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Canon Perfect Binder-C1 Replacement Manual

For durability enhancement parts finisher, sorter, deliverytray
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Replacement Manual for Durability
Enhancement Parts
Finisher, Sorter, DeliveryTray
Perfect Binder-C1
Sep 29 2009

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  Summary of Contents for Canon Perfect Binder-C1

  • Page 1 Replacement Manual for Durability Enhancement Parts Finisher, Sorter, DeliveryTray Perfect Binder-C1 Sep 29 2009...
  • Page 3 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.
  • Page 4 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.
  • Page 5 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.
  • Page 7: Table Of Contents

    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) .........................
  • Page 8 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...
  • Page 9: Chapter 1 Replacement Parts

    Chapter 1 Replacement Parts...
  • Page 11 Contents Contents 1.1 List of Replacement Parts ..............................1-1...
  • Page 13: List Of Replacement Parts

    1.1 List of Replacement Parts 0024-2987 T-1-1 Parts No. Replacement Interval Category Parts Name Q'ty Remarks 4A3-2823-000 15,000,000 sheets Stacking tray assembly SB flapper Gear 4G3-1221-000 15,000,000 sheets Stacking tray assembly SB flapper unit 4G3-2243-000 15,000,000 sheets Stacking tray assembly Alignment rack (front) 4G3-2244-000 15,000,000 sheets...
  • Page 15: Parts Replacement Procedure

    Chapter 2 Parts Replacement Procedure...
  • Page 17 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..............................
  • Page 18 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) ..................
  • Page 19: Points To Note On Disassembly And Reassembly

    Chapter 2 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.
  • Page 20: Removing From The Host Machine

    Chapter 2 4) Turn the two nuts [1] in the direction of the arrow to lift up the stoppers. 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].
  • Page 21: Removing The Front Covers (Left/Right)

    Chapter 2 6) Remove the screw [1] and move the power switch assembly [2] out of the 8) Remove the scerws [1] and turn up the locking claws [2], then separate the way. perfect binder from the host machine. F-2-7 2.1.3 Removing the Front Covers (Left/Right) 0024-2989 1) Open the front covers (left/right).
  • Page 22: Removing The Rear Cover

    Chapter 2 2.1.6 Removing the Rear Upper Cover 2) Remove the front cover [1] of the stacking assembly. - 3 screws [2] 0024-6643 1) Remove the rear upper cover [1]. - 6 screws [2] F-2-9 3) Pull out the glue supply port [1]. Loosen the three screws [2] and remove the one screw [3], then remove the upper front cover [4].
  • Page 23: Removing The Inner Cover (Upper)

    Chapter 2 3) Remove the left upper cover [1]. 4) Remove the jam removal knob [1]. With the three jam removal levers [2] - 4 screws [2] released, remove the inner cover (lower) [3]. - 7 screws [4] MEMO: The inner cover (lower) [3] must be removed with it lifted to prevent the stopper [5] from being caught on the surrounding parts.
  • Page 24: Removing The Cover Horizontal Registration Unit

    Chapter 2 6) Remove the four screws [1], loosen the four screws [2], and then draw out 3) Push the roller [1] backward, pull out the bearing [2] backward, release the cover transport assembly [3]. the roller pulley [3] from the belt, and then remove the roller. F-2-21 4) Remove the transport roller 1 unit [1].
  • Page 25 Chapter 2 6) Remove the guide plate by shifting it in the sequence shown in the figure. 8) Remove the roller unit mount [1]. 6-1) Shift the guide plate forward, and then pull it out of the hole [2] in - Each one screw [3] the rear panel of the transport assembly.
  • Page 26: Drawing Out The Trimming Assembly

    Chapter 2 11) Release the harness from the wire saddle [1], disconnect the three con- (left/right). nectors [2], and then remove the cover horizontal registration unit. 3) Draw out the stacking assembly. 4) Draw out the waste paper basket. 5) Remove the inner cover (lower). 6) Turn on the right front cover switch [1] and left front cover switch [2] by inserting the service tool or the like.
  • Page 27: Replacement Parts In Stacking Tray Assembly

    Chapter 2 11) Turn on SW2-2, SW2-3, and SW2-7 [1] on the service PCB and press Parts Name Q'ty the push switch PSW1 [2]. Alignment rack (front) Alignment rack (rear) CAUTION: Pressing the push switch PSW1 operates the trimming blade, pressing plate, Alignment motor and stack rotation assembly.
  • Page 28: Before Replacing The Sb Flapper Unit (15 Million Sheets)

    Chapter 2 3) Remove the top cover mount [1]. 6) Remove the SB flapper gear [2]. - 5 screws [2] - E-ring [1] - Straight pin [3] F-2-42 CAUTION: While reassembling, attach the SB flapper gear so that the sensor flag of the gear is positioned downwards when the flapper hangs down.
  • Page 29: Sb Flapper Unit (15 Million Sheets)

    Chapter 2 2.1.17 SB flapper unit (15 million sheets) 3) Remove the E-ring [1], flange [2], belt [3], pulley [4], and parallel pin [5]. 0024-6837 1) Remove the SB flapper unit [1]. CAUTION: - E-rings [2] 2 pcs. Be careful not to drop parts into the machine. - Bushings [3] 2 pcs.
  • Page 30 Chapter 2 6) Turn the knob [1] to lower the stacking tray to the lower limit. 8) Open the transport guide [1]. Remove the signature delivery assembly [2]. - 4 screws [3] F-2-49 7) Go around to the front of the machine, and then remove the E-ring [1], bearing [2], and signature delivery roller [3].
  • Page 31 Chapter 2 10) Remove the top cover switch [1]. - 2 screws [2] CAUTION: 1. After removal of the signature delivery assembly, the drive belt [4] remains on the motor shaft in the back. Be careful not to drop this belt into the machine.
  • Page 32 Chapter 2 13) Remove the switch-back flapper motor assembly. 16) Remove the E-ring [1] and bearing [2]. - 2 screws [2] F-2-60 17) Remove the stacking upper unit [1]. - 4 screws [2] F-2-57 CAUTION: 14) Remove the alignment assembly top cover [1]. Be careful not to drop the rear belt [3] into the machine.
  • Page 33: Alignment Motors (Front/Rear) (M4/M5) (15 Million Sheets)

    Chapter 2 2.1.21 Replecement parts in cover transport assembly 18) Remove the Alignment rack (front) [1] and the Alignment rack (rear) [2]. - Each 2 screws [3] 0024-6684 T-2-2 Parts Name Q'ty Transport roller 1 Transport roller 2 Transport roller 3 Transport roller 4 Transport roller 5 Transport driven roller 1...
  • Page 34: Before Replacing The Transport Roller 2 (15 Million Sheets)

    Chapter 2 2) Push the roller [1] backward, pull out the bearing [2] backward, release 2) Remove the resin retaining ring [1], idle gear [2] and E-ring [3]. the roller pulley [3] from the belt, and then remove the roller. F-2-67 F-2-69 3) Pull out the bearing [1] towards front.
  • Page 35: Transport Roller 3 (15 Million Sheets)

    Chapter 2 2.1.27 Transport roller 3 (15 million sheets) 2.1.29 Transport rollers 4/5 (15 million sheets) 0024-6844 0024-6846 1) Remove the 2 E-rings [1]. Open the transport roller 2/3 unit, shift the 1) Remove each 2 E-rings at the front and rear sides. Remove the transport transport roller 3 [3] towards rear, release the timing belt [4] and then re- roller 4 and transport roller 5 after shifting them towards rear.
  • Page 36: Transport Driven Roller 1 (Cover Transport Entrance) (15 Million Sheets)

    Chapter 2 2.1.31 Transport driven roller 1 (Cover transport 2.1.33 Transport driven roller 1 (Cover transport exit) (15 entrance) (15 million sheets) million sheets) 0024-6848 0024-6850 1) Remove the springs [1] to remove the transport driven roller 1 [2]. 1) Remove the springs [1] to remove the transport driven roller 1 [2]. F-2-74 F-2-76 NOTE:...
  • Page 37: Transport Driven Roller 2 (Spine Bending Roller 2/3 Unit) (15 Million Sheets)

    Chapter 2 2.1.35 Transport driven roller 2 (Spine bending roller 2/3 4) Remove the transport roller unit 2/3 [1]. - 4 screws [2] unit) (15 million sheets) 0024-6854 1) Open the transport roller 2/3 unit [1]. F-2-81 F-2-78 CAUTION: 2) Remove the harness protection cover [1]. Install the spine bending unit so the locking arm [3] on the back of the - Screw [2] transport roller 2/3 unit will fit into the hole [4] in the spine bending unit.
  • Page 38: Transport Driven Roller 2 (Spine Bending Roller 2/3 Unit) (15 Million Sheets)

    Chapter 2 2.1.37 Transport driven roller 2 (Spine bending unit 5) Remove the arm springs [1] and shaft spring [2], and then take out the transport driven roller 2. (right)) (15 million sheets) 0024-6859 1) Open the transport roller 2/3 unit [1]. F-2-85 2) Remove the harness protection cover [1].
  • Page 39 Chapter 2 4) Remove the transport roller unit 2/3 [1]. 5) Remove the reuse band [1], free the harness [2] from the four wire saddles - 4 screws [2] [3], and then pull out the connector [4]. F-2-88 CAUTION: Install the spine bending unit so the locking arm [3] on the back of the transport roller 2/3 unit will fit into the hole [4] in the spine bending unit.
  • Page 40 Chapter 2 7) Opening the transport roller 2/3 unit [1], remove two screws [2]. CAUTION: Install the spine bending unit (right) [1] to keep it in parallel with the transport roller 2/3 unit [2]. F-2-92 8) Turn the spine bending drive pulley [1] by a hand to move the spine bend- F-2-95 ing unit (right) [2] fully to the right side.
  • Page 41: Transport Driven Roller 2 (Spine Bending Unit (Left)) (15 Million Sheets)

    Chapter 2 3) Remove the connector [1] and the three screws [2] in the rear side. NOTE: There is a groove on the roller shaft to slide the slit of the roller shaft mount. Remove and install the transport driven roller sliding the groove. F-2-98 2.1.38 Before replacing the transport driven roller 2 (Spine bending unit (left)) (15 million sheets)
  • Page 42 Chapter 2 6) Turn the spine bending drive pulley [1] by a hand to move the spine bend- ing unit (left) [2] towards the left side. Remove the four screws [3], and CAUTION: then remove the spine bending unit (left). When reinstalling the delivery roller 1/2 unit, position it with the pressure arms [4] on its reverse side in the holes [5] of the spine unit.
  • Page 43: Transport Driven Roller 2 (Delivery Roller 1/2 Unit) (15 Million Sheets)

    Chapter 2 8) Remove the arm springs [1] and the shaft spring [2] to detach the transport 2) Remove the connector cover [1]. driven roller 2. - Screw [2] F-2-107 F-2-110 NOTE: There is a groove on the roller shaft to slide the slit of the roller shaft mount. 3) Remove the connector [1] and the three screws [2] in the rear side.
  • Page 44: Before Replacing The Delivery Roller 1/Delivery Roller 2 (15 Million Sheets)

    Chapter 2 5) Remove the arm springs [1] and the shaft spring [2] to detach the transport driven roller 2. CAUTION: When reinstalling the delivery roller 1/2 unit, position it with the pressure arms [4] on its reverse side in the holes [5] of the spine unit. If it is difficult to position the delivery roller 1/2 unit, turn the spine drive pulley [6] manually to move the spine unit.
  • Page 45: Delivery Roller 1/Delivery Roller 2 (15 Million Sheets)

    Chapter 2 2.1.43 Delivery roller 1/Delivery roller 2 (15 million sheets) 4) Remove the three scerws [1], and then remove the delivery roller 1/2 unit [2]. 0024-6853 1) Open the transport roller 4/5 unit [1]. F-2-116 2) Remove the connector cover [1]. - Screw [2] F-2-119 CAUTION:...
  • Page 46: Before Replacing The Spine Bending Harness (Right) (120,000 Sets)

    Chapter 2 2.1.45 Spine bending harness (right) (120,000 sets) 5) Remove the E-ring [1] and the bearing [2]. 0024-6863 1) Remove the reuse band [1] and release the spine bending harness (right) [2] from the 4 wire saddles [3]. Disconnect the 2 connectors [4] and then remove the spine bending harness (right).
  • Page 47 Chapter 2 2) Remove the connector cover [1]. - Screw [2] CAUTION: When reinstalling the delivery roller 1/2 unit, position it with the pressure arms [4] on its reverse side in the holes [5] of the spine unit. If it is difficult to position the delivery roller 1/2 unit, turn the spine drive pulley [6] manually to move the spine unit.
  • Page 48: Replecement Parts In Trimming Assembly

    Chapter 2 3) Release the harness from the 2 edge saddles [1] and the wire saddle [2], 2.1.48 Replecement parts in trimming assembly and remove the 7 screws [3]. Then turn the chain guide to the arrow di- rection. 0024-6867 T-2-3 Parts Name Q'ty...
  • Page 49: Sprocket Shaft 1/Sprocket/Sprocket Bearing (Middle) (150,000 Sets)

    Chapter 2 2.1.52 Sprocket shaft 1/Sprocket/Sprocket bearing 2.1.54 Sprocket shaft 2/Sprocket/Sprocket bearing (right) (middle) (150,000 sets) (150,000 sets) 0024-6874 0024-6876 1) Remove the E-ring [1], sprocket shaft 1 [2], sprocket [3], sprocket bearing 1) Remove the E-ring [1], sprocket shaft 2 [2], sprocket [3], sprocket bearing [4] and bushing [5].
  • Page 50: Replacement Parts In Book Stacking Assembly

    Chapter 2 2.1.57 Replacement parts in book stacking assembly 3) Remove the drawer connector (male) [1]. - 2 stepped screws [2] 0024-6879 T-2-4 - 2 springs [3] - 2 spacer nuts [4] Parts Name Q'ty - 2 connectors [5] Drawer connector (male) Drawer connector (female) 2.1.58 Before replacing the drawer connector (male) (20,000 times)
  • Page 51 2) Remove the drawer connector (female) [1]. - 2 screws [2] - Wire saddle [3] - 2 cnnnectors [4] F-2-141...
  • Page 53 Sep 29 2009...