Page 1 Perfect Binder-C1 SERVICE MANUAL March 7, 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: Symbols Used
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 Specifications 1.1 Product Specifications ..........................1- 1 1.1.1 Specifications ................................1- 1 1.1.2 Recommended Default Sizes ..........................1- 3 1.2 Names of Parts ............................1- 4 1.2.1 External View................................1- 4 1.2.2 Cross Section ................................1- 5 1.2.3 Cross Section of Signature Transport Assembly/Signature Delivery Assembly/Stacking Tray Assembly ....1- 6 1.2.4 Cross Section of Sub Gripper Assembly/Main Gripper Assembly................
Page 8 Contents 2.5.7 Locking the Stoppers of the Perfect Binder ......................2- 17 2.5.8 Connecting the Cables............................2- 18 2.5.9 Supplying Glue...............................2- 19 2.6 Checking the Operation..........................2- 20 2.6.1 Checking the Settings/ Operation ..........................2- 20 2.6.2 Adjusting the Spread Glue Amount When Coated Paper is Used .................2- 21 2.7 Relocationg the Machine ..........................
Page 9 Contents 4.2.1 Binding Assembly ..............................4- 2 4.2.1.1 Removing from the Host Machine............................4- 2 4.3 External Covers ............................4- 4 4.3.1 Front Cover................................4- 4 4.3.1.1 Removing the Front Covers (Left/Right) ..........................4- 4 4.3.1.2 Removing the Deodorizing Sheets (Front Cover R1/Front Cover R2)..................4- 4 4.3.1.3 Removing the Deodorizing Sheets (Front Cover L1/Front Cover L2) ..................
Page 10 Contents 4.4.6.1 Removing the Deodorizing Filters (glue vat unit) ........................4- 31 4.4.6.2 Removing the Glue Vat Unit ..............................4- 31 4.4.6.3 Removing the Glue Motor (M25)............................4- 34 4.4.6.4 Removing the Glue Vat Shift Motor (M32) ..........................4- 36 4.4.6.5 Removing the Glue Supply Motor (M33)..........................
Page 11 Contents 4.4.12.4 Removing the Relay PCB (Option Controller)........................4- 76 4.4.12.5 Removing the EEP-ROM PCB (Option Controller) ......................4- 76 4.4.12.6 Removing the Power Supply Unit 1 ............................. 4- 77 4.4.12.7 Removing the Power Supply Unit 2 ............................. 4- 77 4.4.12.8 Removing the Front Cover Switch Unit ..........................
Page 12 Contents 5.4.15 Motors in Cover Transport Assembly (1/4) ......................5- 32 5.4.16 Motors in Cover Transport Assembly (2/4) ......................5- 33 5.4.17 Motors in Cover Transport Assembly (3/4) ......................5- 34 5.4.18 Motors in Cover Transport Assembly (4/4) ......................5- 35 5.4.19 Sensors in Stack Rotation Assembly ........................5- 36 5.4.20 Motors in Stack Rotation Assembly ........................5- 37 5.4.21 Sensors in Trimming Assembly..........................5- 38 5.4.22 Solenoids in Trimming Assembly .........................5- 39...
Page 13: Chapter 1 Specifications
Chapter 1 Specifications...
Page 15 Contents Contents 1.1 Product Specifications..............................1-1 1.1.1 Specifications ....................................1-1 1.1.2 Recommended Default Sizes ............................... 1-3 1.2 Names of Parts ................................1-4 1.2.1 External View ....................................1-4 1.2.2 Cross Section ....................................1-5 1.2.3 Cross Section of Signature Transport Assembly/Signature Delivery Assembly/Stacking Tray Assembly ........ 1-6 1.2.4 Cross Section of Sub Gripper Assembly/Main Gripper Assembly .....................
Page 17: Product Specifications
Chapter 1 1.1 Product Specifications 1.1.1 Specifications 0022-5353 Item Description Remarks Binding mode Case-binding Trimming mode 3-direction trimming (top, bottom, foredge trimming), 1-direction trimming (foredge trimming), No trimming Finish size Paper width: 203 to 297mm When the cutting width is 28 (after trimming) Paper length: 138 to 216mm mm or more, the signature...
Page 18 Chapter 1 the available value of this machine. This manual is subject to change for improvement without prior notice. F-1-1...
Page 19: Recommended Default Sizes
Chapter 1 1.1.2 Recommended Default Sizes 0022-5374 [Signature:9" X12" / Finish:LTR] [Signature:SRA4 / Finish:A4] [Signature:A4 / Finish:B5] 226mm 210mm 225mm 216-/+1mm 182-/+1mm 210-/+1mm [Signature:A4 / Finish:7" X 9"] [Signature:B5 / Finish:A5] [Signature:LTR / Finish:7" X 9"] 210mm 182mm 216mm 178-/+1mm 148-/+1mm 178-/+1mm F-1-2...
Page 20: Names Of Parts
Chapter 1 1.2 Names of Parts 1.2.1 External View 0022-5389 [11] [10] F-1-3 [1]Top cover [7]Breaker [2]Glue supply cover [8]Waste paper case [3]Power switch [9]Book stacking case [4]Power save button/LED [10]Book stacking case open button [5]Front cover LED [11]Full stack LED [6]Front cover...
Page 21: Cross Section
Chapter 1 1.2.2 Cross Section 0022-5514 [11] [10] F-1-4 [1]Signature transport assembly [7]Cover transport assembly [2]Signature delivery assembly [8]Stack rotation assembly [3]Stacking tray assembly [9]Trimming assembly [4]Sub gripper assembly [10]Waste paper case [5]Main gripper assembly [11]Book stacking assembly [6]Gluing assembly...
Page 22: Cross Section Of Signature Transport Assembly/Signature Delivery Assembly/Stacking Tray Assembly
Chapter 1 1.2.3 Cross Section of Signature Transport Assembly/Signature Delivery Assembly/Stacking Tray Assembly 0012-1389 [12] [15] [14] [11] [13] [10] F-1-5 [1]Inlet roller [9]Signature delivery roller [2]Signature transport roller 1 [10]Trail edge retaining lever [3]Inlet flapper [11]Switch-back flapper [4]Signature transport roller 2 [12]Switch-back roller [5]Signature transport roller 3 [13]Stacking tray...
Page 23: Cross Section Of Sub Gripper Assembly/Main Gripper Assembly
Chapter 1 1.2.4 Cross Section of Sub Gripper Assembly/Main Gripper Assembly 0012-1417 F-1-6 [1]Sub gripper [2]Main gripper 1.2.5 Cross Section of Gluing Assembly 0012-1420 F-1-7 [1]Glue vat [5]Thermistor [2]Glue vat roller [6]Glue supply rotary block [3]Thermostat [7]Glue replenishing bottle [4]Heater...
Page 24: Cross Section Of Cover Transport Assembly
Chapter 1 1.2.6 Cross Section of Cover Transport Assembly 0012-1421 [13] [15] [14] [17] [16] [10] [11] [12] [12] F-1-8 [1]Transport roller 1 [10]Left spine bending plate [2]Cover registration unit [11]Spine plate [3]Cover gripper [12]Stack delivery roller [4]Transport roller 2 [13]Left cover trans port path guide [5]Transport roller 3 [14]Transport roller 4...
Page 25: Cross Section Of Waste Paper Case
Chapter 1 1.2.8 Cross Section of Waste Paper Case 0012-1423 F-1-10 [1]Waste buffer [4]Shutter [2]Waste basket [5]Paper pushing plate [3]Waste buffer full sensor flag 1.2.9 Cross Section of Book Stacking Assembly 0012-1424 F-1-11 [1]Book stacking tray [3]Book lift tray [2]Stacking buffer tray...
Page 26: Book
Chapter 1 1.2.10 Book 0012-1774 Let’s take a look at the components of a book and their names. F-1-12 [1] Signature: The part of a book which is wrapped with a cover. In other words, it means all pages of a book excluding the cover. [2] Spine: The side of a book where the signature and cover are glued.
Page 27: Using The Machine
Chapter 1 1.3 Using the Machine 1.3.1 Switches Related to Power Supply 0022-5520 This machine has three switches related to power supply, the Power switch, the Power Save button, and the breaker. Turning on the Power switch powers this machine. To shut off the energy completely, plug off the power cord.
Page 28 Chapter 1 3) Make sure that the breaker switch [3] turns to the OFF position to shut off the power supply. F-1-15 4) Turn off the Power switch [4]. F-1-16 5) Turn the breaker switch [5] back to the ON position. F-1-17 6) Turn on the Power switch [6].
Page 29: Safety And Caution
Chapter 1 1.4 Safety and Caution 1.4.1 Handling the Trimming Assembly 0022-5523 1.Precautions to Observe When Servicing the Trimming Assembly and/or Its Surrounding Assemblies When servicing the trimming assembly and/or its surrounding assemblies, be extremely careful not to cut your fingers with the sharp trimming blade. The following label is affixed on the front side of the trimming assembly where the trimming blade is incorporated.
Page 30 Chapter 1 2.Precaution on replacing the Press Motor(M36) When stack of paper is stuck at the press assembly due to malfunction, press plate is highly pressurized. (approx. 640kg) If the press motor is detached at this situation, there is a possibility of severe injury. Therefore, there is a caution label attached on the location that is shown on the figure below.
Page 31: Handling The Gluing Assembly
Chapter 1 1.4.2 Handling the Gluing Assembly 0022-5525 Precautions to Observe When Servicing the Gluing Assembly and/or Its Surrounding Assemblies When servicing the gluing assembly and its surrounding assemblies, be extremely careful not to get burned by the hot glue vat. Servicing must be done after more than 50 minutes from switching off the power supply.
Page 32: Precaution On Servicing
Chapter 1 1.4.3 Precaution on Servicing 0022-5528 1. Precaution on Power Supply. Power supply cord must be unplugged that needs disassembly and assembly servicing. A tag will be attached on the power supply cord at installment on the location that is shown on the figure below (for Europe only). Do not function the main unit by bypassing the interlock assembly when the front cover or the upper cover is detached.
Page 33: Disposal Of The Machine
Chapter 1 2. Precaution on Stacking Assembly and Cover Transport Assembly. When servicing the stacking assembly and the cover transport assembly, make sure to service after the function of the main unit has come to a complete halt. Caution label is attached on the location that is shown on the figure below for servicing. F-1-23 1.4.4 Disposal of the Machine 0012-7479...
Page 35: Chapter 2 Installation
Chapter 2 Installation...
Page 37 Contents Contents 2.1 Making Pre-Checks................................2-1 2.1.1 Precautions to Follow before Installation ............................ 2-1 2.1.2 Selecting the Installation Site............................... 2-1 2.2 Unpacking and Checking the Components ........................2-2 2.2.1 Checking the Supplied Accessories ............................. 2-2 2.2.2 Unpacking ....................................2-3 2.3 Installation Procedure ..............................2-4 2.3.1 Removing the Fixing Tapes/ Brackets (Exterior) ........................
Page 39: Making Pre-Checks
Chapter 2 2.1 Making Pre-Checks 2.1.1 Precautions to Follow before Installation 0022-0603 1. The installation work must be carried out by trained service engineers. 2. Since this machine is heavy (about 306 kg), four or more persons are required to install it. 3.
Page 40: Unpacking And Checking The Components
Chapter 2 2.2 Unpacking and Checking the Components 2.2.1 Checking the Supplied Accessories 0022-0602 Accessories that come with this machine are as follows: [10] [11] [12] F-2-2 Latch catches 2 pcs. Positioning pin 1 pc. Ground plate 1 pc. Lock plates 2 pcs.
Page 41: Unpacking
Chapter 2 2.2.2 Unpacking 0022-0677 MEMO: The machine is packed with tapes, cushioning materials, fixing brackets, and so forth to protect the machine against vibration and shock caused during transportation. Before starting the installation work, be sure to remove all the fixing tapes and packing materials following the procedure described below.
Page 42: Installation Procedure
Chapter 2 2.3 Installation Procedure 7) Remove the two pins affixed to the slope boards. 8) After placing slope boards [1] as shown below, insert the pins [2] in the holes in the skids (one pin/hole) with the hole in each skid aligned with 2.3.1 Removing the Fixing Tapes/ Brackets (Exterior) the hole in each slope.
Page 43: Removing The Fixing Tapes/ Brackets (Interior)
Chapter 2 3) Remove the fixing tapes/bubble wrap [1] to [6] on the rear and right sides. 5) Open the top cover. Perform steps [4] and [5] only for the model with a direct-mount power 6) Remove the fixing tapes/cushioning materials [1] to [6]. cord.
Page 44 Chapter 2 3) Remove the fixing tapes /cushioning materials [1] provided on the rear 8) Remove the three fixing tapes [1]. side. 9) Raise the jam clear lever (B)[2]. 4) Remove the tagged fixing brackets/screws <1> to <3>. 10) Remove the six screws [3], and then detach the upper-inner cover [4]. - <1>...
Page 45 Chapter 2 11) Draw out the book stacking tray [2] by pushing the stacking tray release 14) Remove the fixing tape/cushioning material [1] and remove the jam clear lever [1]. knob [2]. 15) Remove the seven screws [3] retaining the lower-inner cover. F-2-18 16) Detach the lower-inner cover [2] after releasing the two jam clear levers (E2/E3)[1].
Page 46: Removing The Fixing Tapes/ Brackets (Main Gripper Assembly/Cover Transport Assembly)
Chapter 2 2.3.3 Removing the Fixing Tapes/ Brackets (Main Gripper <Releasing the Front-side Pressure> Assembly/Cover Transport Assembly) Turn the motor pulley [4] toward you until dimension A at the gripper 0022-0705 assembly becomes 18 mm (its initial value is 15 mm). 1) Remove the fixing tapes/cushioning materials [1] to [4] that secure the cover transport assembly.
Page 47 Chapter 2 <Releasing the Rear-side Pressure> - Main gripper assembly movement procedure (hoisting) Turn the motor pulley [1] (mounted at the back of the main body) Rotate the motor knob [1] in the direction of the arrow to hoist the toward you until dimension B at the gripper assembly becomes 18 mm main gripper assembly.
Page 48 Chapter 2 - Main gripper movement procedure (rotation) 6) Remove the fixing tapes/cushioning materials [1] and [2] at the front. Retract the jam clear lever (E1)[3] when removing the fixing tape/cush- Rotate the pulley [1] in the direction of the arrow to rotate the main ioning material [2].
Page 49: Removing The Fixing Tapes/ Brackets (Trimmer Assembly)
Chapter 2 2.3.4 Removing the Fixing Tapes/ Brackets (Trimmer 10) Release the jam clear lever (E3)[1], and then remove the three fixing tapes/cushioning materials [2]. Assembly) When removing the encircled rear cushioning material, pull the tag from 0022-0706 behind the machine. 1) Detach the front-right cover [1].
Page 50: Removing The Fixing Tapes/ Brackets (Book Stacking Tray)
Chapter 2 4) Remove the cushioning material [1]. 4) Remove the fixing tape [1]. To remove the cushioning material [1], rotate the gripper motor knob (white color)[2] by one turn in the direction shown below and then re- move the cushioning material [1] from the front side. 5) Remove the tagged screw <1>.
Page 51 Chapter 2 3) Keep the removed transport fixtures, screws and the above cushioning ma- 6) Using the seven screws [2], install the lower-inner cover [3] with the two terials [1] - [3] for the event that the machine is moved in the future. jam clear levers (E1/E3)[1] released.
Page 52: Making Adjustments
Chapter 2 2) Adjust the heights of four casters [2] by inserting the wrench [1] from the direction of the arrow. 2.4 Making Adjustments 3) Using the wrench [1], loosen the lock nut [3] of the caster by turning it in the direction of the arrow.
Page 53: Connecting To The Host Machine
Chapter 2 2.5 Connecting to the Host Machine 4) Using the wrench [2], turn the nut [1] of the caster to adjust the caster height. - To increase the height, turn the nut in the direction [B]. 2.5.1 Preparing the Host Machine (When Connecting to - To reduce the height, turn the nut in the direction [A].
Page 54: Preparing The Host Machine (When Connecting To Document Insertion Unit-F1)
Chapter 2 2.5.3 Preparing the Host Machine (When Connecting to 2) Using the four supplied screws [1], install the two latch catches [2] to the high capacity stacker unit. At this time, secure the supplied ground plate Document Insertion Unit-F1) [3] along with the rear latch catch.
Page 55 Chapter 2 2) Remove the two screws [1], and then turn the locking pawls [2]. 5) Turn down the locking claws [1]. F-2-53 3) Move the perfect binder to let the positioning pin [1] of the host machine or the other equipment into the pin hole [2]. F-2-56 6) Install the supplied fixing brackets [1] (one at the front and the other at the rear), and then secure each fixing bracket using the supplied screw [2] and...
Page 56: Locking The Stoppers Of The Perfect Binder
Chapter 2 7) Using the two supplied screws [2], attach the supplied shunt cable [1] to 1) When this equipment is connected to the host machine, remove the termi- the lower back of the host machine or the other equipment and the lower nating connector [1] from the coaxial connector of the host machine, and back of the perfect binder.
Page 57: Supplying Glue
Chapter 2 3) Connect the T-shaped connector [1] to the perfect binder. 2) Open the two glue supply unit covers [1], and then supply glue [3] with the supplied scoop [2]. Be careful not to exceed the limit mark. 4) Attach the wire saddle [1] to the rear cover of the perfect binder, and then bundle the interface cable [2].
Page 58: Checking The Operation
Chapter 2 2.6 Checking the Operation 2.6.1 Checking the Settings/ Operation 0022-0808 1) For the 230V model only; Insert the power plug of the supplied power cord in the inlet of the perfect binder. The package contains several power cables intended for use in the 230V area.
Page 59: Adjusting The Spread Glue Amount When Coated Paper Is Used
Chapter 2 2) Remove the service PCB cover [1]. 2.6.2 Adjusting the Spread Glue Amount When Coated - Screw [1] 1 pc Paper is Used 0022-0811 When coated papers are used as book signature, the amount of spread glue may get less. Accordingly, the amount of spread glue must be adjusted ac- cording to the type and stack thickness of the coated paper used by the user.
Page 60 Chapter 2 6) Turn on SW2-2, SW2-5, SW2-6 and SW2-7 [1]. MEMO: MEMO: 1. The glue layer decreases by 0.05mm whenever the switch is pushed once. This setting is the adjustment mode for the thickness of the book-block In this step, the glue layer decreases by 0.15mm. (0.05mm X 3 = 0.15mm) from 3.5 mm to 6.4 mm.
Page 61: Relocationg The Machine
Chapter 2 2.7 Relocationg the Machine 2.7.1 Moving the Host Machine 0014-5461 If the host machine has to be moved to another location (except a location on the same floor and at the same level) after it has been installed, make sure to follow the procedure described below.
Page 62 Chapter 2 2. Discharging Glue Granules and Initialization 1) Remove the rear cover. 2) Remove the service PCB cover. 3) Set SW1 and SW2 on the service PCB as follows and turn ON the pow- er switch. The glue supply assembly enters the glue granule discharge mode.
Page 63 Chapter 2 Number of Operation Unit times PSW1 is pressed The stacking tray moves down. Stacking tray assembly The right and left upper cover guides Cover unit separate. The spine bending plate opens (only on the movable side) The right and left cover upper guides close. The main gripper rotates.
Page 64 Chapter 2 have been moved into transport position. 9) Turn OFF the power switch. 10) Remove the tool, etc. inserted into the right and left front cover switches. 11) Set all SW1 and SW2 switches on the service PCB to OFF. 12) Fix the main gripper with two pieces of packing tape [1] (20 cm).
Page 65 Chapter 2 F-2-90 6) Draw out the book stacking tray by pushing the book stacking tray release F-2-93 lever [1] at the rear of the host machine in the direction of the arrow. 11) Attach the fixing bracket H [1] with two TP screws (M4X8). 12) Attach the fixing bracket I [2] with two TP screws (M3X6).
Page 66 Chapter 2 tape. Do not transport the machine over surfaces where it is exposed to vibration, such as asphalt. If unavoidable, move it carefully and slowly. F-2-95 15) Fix the book stacking tray in closed condition with the knurled screw [1]. 16) Install the stepped screw [2].
Page 67: Chapter 3 Functions
Chapter 3 Functions...
Page 69 Contents Contents 3.1 Basic Construction .................................3-1 3.1.1 Overview...................................... 3-1 3.1.2 Overview of Electrical Circuitry..............................3-2 3.2 Basic Operation................................3-3 3.2.1 Basic Operations ..................................3-3 3.3 Feed Drive System .................................3-4 3.3.1 Overview...................................... 3-4 3.3.2 Delivery Path ..................................... 3-10 3.3.3 Simple Delivery Operation ................................ 3-12 3.3.4 Blank Sheet Delivery Operation ..............................
Page 71: Basic Construction
Chapter 3 3.1 Basic Construction 3.1.1 Overview 0022-5539 This machine consists of two main units: the gluing unit and trimming unit. The gluing unit aligns the sheets (signature) fed from the host machine and applies glue to them. The trimming unit trims the stack of glued sheets. The gluing unit consists of seven blocks: the signature transport assembly, signature delivery assembly, stacking tray assembly, sub gripper assembly, main gripper assembly, gluing assembly, and cover transport assembly .
Page 72: Overview Of Electrical Circuitry
Chapter 3 3.1.2 Overview of Electrical Circuitry 0010-6895 The machine's sequence of operations is controlled by its mas ter controller PCB, slave controller PCB, and trimmer controller PCB. These controller PCBs are 16-bit CPUs , and the mas ter controller PCB also controls the communication with the host machine by way of the acces sories controller PCB in addition to controlling the machine's operation sequence.
Page 73: Basic Operation
Chapter 3 3.2 Basic Operation 3.2.1 Basic Operations 0022-5553 This machine binds the sheets fed from the host machine in response to the commands sent from the host machine, and delivers the finished book to the book stack- ing tray. This machine can just deliver sheets to the subsequent machine without binding them. These operations are controlled by the master controller PCB, slave controller PCB, and trimmer controller PCB in response to various commands sent from the host machine.
Page 74: Feed Drive System
Chapter 3 3.3 Feed Drive System 3.3.1 Overview 0022-5555 This machine feeds the sheets fed from the host machine to the signature transport assembly, signature delivery assembly, stacking tray assembly, or cover transport assembly depending on the current delivery mode. In the simple delivery, the machine feeds a cover to the cover transport assembly and then delivers sheets to the subsequent machine.
Page 75 Chapter 3 2. Sub Gripper Assembly F-3-5 Symbol Name Symbol Name M17: Sub gripper lift motor M20: Sub gripper motor M18: Stack shift motor S39: Sub gripper paper sensor M19: Size shift motor Slave controller PCB 3. Main Gripper Assembly F-3-6 Symbol Name...
Page 76 Chapter 3 4. Gluing Assembly F-3-7 Symbol Name Symbol Name M25: Glue roller motor M33: Glue supply motor M32: Glue vat shift motor Slave controller PCB...
Page 77 Chapter 3 5. Cover Transport Assembly S64T S64L S65T S65L F-3-8 Symbol Name Symbol Name M12: Cover motor (right) SL1: Cover gripper solenoid M13: Cover motor (left) S20: Cover path 1 sensor M14: Delivery motor S21: Cover registration sensor M15: Shift motor (left) S25: Through delivery sensor...
Page 78 Chapter 3 6. Stack Rotation Assembly S92T S92L F-3-9 Symbol Name Symbol Name M41: Rotation motor 2 M44: Slide motor M42: Rotation motor 1 S92T/S92L: Inlet path sensor M43: Gripper motor Trimmer controller PCB 7. Trimming Assembly S88L S88T F-3-10 Symbol Name Symbol...
Page 79 Chapter 3 8. Waste Paper Case Assembly S96L S96T F-3-11 Symbol Name Symbol Name M37: Waste paper buffer shift motor S97: Waste paper basket full sensor S96T/S96L: Waste paper buffer full sensor Trimmer controller PCB 9. Book Stacking Assembly F-3-12 Symbol Name Symbol...
Page 80: Delivery Path
Chapter 3 3.3.2 Delivery Path 0022-5558 This machine has two delivery modes: the simple delivery mode and the book stack delivery mode. Mode of delivery Simple delivery - to delivery tray - to subsequent machine Book stack delivery F-3-13 [Delivery Path in Simple Delivery Mode] In the simple delivery mode, sheets are delivered to the subsequent machine through the path shown below.
Page 81 Chapter 3 [Delivery Path in Book Stack Mode] In the simple delivery mode, sheets are delivered to the book stacking tray through the path shown below. Cover Paper F-3-15 3-11...
Page 82: Simple Delivery Operation
Chapter 3 3.3.3 Simple Delivery Operation 0022-5561 The paper delivered from the host machine is fed to the cover transport assembly with the inlet roller, and then fed to the subsequent machine with rollers. The paper feed status is detected by the paper sensors provided along the paper transport path. 1) The inlet motor (M10), cover motor (right)(M12), cover motor (left)(M13), and delivery motor (M14) are driven before the paper delivered from the host machine is fed by this machine.
Page 83: Blank Sheet Delivery Operation
Chapter 3 3.3.4 Blank Sheet Delivery Operation 0022-5563 The blank sheet delivery operation is performed to recover the status where a blank sheet of paper has been delivered from the host machine. Depending on the current delivery mode, the machine will perform the following operation: 1.
Page 84: Auto Delivery Operation
Chapter 3 2. Operation in Book Stack Mode The blank sheet of paper from the host machine is fed to the signature transport assembly with the inlet roller and signature transport roller. When the signature path 1 sensor (S 18) detects the paper, the master controller PCB stops the paper and reports occurrence of a jam to the host machine. This way, the machine can continue to operate without causing the sheets in the stacking tray assembly to go to waste.
Page 85: Cutting Operation Performed When The Job Is Cancelled
Chapter 3 3.3.6 Cutting Operation Performed When the Job is Cancelled 0018-8381 When the job is cancelled, the relevant stack is delivered to the book stacking assembly. In this case, a stack without a cover is delivered with glue put on the spine. Under the following conditions, the stack is cut before delivery because its size is larger than that of the mechanism.
Page 86: Binding Operation
Chapter 3 3.4 Binding Operation 3.4.1 Overview 0022-5564 The machine stacks the sheets (signature) coming from the host machine in the stacking tray assembly, and then moves the stack to the gluing position, where it applies glue to the spine of the stack for adhesion to the cover. Next, the machine trims the stack and delivers the trimmed stack to the book stacking assembly. The operation flow is summarized below.
Page 87: Signature Transport Assembly Operation Control
Chapter 3 3.4.2 Signature Transport Assembly Operation Control 0011-1806 The signature transport assembly is designed to move the sheets coming from the host machine toward the stacking tray. The master controller PCB drives the inlet motor (M10) and signature motor (M11) at the same speed as the delivery speed of the host machine before the lead edge of paper arrives at this machine.
Page 88: Signature Delivery Assembly Operation Control
Chapter 3 3.4.3 Signature Delivery Assembly Operation Control 0011-1807 The signature delivery assembly is designed to deliver the sheets coming from the signature transport assembly to the stacking tray, retain the trail edge of the sheets in the stacking tray, and detect the height of the sheets in the stacking tray. As soon as the signature transport assembly starts, the master controller PCB starts driving the stacking roller motor (M1) at the same speed as the delivery speed of the host machine before the lead edge of a sheet arrives at this machine.
Page 89: Operation Of Stacking Tray Assembly
Chapter 3 3.4.4 Operation of Stacking Tray Assembly 0022-5586 The stacking tray assembly is designed to stack sheets from the signature transport path in its tray. [23] [25] [15] [11] [1] [20] [10] [26] [13] [22] [24] [16] [21] [12] [17] [19] [18]...
Page 90 Chapter 3 1) Before the lead edge of a sheet arrives from the host machine, the machine starts the inlet motor (M10), signature motor (M11), and stacking roller motor (M1) at the same speed as the delivery speed of the host machine. At the same time, the machine turns on the inlet flapper solenoid (SL2) to switch the inlet flapper in the direction of the signature transport assembly.
Page 91 Chapter 3 4) When the timing sensor (S5) detects the trail edge of the sheet, the machine moves the sheet over the specified distance and stops the sheet at the switch-back position. 5) After stopping the sheet, the switch-back flapper motor (M8) is driven to move the switch-back flapper to the trail edge guide assembly. F-3-26 [1] Switch-back flapper [2] Sheet...
Page 92 Chapter 3 8) The machine then drives the stacking roller motor (M1) to move the sheet in the switch-back direction at 700 mm/sec. At this time, the trail edge retaining lever is opened by the drive of the trail edge retaining lever motor (M3) to move the sheet in the switch-back direction over the specific distance, at the end of which the tailing edge retaining lever is used to hold down the trail edge of the sheet.
Page 93 Chapter 3 [Aligning Plate Standby Positions] The machine switches between aligning plate home position sensors depending on the size of paper. - Aligning HP sensor (front/small)(S12): Used when the paper width is 298 mm or shorter. - Aligning HP sensor (rear/small)(S13): Used when the paper width is 298 mm or shorter. - Aligning HP sensor (front/large)(S14): Used when the paper width is longer than 298 mm or less.
Page 94: Sub Gripper Assembly Operation Control
Chapter 3 3.4.5 Sub Gripper Assembly Operation Control 0010-6944 The sub gripper assembly is designed to hand over the stack of sheets stacked in the stacking tray to the main gripper. [10] [11] [12] [13][14] F-3-33 [3] Sub gripper lift motor (M17) [8] Stack shift main gripper position sensor (S35) [13] Sub gripper open sensor (S40) [4] Stack shift motor (M18)
Page 95 Chapter 3 1) When a stack has been stacked in the stacking tray, the size shift motor (M19) is driven to turn the size shift gear, moving the sub gripper inward. F-3-34 [1] Size shift gear [2] Sub gripper [3] Stack of sheets 2) Then, the sub gripper lift motor (M17) is driven to move the sub gripper assembly 10 mm downward so that the sub gripper (upper) reaches the surface of the stack.
Page 96 Chapter 3 3) The stacking tray lift motor (M2) and the sub gripper lift motor (M17) are driven to move down both the stacking tray and sub gripper assembly to the position where the tray lower limit sensor (S7) detects the lower limit of the tray. F-3-36 [1] Stacking tray [2] Sub gripper assembly...
Page 97 Chapter 3 5) The gripper motor (front)(M24) and the gripper motor (rear)(M23) are driven to hold the stack of sheets in the main gripper assembly. Thereafter, the sub gripper motor (M20) is driven to cause the sub gripper assembly to release the stack. The sub gripper lift motor (M17) is then driven to move up the sub gripper assembly 1 mm from the surface of the stack.
Page 98: Main Gripper Assembly Operation Control
Chapter 3 3.4.6 Main Gripper Assembly Operation Control 0010-6945 The main gripper is designed to align the edge of the stack of sheets coming from the sub gripper assembly and moves the stack to the gluing position. [13] [12] [10] [19] [15] [14]...
Page 99 Chapter 3 1) The gripper motor (front)(M24) and gripper motor (rear)(M23) are driven to clamp the stack of sheets coming from the sub gripper assembly. At this time, the stack thickness volume sensor (S50) is used to measure the thickness of the stack. F-3-40 [1] Main gripper [2] Stack of sheets...
Page 100 Chapter 3 3) The main gripper lift motor (M22) is driven to move the main gripper assembly down to the stack registration guide. F-3-42 [1] Main gripper assembly [2] Stack registration guide [3] Stack of sheets 4) The gripper motor (front)(M24) and gripper motor (rear)(M23) are driven to open the main gripper by 7 mm. At this time, the stack is held only by the mini gripper and is moved down together with the mini gripper.
Page 101 Chapter 3 5) The gripper motor (front)(M24) and gripper motor (rear)(M23) are driven to grip the stack. F-3-44 [1] Main gripper [2] Stack of sheets 6) The main gripper lift motor (M22) is driven to move the stack up to the gluing position. F-3-45 [1] Main gripper assembly [2] Stack of sheets...
Page 102: Cover Transport Operation
Chapter 3 3.4.7 Cover Transport Operation 0022-5606 In cover transport operation, a cover coming from the host machine is moved to the specified point in the cover path. [21] [13] [12] [11] [19] [14] [22] [20] [25] [24] [17] [5] [8] [18] [15] [23]...
Page 103 Chapter 3 1) Before the lead edge of a cover arrives the host machine, the inlet motor (M10), signature motor (M11), and cover motor (left)(M13) are driven at the same speed as the delivery speed of the host machine. At the same time, the inlet flapper solenoid (SL2) is turned on to configure the inlet flapper so that the cover will be moved to the cover path.
Page 104 Chapter 3 6) The spine binding motor (left)(M28) is driven to move down the transport roller to release the cover. 7) The cover grip solenoid (SL1) is driven to open the cover gripper. F-3-50 [1] Transport roller [2] Cover gripper [3] Cover 8) The cover motor (right)(M12) is driven in the reverse direction at 500mm/s so that the buffer roller moves the cover in the switch-back direction.
Page 105 Chapter 3 11) The cover horizontal registration motor (M31) is driven to align the cover in the horizontal direction. The sensor used for horizontal alignment varies depending on the paper size. If the paper is 297 mm or less in width, the cover horizontal registration sensor (small)(S71) is used. If the paper is more than 297 mm in width, the cover horizontal registration sensor (large)(S72) is used.
Page 106 Chapter 3 12) The spine bending motor (right)(M29) is driven to move up the transport roller at the right of the cover, thereby nipping the cover. 13) The spin bending motor (left)(M28) is driven to move up the roller at the left of the cover, thereby nipping the cover. 14) The cover grip solenoid (SL1) is turned on to open the cover gripper.
Page 107: Gluing Operation
Chapter 3 3.4.8 Gluing Operation 0010-6948 In gluing operation, glue is applied to the spine of the stack of sheets to bond the cover there. [18] [13] [17] [11] [12] [19] [15] [14] [10] [16] F-3-59 [1] Glue vat roller [8] Glue case empty sensor (S31T/S31L) [15] Glue vat shift HP sensor (S73) [2] Glue vat...
Page 108 Chapter 3 1) When the glue temperature has been adjusted to the specified value, the glue roller motor (M25) is driven to turn the glue vat roller, stirring the glue. 2) The glue shift motor (M32) is driven to move the glue vat 5 mm away from the edge of the stack. 3) The main gripper lift motor (M22) is driven to move the main gripper assembly down to the gluing position.
Page 109 Chapter 3 5) The main gripper lift motor (M22) is driven to move the main gripper up to the thick coating position. The glue vat roller motor (M25) is driven in the reverse direction to turn the glue vat roller in the reverse rotation. F-3-62 [1] Glue vat roller [2] Main gripper assembly...
Page 110: Glue Supply Operation Control
Chapter 3 3.4.9 Glue Supply Operation Control 0018-8371 In glue supply operation, glue is supplied from the glue bottle to the glue vat. The slave controller PCB monitors the temperature of the glue in the glue vat using the thermistor (S56) and detects the upper limit of the glue level using the level thermistor (S58).
Page 111 Chapter 3 When the machine temperature is 19 deg C or lower at the time of a binding operation start, the target startup temperature of the glue vat is set to 175 deg C. When it is 19-20 deg C, the target startup temperature of the glue vat is set to the preceding target temperature. When it is higher than 20 deg C, the target startup temper- ature of the glue vat is set to 153 deg C.
Page 112 Chapter 3 5.During Switching of Glue Vat Temperature 6.During Switching of Glue Vat Temperature to 175 deg C from 175 deg C to 153 deg C The machine temperature has risen over 20 deg C. The job has started. Completion of switching Start of job between temperatures Completion of switching...
Page 113: Binding The Cover And The Stack Of Sheets
Chapter 3 3.4.11 Binding the Cover and the Stack of Sheets 0010-6951 In bonding operation, the glued stack of sheets is pressed against the cover and the cover is bent to accommodate the stack. [12] [10] [11] F-3-68 [1] Spine [5] Spine bending motor (left)(M28) [9] Spine open sensor (S62) [2] Spine bending plate...
Page 114 Chapter 3 1) The spine bending motor (left)(M28) and spine bending motor (right)(M29) are driven to move the left spine bending plate and right spine bending plate from the spine bending closed position to the home position. 2) According to the result of stack thickness detection, the spine bending motor (left)(M28) and spine bending motor (right)(M29) are driven to move the spine bending plate to the standby position which is away from the stack by the specified distance.
Page 115 Chapter 3 5) The shift motor (right)(M16) is driven to open the right cover transport path guide, causing the transport roller to release the stack. 6) The spine bending motor (left)(M28) and spine bending motor (right)(M29) are driven to nip the stack with the spine bending plate. F-3-71 [1] Right cover transport path guide [3] Right spine bending plate...
Page 116 Chapter 3 8) The main gripper lift motor (M22) is driven to move the main gripper assembly up to the stack hand-over position. F-3-73 [1] Main gripper assembly [2] Cover [3] Stack of sheets 9) When the main gripper assembly has moved up to the stack hand-over position, the gripper motor (front)(M24) and gripper motor (rear)(M23) are driven to grip the stack.
Page 117 Chapter 3 10) The main gripper lift motor (M22) is driven to move the stack of sheets from the spine over the specified distance and the spine shift motor (M26) is driven to move away the spine plate. F-3-75 [1] Main gripper assembly [3] Cover [2] Spine plate [4] Stack of sheets...
Page 118: Stack Hand-Over Operation
Chapter 3 3.4.12 Stack Hand-over Operation 0010-6952 In stack hand-over operation, the stack (bonded signature and cover) is handed over to the trimming unit. F-3-76 [1] Stack delivery roller [4] Stack delivery path shift motor (M30) [7] Stack delivery path home position sensor (S67) [2] Stack deliver path guide [5] Stack delivery sensor (S64T / S64L) [8] Stack delivery path sensor (S68)
Page 119 Chapter 3 1) The main gripper lift motor (M22) is driven to move down the main gripper assembly and the stack is moved to the stack delivery roller. The stack transport path is provided with stack deliver sensors (S64T/S64L) and leading edge sensors (S65T/S65L) to detect the stack transport status. S64L S64T S65L...
Page 120 Chapter 3 3) After the stack of sheets have been nipped, the gripper motor (front)(M24) and gripper motor (rear)(M23) are driven, thus causing the main gripper to release the stack. The main gripper lift motor (M22) is driven to move the main gripper assembly to the home position. F-3-79 [1] Main gripper [3] Cover...
Page 121 Chapter 3 5) With the stack gripped in the trimming assembly, the stack delivery path shift motor is driven to shift the stack delivery roller. F-3-81 [1] Stack delivery roller [2] Stack delivery path guide [3] Stack of sheets 6) After the stack delivery roller has shifted, the slide motor (M44) is driven to move the stack to the stack alignment position in the trimming assembly. 7) The spine plate shift motor (M26) is driven to move the spine plate to the home position.
Page 122: Trimming The Stack Of Sheets
Chapter 3 3.4.13 Trimming the Stack of Sheets 0010-6953 In trimming, the stack of sheets that has been handed over to the trimming unit is trimmed to a specific size. The stack that is clamped in the trimming assembly is trimmed by the trimming blade in 3 directions in the order of head, tail, and fore edge. [11] [10] F-3-83...
Page 123 Chapter 3 [13] [12] [14] [15] [10] [11] F-3-84 [1] Trimming blade [6] Trimming blade plate shift motor (M40) [11] Cutter limit sensor (S86*1) [2] Trimming blade plate [7] Waste paper pushing solenoid (SL4) [12] Press end sensor (S87) [3] Pressing plate [8] Trimming blade plate HP sensor (S83) [13] Residual paper sensor (S88T/S88L) [4] Cutter motor (M35)
Page 124 Chapter 3 1) The gripper motor (M43) is driven to release the stack of sheets. The stack falls onto the trimming blade by its own weight, allowing its spine to be flush with the trimming blade upper surface. 2) The stack is gripped again with the rotating plate. F-3-85 [1] Rotating plate [2] Trimming blade...
Page 125 Chapter 3 5) The slide motor (M44) is driven to move up the stack of sheets until the trailing/leading edge sensor (S65T/S65L) or registration sensor (S88T/S88L) detects the edge of the stack. S65L S65T S88L S88T F-3-87 [1] Rotation gripper unit [2] Stack of paper 6) The slide motor (M44) is driven to move the stack down or up to the trimming position.
Page 126 Chapter 3 7) The press motor (M36) is driven to cause the pressing plate to press and hold the trimming edge of the stack. F-3-89 [2] Stack of sheets [1] Pressing plate 8) The trimmer motor (M35) is driven to move the trimming blade from the front to the rear to trim the head. F-3-90 [1] Trimming blade [2] Stack of sheets...
Page 127 Chapter 3 9) The press motor (M36) is driven to release the stack of sheets. 10) The rotation motor 1 (M42) and rotation motor 2 (M41) are driven to turn the stack by 180 degrees. Front Rear F-3-91 [1] Pressing plate [2] Rotation plate [3] Stack of sheets 11) The slide motor (M44) is driven to move the stack down or up to the trimming position.
Page 128 Chapter 3 12) The press motor (M36) is driven to cause the pressing plate to press and hold the trimming edge of the stack. F-3-93 [1] Pressing plate [2] Stack of sheets 13) The trimmer motor (M35) is driven to move the trimming blade from the rear to the front to trim the tail. F-3-94 [1] Trimming blade [2] Stack of sheets...
Page 129 Chapter 3 14) The press motor (M36) is driven to release the stack of sheets. 15) The rotation motor 1 (M42) and rotation motor 2 (M41) are driven to rotates the stack by 90 degrees. Front Rear F-3-95 [1] Pressing plate [2] Rotation plate [3] Stack of sheets 16) The slide motor (M44) is driven to move the stack down or up to the trimming position.
Page 130 Chapter 3 17) The press motor (M36) is driven to cause the pressing plate to press and hold the trimming edge of the stack. F-3-97 [1] Pressing plate [2] Stack of sheets 18) The trimmer motor (M35) is driven to move the trimming blade from the front to the trimming blade plate to trim the fore edge. NOTE: When the fore edge is trimmed by 35mm or more, the fore edge is trimmed twice so that the waste paper becomes small.
Page 131 Chapter 3 19) The trimmer motor (M35) is driven to return the trimming blade to the front side. F-3-99 [1] Trimming blade [2] Stack of sheets 20) The press motor (M36) is driven to release the stack. 21) The rotation motor 1 (M42) and rotation motor 2 (M41) are driven to rotates the stack by 180 degrees so that the spine of the stack is at the bottom. Front Rear F-3-100...
Page 132 Chapter 3 [Trimming Blade Operation] The trimming blade is secured to the base plate. The cutter motor (M35) moves the trimming blade between the front and rear sides along with the base plate. Front escape position Cut end position Rear escape position Trimming Rear side blade...
Page 133: Scraping Operation Of Waste Paper
Chapter 3 3.4.14 Scraping Operation of Waste Paper 0016-8432 When a stack of sheets is trimmed, the waste paper generated from the head/tail of the stack may stick to the trimming blade due to the glue sticking to the tip of the trimming blade.
Page 134 Chapter 3 3) The trimmer motor (M35) is driven to move the trimming blade back to the home position. The waste paper sticking to the trimming blade is scraped away by the scraping sheet. F-3-105 [1] Trimming blade [3] Scraping unit [2] Waste paper [4] Scraping sheet 3-64...
Page 135: Trimming Blade Plate Control
Chapter 3 3.4.15 Trimming Blade Plate Control 0018-8372 The machine forces the trimming blade against the blade plate to trim a stack of sheets. The trimming blade plate is moved up 1 mm per 1100 trimming operations to prevent the trimming blade plate from being worn by the trimming blade. The trimming blade plate position used for head/tail trimming is different from the trimming blade position used fro fore edge trimming.
Page 136: Waste Paper Treatment Control
Chapter 3 3.4.16 Waste Paper Treatment Control 0022-5616 Waste paper treatment control is performed to store the waster paper generated as the result of trimming the stack of glued sheets in the waste paper buffer from which the waste paper is ejected to the waste paper basket. [10] F-3-107 [1] Paper pressing plate...
Page 137 Chapter 3 [ Waste paper treatment ] Let's take a look at the operation performed to eject waste paper generated from a stack of sheets (10-99 sheets). MEMO: The waste paper ejection operation varies depending on the number of sheets of a stack due to the limitation on the waste paper buffer depth. When the number of sheets of a stack is 10-99, waste paper is ejected to the waste paper basket after the head, trail, and fore edge of the stack have been trimmed.
Page 138 Chapter 3 3) The waster paper buffer shift motor (M37) is driven to move the waste paper buffer to the left by the specified distance. The hook of the waste paper sub-buffer interlocked with the paper pressing plate is released, returning the waste paper buffer to the original position. The waste paper falls onto the waste paper buffer. F-3-110 [1] Waster paper buffer [3] Paper pressing plate...
Page 139 Chapter 3 [ Waste Paper Full Detection ] A waste paper basket full sensor (S97) is provided to detect that the waste paper basket is full of waste paper. The waste paper basket full sensor (S97) and sensor lever move in conjunction with the waste paper buffer. If the waste paper basket full sensor (S97) is turned on twice during operation of the waste paper buffer, the trimmer controller PCB notifies the host machine of the waste paper nearly full status.
Page 140: Book Stacking Operation
Chapter 3 3.4.17 Book Stacking Operation 0010-6955 In the book stacking operation, the stack of sheets moved to the binding lift tray is then moved to the book stacking tray. [13] [14] [11] [12] [15] [10] F-3-114 [1] Book stacking tray [6] Stack buffer tray motor (M39) [11] Stack tray HP sensor (S80) [2] Stacking buffer tray...
Page 141 Chapter 3 1) Drives the waste paper buffer shift motor (M37) to retract the paper pressing plate from the transfer path. F-3-115 [1] Paper pressing plate 2) The subsequent sequence of binding stacking operation takes place in parallel with waste paper disposal control. 3) Drives the binding lift tray motor (M38) to raise the binding lift tray.
Page 142 Chapter 3 4) Drives the binding lift tray motor (M38) to lower the binding lift tray, passing the stack of sheets on to the stack buffer. F-3-117 [1] Stack of sheets [2] Binding lift tray [3] Stack buffer 5) Waits for the waste paper disposal sequence to complete as it proceeds in parallel with the binding stack operation. 6) Drives the stack belt motor (M34) to shift the binding stack tray to the left for the stack width plus a specified length.
Page 143 Chapter 3 8) The stack of sheets falls into the binding stack tray by gravity. F-3-119 [1] Binding stack tray [2] Stack of sheets 9) Drives the waste paper buffer shift motor (M37) to push out the stack of sheets towards the binding stack tray with the paper pressing plate. F-3-120 [1] Paper pressing plate [2] Stack of sheets...
Page 144 Chapter 3 10) Drives the stack buffer tray motor (M39) to shift the stack buffer to the home position. 11) Drives the stack belt motor (M34) to shift the binding stack tray 10 mm to the left and 10 mm to the right for aligning the stack. 12) Drives the waste paper buffer shift motor (M37) to shift the waste paper buffer to the home position.
Page 145: Detecting Jams
Chapter 3 3.5 Detecting Jams 3.5.1 Overview 0022-5634 This machine is provided with the paper sensors shown below to detect presence of paper and whether paper is fed properly. Occurrence of a jam is detected according to whether paper is detected by a sensor at the check timing memorized in the microcomputer (CPU) on the master con- troller PCB, slave controller PCB, or trimmer controller PCB.
Page 146: Delay Jam
Chapter 3 3.5.2 Delay Jam 0010-6920 Sensor Description Code Inlet sensor delay jam The inlet sensor (S17) does not detect paper within a specific time after the delivery signal 1011 from the host machine has been received. Signature path 1 sensor delay jam S18 The signature path 1 sensor (S18) does not detect paper within a specific time after the 1012 inlet path sensor (S17) has detected paper.
Page 147 Chapter 3 Sensor Description Code Spine bending home position The spine bending home position sensor (right) (S66) would not turn on even after driving the 1FA8 sensor (right) stationary jam spine bending motor for a specified period of time to open the spine plate. The spine bending home position sensor (right) (S66) was off when the spine plate closed.
Page 148: Other Jams
Chapter 3 3.5.4 Other Jams 0010-6922 Sensor Description Code Timing jam The inlet sensor (S17) detects paper, and detects the next paper before the period of time the 1200 machine has communicated to the host machine (as being necessary for handling of paper) has passed.
Page 149: Power Supply
Chapter 3 3.6 Power Supply 3.6.1 Overview 0022-5641 This machine incorporates power supply units 1 and 2 to supply DC power to every PCB. The following table summarizes functions of DC power supply units and so on as well as the names of the circuits supplied with DC and AC power. Name Function power supply unit 1...
Page 150: Protective Functions
Chapter 3 3.6.2 Protective Functions 0010-6924 The 24-/36-VDC circuits (used for driving sensors, solenoids, etc.) on the master controller PCB, slave controller PCB, and trimmer controller PCB are provided with a fuse or a motor driver with an overcurrent protective function. The 24-/36-VDC input circuit of each controller PCB is also provided with a fuse which is blown when an excessive current flows.
Page 151 Chapter 3 3-81...
Page 153: Chapter 4 Parts Replacement Procedure
Chapter 4 Parts Replacement Procedure...
Page 155 Contents Contents 4.1 Points to Note on Disassembly and Reassembly ......................4-1 4.1.1 Points to Note on Disassembly and Reassembly ......................... 4-1 4.2 Removing from the Host Machine..........................4-2 4.2.1 Binding Assembly..................................4-2 4.2.1.1 Removing from the Host Machine ..................................4-2 4.3 External Covers................................4-4 4.3.1 Front Cover ....................................
Page 156 Contents 4.4.4.2 Removing the Stack Shift Motor (M18) ............................... 4-22 4.4.4.3 Removing the Size Shift Motor (M19) ................................. 4-23 4.4.4.4 Removing the Sub Gripper Motor (M20) ..............................4-23 4.4.5 Main Gripper Assembly................................4-24 4.4.5.1 Removing the Stack Thickness Volume Sensor ............................4-24 4.4.5.2 Removing the Gripper Motor (Front) (M23) ..............................
Page 157 Contents 4.4.11.1 Unlocking the Book Stacking Assembly ..............................4-74 4.4.11.2 Removing the Stacking Tray Assembly..............................4-74 4.4.11.3 Removing the Stacking Belt Motor (M34) ..............................4-75 4.4.11.4 Removing the Bonding Lift Tray Motor (M38)............................4-75 4.4.11.5 Removing the Stack Buffer Tray Motor (M39) ............................4-75 4.4.11.6 Removing the Stacking Tray Sensor Unit..............................4-75 4.4.12 Electrical Assembly .................................
Page 159: Points To Note On Disassembly And Reassembly
Chapter 4 4.1 Points to Note on Disassembly and Reassembly 4.1.1 Points to Note on Disassembly and Reassembly 0013-4799 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 160: Removing From The Host Machine
Chapter 4 4) Turn the two nuts [1] in the direction of the arrow to lift up the stoppers. 4.2 Removing from the Host Machine 4.2.1 Binding Assembly 4.2.1.1 Removing from the Host Machine 0022-8902 1) Disconnect the signal cable [1] from the perfect binder. F-4-1 2) Remove the rear cover.
Page 161 Chapter 4 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-4-7 F-4-5 7) Remove the fixing brackets [1] (one at the front and the other at the back).
Page 162: Front Upper Cover
Chapter 4 2) Peel off the deodorization sheets (front cover L1) [1] and (front cover L2) [2]. 4.3 External Covers 4.3.1 Front Cover 4.3.1.1 Removing the Front Covers (Left/Right) 0022-8913 1) Open the front covers (left/right). 2) While holding the front cover (left) [1] with one hand and pressing the black lever [2] with the other hand, pull the hinge [3] in the direction of the arrow to remove it.
Page 163: Rear Cover
Chapter 4 4.3.3 Rear Cover 4.3.4 Rear Upper Cover 4.3.3.1 Removing the Rear Cover 4.3.4.1 Removing the Rear Upper Cover 0022-8915 0022-8916 1) Remove the rear cover [1]. 1) Remove the rear upper cover [1]. - 6 screws [2] - 4 screws [2] F-4-13 F-4-15 4.3.3.2 Removing the Deodorizing Sheet (Rear Cover)
Page 164: Removing The Deodorizing Sheet (Top Cover)
Chapter 4 4.3.5.2 Removing the Deodorizing Sheet (Top Cover) 2) Remove the fixing plate [2]. - Screw [1] 0018-9570 1) Remove the top cover. 2) Peel off the deodorization sheet (top cover) [1]. F-4-18 3) Remove the angle regulating plate [2]. - 2 screws [1] F-4-21 4.3.6 Left Upper Cover...
Page 165: Inside Cover (Upper)
Chapter 4 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 166: Binding Assembly
Chapter 4 2) Remove the glue supply cooling fan (lower) [1]. - Connector [2] 4.4 Binding Assembly - 2 screws [3] 4.4.1 Signature Transport Assembly 4.4.1.1 Removing the Inlet Motor (M10) 0013-1878 1) Remove the rear cover. 2) Remove the inlet motor [1]. - Connector [2] - 2 screws [3] F-4-28...
Page 167: Removing The Inlet Flapper Solenoid (Sl2)
Chapter 4 2) Remove the reusable band [1] and connector [2]. MEMO: When reinstalling the transport motor, manually place the drive belt [1] as shown and hang the drive belt on the motor pulley. F-4-31 4.4.1.3 Removing the Inlet Flapper Solenoid (SL2) 0013-1882 1) Remove the rear cover.
Page 168: Signature Delivery Assembly
Chapter 4 4) Slide the signature transport roller 4 unit [1] downward to remove it. 4) Remove the harness cover [1]. - 2 screws [2] F-4-37 4.4.2 Signature Delivery Assembly F-4-40 4.4.2.1 Removing the Signature Delivery Assembly 5) Go around to the back of the machine, and then remove the top cover and rear upper cover.
Page 169 Chapter 4 8) Disconnect the two connectors [1]. 11) Open the transport guide [1]. Remove the signature delivery assembly [2]. - 4 screws [3] F-4-43 9) Turn the knob [1] to lower the stacking tray to the lower limit. F-4-46 F-4-44 10) Go around to the front of the machine, and then remove the E-ring [1], bearing [2], and signature delivery roller [3].
Page 170: Removing The Corrugation Rollers
Chapter 4 2) Release the harness from the eleven wire saddles [1], and then disconnect the connectors [2] from the two sensors. 1. After removal of the signature delivery assembly, the drive belt [4] re- mains on the motor shaft in the back. Be careful not to drop this belt into the machine.
Page 171: Removing The Static Eliminators (Signature Delivery Assembly)
Chapter 4 5) Shift the pressure shaft [1] in the direction of the arrow, release the bearing 6) Remove the trail edge retaining plate unit [1]. [2] from the side plate, and then remove the pressure shaft. - 4 screws [2] F-4-52 F-4-54 7) Remove the trail edge retaining roller unit [1].
Page 172: Removing The Trail Edge Retaining Lever Motor (M3)
Chapter 4 2) Open the transport guide [1]. Remove the static eliminator (upper) [2] and MEMO: the static eliminator (lower) [3]. When reinstalling the transport motor, manually place the drive belt [1] as - Each 2 screws [4] shown and hang the drive belt on the motor pulley. F-4-58 4.4.3 Stacking Tray Assembly 4.4.3.1 Removing the Switch-back Rollers (Stacking Tray...
Page 173: Removing The Alignment Motors (Front/Rear) (M4/M5)
Chapter 4 2) Remove the alignment assembly top cover [1]. 4) Remove the static eliminator (stacking tray) [1]. - 4 screws [2] - 2 screws [2] F-4-61 F-4-63 3) Remove the two screws [1], and then lift and slide the stack weight shift motor [2] aside to disengage the drive train.
Page 174: Removing The Stacking Roller Motor (M1)
Chapter 4 3) Remove the alignment motors (front) [1] and (rear) [2]. 4) Remove the top cover switch [1]. - Each one connector [3] - 2 screws [2] - Each 2 screws [4] F-4-69 5) Remove the top cover mount [1]. - 5 screws [2] F-4-66 4.4.3.4 Removing the Stacking Roller Motor (M1)
Page 175: Removing The Stack Weight Shift Motor (M6)
Chapter 4 7) Remove the stacking tray drive assembly [1]. 3) Remove the stack weight shift motor [1]. - 4 screws [2] - 3 wire saddles [2] - 3 connectors [3] - Reusable band [4] MEMO: - 2 screws [5] When the drive assembly is removed, the stacking tray will lower by its own weight.
Page 176: Removing The Switch-Back Flapper Motor (M8)
Chapter 4 3) Remove the switch-back roller lift motor unit [1]. 3) Remove the frame upper cover [1]. - Wire saddle [2] - 4 screws [2] - 2 connectors [3] - Reusable band [4] - 2 screws [5] F-4-79 4) Remove the top cover switch [1]. - 2 screws [2] F-4-80 5) Remove the top cover mount [1].
Page 177: Removing The Stacking Tray
Chapter 4 6) Release the harness from the three wire saddles [1], and then remove the 6) Disconnect the four connectors [1]. six connectors [2]. F-4-82 F-4-85 7) Remove the switch-back flapper motor assembly. 7) Remove the E-ring [1], flange [2], belt [3], pulley [4], and parallel pin [5]. - 2 screws [2] F-4-86 F-4-83...
Page 178 Chapter 4 9) Remove the stacking upper unit [1]. 10) Release the harness from the wire saddle [1], and then remove the wire - 4 screws [2] saddle. Remove the two screws [2], and then remove the sensor unit [3]. Be careful not to drop the rear belt [3] into the machine.
Page 179: Removing The Stacking Tray Shift Motor (M9)
Chapter 4 12) Remove the three screws [1] at the front. 2) Remove the two connectors [1], one reusable band [2], and one screw [3]. Release the ground cable [4] from the wire saddle [5]. F-4-92 13) Remove the stacking tray assembly [1]. - 4 screws [2] F-4-94 3) Remove the rack support plate (front) [1] and rack support plate (rear) [2],...
Page 180: Sub Gripper Assembly
Chapter 4 4) Remove the reusable band [1], and then release the harness from the wire 2) Remove the sub gripper lift motor [1]. saddle [2]. Disconnect the two connectors [3]. Remove the two screws [4] - Connector [2] and the ground cable [5], and then remove the stacking tray shift motor - 2 screws [3] [6].
Page 181: Removing The Size Shift Motor (M19)
Chapter 4 3) Remove the stack shift motor unit [1] with the sub gripper assembly held being in position by hand. - 4 screws [2] Mount the size shift motor after opening the gripper [1] to its maximum po- sition. If the stack shift motor unit is removed, the sub gripper assembly [3] would sink under its own weight.
Page 182: Main Gripper Assembly
Chapter 4 3) Remove the sub gripper motor [1]. 5) Turn on the SW1-1[1] on the service PCB and set the machine in service - Connector [2] mode. - 2 screws [3] To keep the machine running in service mode, be sure to do so with the trim- ming assembly stowed inside.
Page 183 Chapter 4 13) Remove the filter case unit [1]. 15) Remove the sensor mount [1] - 4 scerws [2] - Screw [2] F-4-114 Since the sensor flag is in the sensor detection area, be careful not to damage the sensor [1] and flag [2] when removing the sensor mount. F-4-111 14) Remove the glue transport stay [1].
Page 184: Removing The Gripper Motor (Front) (M23)
Chapter 4 7) Turn on SW2-1, SW2-2, and SW2-7 [1] on the service PCB and press the push switch PSW1 [2]. 1. When reinstalling the sensor mount, place it with the pin [1] of the stack thickness volume sensor in the cut [2] of the sensor mount. 2.
Page 185: Removing The Gripper Motor (Rear) (M24)
Chapter 4 11) Remove the gripper motor (front) [1]. 2) Remove the service PCB cover [1]. - Reusable band [2] - Screw [2] - Wire saddle [3] - Connector [4] F-4-123 12) Remove the sensor mount [1]. - Screw [1] F-4-127 3) Turn on the left front cover switch [1] by inserting the service tool or the like.
Page 186 Chapter 4 7) Turn on SW2-1, SW2-2, and SW2-7 [1] on the service PCB and press the 14) Remove the glue transport stay [1]. push switch PSW1 [2]. - Screw [2] Pressing the push switch PSW1 operates the main gripper assembly. Be care- ful not to have your hand and clothes caught in the main gripper assembly LED1 LED2 LED3...
Page 187: Removing The Rotation Motor (M21)
Chapter 4 17) Disconnect the sensor connector [1] and remove the screw [2] retaining the earth wire. Since the encoder plate [1] is in the sensor detection area [2], be careful not to damage the sensor and encoder plate when removing the gripper motor (rear) assembly.
Page 188: Removing The Main Gripper Lift Motor (M22)
Chapter 4 4) Remove the frame upper cover [1]. 7) Remove the rotation motor [1]. - 4 screws [2] - Connector [2] - Wire saddle [3] - 3 screws [4] If the rotation motor is removed, the main gripper assembly would flutter as it is freed.
Page 189: Gluing Assembly
Chapter 4 - Connector [3] 2) Remove the filter case [1]. - 2 screws [4] - 3 screws [2] F-4-148 F-4-151 3) Remove the deodorizing filters [1]. F-4-149 F-4-152 4.4.6.2 Removing the Glue Vat Unit Remember to reattach the belt [4] at reinstallation. 0022-8984 During binding operation, the temperature of the glue in the glue vat unit reaches 150 degree or more.
Page 190 Chapter 4 3) Turn on the left front cover switch [1] by inserting the service tool or the 12) Remove the filter case unit [1]. like. - 4 scerws [2] F-4-154 4) Plug the power cord in the wall outlet. 5) Turn on the SW1-1[1] on the service PCB and set the machine in service mode.
Page 191 Chapter 4 14) Free the harness from eight wire saddles [1] and pull out five connectors 17) Remove the screw [1] securing the sensor support in position. [2]. F-4-163 18) Free the harness from the edge saddle [1] and remove the sensor [2]. - Connector [3] F-4-160 15) Remove the reuse band [1] and two screws [2].
Page 192: Removing The Glue Motor (M25)
Chapter 4 3) Turn on the left front cover switch [1] by inserting the service tool or the like. At reinstallation, attach the belt [1] to the motor shaft [2] and the glue vat pul- ley [3]. F-4-169 4) Plug the power cord in the wall outlet. 5) Turn on the SW1-1[1] on the service PCB and set the machine in service mode.
Page 193 Chapter 4 12) Remove the filter case unit [1]. 14) Loosen the two screws [1], and then remove the belt [2] from the motor - 4 scerws [2] gear. F-4-175 15) Release the motor harness from the wire saddle [1], and then remove the two screws [2].
Page 194: Removing The Glue Vat Shift Motor (M32)
Chapter 4 16) Pull out the glue roller motor [1], and then disconnect the connector [2]. 5) Turn on the SW1-1[1] on the service PCB and set the machine in service mode. When pulling out the motor, be careful not to damage the thermistor harness [3].
Page 195: Removing The Glue Supply Motor (M33)
Chapter 4 11) Remove the glue vat shift motor [1]. - Connector [2] - 2 screws [3] In mounting the motor, move the glue vat unit to the front and attach the belt to the motor gear [1]. If the gripper [3] interferes with the movement of the vat unit [2], turn the motor knob [4] to raise the main gripper.
Page 196: Cover Transport Assembly
Chapter 4 2) Remove the glue supply motor [1]. 5) Remove the fixing bracket [1]. - Connector [2] - 2 screws [2] - 2 screws [3] F-4-188 6) Remove the four screws [1], loosen the four screws [2], and then draw out the cover transport assembly [3].
Page 197: Removing The Static Eliminator (Cover Transport Path/ Right Upper)
Chapter 4 4.4.7.4 Removing the Static Eliminator (Cover Transport 2) Remove the roller release lever shaft [1]. - Resin retaining ring [2] Path/ Right Upper) - Bushing [3] 0013-0325 1) Draw out the cover transport assembly. 2) Remove the E-ring [1] and bearing [2]. F-4-193 3) Push the roller [1] backward, pull out the bearing [2] backward, release the roller pulley [3] from the belt, and then remove the roller.
Page 198: Removing The Static Eliminator (Cover Transport Path/ Left)
Chapter 4 2) Remove the E-ring [1] and bearing [2]. 5) Remove the static eliminator (cover transport path/right lower) [1]. F-4-199 4.4.7.6 Removing the Static Eliminator (Cover Transport F-4-196 Path/ Left) 3) Push the roller [1] backward, pull out the bearing [2] backward, release 0014-2919 1) Draw out the cover transport assembly.
Page 199 Chapter 4 3) Push the roller [1] backward, pull out the bearing [2] backward, release 6) Remove the guide plate by shifting it in the sequence shown in the figure. the roller pulley [3] from the belt, and then remove the roller. 6-1) Shift the guide plate forward, and then pull it out of the hole [2] in the rear panel of the transport assembly.
Page 200: Removing The Delivery Roller 1/2 Unit
Chapter 4 8) Remove the roller unit mount [1]. 11) Release the harness from the wire saddle [1], disconnect the three con- - Each one screw [3] nectors [2], and then remove the cover horizontal registration unit. F-4-207 9) Mark off the position of the positioning plate [1], and then remove the po- sitioning plate.
Page 201: Removing The Spine Bending Unit (Right)
Chapter 4 3) Remove the connector cover [1]. - Screw [2] 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] manu- ally to move the spine unit.
Page 202 Chapter 4 3) Remove the harness protective cover [1]. - Screw [2] Install the spine bending unit so the locking arm [3] on the back of the trans- port roller 2/3 unit will fit into the hole [4] in the spine bending unit. If you have difficulty precisely locating the spine bending unit, turn the spine bend- ing drive pulley [5] by a hand to move the spine bending unit.
Page 203: Removing The Spine Bending Unit (Left)
Chapter 4 7) With the transport roller (4/5) unit [1] moved to the left side, remove the 10) Lift up the spine bending unit (right) [1] in the arrow direction to remove spine bending plate (right) [2]. - 2 scerws [3] F-4-225 Install the spine bending unit (right) [1] to keep it in parallel with the trans- port roller 2/3 unit [2].
Page 204: Removing The Cover Motor (Right) (M12)
Chapter 4 3) Turn the spine bending drive pulley [1] by a hand to move the spine bend- 3) Remove the cover motor (right) [1]. ing unit (left) [2] towards the left side. Remove the four screws [3], and - Connector [2] then remove the spine bending unit (left).
Page 205: Removing The Delivery Motor (M14)
Chapter 4 3) Remove the cover motor (left) [1]. 6) Remove the fixing bracket [1]. - Spring [2] - 2 screws [2] - Connector [3] - 2 Screws [4] F-4-235 7) Remove four screws [1] and loosen four screws [2], and draw out the cov- er transport assembly [3].
Page 206: Removing The Shift Motor (Left) (M15)
Chapter 4 8) Remove the connector cover [1]. 2) Open the controller mount [1]. - Screw [2] - 13 connectors [2] - 2 flexible cable retainers [3] - 2 flexible cables [4] - 2 screws [5] F-4-237 9) Remove the harness guide [1] in the rear of the delivery part. - 2 screws [2] [4] [3] F-4-240...
Page 207: Removing The Spine Plate Shift Motor (M26)
Chapter 4 3) Remove the screw [1] securing the cover transport assembly in position. 7) Remove four screws [1] and loosen four screws [2], and draw out the cov- er transport assembly [3]. F-4-243 4) Go around to the front of the machine, and remove the front cover (left/ right).
Page 208 Chapter 4 2) Open the transport roller 2/3 unit [1]. 5) Remove the transport roller unit 2/3 [1]. - 4 screws [2] F-4-247 3) Remove the harness protective cover [1]. F-4-250 - Screw [2] Install the spine bending unit so the locking arm [3] on the back of the trans- port roller 2/3 unit will fit into the hole [4] in the spine bending unit.
Page 209: Removing The Stack Delivery Roller Motor (M27)
Chapter 4 3) Loosen the two screws [1] securing the spine motor (left). MEMO: If the spine bending assembly [4] prevents you from accessing the screws to remove, turn the spine drive pulley [5] manually to move the spine bending assembly out of the way.
Page 210: Removing The Spine Bending Motor (Right) (M29)
Chapter 4 6) Remove the spine bending motor (left) [1]. 4) Remove the two connectors [1], and then release the harness from the two - 2 screws [2] edge saddles [2]. - Connector [3] F-4-258 F-4-261 5) Remove the transport roller unit 2/3 [1]. - 4 screws [2] When reinstalling the spine bending motor, temporarily secure it with two screws, attach the two springs to apply tension to the belt, and then tighten...
Page 211: Removing The Stack Delivery Path Shift Motor (M30)
Chapter 4 6) Loosen the two screws [1] securing the spine bending motor (right). 9) Remove the spine bending motor (right) [1]. - 2 screws [2] - Connector [3] F-4-264 7) Remove the two springs [1]. F-4-267 Since the spring force is very strong, use pliers or the like to help prevent in- jury.
Page 212: Removing The Cover Horizontal Registration Motor (M31)
Chapter 4 3) Remove the two E-rings [1], and then move the support arm [2] forward. 2) Remove the spine plate lower cooling fans (front/rear) [1]. - Each one connector [2] - Each one wire saddle [3] - Each one reusable band [4] - Each two screws [5] F-4-269 4) Remove the stack delivery path shift motor [1].
Page 213: Removing The Torque Diode (Stack Rotation Assembly)
Chapter 4 2) Turn the knob [1] to lower the stack rotation unit [2] to the lower limit. 4) Remove the link arm [1]. - 2 springs [2] - E-ring [3] - 2 screws [4] F-4-275 3) Remove the scerew [1] and the washer [2]. F-4-277 5) Remove the E-ring [1] and the bushing [2].
Page 214 Chapter 4 2) Remove the left stay [1]. 4) Turn the knob [3] counterclockwise until the sensor plate [1] is removed - 4 screws [2] from the sensor [2]. F-4-280 3) Remove the harness guide plate [1]. - 11 wire saddles [2] - Connector [3] - 2 edge saddles [4] - 4 screws [5]...
Page 215: Removing The Torque Limiter (Stack Rotation Assembly)
Chapter 4 6) Disconnect the connector [1] from the sensor. 9) Remove the E-ring [1] and bearing [2], and then remove the gear [3] to- gether with the shaft. F-4-284 7) Disconnect the connector [1], push down on the stack rotation unit, and then remove the harness guide [2].
Page 216: Removing The Rotation Motor 1 (M42)
Chapter 4 3) Remove the connector [1], the reusable band [2], the wire saddle [3], the 6) Remove the E-ring [1] and the gear [2]. E-ring [4] and the bushing [5]. F-4-293 7) Insert the pliers or the like to the bottom of the torque limiter [1] and apply F-4-290 the force to the arrow direction to remove the torque limiter.
Page 217: Removing The Rotation Motor 2 (M41)
Chapter 4 2) Turn the knob [1] to change the position of the stack rotation unit for each 2) Turn the knob [1] to change the position of the stack rotation unit for each work, and then remove the rotation motor [2]. work, and then remove the rotation motor [2].
Page 218: Removing The Slide Motor (M44)
Chapter 4 3) Remove the gripper motor [1]. 2) Go around to the right side of the trimming assembly, remove the three - Connector [2] connectors [1] and two reusable bands [2], and then release the harness - 2 screws [3] from the edge saddle [3] and wire saddle [4].
Page 219 Chapter 4 4) Go around to the right side of the trimming assembly, remove the screw 6) Remove the stack rotation assembly [2] by holding it left and right stays [1] retaining the earth wire. Remove the reusable band [2], release the [2].
Page 220: Trimming Assembly
Chapter 4 4.4.9 Trimming Assembly 8) Remove the service PCB cover [1]. - Screw [2] 4.4.9.1 Drawing out the Trimming Assembly 0022-9006 Before drawing out the trimming unit, move the trimming blade rearward in the service mode ( ) following the below procedure except when replacing the trimming blade.
Page 221: Removing The Trimming Blade Plate
Chapter 4 assembly [3] operate and that the trimming blade moves to the safe posi- 4) Draw out the waste paper basket. tion. 5) Remove the inner cover (lower). 13) Remove the fixing bracket [1]. 6) Turn on the right front cover switch [1] and left front cover switch [2] by - 2 screws [2] inserting the service tool or the like.
Page 222 Chapter 4 11) Turn on SW2-2, SW2-3, and SW2-7 [1] on the service PCB and press 14) Remove the fixing bracket [1]. the push switch PSW1 [2]. - 2 Screws [2] Pressing the push switch PSW1 operates the trimming blade, pressing plate, and stack rotation assembly.
Page 223 Chapter 4 16) Insert the blade of the screw driver at the front and end as shown, press it in the direction of the arrow to release the hooks of the trimming blade plate, and then remove the trimming blade [1]. 1.
Page 224: Replacing The Trimming Blade
Chapter 4 2. After installing the trimming blade plate, check that it does not float at the 3. If the trimming blade plate has been replaced, remember to reset the coun- front and rear on the trimming assembly mount. ter of the trimming blade plate to "0" with the service mode of the perfect [A]: OK (Not floating) binder or the iR unit.
Page 225 Chapter 4 8) Remove the service PCB cover [1]. 12) Check that the trimming blade [1], pressing plate [2], and stack rotation - Screw [2] assembly [3] operate and that the trimming blade moves to the replace- ment position shown in the figure. F-4-329 9) Turn on the SW1-1[1] on the service PCB and set the machine in service mode.
Page 226 Chapter 4 15) Remove the fixing bracket [1]. - 2 Screws [2] Insert the sheath so that the cutting edge [3] of the trimming blade is accom- modated in the groove [2] of the sheath. F-4-334 16) Remove the four screws [1] securing the trimming assembly, and then draw out the trimming assembly [2].
Page 227 Chapter 4 18) Secure the trimming blade using the screw [1] supplied with the replace- 20) Holding the grip [1] of the sheath, draw out the trimming blade. ment trimming blade. Be sure to carry the trimming blade with it sheathed. Otherwise, you may get While pressing the trimming blade so that the sheath positioning tab [2] fits a cut by the cutting edge.
Page 228: Removing The Waste Paper Wiper Plate
Chapter 4 22) While pushing the sheath to the rear, secure the trimming blade using the 25) Turn off all SW1 and SW2 switches on the service PCB, and reinstall all four screws [1] supplied with the replacement trimming blade. the removed parts.
Page 229: Removing The Trimmer Motor (M35)
Chapter 4 4.4.9.5 Removing the Trimmer Motor (M35) 3) Release the harness from the edge saddle [1], remove the guide pin [2], and then remove the waste paper wiper unit [3]. 0013-3671 1) Draw out the trimming assembly. - Screw [4] 2) Release the motor harness from the four wire saddles [1] and one edge saddle [2], and then disconnect the connector.
Page 230: Removing The Trimming Blade Plate Shift Motor (M40)
Chapter 4 3) Remove the press motor [1]. 2) Remove the trimming blade plate shift motor [1]. - 3 wire saddles [2] - Connector [2] - Edge saddle [3] - 2 screws [3] - Connector [4] - 4 screws [5] F-4-351 When a stack of paper is caught in the press assembly, a high pressure (about 640 kg) is applied to the pressing plate.
Page 231: Waste Paper Case Assembly
Chapter 4 4.4.10 Waste Paper Case Assembly 6) Disconnect the four connectors [4] and remove the waste paper buffer drive unit [2] 4.4.10.1 Removing the Waste Paper Buffer Drive Unit 0013-3676 1) Remove the inner cover (lower). 2) Release the book stack assembly lock, and then draw out the book stack- ing assembly.
Page 232 Chapter 4 2) Remove the two screws [1]. 7) Shift the waste paper buffer unit [1] to the allow direction to release the hook [2] of the unit from the rail, and then remove the waste paper buffer unit. F-4-360 3) Draw out the trimming assembly.
Page 233: Book Stacking Assembly
Chapter 4 4.4.11 Book Stacking Assembly 3) Remove the three screws [1] from the right rail, and then remove the stacking tray assembly [2]. 4.4.11.1 Unlocking the Book Stacking Assembly 0013-0247 1) Insert the blade of a small-size screwdriver in the hole of the rear cover, During the work, hold the stacking tray assembly so that it does not fall and then turn it in the direction of the arrow to unlock the book stacking down.
Page 234: Removing The Stacking Tray Sensor Unit
Chapter 4 3) Remove the stacking buffer tray motor [1]. 7) Remove the stacking tray sensor unit [1] from waste paper unit. - Connector [2] - 2 screws [2] - 2 screws [3] F-4-373 F-4-370 When the stacking tray sensor unit is reinstalled, align the notch [3] of the 4.4.11.6 Removing the Stacking Tray Sensor Unit sensor mounting plate with the plate guide [4].
Page 235: Removing The Slave Controller Pcb
Chapter 4 2) Disconnect the connectors, and then remove the master controller PCB 2) Disconnect the connectors, and then remove the cutter controller PCB [1]. [1]. - 3 locking supports [2] - 5 locking supports [2] - Screw [3] - Screw [3] F-4-377 4.4.12.4 Removing the Relay PCB (Option Controller) 0013-3830...
Page 236: Removing The Power Supply Unit 2
Chapter 4 2) Remove the connectors, and then remove the power supply unit 1 [1]. 4) Remove the front cover switch unit [1]. - 4 screws [2] - 3 screws [5] F-4-380 4.4.12.7 Removing the Power Supply Unit 2 0013-3842 1) Remove the rear cover.
Page 237: Removing The Power Supply Cooling Fan (Left) (Fm3)
Chapter 4 2) Remove the power supply cooling fan (center) [1]. 2) Remove the fan cover [1]. - Wire saddle [2] - 3 screws [2] - Connector [3] - 2 screws [4] F-4-387 2) Remove the glue supply cooling fan (upper) [1] - Edge saddle [2] - Wire saddle [3] - Connector [4]...
Page 238: Removing The Signature Cooling Fans 2 (Front/Rear) (Fm6/Fm7)
Chapter 4 4) Open the signature transport guide [1]. 4.4.12.14 Removing the Signature Cooling Fans 2 (Front/ Rear) (FM6/FM7) 0013-3822 1) Remove the signature cooling fan 2 unit. 2) Remove the cooling fans 2 (front/rear) [1]. - Each two screws [2] - Each two nuts [3] F-4-392 5) Remove the signature cooling fan 1 unit [1].
Page 239 Chapter 4 4-81...
Page 241: Chapter 5 Maintenance
Chapter 5 Maintenance...
Page 243 Contents Contents 5.1 User Maintenance ................................5-1 5.1.1 User Maintenance Items ................................5-1 5.2 Maintenance and Inspection............................5-1 5.2.1 Periodically Replaced Parts ................................. 5-1 5.2.1.1 Periodically Replaced Parts.....................................5-1 5.2.2 Durables ....................................... 5-1 5.2.2.1 Durables ..........................................5-1 5.2.3 Periodical Servicing ..................................5-3 5.2.3.1 Periodical Servicing ......................................5-3 5.3 Adjustment ..................................5-4 5.3.1 Adjustment at Time of Parts Replacement ..........................
Page 244 Contents 5.4.23 Motors in Trimming Assembly..............................5-40 5.4.24 Sensors in Waste Paper Case Assembly ..........................5-41 5.4.25 Motors in Waste Paper Case Assembly ........................... 5-42 5.4.26 Sensors in Book Staking Assembly ............................5-43 5.4.27 Solenoids in Book Stacking Assembly ............................ 5-44 5.4.28 Motors in Book Stacking Assembly ............................
Page 245: User Maintenance
Chapter 5 5.1 User Maintenance 5.1.1 User Maintenance Items 0010-7094 Item Timing Glue supply Indicator on (on the control panel of the host machine) Waste paper disposal Indicator on (on the control panel of the host machine) 5.2 Maintenance and Inspection 5.2.1 Periodically Replaced Parts 5.2.1.1 Periodically Replaced Parts 0010-7095...
Page 246 Chapter 5 No. Parts name Parts No. Q'ty Life Remarks Glue vat unit 4G3-1133 2,000 hours Glue temperature control time (Equivalent to 5,000,000 sheets at the following condition; glue temperature control time: 4 hours/day, MCV: 200,000 sheets.)
Page 247: Periodical Servicing
Chapter 5 5.2.3 Periodical Servicing 5.2.3.1 Periodical Servicing 0022-8806 Parts name Parts No. Q'ty Intervals Action Remarks Switchback roller (Stacking tray assembly) FC9-2351 360,000 sheets Cleaning Air blower (Carry it out at the replacement timing of the trimming blade plate.) Flapper (Stack rotation assembly) FL2-9850 360,000 sheets Cleaning...
Page 248: Adjustment
Chapter 5 ment work is complete, and reset SW1/SW2 to off. * If a sensor adjustment error is encountered, press the PSW2 on the service 5.3 Adjustment PCB to exit to the adjustment standby state without writing changes to the EEPROM (IC9).
Page 249: Cover Skew Alignment Adjustment
Chapter 5 6) Set the 2 adjustment blocks supplied with the replacement part in the main 2) Loosen screw [1], and adjust the position of positioning plate [2] of the gripper as shown in the figure, press the PSW1 on the service PCB (max- cover horizontal registration unit.
Page 250: Cover Center Position Adjustment
Chapter 5 Switch position Adjustment item Large size adjustment (paper width: 298mm or more) F-5-9 2) Set SW2 on the service PCB as shown below. Small size adjustment (paper width: 297 mm or less) Adjust in the + direction to adjust the cover toward the front or in the - direc- F-5-10 tion to adjust the cover towards the rear.
Page 251: Alignment Plate Shift Adjustments
Chapter 5 2) Set SW2 on the PCB as shown below. ment plate or in the - direction to reduce the depth of paper push-in by the alignment plate. 3) Press the PSW1 switch on the service PCB once to view the current ad- justment value on the LED indicator.
Page 252: Gluing Start Position Adjustment
Chapter 5 Switch Position Stack Thickness 6.5mm to 11.4mm 11.5mm to 22.4mm 22.5mm to 25mm Adjust in the + direction to increase the glue amount (the gap between the stack end and the gluing rod becomes wider). Adjust in the - direction to re- duce the glue amount (the gap between the stack end and the gluing rod be- comes narrower).
Page 253: Edge Gluing Exclusion Area Setting
Chapter 5 4) Each time the PSW2 on the service PCB is pressed, the value increments by 1 (0.05 mm). Each time the PSW3 on the service PCB is pressed, the State value decrements by 1 (0.1 mm). * Adjustment range: -/+80 (-/+8.0 mm) Designates the ten's place.
Page 254: Main Gripper Stack Regripping Adjustment
Chapter 5 7) Repeat Steps 4) to 6) until the desired adjustment value is attained. 1) Set SW1 on the service PCB as shown below and turn on the power 8) Press the PSW1 on the service PCB to save the new adjustment values to switch.
Page 255: Trimming Perpendicularity Adjustment
Chapter 5 State Display switching Designates the unit's place. LED3 blinks three times at 300-ms intervals. Display switching 4) Each time the PSW2 on the service PCB is pressed, the value increments 90 degree by 1 (0.1 mm). Each time the PSW3 on the service PCB is pressed, the value decrements by 1 (0.1 mm).
Page 256: Trimming Blade Plate Usage Count Setting
Chapter 5 State Setting range Setting interval Default Display switching 10,000 - 100,000 1,000 40,000 3) Press PSW1 on the service PCB once to view the current adjustment value 4) Each time PSW2 on the service PCB is pressed, the value increments by in the LED indicator.
Page 257: Clearing Durables Counters
Chapter 5 7) Repeat Steps 4) to 6) until the desired value is attained. Switch position Durables 8) Press the PSW1 on the service PCB to save the new adjustment values to Not used. the EEPROM (IC9). Press ball screw (Stack rotation 9) The LED1 on the service PCB enters the adjustment standby state with assembly) LED1 blinking (1000-ms) and LED2/LED3 going off.
Page 258: Outline Of Electrical Components
Chapter 5 5.4 Outline of Electrical Components 5.4.1 Sensors in Signature Delivery Assembly/ Signature Transport Assembly/ Stacking Tray Assembly 0010-7111 F-5-35 5-14...
Page 259 Chapter 5 Symbol Name Description Part No. Jamcode Error Paper surface sensor (front) Detection of paper surface WG8-5696 E5C5 Paper surface sensor (rear) Detection of paper surface WG8-5696 E5C5 Trail edge retaining lever home position Detection of trail edge retaining lever WG8-5696 E5C1 sensor...
Page 260: Solenoids In Signature Delivery Assembly/ Signature Transport Assembly/ Stacking Tray Assembly
Chapter 5 5.4.2 Solenoids in Signature Delivery Assembly/ Signature Transport Assembly/ Stacking Tray Assembly 0012-2178 F-5-36 Symbol Name Part No. Error Master controller PCB Inlet flapper solenoid FH7-5974 CN25 5-16...
Page 261: Motors In Signature Delivery Assembly/ Signature Transport Assembly/ Stacking Tray Assembly
Chapter 5 5.4.3 Motors in Signature Delivery Assembly/ Signature Transport Assembly/ Stacking Tray Assembly 0012-2177 F-5-37 Symbol Name Part No. Error Stacking roller motor 4H3-0183 Stacking tray lift motor 4H3-0145 E5C5 Trail edge retaining lever motor 4H3-0183 E5C1 Alignment motor (front) FH5-1040 E5C2 Alignment motor (rear)
Page 262 Chapter 5 Symbol Master controller PCB Symbol Master controller PCB Symbol Master controller PCB CN22 CN23 CN21 CN24 CN23 5-18...
Page 263: Sensors In Sub Gripper Assembly
Chapter 5 5.4.4 Sensors in Sub Gripper Assembly 0012-3267 F-5-38 Symbol Name Description Part No. Jamcode Error Stack shift home position sensor Detection of home position where a WG8-5696 E5D3 paper stack is passed to the main gripper assembly Stack shift main gripper position sensor Detection of home position where a WG8-5696 E5D3 paper stack is passed to the main gripper...
Page 264: Motors In Sub Gripper Assembly
Chapter 5 5.4.5 Motors in Sub Gripper Assembly 0012-3274 F-5-39 Symbol Name Part No. Error Sub gripper lift motor 4H3-0183 E5D0 Stack shift motor 4H3-0382 E5D3 Size shift motor 4H3-0181 E5D1 Sub gripper motor 4H3-0430 E5D2 Symbol Sub grip relay PCB 2 Sub grip relay PCB 3 Sub grip relay PCB 4 Slave controller PCB...
Page 265: Sensors In Main Gripper Assembly
Chapter 5 5.4.6 Sensors in Main Gripper Assembly 0012-3275 F-5-40 5-21...
Page 266 Chapter 5 Symbol Name Description Part No. Jamcode Error Rotation binding position sensor Detection of binding direction during WG8-5696 E5D5 main gripper assembly rotation Rotation home position sensor Detection of main gripper home WG8-5696 E5D5 position Main gripper home position sensor Detection of position where the main WG8-5696 E5D4...
Page 267: Motors In Main Gripper Assembly
Chapter 5 5.4.7 Motors in Main Gripper Assembly 0012-3276 F-5-41 Symbol Name Part No. Error Rotation motor 4H3-0382 E5D5 Main gripper lift motor 4H3-0182 E5D4 Gripper motor (rear) 4H3-0430 E5D6 Gripper motor (front) 4H3-0430 E5D7 Symbol Main grip relay PCB 1 Main grip relay PCB 2 Main grip relay PCB 3 Slave controller PCB...
Page 268: Sensors In Gluing Assembly
Chapter 5 5.4.8 Sensors in Gluing Assembly 0012-3277 S31L S32T S32L S31T F-5-42 5-24...
Page 269 Chapter 5 Symbol Name Description Part No. Jamcode Error S31T Glue case empty sensor (light- Detection of presence of glue grain 4H3-0152 receiving) S31L Glue case empty sensor (light-emitting) Detection of presence of glue grain 4H3-0151 S32T Glue case full sensor (light-receiving) Detection of full status of glue grain 4H3-0152 S32L...
Page 270: Motors In Gluing Assembly
Chapter 5 5.4.9 Motors in Gluing Assembly 0012-3278 F-5-43 Symbol Name Part No. Error Glue roller motor 4H3-0181 E5B8 Glue vat shift 4H3-0183 E5B7 Glue supply motor FH5-1040 E5B9 Symbol Glew relay PCB Slave controller PCB CN154 / CN152 CN54 CN64 CN71 5-26...
Page 271: Sensors In Cover Transport Assembly (1/4)
Chapter 5 5.4.10 Sensors in Cover Transport Assembly (1/4) 0012-3297 F-5-44 Symbol Name Description Part No. Jamcode Error Cover path 1 sensor Detection of presence of paper during WG8-5696 1017 / 1127 / 1300 paper feeding or spine bending / 1700 Shift home position sensor (right) Detection of home position of right WG8-5696...
Page 272: Sensors In Cover Transport Assembly (2/4)
Chapter 5 5.4.11 Sensors in Cover Transport Assembly (2/4) 0012-3302 F-5-45 Symbol Name Description Part No. Jamcode Error Cover registration sensor Detection of presence of paper during 4H1-6450 101A / 112A / E5B4 cover gripping 101B / 112B / 1300 / 1700 / 1F75 Registration unit home position sensor Detection of registration unit home WG8-5696...
Page 273: Sensors In Cover Transport Assembly (3/4)
Chapter 5 5.4.12 Sensors in Cover Transport Assembly (3/4) 0012-3304 F-5-46 Symbol Name Description Part No. Jamcode Error Spine bending home position sensor Detection of home position of left spine WG8-5696 E5BA (left) bending plate Spine plate closed sensor (left) Detection of closed position of left WG8-5696 E5BA...
Page 274: Sensors In Cover Transport Assembly (4/4)
Chapter 5 5.4.13 Sensors in Cover Transport Assembly (4/4) 0012-3305 S64L S65L S64T S65T F-5-47 Symbol Name Description Part No. Jamcode Error S64T Stack delivery sensor (light-receiving) Detection of presence of paper during 4H3-0152 E5B4 / E5B5 / stack feeding E5D4 S64L Stack delivery sensor (light-emitting)
Page 275: Solenoids In Cover Transport Assembly
Chapter 5 5.4.14 Solenoids in Cover Transport Assembly 0012-3329 F-5-48 Symbol Name Part No. Error Master controller PCB Cover gripper solenoid 4H3-0180 CN25 5-31...
Page 276: Motors In Cover Transport Assembly (1/4)
Chapter 5 5.4.15 Motors in Cover Transport Assembly (1/4) 0022-5657 F-5-49 Symbol Name Part No. Error Cover motor (right) 4H3-0183 Cover motor (left) 4H3-0181 Delivery motor 4H3-0181 Shift motor (left) 4H3-0185 E5C9 Shift motor (right) 4H3-0185 E5CA Symbol Master controller PCB Symbol Master controller PCB CN20...
Page 277: Motors In Cover Transport Assembly (2/4)
Chapter 5 5.4.16 Motors in Cover Transport Assembly (2/4) 0012-3333 F-5-50 Symbol Name Part No. Error Cover horizontal registration motor 4H3-0181 E5CB Symbol Slave controller PCB CN64 5-33...
Page 278: Motors In Cover Transport Assembly (3/4)
Chapter 5 5.4.17 Motors in Cover Transport Assembly (3/4) 0012-3334 F-5-51 Symbol Name Part No. Error Spine plate shift motor FH5-1040 E5BC Spine bending motor (left) 4H3-0184 E5BA Spine bending motor (right) 4H3-0184 E5BB Symbol Slave controller PCB Symbol Slave controller PCB CN65 CN56 CN56...
Page 279: Motors In Cover Transport Assembly (4/4)
Chapter 5 5.4.18 Motors in Cover Transport Assembly (4/4) 0012-3335 F-5-52 Symbol Name Part No. Error Stack delivery roller motor 4H3-0183 E5D9 Stack delivery path shift motor 4H3-0430 E5D8 Symbol Slave controller PCB Symbol Slave controller PCB CN56 CN56 5-35...
Page 280: Sensors In Stack Rotation Assembly
Chapter 5 5.4.19 Sensors in Stack Rotation Assembly 0012-3347 S92L S92T F-5-53 Symbol Name Description Part No. Jamcode Error Slide home position sensor Detection of home position of rotary WG8-5696 E5A5 gripper unit Rotation home position sensor 2 Detection of stop position of rotation FH7-7485 E5A8 plate...
Page 281: Motors In Stack Rotation Assembly
Chapter 5 5.4.20 Motors in Stack Rotation Assembly 0012-3349 F-5-54 Symbol Name Part No. Error Rotation motor 2 4H3-0174 E5A8 Rotation motor 1 4H3-0174 E5A9 Gripper motor 4H3-0145 E5A1 Slide motor 4H3-0145 E5A5 Symbol Trimmer controller PCB Symbol Trimmer controller PCB CN17 CN16 CN17...
Page 282: Sensors In Trimming Assembly
Chapter 5 5.4.21 Sensors in Trimming Assembly 0012-3365 S88T S88L F-5-55 Symbol Name Description Part No. Jamcode Error Trimming blade plate home position Detection of home position of trimming WG8-5696 E5AD sensor blade plate S84 *1 Trimmer area sensor 1 Detection of left and right positions of 4H3-0150 E5AA...
Page 283: Solenoids In Trimming Assembly
Chapter 5 5.4.22 Solenoids in Trimming Assembly 0012-3368 F-5-56 Symbol Name Part No. Error Trimmer controller PCB Waste paper pushing solenoid 4K1-1083 CN22 5-39...
Page 284: Motors In Trimming Assembly
Chapter 5 5.4.23 Motors in Trimming Assembly 0012-3366 F-5-57 Symbol Name Part No. Error Trimmer motor 4H3-0144 E5AA Press motor 4H3-0144 E5A4 Trimming blade plate shift motor FH5-1040 E5AD Symbol Trimmer controller PCB Symbol Trimmer controller PCB CN19 5-40...
Page 285: Sensors In Waste Paper Case Assembly
Chapter 5 5.4.24 Sensors in Waste Paper Case Assembly 0012-3380 S96T S96L S103 S101 S104 S100 F-5-58 Symbol Name Description Part No. Jamcode Error Waste paper basket full sensor Detection of full status of waste paper WG8-5696 basket S100 Waste paper home position sensor Detection of right home position of WG8-5696 E5A2...
Page 286: Motors In Waste Paper Case Assembly
Chapter 5 5.4.25 Motors in Waste Paper Case Assembly 0012-3383 F-5-59 Symbol Name Part No. Error Waste paper buffer shift motor 4G3-2004 E5A2 Symbol Trimmer controller PCB CN23 5-42...
Page 287: Sensors In Book Staking Assembly
Chapter 5 5.4.26 Sensors in Book Staking Assembly 0012-3388 S102 F-5-60 Symbol Name Description Part No. Jamcode Error Stack arrival sensor Detection of arrival of paper at stack WG8-5696 E5B5 buffer Stack buffer tray home position sensor Detection of home position of stack WG8-5696 E5A3 buffer tray...
Page 288: Solenoids In Book Stacking Assembly
Chapter 5 5.4.27 Solenoids in Book Stacking Assembly 0012-3389 F-5-61 Symbol Name Part No. Error Trimmer controller PCB Stack door lock solenoid FK2-0127 E5AE CN27 5-44...
Page 289: Motors In Book Stacking Assembly
Chapter 5 5.4.28 Motors in Book Stacking Assembly 0012-3390 F-5-62 Symbol Name Part No. Error Stack belt motor FH5-1040 E5AC Binding lift tray motor 4G3-2004 E5AB Stack buffer tray motor FH5-1040 E5A3 Symbol Trimmer controller PCB Symbol Trimmer controller PCB CN20 CN21 CN23...
Page 290: Other Sensors
Chapter 5 5.4.29 Other Sensors 0022-8912 S105 F-5-63 Symbol Name Description Part No. Jamcode Error Upper cover open/closed sensor Detection of upper cover opening/ WG8-5696 1400 E550 closing Front cover lock release sensor Detection of release of lock of front WG8-5696 E5BD cover...
Page 291: Other Solenoids
Chapter 5 5.4.30 Other Solenoids 0022-8911 F-5-64 Symbol Name Part No. Error Master controller PCB Front cover locking solenoid 4H3-0146 E5BD CN18 5-47...
Page 292: Other Motors
Chapter 5 5.4.31 Other Motors 0022-8910 FM13 FM12 FM10 FM11 F-5-65 Symbol Name Part No. Error Power supply cooling fan (right) FH5-1061 E551 Power supply cooling fan (center) FH5-1061 E551 Power supply cooling fan (left) FH5-1061 E551 Glue supply cooling fan (upper) FK2-0103 E551 Glue supply cooling fan (lower)
Page 293: Microswitches
Chapter 5 5.4.32 Microswitches 0022-8909 MSW3 MSW1 MSW4 PSW1 MSW6 MSW2 MSW5 MSW7 F-5-66 Symbol Name Description Part No. Jamcode Error Remarks MSW1 Left front cover switch Detection of opening/closing of left- FH7-6336 1400 for USA only front cover MSW2 Right front cover switch Detection of opening/closing of right- FH7-6336...
Page 294: Pcbs
Chapter 5 5.4.33 PCBs 0022-8908 [7] [6] [11] [18] [13] [12] [16] [10] [15] [21] [17] [20] [19] [14] [22] F-5-67 5-50...
Page 295 Chapter 5 Symbol Name Part No. Error Master controller PCB FM3-6646 E501 / E505 / E508 / E550 / E551 / E5B4 / E5BD / E5C0 / E5C1 / E5C2 / E5C3 / E5C4 / E5C5 / E5C6 / E5C7 / E5C9 / E5CA Slave controller PCB FM3-6647...
Page 296: Others
Chapter 5 5.4.34 Others 0012-3670 HTR1 THSW F-5-68 Symbol Name Description Part No. Error HTR1 *1 Heater Melting of glue 4G3-1133 E5B0 THSW *1 Thermostat Power-off at detection abnormal glue temperature 4G3-1133 E5B0 *1: In glue vat unit Symbol Glew relay PCB Slave controller PCB HTR1 CN153 / CN151...
Page 297: Variable Resistors (Vr), Light-Emitting Diodes (Led), And Check Pins By Pcb
Chapter 5 5.5 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB 5.5.1 Outline 0010-7118 Of the variable VRs, LEDs, switches and check pins used in the machine, those needed when servicing in the field are discussed. Do not touch the VRs and check pins not discussed herein. They are exclusively for use at the factory, and require special tools and high precision. 5.5.2 Cutter Controller PCB 0015-7225 F-5-69...
Page 298 Chapter 5 State LED1 LED2 LED3 Remarks Normal Normal mode Blinking LED1 blinks at 500-ms intervals. Service mode Blinking LED1 blinks at 1,000-ms intervals. Abnormal Door open Blinking LED1 blinks at 100-ms intervals. Alarm Blinking Blinking Error Blinking Detailed indication of door open - LED1 turns on.
Page 299: Service Pcb
Chapter 5 Press PSW3 to switch from the error location display to the detailed error display. LED1 LED2 LED3 State Blinking Designates the ten's place. LED2 blinks 10 times at 300-ms intervals. Display switching Designates the unit's place. LED3 turns on for 2 seconds. Display switching [Pushbutton switches] PSW1: Enters, confirms and otherwise handles service mode adjustment values.
Page 300 Chapter 5 State LED1 LED2 LED3 Remarks Abnormal Door open Blinking LED1 blinks at 100-ms intervals. Alarm Blinking Blinking Error Blinking Detailed indication of door open - LED1 turns on. - LED2 makes distinction between the perfect binder (off) and the inserter (on). - LED3 points to a door open position according to how many times it blinks.
Page 301: Dip Switch Function List
Chapter 5 LED1 LED2 LED3 State Blinking Designates the ten's place. LED2 blinks 10 times at 300-ms intervals. Display switching Designates the unit's place. LED3 turns on for 2 seconds. Display switching [Pushbutton switches] PSW1: Enters, confirms and otherwise handles service mode adjustment values. PSW2: Enters, confirms and otherwise handles service mode adjustment values.
Page 302 Chapter 5 Switch position Operation mode Description Maintenance mode (Release Press PSW1 to release the sub gripper, release the main gripper, open the spine bending grippers) plate, open the spine plate, shift the stack delivery path, release the trimmer gripper, park the waste paper buffer to the right and lift up the binding lift tray.
Page 303 Chapter 5 - The spine bending plates of the cover transport assembly open. - The right and left upper guides of the cover transport assembly move down. - The main gripper assembly rotates to the binding position. - The main gripper assembly moves down. - The main gripper of the main gripper assembly closes.
Page 304 Chapter 5 Switch position Operation mode Description Stacking tray operation test The machine performs the following operations in sequence at each depression of PSW1: - Drive the stacking roller motor at 1100 mm/s. - Drive the stacking roller motor in the switchback direction at 700 mm/s. - After the stacking roller motor has stopped, drive the switchback roller lift motor to the home position (shift position) and to the paper feed position 2 seconds later.
Page 305 Chapter 5 Switch position Operation mode Description Main gripper operation test The machine performs the following operations in sequence at each depression of PSW1: - Drive the rotation motor to shift the main gripper to the binding position. The glue vat will move to the rear home position if it is positioned elsewhere.
Page 306 Chapter 5 Switch position Operation mode Description Glue supply operation test 2 Each time PSW1 is pressed, the machine performs the next in the following sequence (Continuous supply) of operations. - Drive the rotation motor to move the main gripper to the binding position. Drive the main gripper lift motor to raise the main gripper to its upper limit.
Page 307 Chapter 5 Switch position Operation mode Description Stack rotation unit operation Press PSW1 to let the machine perform the following operations in sequence: (Lift up and down the rotation - Shift the rotation gripper unit to its home position if it is positioned elsewhere. gripper unit) - Shift the rotation gripper unit to the uppermost position.
Page 308 Chapter 5 Switch position Operation mode Description Stack buffer tray operation test Press PSW1 to let the machine perform the following operations in sequence: - Shift the stack buffer tray to its home position if it is positioned elsewhere. - Shift the stack buffer tray to a stacking position. Turn off the power switch to shut down the sequence.
Page 309 Chapter 5 Switch position Operation mode Description Cover feed operation - Set a paper size with SW2-1 to SW2-3. test - Set a feed speed with SW2-4. The ON position sets 665 mm/s, the OFF position, 1300 mm/s. - Press PSW1 to get ready for performing a cover feed operation. - Insert paper through the paper feed slot.
Page 310 Chapter 5 Switch position Operation mode Description Signature: A4, cover: A3, finish: B5 Binding operation - Set SW1-4 to ON to run a binding operation test without test 1 trimming. - Set a signature size, a cover size and a finish size with SW2-1 to SW2-4.
Page 311 Chapter 5 Switch position Operation mode Description Signature: A4, cover: A3, Binding operation test 2 - Set SW1-4 to ON to run a binding operation test without trimming. finish: B5 - Set a signature size, a cover size and a finish size with SW2-1 to SW2- - Set a feed speed with SW2-5.The ON position sets a signature feed speed of 665 mm/s and a cover feed speed of 665 mm/s, OFF a signature feed speed of 522 mm/s and a cover feed speed of 1012 mm/s.
Page 312: Upgrading
Chapter 5 5.6 Upgrading 5.6.1 Before Upgrade 0010-7122 There are two ways to upgrade this machine as follows: A. Upgrade the machine from the system while it is connected with the system. B. Upgrade the machine independently. Method B is covered here. For information about Method A, refer to the service manual of the host machine. 5.6.2 Overview of Upgrade 0013-7352 This machine can be upgraded by downloading system software programs from the personal computer (hereafter called as the PC) in which a service support tool...
Page 313 Chapter 5 [Preparation] Have the following ready: - PC in which SSTv3.35 or later is installed - Each system software [System Software Registration Procedure] 1) Start the PC. 2) Add each software to be downloaded to the folder C:\ServTool\NewROM. 3) Start SST. 4) Click the "Register Firmware"...
Page 314: Connection
Chapter 5 F-5-76 7) When the system software program registration result appears, click the "OK" button. F-5-77 5.6.4 Connection 0013-7369 1) Turn off the main power switch of this machine, and then disconnect the cables connected to this machine. 2) Remove the rear cover of this machine. 3) Connect the cable B of the downloader PCB to the following connector on the controller PCB.
Page 315 Chapter 5 T-5-4 System software to be downloaded Remarks OP_CON OP_BOOT (Default setting) When the download completes, reset SW1 to the default setting (SW1-1/2: ON/ON). 1) Turn on the power switch of the PC and start SST. 2) Select "MFP" in "Target Selection", and then select "BND_C1" in "Model List". F-5-78 3) Double-click the "MST_CON"...
Page 316 Chapter 5 F-5-80 7) Select the the system software to download from the list. F-5-81 8) Press "START" to start downloading. F-5-82 9) When downloading starts, the progress of downloading is displayed by the progress bar. 5-72...
Page 317 Chapter 5 F-5-83 10) When writing of the data to the Flash ROM is complete, its result is displayed. Click the "OK" button. F-5-84 11) Return to the main menu and finish the download. F-5-85 5-73...
Page 318 Chapter 5 5-74...
Page 319: Chapter 6 Error Code
Chapter 6 Error Code...
Page 321 Contents Contents 6.1 Service Error Code.................................6-1 6.1.1 Service Error Code List ................................6-1 6.1.2 Failsoft ....................................... 6-13 6.2 Jam Codes ..................................6-15 6.2.1 Jam Code List .................................... 6-15 6.3 Alam Code ...................................6-17 6.3.1 Alam Code List ..................................6-17...
Page 323: Service Error Code
Chapter 6 6.1 Service Error Code 6.1.1 Service Error Code List 0022-3854 Code Error description Details Detection timing indication E501 Perfect binder internal communication error 0080 A communication failure has occurred between the master controller PCB and the slave controller PCB. 0081 A communication failure has occurred between the master controller PCB and the slave controller PCB.
Page 324 Chapter 6 Code indication Error description Details Detection timing E5A1 Gripper motor (M43) 8081 The gripper home position sensor (S93) would not turn off within a specified period of time after gripper actuation. 8082 The gripper home position sensor (S93) would not turn on within a specified period of time after gripper release.
Page 325 Chapter 6 Code indication Error description Details Detection timing E5AA Cutter motor (M35) 8001 Cutter area sensor 2 (S85) would not turn off within a specified period of time after trimming from the front side. 8002 Cuter area sensor 2 (S85) would not turn on within a specified period of time after shifting the trimming blade to the rear side (cutting release).
Page 326 Chapter 6 Code indication Error description Details Detection timing E5B0 Heater (HTR1) 8001 The thermistor (S56) would not detect a temperature setting -/+5 deg C within 600 sec after the power save mode was released. 8002 The thermistor (S56) has detected 200 deg C or higher for 1 sec. 8003 The thermistor (S56) has detected 5 deg C or lower for 1 sec (the thermistor, when started up, begins detecting after 10 sec).
Page 327 Chapter 6 Code indication Error description Details Detection timing E5B4 Automatic sensor adjustment 8001 The A/D input value would not fit into a specified range when the D/A output of the timing sensor (S5) was varied to the upper-limit value. 8002 The A/D input value would not fit into a specified range when the D/A output of the cover registration sensor (S21) was varied to the upper-limit value.
Page 328 Chapter 6 Code indication Error description Details Detection timing E5B5 Sub gripper paper sensor (S39), main gripper 8001 Leading edge sensor (S65T/S65L) has not detected the presence of paper. paper sensor (S55), stack delivery sensor (S64T/S64L), leading edge sensor (S65T/ S65L), stack arrival sensor (S76), stack tray 8002 Inlet path sensor (S92T/S92L) has not detected the presence of paper.
Page 329 Chapter 6 Code indication Error description Details Detection timing E5B9 Glue supply motor (M33) 8001 The glue supply home position sensor (S75) would not turn on even after driving the glue supply motor for a specified period of time to supply glue. 8002 The glue supply home position sensor (S75) would not turn off even after driving the glue supply motor for a specified period of time to supply glue.
Page 330 Chapter 6 Code indication Error description Details Detection timing E5BD Front cover lock release sensor (S30) 8001 The front cover lock release sensor (S30) would not turn off when the front cover closed. 8002 The front cover lock release sensor (S30) would not turn on in time when the front cover opened.
Page 331 Chapter 6 Code indication Error description Details Detection timing E5C5 Stacking tray lift motor (M2) 8001 The tray lower limit sensor (S7) would not turn on even after driving the stacking tray lift motor for a specified period of time to lift down the stacking tray. 8002 The tray lower limit sensor (S7) would not turn off even after driving the stacking tray lift motor for a specified period of time to lift up the stacking tray.
Page 332 Chapter 6 Code indication Error description Details Detection timing E5CB Cover horizontal registration motor (M31) 0001 The registration unit home position sensor (S70) would not turn on even after driving the cover horizontal registration motor for a specified period of time to return the registration unit to the home position.
Page 333 Chapter 6 Code indication Error description Details Detection timing E5D4 Main gripper lift motor (M22) 8001 The main gripper home position sensor (S44) would not turn on even after driving the main gripper motor for a specified period of time to lift up. The main gripper home position sensor (S44) was off when the main gripper lifted down.
Page 334 Chapter 6 Code indication Error description Details Detection timing E5D6 Main gripper motor (rear) (M24) 8001 The main gripper open sensor (rear) (S47) would not turn on even after driving the main gripper motor for a specified period of time to open. 8002 The main gripper open sensor (rear) (S47) would not turn off even after driving the main gripper motor for a specified period of time to close.
Page 335: Failsoft
Chapter 6 6.1.2 Failsoft 0010-7129 1. Outline This unit supports a failsoft feature enabling it to provide continued service with its functionality narrowed down to the delivery function (simple delivery only) when it encounters errors while running, until the handling of the errors is completed. 2.
Page 336 Chapter 6 5. Failsoft Availability Code Error description Failsoft Remarks indication availability E501 Perfect binder internal communication error Failsoft is disabled, because the status of each unit is unknown. E505 EEPROM error Failsoft is disabled, because the counter value cannot be saved. E508 Inserter communication error Failsoft is disabled, because the status of each unit is unknown.
Page 337: Jam Codes
Chapter 6 6.2 Jam Codes 6.2.1 Jam Code List 0022-8901 Code Jam type Sensor No. Description 1011 Inlet sensor delay jam No paper is detected by the inlet sensor (S17) within a predetermined period of time after a delivery signal has been received from the connected equipment. 1012 Signature path 1 sensor delay jam No paper is detected by the signature path 1 sensor (S18) within a predetermined period of...
Page 338 Chapter 6 Code Jam type Sensor No. Description 116B Feed sensor 2 delay jam S18(Inserter) Paper won't exit Feed sensor 2 (S18 (Inserter)) within a predetermined period of time after its detection by the sensor. 1FA0 Excessive number of sheets stacked (to be The stacking tray overflow sensor has detected the overflow state of the stacking tray, or a stacked) command requiring stacking of 201 or more sheets has been received.
Page 339: Alam Code
Chapter 6 6.3 Alam Code 6.3.1 Alam Code List 0019-6495 Code *1 Error explanation Occurrence condition Post-alarm status How to reset Glue near empty The glue supply bottle is nearly running Perform a normal operation. Replenish the glue supply bottle with out of glue.
Page 341 Appendix...
Page 343 1 General Circuit Diagram General Circuit Diagram General Circuit Diagram (1/11) CN420 CN425 CN250 CN269 Paper surface CN13.1 S+5V AFMOT_A CN24.1 Alignment motor (F) sensor (F) CN13.2 SGND AFMOT_*A CN24.2 CN13.3 DSFS AFMOT_B CN24.3 CN251 CN13.4 S+5V AFMOT_*B CN24.4 Paper surface CN13.5 SGND ARMOT_A...
Page 344 General Circuit Diagram (2/11) CN434 CN280 Cover path 1 sensor CN438 CN289 +24V1 CN20.1 CN281 CN435 +24V1 CN20.2 CRMOT_A CN20.3 Cover registration CN437 Cover motor (R) CRMOT_*A CN20.4 sensor CN14.1 S+5V CRMOT_B CN20.5 CN14.2 SGND CRMOT_*B CN20.6 CN14.3 CP1S CN282 +24V1 CN20.7 CN14.4...
Page 345 General Circuit Diagram (3/11) N.C, CN59.11 CN444 S31-T M_TXD CN59.10 CN6.1 S_RXD CN12.1 J401.3 Glue case empty sensor M_RXD CN59.9 CN6.2 S_TXD GEMPS CN12.2 J401.2 (light-receiving) *DL_MD2 CN59.8 CN6.3 *DL_MD2 GEMPLED CN12.3 J401.1 N.C. CN59.7 CN6.4 CN12.4 *DL_RESET *DL_RESET S31-L M_OUT1 CN59.6 CN6.5...
Page 346 General Circuit Diagram (4/11) CN300 Stack shift HP sensor CN449 S+5V CN50.1 SGND CN50.2 CN301 Stack shift main gripper BMHPS CN50.3 position sensor S+5V CN50.4 SGND CN50.5 CN302 BMGPS CN50.6 Main gripper rotation S+5V CN50.7 enable sensor SGND CN50.8 MGRENS CN50.9 SZHPS CN50.10...
Page 347 General Circuit Diagram (5/11) Main Grip Relay PCB 2 Main Grip Relay PCB 3 Main Grip Relay PCB 1 Slave Controller PCB F-1-5...
Page 348 General Circuit Diagram (6/11) +24VT CN53.1 CN151.40 +24VT CN6.10 *TRM_SEL CN59.1 *TRM_SEL +24VT CN53.2 CN151.39 +24VT CN6.9 *S_SEL CN59.2 *S_SEL +24VT CN53.3 CN151.38 +24VT CN6.8 S_OUT2 CN59.3 M_IN2 +24VT CN53.4 CN151.37 +24VT CN6.7 S_IN2 CN59.4 M_OUT2 +24VT CN53.5 CN151.36 +24VT CN6.6 S_OUT1 CN59.5...
Page 349 General Circuit Diagram (7/11) CN336 Spine bending CN457 CN455 HP sensor (L) CN463 CN464 CN350 CN55.1 S+5V +24V2 CN56.1 CN55.2 SGND +24V2 CN56.2 Stack delivery CN337 CN452 CN55.3 FLHPS BEMOT_A CN56.3 Spine bending CN55.4 S+5V BEMOT_*A CN56.4 roller motor closed sensor CN55.5 SGND BEMOT_B...
Page 350 General Circuit Diagram (8/11) CN467 CN356 REMOT_A CN71.1 Glue supply motor REMOT_*A CN71.2 REMOT_B CN71.3 REMOT_*B CN71.4 S+5V CN71.5 SGND CN71.6 CN357 REHPS CN71.7 Glue supply HP sensor REFAN CN71.8 PGND CN71.9 CN468 REFLOCK1 CN71.10 REFAN CN71.11 CN358 PGND CN71.12 Glue supply cooling fan (H) CN70.1 DFAN...
Page 351 General Circuit Diagram (9/11) CN382 Slide HP sensor CN477 S+5V CN9.1 CN383 Trimming blade plate SGND CN9.2 CN7.13 N.C. SLIDEHPS CN9.3 HP sensor CN7.12 ARRIVES S+5V CN9.4 CN7.11 SGND SGND CN9.5 CN472 CN7.10 S+5V CN370 EDGRTHPS CN9.6 Stack arrival CN7.9 SENSOR SGND CN9.7...
Page 352 General Circuit Diagram (10/11) CN484 S92-L Inlet path sensor ENTLED CN10.1 J301.3 (light-emitting) CN76.1 +5V2 CN4.10 CN10.2 J301.2 CN76.2 SGND CN4.9 SGND S+5V CN10.3 J301.1 N.C. CN76.3 TRM_RXD CN4.8 SLV_TXD SGND CN10.4 CN391 CN76.4 TRM_TXD CN4.7 SLV_RXD GRIPENDS CN10.5 Gripper end sensor CN76.5 *DL_MD2 CN4.6...
Page 353 General Circuit Diagram (11/11) CN396 CN488 CN22.3 N.C. Waste paper pushing CN22.2 DPUSHSOL CN22.1 +24V solenoid CN494 CN404 S+5V CN8.1 Waste paper HP sensor (R) S100 SGND CN8.2 CN397 DBUFRHPS CN8.3 Book stacking tray CN27.2 DLOCKSOL S+5V CN8.4 CN405 Waste paper buffer lock locking solenoid CN27.1 +24V...

Canon Perfect Binder-C1 Service Manual

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