable from the Power supply PCB mount to the PCB mount. 4-8) Disconnect the 4 connectors [1] of the Slave controller PCB. [Note] The connector can easily be located by following the cable from the Power supply PCB mount to the PCB mount.
  • Page 269 4-9) Disconnect the 5 connectors [1] of the Master controller PCB. [Note] The connector can easily be located by following the cable from the Power supply PCB mount to the PCB mount. 4-10) Disconnect the 1 connector [2] at the lower-left corner of the PCB mount [1].
  • Page 270 4-11) Disconnect the 1 connector [1] of the Relay PCB (option controller). 4-12) Remove the 7 screws [1] to remove the Power supply PCB mount [2].
  • Page 271 5) Replacement of the detection sensor bracket 5-1) Move to in front of the machine, remove the 2 screws [1] and the metal plate [2]. 5-2) Rotate the gear of the Waste paper buffer drive unit counterclockwise and move the Stack buffer tray to the upper limit.
  • Page 272 5-3) Disconnect the Sensor connector[1], release cable [2] from 5 wire saddles [3]. 5-4) Move to at the back of the machine, release the cable [1] from the edge saddle [2] and the reuse band [3].
  • Page 273 5-5) Release the cable [1] from the edge saddle [2] and the wire saddle [3]. 5-6) Disconnect the sensor connector [4] and release the cable from the detection sensor bracket [5]. 5-7) Remove the 2 screws [1] and the detection sensor bracket [2]. The photo shows the detection sensor bracket viewed from the left side.
  • Page 274 5-8) Attach the sensor and the sensor flag those were attached on the detection sensor bracket to the new type detection sensor bracket (FE4-9766-000). 6) Reassemble the parts in reverse order from the step 5-7).

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