Page 1 Perfect Binder Machine Code: D391 SERVICE MANUAL 8 December, 2010 Revised...
Page 3: Safety, Conventions, Trademarks
Safety, Conventions, Trademarks Conventions Common Terms This is a list of symbols and abbreviations used in this manual. Symbol What it means  Core Tech Manual  Screw  Connector  E-ring  C-ring  Harness clamp Flexible Film Cable Junction Gate Leading Edge of paper Long Edge Feed...
Page 4 The notations "SEF" and "LEF" describe the direction of paper feed, with the arrows indicating paper feed direction. Binding Terms Here are some commonly used binding terms that appear in this service manual. The sheets collected and aligned for binding to the book cover are collectively Signature referred to as the signature.
Page 5: Warnings, Cautions, Notes
Top Edge The top edge of the book. The front edge of the book; the edge of the signature opposite the spine. This Fore Edge is edge of the book that the reader opens. Bottom Edge The bottom edge of the book. Covers the pages (signature) of the book.
Page 6: Responsibilities Of The Customer Engineer
Where symbols are used on or near switches on finishers for Europe and other areas, the meaning of each symbol conforms with IEC60417. Responsibilities of the Customer Engineer Reference Material for Maintenance • Maintenance shall be done using the special tools and procedures prescribed for maintenance of the finisher described in the reference materials (service manuals, technical bulletins, operating instructions, and safety guidelines for customer engineers).
Page 7: During Maintenance
• Before you do any checks or adjustments after turning the finisher off, work carefully to avoid injury. After removing covers or opening the finisher to do checks or adjustments, never touch electrical components or moving parts (gears, timing belts, etc.). •...
Page 8 Safety Devices • Never remove any safety device unless it requires replacement. Always replace safety devices immediately. • Never do any procedure that defeats the function of any safety device. Modification or removal of a safety device (fuse, switch, etc.) could lead to a fire and personal injury. Always test the operation of the finisher to ensure that it is operating normally and safely after removal and replacement of any safety device.
Page 9: After Installation, Servicing
Power Plug and Power Cord • Before servicing the finisher (especially when responding to a service call), always make sure that the power plug has been inserted completely into the power source. A partially inserted plug could lead to heat generation (due to a power surge caused by high resistance) and cause a fire or other problems.
Page 10: Safety Instructions For This Finisher
• Show operators how to remove jammed paper and troubleshoot other minor problems by following the procedures described in the operating instructions. • Point out the parts inside the finisher that they should never touch or attempt to remove. • Confirm that operators know how to store and dispose of consumables. •...
Page 11 Trademarks • Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation in the United States and /or other countries. ® • PostScript is a registered trademark of Adobe Systems, Incorporated. ® • PCL is a registered trademark of Hewlett-Packard Company. ®...
Page 12: Field Service Manual Revision History
Field Service Manual Revision History Field Service Manual Version 2 Perfect Binder Machine Code: D391 Field Service Manual Version 2 Revision History Section Description Replaced with correct photo; photo of the Replacement and Adjustment > Common Signature Transport unit was falsely inserted Procedures >...
Page 13 Section Description Troubleshooting > Service Mode > Critical Revised description of the glue amount Adjustments > Adjustment 5: Glue Amount adjustment process Adjustment Troubleshooting > Service Mode > Critical Deleted; the adjustment is required only when Adjustments > Adjustment 8: Glue Amount replacing the EEPROM and its procedure is Adjustment described in #3 above.
Page 14: Table Of Contents
TABLE OF CONTENTS Safety, Conventions, Trademarks........................1 Conventions..............................1 Warnings, Cautions, Notes...........................3 General Safety Instructions..........................3 Responsibilities of the Customer Engineer....................4 Before Installation, Maintenance........................4 During Maintenance............................5 After Installation, Servicing..........................7 Safety Instructions for this Finisher.........................8 Field Service Manual Revision History......................10 Field Service Manual Version 2.........................10 1.
Page 15 Another Floor (by Elevator).........................94 Shipping the Bookbinder..........................95 2. Preventive Maintenance PM Tables.................................97 3. Replacement and Adjustment Basics................................99 Parts Dangerous to Touch...........................99 Using the Dials............................107 Common Procedures.............................113 Setting and Releasing Low Performance Mode..................113 Inserter Unit..............................115 Front Doors ...............................116 Covers................................119 Signature Path Exit Unit..........................122 Cover Transport Unit..........................126 Trimming Unit.............................128 Opening Locked Doors Manually......................132...
Page 16 Grip Motor: Front (M23)..........................161 Grip Motor (Rear) (M24).........................166 Grip Unit Rotation Motor (M21)......................172 Main Grip Lift Motor (M22)........................174 Gluing Unit..............................175 Filters................................175 Glue Heater...............................176 Cover Transport Unit.............................184 Switchback Rollers: Cover Transport.......................184 Torque Limiter.............................184 Anti-Static Brushes: Upper and Lower Right....................186 Anti-Static Brush: Left..........................188 Exit Rollers 1/2 Unit..........................189 Trimming Unit..............................191 Torque Diode: Signature Rotation Unit....................191...
Page 17 Power Supply Unit 1..........................259 Power Supply Unit 2..........................261 Inserter................................263 Common Procedures..........................263 Feed Rollers...............................265 Separation Rollers.............................267 Pickup Rollers.............................270 Inserter Control Board..........................273 4. Troubleshooting Service Call Tables............................275 Jams................................276 Handling Paper Jams..........................276 When an Error Occurs..........................276 Low Performance Mode...........................283 Service Board Basics.............................284 Service Board Switches..........................284 Service Board LEDs...........................285 Service Mode..............................311 Before You Begin............................311...
Page 18 Downstream Delivery..........................374 Blank Paper Handling..........................375 Automatic Exit............................375 Book Binding..............................377 Overview..............................377 Cover Transport: Vertical Path........................379 Paper/Signature Transport........................380 Cover Transport and Registration......................398 Gluing.................................404 Trimming Unit.............................417 Jam Detection..............................437 Overview..............................437 Jams................................438 Power Supply..............................443 Overview..............................443 Electrical Circuit Protection Features......................444 Energy Save Mode...........................444 Inserter-C1 (D391)............................446 Overview..............................446 Basic Electrical Layout..........................446 Basic Operation............................447 Motors and Sensors..........................448...
Page 19: Installation
1. Installation Installation Requirements Choosing a Location Required Space Place the bookbinder near the power source, with at least the minimum amount of clearance around it, as shown below: These are minimum space requirements. More space is recommended for easier maintenance. At least 900 mm (36 in.) Allows proper cooling At least 1407 mm (56 in.)
Page 20: Power Supply
1. Installation Power Supply NA: 208V 60 Hz Input voltage level EU: 220-240V 50/60 Hz Permitted voltage Fluctuation: +10, -15 % • The bookbinder must have an independent power source. Avoid multi-wiring. • The bookbinder must be properly grounded at the power source. What You Need Here are some points to check before installation: •...
Page 21: Perfect Binder (D391) Installation
Perfect Binder (D391) Installation Perfect Binder (D391) Installation This section describes installation of these items: • Perfect Binder GB5000 (D391) (hereafter the "bookbinder") • Inserter-C1 (D391-18) (hereafter the "inserter") • Transit Pass Unit Type GB5000 (D391-19) (hereafter the "relay unit") Bookbinder Accessories There are no accessories provided in the bookbinder box.
Page 22 1. Installation Unloading the Bookbinder • The bookbinder weighs 316 kg (695 lb.). At least four service technicians are required to unload the bookbinder from its pallet. • You will need a manual forklift to position the pallet for unloading. 1.
Page 23 Perfect Binder (D391) Installation 3. Remove the packing from the top of the machine [A]. 4. Pull down the protective plastic cover [B] on all four sides. • Collapsible metal handles are provided on the right and left side of the bookbinder. •...
Page 24 1. Installation 5. Position one person at the left to prevent the bookbinder from tipping over. 6. On the right [A], have two people use the handles to lift the machine, while another person removes the Styrofoam block and then pulls the plastic cover under the machine to the left as far as possible. 7.
Page 25 Perfect Binder (D391) Installation 11. Confirm that: • Both ramps are firmly attached to the edge of the pallet with nails [A] and [B]. • Both ramps extend straight out from the side of the pallet. • Area [C] between the ramps is free of obstacles. •...
Page 26 1. Installation 13. Once the bookbinder [A] is off the pallet, it can be pushed or rotated on its casters. 14. Remove the nail from each ramp and reattach the ramps [B] and [C] to the pallet. 15. Tape the nails [D] to the pallet. Bookbinder Exterior Tape, Braces •...
Page 27 Perfect Binder (D391) Installation 1. Remove all strips of tape and packing from the front and top. 2. Remove tape [A]. 3. Pull out the glue supply drawer [B] and remove long tape [C].
Page 28 1. Installation Left Side 4. Remove upper braces [A] and [B] (x3 ea.) Left Side 5. Remove lower braces [A], [B], [C] (x2 ea.)
Page 29 Perfect Binder (D391) Installation 6. Mark the two (large) upper braces "D". 7. Mark the three (small) lower braces "H". Rear 8. At the rear, remove all tape (as shown) from the back, top, power cord and interface cable.
Page 30 1. Installation Right Side: Near Bottom 9. Remove brace x1 [A], brace [B] x1 and tags (x2 ea.) 10. Mark the removed large brace "I" and mark the removed small brace "H". Left Side 11. Open the top cover [A]. 12.
Page 31 Perfect Binder (D391) Installation Front: Top 13. Remove the tape, cushions [A], [B]. 14. Disconnect the tape at [C] then lower lever Mk4. 15. Carefully cut the strips of tape at [D] then remove the strips of tape and the cushions. •...
Page 32 1. Installation Bookbinder Interior Tape, Braces Rear 1. Remove rear cover [A] (x8)
Page 33 Perfect Binder (D391) Installation 2. Remove rear upper cover [A] (x5) 3. Remove tape, cushion [A]...
Page 34 1. Installation 4. Remove: [A] Brace, tag (x2) [B] Brace, tag (x4) [C] Brace, tag (x4). (These four screws are tagged with wire.) 5. Mark the removed braces "G", "A", "B" as shown.
Page 35 Perfect Binder (D391) Installation Front 1. Open the right front door [A] then left front door [B] 2. On the left door [A], remove the top hinge [B] and bottom hinge [C]. • While holding the left front door with one hand, behind the top hinge [B], push the black lever [1] in the direction of the arrow to release the top hinge.
Page 36 1. Installation • Remove the left door [A]. 3. Repeat Step 2 to remove the top hinge [A] and bottom hinge [B] then remove the right front door [C]. (You may have to lower lever Mk11 so you can remove the right door.) 4.
Page 37 Perfect Binder (D391) Installation 1. Raise lever Mk12 [A]. 2. Remove the screws of the upper inner cover on the left side [A] and right side [B] (x6). 3. Release jam release levers [C] and [D], then hold them in the released position as you remove the upper inner cover.
Page 38 1. Installation Rear 1. At the left rear corner, push the book stack release lever [A] completely to the right to release the book stacking tray.
Page 39 Perfect Binder (D391) Installation Front 2. Pull out the book stacking tray [A] and trimmings box [B] together. 3. Remove the strips of tape and cushions shown above. 4. Remove: [A] Tape, cushion [B] Jam clear knob Mk10. • Mk10 must be reattached at the end of installation.
Page 40 1. Installation 5. Remove the screws of the lower inner cover [A] (x7). 6. Raise the jam clear levers [B] and [C] as you remove the cover [A]. 7. Return the jam clear levers [B] and [C] to their original positions.
Page 41 Perfect Binder (D391) Installation Main Grip, Cover Transport Tape, Braces, etc. Front 1. Remove the strips of tape and cushions from the horizontal transport unit at the left [A], right [B], and center [C].
Page 42 1. Installation 2. Remove tape [A] with tag. 3. Slide the registration unit to the rear then remove tape, cushion [B]. 4. Remove cushion [A] shown above:...
Page 43 Perfect Binder (D391) Installation Front • First, at the front, rotate the grip motor pulley [A] counter-clockwise about 3 mm to release the pressure on the cushion. • Rotate the pulley only enough to release the cushion. Rear • Second, at the rear, manually rotate the grip motor pulley [A] counter-clockwise about 3 mm to release the pressure on the cushion.
Page 44 1. Installation • Rotate the pulley until the gap is about 18 mm (no wider). • To prevent changing the correct value (15 mm), do not make this gap wider than 18 mm. 1. Remove the cushion at the front. Front 2.
Page 45 Perfect Binder (D391) Installation 3. Mark the braces "F, "C", "E" as shown. Rear 4. Rotate knob [A] in the direction of the arrow to raise the grip unit until the actuator [B] reaches sensor [C].
Page 46 1. Installation Rear 5. Push up the right side of the timing belt [A] to rotate the gear counter-clockwise until the actuator [B] reaches sensor [C]. 6. At the rear remove the tape and cushions [A].
Page 47 Perfect Binder (D391) Installation Front 7. At the front remove the tape and cushion [A]. 8. Lift and push Mk7 [A] to the left and remove the tape and cushion [B].
Page 48 1. Installation 9. Raise lever Mk7 [A]. 10. Remove all strips of tape and cushions. 11. Return Mk7 to its original position. 12. Raise Mk9 [A]. 13. Remove the long strips of tape [B] and [C]...
Page 49 Perfect Binder (D391) Installation 14. Label the small cushions "B" and the large cushions "C". Right Side 1. Remove the two strips of tape [A]. 2. At the front lower lever Mk8. 3. Remove the cushion [B]. 4. Return lever Mk8 to its original position.
Page 50 1. Installation Trimming Unit Tape Right Side 1. Remove front right corner cover (x3).
Page 51 Perfect Binder (D391) Installation 2. Remove: [A] Brace, tag (x3) [B] Brace, tag (x3) 3. Remove delivery bracket [A] (x4)
Page 52 1. Installation 4. Remove: [A] Brace, tag (x2) [B] Brace, tag (x2) [C] Long tapes (x2) 5. Label both braces "H".
Page 53 Perfect Binder (D391) Installation Front 1. Remove stepped screw, tag [A] (x1) 2. Mark the stepped screw "1". • Cushion [B] (shown in the previous illustration) is firmly clamped in place and must be released before it can be removed. 3.
Page 54 1. Installation Left Side • Remove left flat panel [A] (x4),...
Page 55 Perfect Binder (D391) Installation • Remove tape, cushions [A] and [B].
Page 56 1. Installation Front Left Corner • Behind the brace [A] near the carrying handle [B], rotate the white knob [C] to release the clamped cushion. (One full rotation should be enough to release the cushion.) Front • Remove cushion [A].
Page 57 Perfect Binder (D391) Installation Book Stacking Tray Tape Left Side: Book Stacking Delivery Tray Pulled Out 1. Pull out the book stacking delivery tray trimmings box drawer. 2. Remove: [A] Tape, tag [B] Tape tag [C] Knurled head screw (x1). Remove with fingers. 3.
Page 58 1. Installation Mark Item Quantity Brace A Brace B Brace C Brace D Brace E Brace F Brace G Brace H Brace I Brace J...
Page 59 Perfect Binder (D391) Installation Screws Mark Item Quantity Step Screw Plastic-head Screw Cushions Mark Item Quantity Cushion A (Long) Cushions B (Short)
Page 60 1. Installation Cushions C (Long) 2. All of these items should be retained. Some of these items must be reattached if the bookbinder is moved to a new location. For more details, please refer to "Preparing the Bookbinder for Moving". Check List Confirm that the following parts have been reinstalled: [1] Left flat panel...
Page 61 Perfect Binder (D391) Installation [1] Front inner cover (upper) [2] Front inner cover (lower) [3] Knob Mk10 [1] Rear cover (upper) [2] Rear cover (lower) • To protect the boards from damage due to accidental short circuiting as result of contact with a metal tool, the rear lower cover should never remain off longer than necessary.
Page 62: Inserter-C1 (D391-18) Installation
1. Installation Inserter-C1 (D391-18) Installation Inserter Accessories Check the accessories and their quantities against this list. Description Q’ty 1. Inserter Unit 2. Shoulder Screws (M5) 3. Limiter Brace 4. Clamp 5. Cap Nut 6. Screw (M4x7) 7. Brace 8. Screws (M4x8) 9.
Page 63: Inserter Installation
Inserter-C1 (D391-18) Installation Inserter Installation Mounting the Inserter Bookbinder Rear Upper Cover 1. Use a pair of nippers to remove the knockout [A] covering the interface cable hole. 2. Smooth the edges of the hole with a knife or file to prevent damage to the interface cable. 3.
Page 64 1. Installation 4. Open the top cover [A], as well as strips of tape and cushion. 5. Attach the shoulder screws [A] and [B] ( x2: M4)
Page 65 Inserter-C1 (D391-18) Installation 6. Hold the inserter [A] behind the bookbinder. 7. Set the keyholes of the hinge plates [B] over the heads of the shoulder screws [C]. 8. Slide the inserter forward so the hinge plates slide under the heads of the shoulder screws. 9.
Page 66 1. Installation 2. Loosen (do not remove) hinge screws [A] (x2: M4). 3. Use a small wrench to loosen adjustment screw [A] (Do not remove!). 4. Insert a hex wrench (Allen key) [B] into the tip of the adjustment screw. •...
Page 67 Inserter-C1 (D391-18) Installation Connecting the Inserter 1. Connect the inserter to the relay panel [A] (x3). 2. Fasten the ground wire [B] ( x1: M4 x8). 3. Wrap the clamp [C] around the harnesses and ground wire. 4. Fasten the clamp ( x1: M4 x8). Inserter Gap Measurement 1.
Page 68 1. Installation If the difference between the measure gaps is less than 1 mm, no adjustment is necessary. Skip the next section. -or- If the difference is more than 1 mm, you must go to the next section and adjust the height. Inserter Gap Adjustment 1.
Page 69 Inserter-C1 (D391-18) Installation 3. Open the top cover [A]. 4. Remove the front cover [B] ( x2). 5. On the right side of the adjustment mechanism, loosen: [A] Screw [B] Hex nut • With a hex wrench turn adjustment screw [C] to adjust the gap by raising or lower the inserter. •...
Page 70 1. Installation 6. On the left side of the adjustment mechanism, adjust the height of the inserter on the left. (The procedure is the same as Step 5.) 7. Reattach: • Inserter front cover ( x2) • Top cover angle adjustment shaft ( x1) Inserter Limiter Brace The limiter brace limits the movement of the inserter unit when it is opened.
Page 71 Inserter-C1 (D391-18) Installation 2. Retrieve the items shown above from the relay unit accessories. 3. Set the limiter brace [A] on the two posts (front and back).
Page 72 1. Installation 4. While holding the limiter brace [A] upright so it does not slip off its posts, attach brace [B] ( x1). (Make sure that this screw is tight.) 5. Attach cap nut [A] to the exposed threads of the screw. 6.
Page 73: Transit Pass Unit (D391-19) Installation
Transit Pass Unit (D391-19) Installation Transit Pass Unit (D391-19) Installation Relay Unit Accessories Check the accessories and their quantities against this list. Description Q’ty 1. Transit Pass Unit D391 (Relay Unit) 2. Ground Plate 3. Joint Bracket (Left) 4. Joint Bracket (Right) 5.
Page 74: Relay Unit Installation
1. Installation Relay Unit Installation 1. From the relay unit remove: [A] Strips of tape x2...
Page 75 Transit Pass Unit (D391-19) Installation [B] Strips of tape x3, cushion x1 [C] Tape x1 2. On the right side of the host machine [A], lower the relay unit [B] onto the two shoulder screws (front and rear). 3. Confirm that the slots on the left side of the relay unit are both hooked correctly on the heads of the shoulder screws [A] and [B].
Page 76 1. Installation 4. Use the accessory screws (long, knurled heads) to fasten the relay unit to the side of the host machine ( x4). 5. Route the two relay unit harnesses through the grommet and hole [A]. 6. Attach the harnesses at [B] below.
Page 77 Transit Pass Unit (D391-19) Installation 7. Attach the rear cover to the relay unit. [A]  x2 [B]  x3 8. Attach the ground plate [A] ( x4)
Page 78 1. Installation 9. Attach the front cover to the relay unit. [A]  x2 [B]  x3 10. At the left rear corner of the host machine, attach the cover [A] ( x6).
Page 79 Transit Pass Unit (D391-19) Installation 11. On the right side of the host machine, attach: [A] Left joint bracket ("L") ( x2) [B] Right joint bracket ("R") ( x2) 12. Open the front door of the relay unit. 13. Remove screw [A]. 14.
Page 80 1. Installation 16. Push in lock bar [A] to raise it and lock it in the cutouts of the joint brackets attached to the host machine. 17. Reattach screw [B] to fasten the lock bar in the raised position. 18. Remove the brace [A] from the right front door of the bookbinder. (x1) 19.
Page 81 Transit Pass Unit (D391-19) Installation 20. Place a shoe [A] under the stoppers at each corner of the bookbinder. 21. Use your fingers (or the wrench) to turn the nut in the direction of the arrow until the nut stops on top of the shoe.
Page 82 1. Installation Testing the Breaker Switch 1. Turn off the host machine. • The power supply to the bookbinder must be off. 2. Plug the bookbinder power cord into its power source. 3. Locate the breaker switch [A] at the right lower corner of the machine below the power cord. 4.
Page 83: Docking, Completing The Installation
Docking, Completing the Installation Docking, Completing the Installation Docking the Bookbinder 1. At the left rear corner of the host machine, confirm that cover [A] has been reattached ( x6). 2. On the right side of the host machine, attach: [A] Left joint bracket ("L") (...
Page 84 1. Installation 3. Open the front door of the relay unit. 4. Remove screw [A]. 5. Pull the lock bar [B] out to lower it. 6. Slowly push the bookbinder against the side of the host machine. 7. Push in lock bar [A] to raise it and lock it in the cutouts of the joint brackets attached to the host machine. 8.
Page 85 Docking, Completing the Installation 9. Remove the brace [A] from the right front door of the bookbinder. (x1) 10. Remove wrench [B]. 11. Place a shoe [A] under the stoppers at each corner of the bookbinder. 12. Use your fingers (or the wrench) to turn the nut in the direction of the arrow until the nut stops on top of the shoe.
Page 86: Filling Bookbinder Glue Supply Unit
1. Installation 13. At each corner use the wrench [A] to turn the nut in the direction of the arrow to raise the bookbinder [B] until the caster [C] raises off the floor. 14. Place a level on the top edge of the front and right edge of the machine to confirm that the bookbinder is level.
Page 87 Docking, Completing the Installation 1. Pull out the glue supply drawer until it stops. 2. Raise the two covers [A] and [B]. 3. Note the load limit marks [C] inside the drawer on both sides.
Page 88 1. Installation 4. Use the scoop [A] to fill the bin with glue pellets as far as the load limit marks on both sides of the drawer. • Two scoops (about 380 g each) should be sufficient. 5. Close both covers. 6.
Page 89: Testing The Breaker Switch
Docking, Completing the Installation Testing the Breaker Switch 1. Turn off the host machine. • The power supply to the bookbinder must be off. 2. Plug the bookbinder power cord into its power source. 3. Locate the breaker switch [A] at the right lower corner of the machine below the power cord. 4.
Page 90: Final Check
1. Installation Final Check 1. Connect the power cord of the copier to its power source. 2. Connect the power cord of the bookbinder to its power source. 3. Turn on the host machine.
Page 91: Preparing The Bookbinder For Moving
Preparing the Bookbinder for Moving Preparing the Bookbinder for Moving This section describes which braces should be reattached to the bookbinder before it is moved to another location. Setting the Bookbinder for Moving Do this procedure to move the internal units to their home positions before moving the machine. •...
Page 92 1. Installation 5. Remove the service board cover [1] ( x1). 6. On the SW1 bank set DIP SW1 to ON. 7. On the SW2 bank set DIP SWs 1, 2, 4, 7 to ON.
Page 93 Preparing the Bookbinder for Moving 8. Turn the host machine on. • Wait about 30 sec. • Make sure that you hands and tools are well clear of the parts inside the machine. 9. Slowly push [PSW1] 11 times. • Each push on the [PSW1] moves a unit to its shipping position (see table below). •...
Page 94: Same Floor
1. Installation Operation Target Unit Lowers the stacking tray. Stacking Tray Retracts the right and left cover path guide plates. Cover Unit Opens the spine fold plate (movable side only) Cover Unit Closes the right and left cover path guide plates. Cover Unit Rotates the main gripper.
Page 95 Preparing the Bookbinder for Moving Gluing Unit Brace Quantity Brace "B" ( x4) Brace "G" ( x4) Sub Grip Unit...
Page 96: Another Floor (By Elevator)
1. Installation Brace Quantity Braces "D" ( x3 ea.) Another Floor (by Elevator) If the bookbinder will be moved by elevator to a different floor in the same building attach the braces to stabilize the gluing unit, sub grip unit (described above) and the two additional locations described below. Left Side (Paper Exit) Brace Quantity...
Page 97: Shipping The Bookbinder
Preparing the Bookbinder for Moving Right Side (Paper Entrance) Brace Quantity Brace "H" ( x2) Shipping the Bookbinder Follow the installation instructions in reverse and reattach as many of the braces and cushions as possible. • Use the Service Board DIP SWs to set the components inside the machine to their correct moving positions before you reattach any braces.
Page 98 1. Installation...
Page 99: Preventive Maintenance
2. Preventive Maintenance PM Tables For details about "PM Tables" for this peripheral, see the main service manual.
Page 100 2. Preventive Maintenance...
Page 101: Replacement And Adjustment
3. Replacement and Adjustment Basics Parts Dangerous to Touch This section points out some areas inside the machine where you should exercise extra precaution when working around the machine with the covers off. Covers Off Rear Gluing Unit...
Page 102 3. Replacement and Adjustment Sub Grip Area (Front) Sub Grip Area (Rear)
Page 103 Basics Front Main Grip Unit Spine Plates Gripper Blade Gluing Unit The gluing unit becomes extremely hot to keep the glue melted and ready for use. The glue and gluing unit remain hot for several minutes after the bookbinder is turned off. •...
Page 104 3. Replacement and Adjustment • After removing the covers, touch the gluing unit only when necessary and only after it has cooled completely. Gluing Unit Gluing Unit The illustration shows the glue vat with the top cover removed.
Page 105 Basics Sub Grip Unit: Front and Back • Never put your fingers or a tool in or near the exposed areas of the sub grip unit at the front [1] or at the rear [2] while the bookbinder is powered on.
Page 106 3. Replacement and Adjustment Main Grip Unit at Signature Turnover (from Sub Grip Unit) • Never put your fingers or a tool in or near the exposed areas of the main grip unit at [1] while the bookbinder is powered on. Main Grip Unit at Turnover to Trimming Unit After Gluing •...
Page 107 Basics Spine Fold Plate • Never put your fingers or a tool in or near the exposed areas of the spine plates at [1] while the bookbinder is powered on.
Page 108 3. Replacement and Adjustment Trimming Unit Gripper and Press Plate • Never put your fingers or a tool in or near the exposed areas of the press plates at [1] or gripper at [2] while the bookbinder is powered on.
Page 109: Using The Dials
Basics Blade at Retracted Position • The blade is extremely sharp. Never touch the edge of the blade [1]. Always work carefully where the blade is exposed. Using the Dials Gluing Unit The gluing unit is equipped with two dials that are used to raise and lower the stacking tray and the main grip unit.
Page 110 3. Replacement and Adjustment Stacking Tray Lift Dial The photo above shows the stacking tray lift dial [1] viewed from the rear of the bookbinder. • Turn this dial clockwise to lower the stacking tray. • Turn this dial counter-clockwise to raise the stacking tray. Main Grip Unit Lift Dial The photo above shows the main grip lift dial [1] viewed from the rear of the bookbinder.
Page 111 Basics Trimming Unit The trimming unit is equipped with four dials that: • Raise the slide • Open and close the grip • Open and close the press plates • Move the blade from side to side There are also two pulleys where you can use a plus (+) screwdriver to raise and lower the book lift tray and move the trimmings buffer from side to side.
Page 112 3. Replacement and Adjustment Main Grip/Press Plate Dials The photo above shows the main grip unit pulled out and viewed from the front. Main Grip Dial Press Plate Dial Main Grip Dial • Turn clockwise to close the main grip. •...
Page 113 Basics Blade Dial The photo above shows the blade dial [1] with the trimming unit pulled out of the front of the bookbinder: • Turn the dial clockwise to push the blade toward the cutting position. • Turn the dial counter-clockwise to pull the blade away from the cutting position. Book Lift Tray/Trimmings Buffer Pulleys The photo above shows the book tray lift pulley [1] and the trimmings buffer [2] viewed from the front.
Page 114 3. Replacement and Adjustment Trimmings buffer pulley • Turn the pulley clockwise to move the trimmings buffer to the left. • Turn the pulley counter-clockwise to move the trimmings buffer to the right.
Page 115: Common Procedures
Common Procedures Common Procedures Setting and Releasing Low Performance Mode Do this procedure to set and release the low performance mode for the bookbinder. The bookbinder automatically enters the low performance mode if a bookbinding component malfunctions and binding is no longer possible.
Page 116 3. Replacement and Adjustment 5. Remove the service board cover [1] ( x1). 6. Set the SW1, SW2 banks as shown below. 7. Switch on the host machine. 8. Press [PSW1]. LED2 and LED3 indicate the current machine mode. • Normal Mode. LED2, LED3 both flash for 2 sec. •...
Page 117: Inserter Unit
Common Procedures • You may need to set the machine for low performance mode if a replacement part is not available so the operator can continue to use the system. • The low performance mode allows the bookbinder to perform downstream delivery so it does not interfere with other operations (bookbinding and trimming, however, are not available.) •...
Page 118: Front Doors
3. Replacement and Adjustment [2] Limiter brace [2] ( x2) 3. Remove the bookbinder rear upper cover. 4. Disconnect the inserter I/F cable [1] ( x2,  x3). 5. Raise the inserter [1]. 6. Disconnect the inserter [2] from the bookbinder and remove it ( x2). Front Doors 1.
Page 119 Common Procedures 2. On the left door [1] remove the top hinge [2] and bottom hinge [3]. • While holding the left front door with one hand, behind the top hinge push the black lever [4] in the direction of the arrow to release the top hinge. •...
Page 120 3. Replacement and Adjustment 3. Repeat Step 2 to remove the top hinge [1] and bottom hinge [2] then remove the right front door [3]. (You may have to lower Mk11 so you can remove the right door.)
Page 121: Covers
Common Procedures Covers Rear Cover 1. Rear cover [1] ( x8) Rear Upper Cover...
Page 122 3. Replacement and Adjustment 1. Rear upper cover [1] ( x5) Left Upper Cover 1. Open the inserter and upper cover. 2. Remove the front bar [1] of the stacking tray unit ( x3). 3. Remove the left upper cover [1] ( x4).
Page 123 Common Procedures Front Inner Cover: Upper 1. Remove both the left and right front door. 2. Raise jam lever Mk12 [1]. 3. Remove the front inner cover (upper) [2] ( x6). Front Inner Cover: Lower 1. At the right rear corner, unlock the book stack door.
Page 124: Signature Path Exit Unit
3. Replacement and Adjustment 2. Pull out the book stacking tray [1] and trimmings box [2] together. 3. Pull off jam clear knob Mk10 [3]. • Mk10 must be reattached. 4. Remove the screws of the lower inner cover [4] (x7). 5.
Page 125 Common Procedures 1. Remove the inserter. 2. Remove the stacking tray front cover [1] ( x3) 3. Remove the top cover [1] ( x3). 4. Remove the harness cover [1] ( x2).
Page 126 3. Replacement and Adjustment 5. Remove the covers around the back and the rear upper cover. 6. Remove: [1]  x1 [2] Flange x1 [3] Belt x1 [4] Gear x1 [5] Lock pin x1 [6]  x1 [7] Bearing x1 7.
Page 127 Common Procedures 8. At the front, remove the signature exit roller [1] (Lock pin x1,  x1, Bearing x1). Before Removing the Signature Path Exit Unit: • Remove the signature path exit unit carefully and avoid dropping the belt [1] of the drive motor into the bookbinder.
Page 128: Cover Transport Unit
3. Replacement and Adjustment 9. Open the transport guide [1]. 10. Remove the signature path exit unit [2] ( x 2 Left,  x 2 Right) Cover Transport Unit 1. Remove: • Rear cover (* p.119) • Both doors (* p.116) •...
Page 129 Common Procedures 3. Disconnect connectors at [1] ( x5) and [2] ( x6). 4. Remove: [1] Left brace ( x4) [2] Right brace ( x4) [3] Lock plate ( x2)
Page 130: Trimming Unit
3. Replacement and Adjustment 5. Pull out the cover transport unit [1] on its rails. Trimming Unit 1. Insert the tip of a small screwdriver into the small hole [1] near the left rear corner of the bookbinder. 2. Gently move the screwdriver in the direction of the arrow to release the stacking tray lock. 3.
Page 131 Common Procedures 6. Remove: [1] Left brace ( x2) [2] Right brace ( x2) [3] Lock plate ( x2) 7. Pull out the trimming unit [1] on its rails. Before Closing the Trimming Unit Drawer...
Page 132 3. Replacement and Adjustment 1. Check the area around the edge press plate motor (M36) [1]. 2. Turning the motor knob [1] away from you releases the pressure exerted by the press plate but also moves the small plate [2] to the right. (You may have done this during the procedure.) 3.
Page 133 Common Procedures 4. Check the area around the cutter motor (M35) [1] and PCB [2] where the trimmer limit sensor (S86) is mounted. The illustration on the left shows the blade cradle at the rear, and the illustration on the right shows the blade cradle at the front.
Page 134: Opening Locked Doors Manually
3. Replacement and Adjustment • To prevent SC795-30 always check the position of the plate before closing the trimming unit drawer. Opening Locked Doors Manually Front Doors If the front doors remain locked after the power was turned off while the bookbinder was operating, cycling the bookbinder off/on will usually unlock the doors.
Page 135: Signature Thickness Sensor (S50) Recalibration
Common Procedures The manual release is located behind a cutout on the left edge of the left front door. Book Stack Door 1. Insert the tip of a small screwdriver into the small hole near the left rear corner of the bookbinder. 2.
Page 136 3. Replacement and Adjustment • EEPROM on the master control board • Signature thickness sensor (S50) • This procedure is not required for replacement of the master control board if the EEPROM is removed from the old board and installed on the new master control board. Special Tools Two special plastic jigs are provided with a new signature thickness sensor (S50).
Page 137 Common Procedures 4. On the SW-1 bank set DIP SW1 to ON. 5. Turn the host machine on. 6. On the SW-2 bank set DIP SW5 to ON. 7. Press [PSW1] on the service board to open the main grip and move it to its home position. 8.
Page 138 3. Replacement and Adjustment 11. Set the jigs [1] and [2] (provided as accessories) in the main grip unit as shown above. 12. Press [PSW1] once. This sets the measurement for the maximum thickness (25 mm). 13. Check the LED display to confirm that the maximum value has been set: LED1: ON, LED2: ON, LED3: Flash (Saving maximum setting) LED1: Flash, LED2: OFF, LED3: OFF (Adjust.
Page 139: Resetting Counters
Common Procedures Resetting Counters The counter for a bookbinder or inserter part must be reset to zero after the part has been replaced. Bookbinder Counters Bookbinder Component Counts This operation clears the counts for PM parts stored in the EEPROM of the bookbinder. 1.
Page 140 3. Replacement and Adjustment Status Anti-Static Brush (Relay Unit) Anti-Static Brush (Exit) Switchback Roller (Stacking Tray) --- Not Used --- Switchback Roller (Cover Registration) TE Press Roller Drawer Connector Signature Thickness Sensor Main Grip, Sub Grip Motors Glue Heater Ripple Roller Torque Diode Limiter (Signature Rotation) Timing Belt (Signature Rotation) Ball Screw Unit...
Page 141 Common Procedures Bookbinder Internal Counter Reset Do this procedure to clear all the counts stored in the EEPROM of the bookbinder. 1. If the system is on, turn the host machine off. 2. On the SW-1 bank set DIP SW1 to ON. 3.
Page 142 3. Replacement and Adjustment Do this procedure to restore all the default factory settings in the EEPROM mounted on the master control board. The also resets all counters to zero. 1. If the system is on, turn the host machine off. 2.
Page 143: Cover Skew Adjustment
Common Procedures 2. On the SW-1 bank set DIP SW1, SW3 to ON. 3. Turn the host machine on. 4. Set the SW2 bank as shown below. Status Upper Tray Pickup Roller Upper Tray Separation Roller Upper Tray Transport Roller Upper Tray Torque Limiter Lower Tray Pickup Roller Lower Tray Separation Roller...
Page 144 3. Replacement and Adjustment Cause: Cover was not aligned correctly in the cover transport path before the signature and cover were jointed. Solution: Adjust the position of the cover horizontal registration unit. 1. Remove the right and left front door. 2.
Page 145 Common Procedures 5. Do some test prints and then repeat the adjustment until the cover and signature are correctly aligned.
Page 146: Path Entrance Motors
3. Replacement and Adjustment Path Entrance Motors Vertical Transport Motor (M5 (INS)) 1. Remove the rear cover. (* p.119) 2. Remove the vertical transport motor (M5 (INS)) [1] ( x2,  x1) Re-installation 1. Be sure to reattach the timing belt [1] with the belt hung on the motor drive gear as shown above...
Page 147: Entrance Motor (M10)
Path Entrance Motors Entrance Motor (M10) 1. Remove the rear cover ( x8). (* p.119) 2. Remove the entrance motor (M10) [1] ( x2,  x1) Reinstallation 1. Be sure to reattach the timing belt [1] with the belt hung on the motor drive gear as shown above.
Page 148: Signature Path Exit Unit
3. Replacement and Adjustment Signature Path Exit Unit Ripple Idle Rollers 1. Remove the signature path exit unit. (* p.122) 2. Remove the 5 ripple idle rollers ( x1 ea.) 3. Reset the counter for the ripple rollers. (* p.137) TE Press Roller Unit 1.
Page 149 Signature Path Exit Unit 4. Remove sensor plate [1] ( x1). 5. Remove: [1]  x1 [2] Bearing x1...
Page 150 3. Replacement and Adjustment 6. Slide the pressure roller [1] in the direction of the arrow, release it from the ring [2], then remove the roller. 7. Remove the TE press plate unit [1] ( x4).
Page 151 Signature Path Exit Unit 8. Remove the TE press roller unit [1]. [2]  x1 [3] Gear x 1 [4] Lock pin x1 [5]  x1 [6] Bearing x1 [7] Ripple idle rollers x2 ( x1 ea.) [8]  x1 [9] Bearing x1...
Page 152 3. Replacement and Adjustment Reinstallation 1. Pressure levers [1] must be positioned between the shaft of the TE pressure plate [2] and the rib [3].
Page 153: Anti-Static Brush
Signature Path Exit Unit Anti-Static Brush 1. Remove: • Inserter unit (* p.115) • Top cover (* p.122) 2. Open the transport guide [1]. 3. Remove the upper anti-static brush [2] ( x2) 4. Remove the lower anti-static brushes. [3] Front ( x2) [4] Rear (...
Page 154: Stacking Tray
3. Replacement and Adjustment Stacking Tray Switchback Roller 1. Remove: • Inserter (* p.115) • Top cover (* p.122) 2. Remove control plates [1] and [2] ( x2 ea.) 3. At the front and rear, remove: [1] Collar x1 [2] Collar x1 4.
Page 155: Anti-Static Brush
Stacking Tray 5. Reset the counter after replacing the switchback roller. (* p.137) Anti-Static Brush 1. Remove: • Inserter (* p.115) • Top cover (* p.122) 2. Remove the top cover of the jogging unit [1] ( x4) 3. Disconnect the stacking weight motor [1] (M6) ( x2). 4.
Page 156 3. Replacement and Adjustment 5. Remove the plate screws [1] ( x2). 6. Shift the weight [1] to the left in the direction of the arrow as far as it will go. 7. Slowly rotate the anti-static brush [2] to the front and remove it. 8.
Page 157: Jogger Motors (Front/Back) (M4/M5)
Stacking Tray Jogger Motors (Front/Back) (M4/M5) 1. Remove: • Inserter (* p.115) • Top cover (* p.122) 2. Remove the top cover of the jogging unit [1] ( x4) 3. Remove: [1] Front jogger motor (M4) ( x2,  x1) [2] Rear jogger motor (M5) (...
Page 158: Main Grip Unit
3. Replacement and Adjustment Main Grip Unit Signature Thickness Sensor (S50) 1. Open the right door and left door. 2. Remove the service board cover [1] ( x1). 3. If the system is on, switch off the host machine. 4. Insert piece of cardboard or folded piece of paper into left door switch slot [1].
Page 159 Main Grip Unit 5. On the SW1 bank set DIP SW1 to ON. • Confirm that the trimmer unit is inside the bookbinder. Before entering Service Mode the trimmer unit must be inside the machine. 6. Turn the host machine on. The bookbinder is now in Service Mode. 7.
Page 160 3. Replacement and Adjustment 8. Press [PSW1] to move the main grip unit. 9. Visually check to confirm that the main grip unit has moved to the binding position (it should be vertical). 10. Turn the host machine off and disconnect the host machine, bookbinder, and any other peripheral devices from the power supply.
Page 161 Main Grip Unit 13. Remove the rear cover of the bookbinder. 14. Remove the sensor plate [1] ( x1). • Work carefully with the protective plate removed to avoid hitting and damaging the exposed sensor [1] and actuator [2].
Page 162 3. Replacement and Adjustment 15. Remove the signature thickness sensor (S50) [1] Band x1 [2]  x2 [3]  x1 Reinstallation 1. When reattaching the sensor plate confirm that the sensor pin [1] is positioned between the sides of the cutout [2] as shown above. 2.
Page 163: Grip Motor: Front (M23)
Main Grip Unit Grip Motor: Front (M23) 1. Turn the host machine off. 2. Remove: • Left door and right door (* p.116) • Front inner cover: upper (* p.121) 3. Insert piece of cardboard or folded piece of paper into the slots of the left [1] and right [2] door switches.
Page 164 3. Replacement and Adjustment 7. On the SW2 bank set DIP SW 1, 2, and 7 to ON. • Make sure your hands, loose clothing, and tools are well clear of the bookbinder. 8. Press [PSW1] to move the main grip unit. 9.
Page 165 Main Grip Unit 12. Remove the bracket screws [1] ( x3). 13. Disconnect the connector [2] ( x1). • Work carefully during removal to avoid damaging the encoder wheel [2] and sensor [1].
Page 166 3. Replacement and Adjustment 14. To free the motor [1], remove: [2] Band x1 [3]  x1 [4]  x1 15. Remove the sensor bracket [1] ( x2).
Page 167 Main Grip Unit 16. Remove the motor [1] from the bracket [2] ( x2). Reinstallation Before reinstalling the motor confirm that the harness [1] and gear [2] are positioned as shown above.
Page 168: Grip Motor (Rear) (M24)
3. Replacement and Adjustment Grip Motor (Rear) (M24) 1. Turn the host machine off. 2. Open the right door and left door. 3. Remove service board cover [1] 4. Insert piece of cardboard or folded piece of paper into the left door switch slot [1].
Page 169 Main Grip Unit 5. On the SW1 bank set DIP SW1 to ON. • Confirm that the trimmer unit is inside the bookbinder. Before entering Service Mode the trimmer unit must be inside the machine. 6. Turn the host machine on. The bookbinder is now in Service Mode. 7.
Page 170 3. Replacement and Adjustment 8. Press [PSW1] to move the main grip unit. 9. Visually check to confirm that the main grip unit has moved to the binding position (it should be vertical). 10. Turn the host machine off and disconnect the host machine, bookbinder, and any other peripheral devices from the power supply.
Page 171 Main Grip Unit 14. Remove the deodorization filter bracket [1] ( x4). 15. Remove the relay board: [1] Plate ( x1) [2] Flexible press plates x2 [3] FFC x1 [4]  x3,  x3 [5]  x1...
Page 172 3. Replacement and Adjustment 16. Disconnect the motor bracket [1] ( x3). • Work carefully during removal to avoid damaging the encoder wheel [1] and sensor [2].
Page 173 Main Grip Unit 17. Remove the sensor plate [1] ( x1). Reinstallation Before reinstalling the motor confirm that the harness [1] and gear [2] are positioned as shown above.
Page 174: Grip Unit Rotation Motor (M21)
3. Replacement and Adjustment Grip Unit Rotation Motor (M21) 1. Open the inserter. 2. Remove: • Top cover (* p.122) • Rear upper cover (* p.119) • Rear cover (* p.119) 3. Remove the harness cover [1] ( x4). 4. Remove the top cover switch [1] ( x2).
Page 175 Main Grip Unit 5. Remove the top cover frame [1] ( x5). 6. Remove the protection plate [1] ( x1,  x1,  x3). 7. While holding the main gripper steady with one hand, remove the grip unit rotation motor.
Page 176: Main Grip Lift Motor (M22)
3. Replacement and Adjustment • Holding the main gripper steady prevents it from wobbling and disturbing the position of the main gripper. Main Grip Lift Motor (M22) 1. Remove the rear cover. (* p.119) 2. Remove the main gripper lift motor [1] ( x1,  x2). Reinstallation 1.
Page 177: Gluing Unit
Gluing Unit Gluing Unit Filters Deodorization Filter: Gluing Unit 1. Remove the rear cover. (* p.119) 2. Remove the rear upper cover. (* p.119) 3. Remove the filter case [1] ( x4). 4. Remove the filter case [1] ( x3). 5.
Page 178: Glue Heater
3. Replacement and Adjustment Deodorization Filter: Rear Upper Cover 1. Remove rear upper cover [1] of the bookbinder ( x5). (* p.119) 2. Remove the deodorization filters (x3). Glue Heater 1. If the system is on, turn it off. 2. Allow the glue heater to cool for at least 30 min. •...
Page 179 Gluing Unit 4. Insert piece of cardboard or folded piece of paper into the slot [1] of the left door switch. 5. Remove the cover [1] of the service board ( x1). 6. If the system is on, switch off the host machine. 7.
Page 180 3. Replacement and Adjustment 8. Turn the host machine on. The bookbinder is now in Service Mode. 9. On the SW2 bank set DIP SW 1, 2, and 7 to ON. • Make sure your hands, loose clothing, and tools are well clear of the bookbinder. 10.
Page 181 Gluing Unit 13. Remove the glue unit transport stay [1] ( x4). 14. Disconnect the harnesses ( x8,  x5).
Page 182 3. Replacement and Adjustment 15. Remove: [1] Standoff x1 [2]  x2 16. Release the thermistor harness [1] at the front side of the glue heater unit ( x4).
Page 183 Gluing Unit 17. Remove sensor bracket [1] ( x1). 18. Remove sensor bracket and sensor [1] ( x1,  x1).
Page 184 3. Replacement and Adjustment 19. Remove the screw from the bottom of the glue heater unit [1] ( x1). 20. Remove the glue heater unit [1] ( x3).
Page 185 Gluing Unit Reinstallation 1. Reconnect the timing belt [1] to the motor drive gear [2] and shaft gear [3]. 2. Reset the counter after replacing the glue heater. (* p.137)
Page 186: Cover Transport Unit
3. Replacement and Adjustment Cover Transport Unit Switchback Rollers: Cover Transport 1. Open the right and left door. 2. Remove the switchback rollers [1] ( x2). 3. Reset the counter after replacing the switchback rollers. (* p.137) Torque Limiter 1. Pull out the cover transport unit drawer. (* p.126) 2.
Page 187 Cover Transport Unit 3. Remove the torque limiter [1] ( x1, Gear x1). Reinstallation When you reinstall the roller release lever shaft, make sure that the pawls [1] of the shaft are below the roller holders [2].
Page 188: Anti-Static Brushes: Upper And Lower Right
3. Replacement and Adjustment Anti-Static Brushes: Upper and Lower Right 1. Pull out the cover transport unit. 2. Disconnect the roller [1] ( x1, Bearing x1). 3. Push the shaft of roller [1] to the rear. 4. Remove bearing, free the timing belt, and remove the roller. Anti-Static Brush: Upper Right...
Page 189 Cover Transport Unit 5. Remove the anti-static brush [1] ( x2). Anti-Static Brush: Lower Right 6. Remove the idle roller unit of transport roller 1 [1] ( x2).
Page 190: Anti-Static Brush: Left
3. Replacement and Adjustment 7. Remove the anti-static brush [1]. 8. Reset the counter after replacing the brushes. (* p.137) Anti-Static Brush: Left 1. Pull out the cover transport unit. (* p.126) 2. Open cover [1]. 3. Remove anti-static brushes [2] and [3]. 4.
Page 191: Exit Rollers 1/2 Unit
Cover Transport Unit Exit Rollers 1/2 Unit 1. Pull out the cover transport unit. (* p.126) 2. Open cover [1]. 3. Remove guide plate [2] ( x1). 4. Remove exit idle roller unit. 5. Open cover [1].
Page 192 3. Replacement and Adjustment 6. Remove exit roller unit [1] ( x6,  x1). Reinstallation Confirm that the pressure arms [1] on the rear of the exit roller unit are inserted into the holes [2] of the spine fold unit. If the fit is difficult, manually turn the gear [3] of the motor to move the spine fold unit.
Page 193: Trimming Unit
Trimming Unit Trimming Unit Torque Diode: Signature Rotation Unit 1. Pull out the trimming unit drawer. (* p.128) 2. Remove left stay [1] ( x4). 3. Remove harness plate [1] ( x4,  x9,  x1)
Page 194 3. Replacement and Adjustment 4. Rotate knob [1] counter-clockwise until sensor plate [2] separates from sensor [3]. 5. Rotate wheel [1] to raise the rotation unit [2] then remove sensor plate [3] ( x1) 6. Disconnect sensor [4].
Page 195 Trimming Unit 7. Release connector [1]. 8. While gently pressing down on the rotation unit [2], remove harness guide [3] ( x2). 9. Turn wheel [1] to move rotation unit until you can see the screw. 10. Remove the sensor plate [2] ( x1).
Page 196 3. Replacement and Adjustment 11. Remove: [1]  x1 [2] Shaft x1 [3] Gear x1 12. Move the rotation unit to a position where it is easy to work and remove the torque diode [1] ( x3). 13. Reset the counter after replacing the torque limiter diode. (* p.137)
Page 197: Blade Cradle
Trimming Unit Blade Cradle 1. Insert the tip of a small screwdriver into the small hole [1] near the left rear corner of the bookbinder. 2. Move the screwdriver in the direction of the arrow to release the stacking tray lock. 3.
Page 198 3. Replacement and Adjustment 6. Remove the service board cover [1] ( x1). 7. If the system is on, switch off the host machine. 8. On the SW1 bank set DIP SW1 to ON. • Confirm that the trimmer unit is inside the bookbinder. Before entering Service Mode the trimmer unit must be inside the machine.
Page 199 Trimming Unit • Make sure your hands, loose clothing, and tools are well clear of the bookbinder. 11. Press [PSW1].
Page 200 3. Replacement and Adjustment This operates the blade [1], edge press plate [2], and signature rotation unit [3]. The blade retracts to the safe position. 12. Turn the host machine off and disconnect the host machine, bookbinder, and any other peripheral devices from the power supply.
Page 201 Trimming Unit Reinstallation 1. When reinstalling the blade cradle confirm that the three pawls [1] of the cradle are inserted in the holes of the trimming unit [2] and locked in the groove [3]. 2. After the blade cradle has been reinstalled, at the front and rear confirm that blade cradle is aligned correctly [A] and not floating away [B] from or misaligned with the trimming unit.
Page 202: Trimming Blade, Trimmings Catcher
3. Replacement and Adjustment • Always replace the trimming blade and trimmings catcher after replacing the cradle. (The trimming blade, trimmings catcher, and blade cradle should always be replaced together.) Trimming Blade, Trimmings Catcher • The trimming blade and trimmings catcher are always replaced together. Removing the Trimming Blade 1.
Page 203 Trimming Unit 5. Insert piece of cardboard or folded piece of paper into the slot [1] of the left door switch and the slot [2] of the right door switch. 6. Remove the service board cover [1] ( x1). 7. If the system is on, switch off the host machine.
Page 204 3. Replacement and Adjustment 8. On the SW1 bank set DIP SW1 to ON. • Confirm that the trimmer unit is inside the bookbinder. Before entering Service Mode the trimmer unit must be inside the machine. 9. Turn the host machine on. The bookbinder is now in Service Mode. 10.
Page 205 Trimming Unit This operates the blade [1], edge press plate [2], and signature rotation unit [3]. The blade retracts to the safe position. 12. Turn the host machine off and disconnect the host machine, bookbinder, and any other peripheral devices from the power supply. 13.
Page 206 3. Replacement and Adjustment [3] Lock plate ( x2) 15. Pull out the trimming unit [4] on its rails. 16. While pushing the lever [1] to the left with a screwdriver, insert the sheath [2] provided with the new blade along the edge of the old blade inside the bookbinder. •...
Page 207 Trimming Unit 17. Press in the direction of the arrow so the home position of the sheath [1] lines up with the cutout of the blade [2]. 18. Use the accessory screw (provided with the sheath) to fasten the sheath at [3] ( x1). •...
Page 208 3. Replacement and Adjustment 20. Hold the sheath by its grip and slowly pull the blade out. • To avoid serious injury, you must pull on the blade by the attached sheath. The edge of the blade can cause a serious cut if the sheath becomes separated. •...
Page 209 Trimming Unit 2. Remove: [1]  x1 [2] Bracket ( x1) 3. Underneath the trimming unit remove the trimmings catcher unit [1].
Page 210 3. Replacement and Adjustment 4. Remove the slider plate [1]. [1] Springs x 2 [2]  x 2 Installing the New Blade 1. Pick up the new blade with the sheath attached. • Never remove the sheath of the new blade until the blade and sheath have been set in the trimmer unit.
Page 211 Trimming Unit • The sheath is removed only after the blade and attached sheath have been inserted in the trimmer unit. 2. While pushing the lever [1] to the left, push the new blade and sheath [2] into the bookbinder. 3.
Page 212: Ball Screw
3. Replacement and Adjustment 6. Remove the sheath. 7. Make sure all the screws on the blade are tight. Reinstallation 1. To prevent SC795-25 always check the position of the plate to the right of the edge press plate motor (M36) before you close the trimming unit drawer.
Page 213 Trimming Unit 3. Release harness [1] ( x1). 4. After removing the screws, move the chain guide [2] in the direction of the arrow ( x3). 5. Remove e-ring [1] and bearing [2]. (If the bearing is too difficult to remove now, you can remove it later when the ball screw is removed.) 6.
Page 214 3. Replacement and Adjustment If a book is jammed at the edge press plate, rotate the knob [1] on the edge press plate motor clockwise about 10 times to relieve the pressure on the jam site before you attempt to remove the motor. •...
Page 215 Trimming Unit 8. Disconnect the edge press plate motor (M36) [1] and chain [2] ( x4,  x1). 9. Mark the positions of the four harness clamps before you remove them. 10. Disconnect harness [3] ( x8) 11. Remove the screws from the motor frame [1] ( x6). 12.
Page 216 3. Replacement and Adjustment 14. Pull out the shafts [1] and [2]. 15. Remove the rings [1], bearing [2], and bushing [3] from the end of the ball screw. 16. Remove the ball screw [1] ( x4). If it is difficult to remove, rotate the shaft.
Page 217: Trimmings Buffer Motor (M37)
Trimming Unit • The screw shaft and ball screw are always replaced together as one unit. Never attempt to separate the ball screw and shaft (you will not be able to reassemble them). 17. Reset the counter after replacing the ball screw unit. (* p.137) Trimmings Buffer Motor (M37) 1.
Page 218 3. Replacement and Adjustment 7. Remove the trimmings buffer motor (M37) ( x2,  x1).
Page 219: Horizontal Path Rollers
Horizontal Path Rollers Horizontal Path Rollers Exit Idle Roller Unit 1. Pull out the cover transport unit. (* p.126) 2. Raise lever Mk8 to open the exit roller cover [1]. 3. Remove the guide plates: [2] Front ( x1) [3] Rear ( x1) 4.
Page 220: Exit Roller, Horizontal Transport Roller 5
3. Replacement and Adjustment 5. To remove the rollers, release and remove spring [1]. 6. Rotate and pull out roller shaft [2] and remove the rollers ( x2 ea.). Exit Roller, Horizontal Transport Roller 5 1. Pull out the cover transport unit. (* p.126) 2.
Page 221 Horizontal Path Rollers 5. Remove the connector protection plate [1] ( x1). 6. Disconnect the connector [2] ( x1). 7. Remove the guide plate [3], turn it over, and lay it on a flat surface. 8. To replace the rollers: . [1] Springs x2 [2] Rollers (...
Page 222 3. Replacement and Adjustment 9. Remove the exit roller and horizontal transport roller 5. [1] Front ( x1, Bushing x2) [2] Rear ( x2, Timing belts x3, Gears x2, Bushings x2). Reinstallation Make sure that the pressure arms [1] behind the exit unit [2] go through the holes of the left spine fold unit [3].
Page 223: Horizontal Transport Roller 4
Horizontal Path Rollers Horizontal Transport Roller 4 1. Pull out the cover transport unit. (* p.126) 2. Remove the exit idle roller unit. (* p.217) 3. Remove the exit roller unit. (* p.218) 4. Disconnect harness: •  x4 (1), (4), (5), (6) •...
Page 224 3. Replacement and Adjustment 6. Remove the screws: [1] Front ( x2) [2] Rear ( x2) 7. Remove the left spine fold unit [3]. 8. Remove the screws [1] ( x2) then remove the brace [2] from the side of the left spine fold unit. 9.
Page 225: Left Cover Transport Path Guide Roller
Horizontal Path Rollers 11. Remove the roller shafts [1] (Springs x1 ea.) 12. Remove the rollers [2] ( x2 ea) Left Cover Transport Path Guide Roller 1. Pull out the cover transport unit. (* p.126) 2. Raise lever Mk7 to open the cover [1]. 3.
Page 226: Horizontal Transport Roller 1 And Idle Rollers
3. Replacement and Adjustment Horizontal Transport Roller 1 and Idle Rollers 1. Pull out the cover transport unit. (* p.126) 2. At the front disconnect the roller [1] ( x1, Bearing x1) 3. Push the roller [2] slightly to the rear. 4.
Page 227: Horizontal Transport Roller 2
Horizontal Path Rollers Horizontal Transport Roller 2 1. Pull out the cover transport unit. (* p.126) 2. Raise lever Mk9 [1] to see the rollers. 3. Remove the harness protection plate [1] ( x1).
Page 228 3. Replacement and Adjustment 4. Disconnect the harness: [1]  x1 [2]  x2 5. Remove the screws at the front [1] and rear [2] ( x4).
Page 229 Horizontal Path Rollers 6. As you slowly remove the plate [1] guide the connectors [2] under the plate. 7. Turn over the plate and lay it on a flat surface. 8. Remove the roller shaft springs [1] (Springs x2 ea.) 9.
Page 230: Horizontal Transport Roller 3
3. Replacement and Adjustment Reinstallation Make sure that the pressure arms [1] behind the exit unit [2] go through the holes [3] of the spine fold unit. If this is difficult to do, turn the pulley [4] of the spine fold motor manually to move the spine fold unit. Horizontal Transport Roller 3 1.
Page 231 Horizontal Path Rollers 3. Pull the guide plate shaft forward and out of the hole at [1]. 4. Push the guide plate to the rear and through the hole at [1]. 5. Pull the guide plate forward again to remove it from the shaft.
Page 232 3. Replacement and Adjustment 6. Remove: [1] Front door interlock unit [1] ( x3) [2] Guide standard plate [2] ( x1) 7. Remove plate [1] ( x1)
Page 233 Horizontal Path Rollers 8. Use a pen or pencil to mark the current position of the notch on the graduated scale. • The notch must be realigned at this mark when it is reattached. 9. Remove the notch plate [1] ( x1). 10.
Page 234 3. Replacement and Adjustment 11. Disconnect the harness: [1]  x1 [2]  x1 [3]  x3 12. Disconnect harness [1] (Band x1,  x2,  x4)
Page 235 Horizontal Path Rollers 13. Move the left transport path guide [1] to the left. 14. Remove the right spine fold plate [2] ( x2). 15. Open the right cover transport path guide [1]. 16. Manually turn the pulley [2] to move the right spine fold plate unit completely to the right. 17.
Page 236 3. Replacement and Adjustment 18. Remove plates [1], [2] ( x4 ea.) 19. Remove the roller assembly screws [3] ( x2). 20. Remove the screws [1] ( x4). 21. Replace the old roller set [2] with the new one.
Page 237: Perfect Binder Boards
Perfect Binder Boards Perfect Binder Boards Master Control Board (PCB1) Slave Control Board (PCB2) Cutter Control Board (PCB3) Relay Board (PCB12) Power Supply Unit 1 (PCB20) Power Supply Unit 2 (PCB21)
Page 238: Master Control Board
3. Replacement and Adjustment Master Control Board 1. Remove the rear cover. (* p.119) 2. Remove the master control board [1] ( x all,  x1, Standoffs x5). 3. Remove the EEPROM [2] from the old board and install it on the new board. When installing a new EEPROM in Master Control Board New EEPROM has no setting data in itself.
Page 239 Perfect Binder Boards 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. • The LED1 count indicates the sign of the value, plus (+) or minus (-). When LED1 is OFF, this indicates plus (+).
Page 240 3. Replacement and Adjustment 3. CV-CENT Cover Center Adjustment 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4. Input a value for the "CV-CENT" on the factory setting data sheet by pushing [PSW2] to add 0.1 mm to the current value or [PSW3] to subtract 0.1 mm from the current value.
Page 241 Perfect Binder Boards 5. ALG-F-A4 Jogger Motor Adjustment (Front jogger motor; Small size; less than 298 mm) 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4.
Page 242 3. Replacement and Adjustment 7. ALG-F-L Jogger Motor Adjustment (Front jogger motor; Large size; 298 mm or more) 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4.
Page 243 Perfect Binder Boards 9. GLUING 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4. Input a value for the "GLUING" on the factory setting data sheet by pushing [PSW2] to add 0.05 mm to the current value or [PSW3] to subtract 0.05 mm from the current value.
Page 244 3. Replacement and Adjustment 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4. Input a value for the "GLUING" on the factory setting data sheet by pushing [PSW2] to add 0.1 mm to the current value or [PSW3] to subtract 0.1 mm from the current value. 11.
Page 245 Perfect Binder Boards 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4. Input a value for the "SIZE-H" on the factory setting data sheet by pushing [PSW2] to add 0.1 mm to the current value or [PSW3] to subtract 0.1 mm from the current value.
Page 246 3. Replacement and Adjustment 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4. Input a value for the "CV-LNG" on the factory setting data sheet by pushing [PSW2] to add 0.1 mm to the current value or [PSW3] to subtract 0.1 mm from the current value.
Page 247 Perfect Binder Boards 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4. Input a value for the "10RGT-2" on the factory setting data sheet by pushing [PSW2] to add 0.1 mm to the current value or [PSW3] to subtract 0.1 mm from the current value.
Page 248 3. Replacement and Adjustment 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4. Input a value for the "200RGT-1" on the factory setting data sheet by pushing [PSW2] to add 0.1 mm to the current value or [PSW3] to subtract 0.1 mm from the current value.
Page 249 Perfect Binder Boards 20. 200RGT-3 Square Cut Adjustment, L3:Square Adj. For 200-Sheet Signature 3 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4.
Page 250 3. Replacement and Adjustment 22. STK-VR0 Stack Thickness Volume Adjustment: 0 mm 1. Enter the SP mode of the mainframe. 2. Use SP6524-001 to input the factory setting data of the STK-VR0. 23. STK-VR25 Stack Thickness Volume Adjustment: 25 mm 1.
Page 251 Perfect Binder Boards 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4. Input a value for the "GLU-TEMP" on the factory setting data sheet by pushing [PSW2] to add 1°C to the current value or [PSW3] to subtract 1°C from the current value.
Page 252 3. Replacement and Adjustment 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4. Input a value for the "GLU-EDG1" on the factory setting data sheet by pushing [PSW2] to add 1 mm to the current value or [PSW3] to subtract 1 mm from the current value.
Page 253 Perfect Binder Boards 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4. Input a value for the "GLU-EDG3" on the factory setting data sheet by pushing [PSW2] to add 1 mm to the current value or [PSW3] to subtract 1 mm from the current value.
Page 254 3. Replacement and Adjustment 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4. Input a value for the "GLU-AMT1" on the factory setting data sheet by pushing [PSW2] to add 0.05 mm to the current value or [PSW3] to subtract 0.05 mm from the current value.
Page 255 Perfect Binder Boards 34. GLU-AMT3 Glue Amount Adjustment, 3 (stack thickness 3.5-6.4mm) 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4.
Page 256 3. Replacement and Adjustment 36. GLU-AMT5 Glue Amount Adjustment, 5 (stack thickness 11.5-22.4mm) 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4.
Page 257 Perfect Binder Boards 38. TBWRNLVL Blade Replacement Alarm Frequency Setting 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4.
Page 258 3. Replacement and Adjustment 40. TBP-POSW Cutting Position Change Setting for the Blade Cradle 1. Set the SW1 bank as shown above. 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4.
Page 259 Perfect Binder Boards Status DIP 4 DIP 5 DIP 6 DIP 7 DIP 8 DIP 9 DIP 10 DIP 11 DIP 12 DIP 13 DIP 14 DIP 15 2. Set the SW2 bank as shown above. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. 4.
Page 260: Slave Control Board
3. Replacement and Adjustment Slave Control Board 1. Remove the rear cover. (* p.119) 2. Remove the slave control board [1] (FFC x all,  x all,  x1, Standoffs x5). Cutter Control Board 1. Remove the rear cover. (* p.119) 2.
Page 261: Relay Board
Perfect Binder Boards Relay Board 1. Remove the rear cover. (* p.119) 2. Remove the relay control board [1] ( x all,  x4). 3. Remove the EEPROM [2] from the old board and install it on the new board. Power Supply Unit 1 1.
Page 262 3. Replacement and Adjustment 3. Remove the protector plate. [1] Top ( x2) [2] Bottom ( x2) 4. Remove the power supply unit 1 PCB [1] ( x9).
Page 263: Power Supply Unit 2
Perfect Binder Boards Power Supply Unit 2 1. Remove the rear cover. (* p.119) 2. Remove power supply unit 2 assembly [1] ( x 3,  x4). Push the board to the right and pull it out from behind the fan. (It is not necessary to remove the fan.) 3.
Page 264 3. Replacement and Adjustment 4. Remove the power supply unit 2 PCB [1] ( x9).
Page 265: Inserter
Inserter Inserter Common Procedures Rear Cover 1. Rear cover [1] ( x2). Releasing Top and Middle Covers 1. Remove rear cover. (* p.263)
Page 266 3. Replacement and Adjustment 2. Remove the shaft [1] of the limiter brace ( x1). 3. Open the top cover [2] completely. 4. Open the middle cover [1]. 5. Remove the limiter brace [2] ( x2). 6. Open the middle cover completely. Front Cover 1.
Page 267: Feed Rollers
Inserter 2. Remove the front cover [1] ( x2). Feed Rollers Feed Roller: Tray A 1. Remove the inserter rear cover. (* p.263) 2. Release and open the top cover completely. (* p.263) 3. Remove the transport guide [1] ( x2).
Page 268 3. Replacement and Adjustment 4. Remove: [1] Feed roller ( x1) [2] Feed roller ( x1) Feed Roller: Tray B 1. Remove the inserter rear cover. (* p.263) 2. Release and open the top and middle cover completely. (* p.263)
Page 269: Separation Rollers
Inserter 3. Remove: [1] Feed roller ( x1) [2] Feed roller ( x1) Separation Rollers Separation Roller and Torque Limiter: Tray A 1. Remove the inserter rear cover. (* p.263) 2. Release and open top cover completely. (* p.263) 3. Remove transport guide [1] ( x5).
Page 270 3. Replacement and Adjustment 4. Remove the separation roller [1] ( x1, Bushing x1) 5. Remove the torque limiter [2]. 6. Reset the counter after replacing the separation roller or torque limiter. (* p.140) Separation Roller, Torque Limiter: Tray B...
Page 271 Inserter 1. Remove the inserter rear cover. (* p.263) 2. Release and open top and middle cover completely. (* p.263) 3. Remove transport guide [1] ( x5). 4. Remove the separation roller [1] ( 1, Bushing x1) 5. Remove the torque limiter [2]. 6.
Page 272: Pickup Rollers
3. Replacement and Adjustment Pickup Rollers Pickup Roller: Tray A 1. Remove the inserter rear cover. (* p.263) 2. Release and open top cover completely. (* p.263) 3. Remove front transport guide [1] ( x2). 4. Remove the pickup roller unit [1]: [2] Front (Spring x1, ...
Page 273 Inserter 5. Remove the pickup roller [1] ( x3, Actuator x1) 6. Reset the counter after replacing the pickup roller. (* p.140) Pickup Roller: Tray B 1. Remove the inserter rear cover. (* p.263) 2. Release and open top and middle cover completely. (* p.263) 3.
Page 274 3. Replacement and Adjustment 4. Remove the pickup roller unit [1]: [2] Front (Spring x1,  x1, Bushing x1) [3] Rear ( x1, Bushing x1) 5. Remove the pickup roller [1] ( x3, Actuator x1) 6. Reset the counter after replacing the pickup roller. (* p.140)
Page 275: Inserter Control Board
Inserter Inserter Control Board 1. Remove the inserter rear cover. (* p.263) 2. Remove the inserter control board [1] ( x all,  x1, Standoffs x3). When replacing the inserter control board The adjustment of the paper width sensor output value for the Inserter Trays (upper/lower) is required when replacing the inserter control board.
Page 276 3. Replacement and Adjustment ON/OFF Upper/ LTR ON/OFF Lower/ LTR 5. Press "PSW1". [Standby status for A4 or LTR -] SEF LED status at standby: LED1 - ON LED2 - OFF LED3 - OFF 6. Set the side fences to PORTRAIT for the required size (A4 or LTR), then press "PSW1" again to start the adjustment.
Page 277: Troubleshooting
4. Troubleshooting Service Call Tables For details about "Service Call Tables" for this peripheral, see the main service manual.
Page 278: Jams
4. Troubleshooting Jams Handling Paper Jams What Happens When a Jam Occurs When a jam occurs open the cover at the jam location, remove the jammed paper and close the cover. However, the operator should be cautioned about opening the top cover of the bookbinder. •...
Page 279 Jams • If a jam forces the bookbinder to enter the low performance mode, the bookbinder cannot recover from the error automatically. The jam must be removed and the machine reset by the service technician. For more details about setting and releasing the low performance mode, see Section 3. Unlocking the Front Doors Manually If the front doors remain locked after the power was turned off while the bookbinder was operating, normally cycling the bookbinder off/on will unlock the doors.
Page 280 4. Troubleshooting The manual release is located behind a cutout [1] on the left edge of the left front door. When the Book Stack Door Cannot Be Opened Follow the procedure below if an problem occurs that prevents opening the book stacking tray. For example, a strip of trimming stuck to the blade and jammed between the trimming unit and trimming buffer could block these mechanisms and prevent the stacking tray door from opening.
Page 281 Jams 4. Insert the tip of a small screwdriver into hole [1]. 5. Turn the trimmings buffer drive pulley [1] counter-clockwise to move the trimmings buffer [2] to the right. 6. Confirm the movement of the trimmings buffer by checking the position of the actuator of the trimmings buffer full sensor.
Page 282 4. Troubleshooting 8. Insert the tip of a small screwdriver into the small hole [1] on the rear cover of the bookbinder. 9. Move the screwdriver in the direction of the arrow to release the stacking tray lock. • If the rear cover has been removed, just push the lever [2] to the right to unlock the book stack door.
Page 283 Jams 4. Remove the braces [1], [2], [3] from the trimming unit frame. (x3 ea.) 5. Pull out the trimming unit [1]. 6. Retract the grip unit, open the press plates, or retract the blade, trimmings buffer as required. 7. Remove the signature and trimmings.
Page 284 4. Troubleshooting Removing Trimmings Jammed at the Blade Follow the procedure below if an problem occurs that prevents the removal trimmings at the blade. For example, a strip of trimming stuck to the blade and jammed between the trimming unit and trimming buffer could block the removal of the signature or trimmings.
Page 285: Low Performance Mode
Jams 6. Rotate the trimmings buffer pulley [1] counter-clockwise to move the trimmings buffer to the right. 7. Follow the procedure in the previous section to remove the jammed scraps from the trimming unit. 8. Insert your hands from the front of the bookbinder to remove the jammed sheets, pulling them in the direction of paper feed or paper exit.
Page 286: Service Board Basics
4. Troubleshooting Service Board Basics This section describes use of the Service Mode for the bookbinder and inserter. Service Board Switches The two banks of DIP switches on the Service Board (SW1, SW2) are used to set modes and do settings. •...
Page 287: Service Board Leds
Service Board Basics Mode Comment Normal Mode Factory setting Bookbinder Adjustment Mode Bookbinder Test Mode 1 With signature trimming Bookbinder Test Mode 2 Without signature trimming Inserter Adjustment Mode For inserter SW2 Settings: Normal Mode Refer to the sections below for more details about SW2 settings in the adjustment mode and test mode. Service Board LEDs LED3 indicates status and details.
Page 288 4. Troubleshooting Mode/ Type Status of Abnormal LED1 LED2 LED3 Comment Status Normal Normal FLASH LED1 flash duration: 0.5 sec. Mode Service Mode FLASH LED1 flash duration: 1 sec. Abnormal Error FLASH FLASH LED1 flash duration: 0.1 sec. Alarm FLASH Open FLASH Order of priority for indicating abnormal status:...
Page 289 Service Board Basics Bookbinder LED1 LED2 LED3 Open Position Comment Count the number of flashes – LED3. x 1: Front Cover x 2: Top Cover FLASH Flash duration: 0.3 sec. x 3: Book Door x 4: Trim Scrap Box Door x 5: Glue Supply Drawer x 6: Relay Unit Front Door Inserter...
Page 290 4. Troubleshooting Sequence LED1 LED2 LED3 Comment 1 ON LED2 ON (2 sec.) 2 ON LED2, LED3 OFF (1 sec.) 3 ON FLASH x6 Flash duration: 0.3 sec. 4 ON LED2, LED3 OFF (1 sec.) Alarm Codes and LED Flash Equivalents Table (Switching with [PSW3] Presses) Alarm Information Alarm Name LED2 Count...
Page 291 Service Board Basics To indicate the error/jam status, LED1 lights and LED2, LED3 flash. Flash duration: 0.3 sec. • The LEDs remain ON for 2 sec. to indicate "0". • The LED2 and LED3 displays alternate automatically. Example 1: Cause: Fan Lock Detection (Signature Fan 1 Lock: Front (FM8)) Sequence 1-4 Sequence LED1...
Page 292 4. Troubleshooting Jam Information Jam Name Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 Signature Path Sensor 1 Late Signature Path Sensor 2 Late Jam Timing Sensor Late Stacking Tray Paper Late Sub Grip Signature Late Cover Path Sensor 1 Late Cover Path Sensor 2 Late Horizontal Path Exit Sensor Late Cover Registration Sensor Late...
Page 293 Service Board Basics Jam Information Jam Name Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 Cover Registration Sensor Lag (During Cover Switchback) Cover Horizontal Registration Sensor: Small Sensor Lag Cover Horizontal Registration Sensor: Large Sensor Lag Paper Size Mismatch Cover Size Short Trim Width Over Finish Size Over Inserter...
Page 294 4. Troubleshooting Jam Information Jam Name Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 Relay Unit At Power On Door Open Paper Lag Transport Sensor Late Transport Sensor Lag Data Error Front Door Open Error and LED Flash Count Equivalency Table Error Information Error Name Error Details...
Page 295 Service Board Basics Error Information Error Name Error Details Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 EEPROM read error EEPROM (Bookbinder) EEPROM write error Communication initialization error Inserter Bookbinder <-> Inserter Communication Communication Error 2 24V Check Signal Error 1 24V Check Signal Error 2 Power Supply Check 24V Check Signal Error 3...
Page 296 4. Troubleshooting Error Information Error Name Error Details Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 Main grip unit did not leave the HP position. Main grip unit did not arrive at the HP position after signature release. Cutter, Signature Grip Motors Grip end sensor did not detect operation end.
Page 297 Service Board Basics Error Information Error Name Error Details Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 Press plate did not leave the HP position at press. Press plate did not arrive at the HP position at release. Cutter, Press Motors Press plate did not leave END at press.
Page 298 4. Troubleshooting Error Information Error Name Error Details Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 Cutter blade did not move. The blade did not move away from the cutting point on the blade cradle. The blade did not move for a rear-to- front cut.
Page 299 Service Board Basics Error Information Error Name Error Details Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 Heater failed to start: Error 1 Heater short. Heater wire break or short circuit Heater failed to start: Error 2 Low temperature detected while regulating glue temperature.
Page 300 4. Troubleshooting Error Information Error Name Error Details Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 The value for the adjustment of the timing sensor exceeded the upper limit. The value for the adjustment of the cover registration sensor exceeded Sensor the upper limit.
Page 301 Service Board Basics Error Information Error Name Error Details Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 The value for the adjustment of the timing sensor was lower than the lower limit. The value for the adjustment of the cover registration sensor was lower Sensor than the lower limit.
Page 302 4. Troubleshooting Error Information Error Name Error Details Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 Trimming unit entrance sensor blocked by paper, cannot detect. Signature registration sensor could not detect the presence of paper. Could not detect the absence of paper at the book exit sensor.
Page 303 Service Board Basics Error Information Error Name Error Details Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 Signature thickness reading smaller than allowed minimum size. Signature Signature thickness reading larger Thickness than allowed maximum size. Sensor The signature thickness reading did not change.
Page 304 4. Troubleshooting Error Information Error Name Error Details Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 The spine fold plate did not reach the right HP sensor. The spine fold plate did not leave the right HP sensor position. Spine Fold The sensor did not turn ON.
Page 305 Service Board Basics Error Information Error Name Error Details Sequence 1-4 Sequence 5-8 LED2 LED3 LED2 LED3 The press lever HP sensor did not go TE Press Lever Motor (Stacking The press lever HP sensor did not go Tray) OFF. Jog Fence HP Sensor: Front/Small (S12) did not go ON.
Page 306 4. Troubleshooting Error Information Error Name Error Details Cause Count Details Count LED2 LED3 LED2 LED3 Switchback Switchback roller HP sensor did not go Roller Lift Motor Switchback roller HP sensor did not go (Stacking OFF. Tray) Stacking tray lower limit sensor did not go Stacking tray lower limit sensor did not go OFF.
Page 307 Service Board Basics Error Information Error Name Error Details Cause Count Details Count LED2 LED3 LED2 LED3 Stacking weight HP sensor did not go Stacking Weight Motor Stacking weight HP sensor did not go OFF. The Cover Guide HP Sensor: Left (S27) did not go ON.
Page 308 4. Troubleshooting Error Information Error Name Error Details Cause Count Details Count LED2 LED3 LED2 LED3 The sub grip open sensor did not go on. The sub grip open sensor did not go OFF. Sub Grip The sub grip close sensor did not go ON. Open Motor The sub grip close sensor did not go OFF.
Page 309 Service Board Basics Error Information Error Name Error Details Cause Count Details Count LED2 LED3 LED2 LED3 The main grip HP sensor did not go ON. Main grip HP sensor did not go OFF. The main grip press sensor 1 did not go The main grip press sensor 1 did not go OFF.
Page 310 4. Troubleshooting Error Information Error Name Error Details Cause Count Details Count LED2 LED3 LED2 LED3 The main grip open sensor rear did not go The main grip open sensor rear did not go OFF. The main grip close sensor rear did not go Grip Motor: Rear The main grip close sensor rear did not go...
Page 311 Service Board Basics Error Information Error Name Error Details Cause Count Details Count LED2 LED3 LED2 LED3 Signature exit path HP sensor did not go Signature exit path HP sensor did not go OFF. Signature Exit Motor Signature exit path press sensor did not go ON.
Page 312 4. Troubleshooting Error Information Error Name Error Details Cause Count Details Count LED2 LED3 LED2 LED3 Inserter Tray B (lower tray) failed to leave its lower limit sensor within the prescribed time after Tray B lift motor turned on. Lift Motor: Tray B Inserter Tray B (lower tray) failed to arrive (Inserter)
Page 313: Service Mode
Service Mode Service Mode Before You Begin The Service Mode settings can be performed independently on the bookbinder for both bookbinder and the inserter. When the bookbinder is turned on it obeys the settings on the Service Board and enters the mode selected with the settings on the SW1 bank.
Page 314 4. Troubleshooting Adjustment Timing Sensor Cover Registration Sensor Cover Horizontal Registration Sensor: Small Cover Horizontal Registration Sensor: Large Book Exit Sensor Cutter Entrance Sensor Signature Registration Sensor Trimmings Buffer Full Sensor Leading Edge Sensor All Sensors 1. Push [PSW1] to confirm that there is no paper at the sensor position. •...
Page 315 Service Mode LED1 LED2 LED3 Status Adjustment in progress. LED1, LED2 flash at 1 sec. FLASH FLASH intervals. Adjustment error. LED1 flashes at 0.1 sec. intervals.(Used FLASH for errors other than the all-sensor adjustment.) All sensor adjustment error (adjustment of all sensors at once failed).
Page 316: Critical Adjustments
4. Troubleshooting 3. Read the LED displays. • The three LEDs remain OFF for 2 sec. if the current value is "0". • When LED1 is OFF this indicates plus (+). • When LED1 is ON this indicates minus (-). •...
Page 317 Service Mode Adjustment 1: Cover Horizontal Registration Position Adjustment Do this adjustment when the cover has slipped up or down beyond either end of the signature spine. • If the cover has slipped toward the front, adjust in the plus (+) direction. •...
Page 318 4. Troubleshooting Status Large size adjustment Small size adjustment • If the cover has slipped toward the front, adjust in the plus (+) direction. • If the cover has slipped toward the rear, adjust in the minus (-) direction. • Check the position of the cover at both ends of the spine. 1.
Page 319 Service Mode LED1 LED2 LED3 Comment Left Digit FLASH (x1) Flash duration: 300 ms LED2, LED3 OFF (1 sec.) Right Digit FLASH (x3) Flash duration: 300 ms LED2, LED3 OFF (1 sec.) Example 2: A Reading of –2.5 mm LED1 LED2 LED3 Comment...
Page 320 4. Troubleshooting Adjustment 2: Cover Center Adjustment Do this adjustment when the fore edges of the signature and cover are not aligned. (The cover/signature in the illustration below have not been trimmed.) The cover slipped out the correct cover stop position before the glued spine of the signature was pressed down onto the cover.
Page 321 Service Mode -or- Push [PSW3] to subtract 0.1 mm from the current value. 5. LED1, LED2, LED3 light for 300 ms. 6. Look at LED1, LED2, LED3 to read the new adjusted value. 7. Repeat the steps above if you want to change the value again. 8.
Page 322 4. Troubleshooting 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. • If you want to increase the length of time that the switchback roller remains in contact with the paper, adjust in the plus (+) direction. •...
Page 323 Service Mode The front and rear jogger fences are not aligning the sheets during the jogging operation in the stacking tray as each sheet arrives in the tray. There are two types of jogger motor adjustments, depending on the size of the paper being stacked to form the signature.
Page 324 4. Troubleshooting • To increase the distance the front jogger motor pushes the front fence toward the rear against the side of the stack, adjust in the plus (+) direction. • To decrease the distance the front jogger motor pushes the front fence toward the rear against the side of the stack, adjust in the minus (-) direction.
Page 325 Service Mode Thickness 1.5 to 3.4 mm 3.5 to 6.4 mm 6.5 to 11.4 mm 11.5 to 22.4 mm 22.5 to 25 mm 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. • Raising the value of the setting increases the distance between the glue removal rod and the spine and increases the amount of glue applied to the spine.
Page 326 4. Troubleshooting • The measured height of the glue at the top edge and bottom edge should be in the range 2.0 mm to 7.0 mm. • The differences between the measured heights should be: |A - C| < 3.0 mm |B - D| <...
Page 327 Service Mode If you suspect that trimmings are sticking to the blade you can visually check at the points shown above. Adjustment 6: Gluing Unit Movement Adjustment Do this adjustment when you see that the glue vat roller is not covering the edge of the signature completely during application of the glue to the spine.
Page 328 4. Troubleshooting 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. • To have the gluing unit apply more glue toward the front of the spine, adjust in the plus (+) direction. • To have the gluing unit apply more glue toward the rear of the spine, adjust in the minus (-) direction.
Page 329 Service Mode 1. Set the SW1 bank as shown below. 2. Set the SW2 bank as shown below. Status Top Edge Corner: 3 Cuts Bottom Edge: 3 Cuts Top Edge: No Trimming or Top Only Bottom Edge: No Trimming or Top Only Note •...
Page 330 4. Troubleshooting • To decrease the size of the area where glue is not applied at the corner of the spine, adjust in the minus (-) direction. 4. Push [PSW2] to raise the current setting by "1". -or- Push [PSW3] to lower the current setting by "1". LED1, LED2, LED3 light for 300 ms.
Page 331 Service Mode Adjustment 8: Main Grip Position Adjustment Do this adjustment when you see that the signature is not being passed properly from the grip unit to the trimming unit below (this adjustment changes the location where the main grip unit grips the signature to pass it to the trimming unit).
Page 332 4. Troubleshooting The size of the book is not correct because the trimming position of the 3rd cut (fore Case [1] edge) was not correct. The size of the book is not correct because the trimming positions of the 1st (bottom) Case [2] and 2nd (top) cuts are not correct.
Page 333 Service Mode • Raising the setting increases the area and the size of the book by shifting the cutting positions toward the bottom and top edges. • Lowering the setting increases the area and the size of the book by shifting the cutting positions away from the bottom and top edges.
Page 334 4. Troubleshooting 5. Do a book binding and check the trimming cuts at the top, bottom, and fore edges. 6. Push [PSW2] to add 0.1 mm to the current value. -or- Push [PSW3] to subtract 0.1 mm from the current value. 7.
Page 335 Service Mode can vary in size from 10 to 200 sheets (see table below). It follows then that adjustments will have to be done for each cut position if this problem occurs. However, if adjustments are done they must be done in very small increments and there is no way do measurements before adjustment, so input for the adjusted values must account for the square angle of the cuts and the differences in the lengths.
Page 336 4. Troubleshooting Status L1: Square Adj. for 200-Sheet Signature L2: Square Adj. for 200-Sheet Signature L3: Square Adj. for 200-Sheet Signature L1 (Top Edge Skew), L2 (Bottom Edge Skew), L3 (Fore Edge Skew) 3. (1) Push [PSW1] then look at LED1, LED2, LED3 to read the current setting. •...
Page 337 Service Mode 1. (1) Set the SW1 bank as shown below. 2. Set the SW2 bank as shown below. Procedure 3. Push [PSW1] then look at LED1, LED2, LED3 to read the value (frequency) of the current setting. • To delay the blade replacement alarm, adjust in the plus (+) direction. •...
Page 338 4. Troubleshooting Example 1: Alarm Set to Trigger After 35,000 Cuts Digit LED1 LED2 LED3 Comment Left :10,000's FLASH x3 Flash duration: 300 ms LED2, LED3 OFF (1 sec.) Right 1,000's FLASH x5 Flash duration: 300 ms LED2, LED3 OFF (1 sec.) Adjustment 12: Setting Threshold Value for Shifting the Cutting Position Do this adjustment to force the cutting blade to shift to the next cutting position on the blade cradle before the standard number of cuts has been done.
Page 339 Service Mode 7. Repeat the steps above if you want to change the threshold value again. 8. Push [PSW1] to write the new threshold value into the EEPROM and shift to adjustment mode standby. LED1 flashes at 1 sec. intervals, LED2, LED3 go OFF. Adjustment Range Adjustment Range Steps...
Page 340 4. Troubleshooting Blade Blade Cradle Cutting Positions 1 to 10. 1. Set the SW1 bank as shown below. 2. Set the SW2 bank as shown below.
Page 341 Service Mode 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current setting for the frequency of shifts in the cuttingi position. • To shift cutting to a point on the blade cradle that has not yet been used for cutting, adjust in the plus (+) direction.
Page 342: Other Adjustments
4. Troubleshooting Other Adjustments Signature Exit Motor Adjustment Do this procedure when you see that the signature is not feeding properly to the trimming unit (this adjustment changes the length of time that the signature exit roller remains in contact with the signature during transport to the trimming).
Page 343 Service Mode 9. Read the current setting from the LED display. (See "How to Read the LEDs".) Slide Motor HP Adjustment Do this adjustment to fine adjust the size of the finished book. 1. Set the SW1 bank as shown below. 2.
Page 344 4. Troubleshooting 2. Set the SW2 bank as shown below. 3. Push [PSW1] then look at LED1, LED2, LED3 to read the current temperature setting. • To raise the temperature, adjust in the plus (+) direction. • To lower the temperature, adjust in the minus (-) direction. 4.
Page 345 Service Mode LED1 LED2 LED3 Comment Left Digit 10's FLASH (x5) Flash duration: 300 ms LED2, LED3 OFF (1 sec.) Left Digit 1's FLASH (x3) Flash duration: 300 ms LED2, LED3 OFF (1 sec.) Shift to Energy Mode Setting Do this adjustment to set the idle time that triggers the independent energy save mode for the bookbinder. One of the following times can be selected.
Page 346: Maintenance Mode
4. Troubleshooting Value Idle Time Value Idle Time No shift 50 min. 10 min. 60 min. 15 min. 90 min. 20 min. 2 hr. 4 (Default) 30 min. 3 hr. 40 min. 4 hr. Maintenance Mode Some of the units inside the bookbinder must be moved and the grippers released before doing maintenance.
Page 347 Service Mode Status Open cover path Close cover path Lower stacking tray Position units for shipping Move trimmings buffer left Move trimmings buffer right 3. Push [PSW1] to have the bookbinder perform the operation selected with the SW2 bank DIP SWs. 4.
Page 348 4. Troubleshooting Operation What Happens Pushing [PSW1] one time: 1) Opens the spine fold plate, 2) Releases the sub grip, 3) Releases the main grip, 4) Opens the spine fold unit, 5) Retracts the cover guides and opens the signature exit path. If the main grip is at the binding position, after Grip release 2 it is released it moves to the upper HP grip sensor.
Page 349 Service Mode LED1 LED2 LED3 Status Maintenance Mode in progress. LED1 flashes at 1 sec. FLASH intervals. FLASH Operation not possible. LED1 flashes at 0.1 sec. intervals.
Page 350: Output Checks
4. Troubleshooting Output Checks Perfect Binder D391 Output Check Self-Diagnostic Mode Do this procedure to check the operation of moving parts. 1. If the system is on, switch it off. 2. Open the right and left front doors. 3. Close the right door. 4.
Page 351 Output Checks 5. Remove the service board cover [1] ( x1). 6. Set the SW1, SW2 banks as shown below. 7. Set the SW2 bank as shown below. Status Glue Vat Empty Sensor Glue Tank Full Sensor Jog Fence HP Sensor: Front Jog Fence HP Sensor: Rear Jog Fence HP Sensor: Front Large Jog Fence HP Sensor: Rear Large...
Page 352 4. Troubleshooting LED1 LED2 LED3 What It Means FLASH Self-diagnostic check standby, or check OK. Self-diagnosis in progress. LED1, LED2 flash at 1 FLASH FLASH sec. intervals. Self-diagnostic check failed. LED1 flashes at 0.1 sec. intervals. Check All self-diagnosis failed. LED1 flashes at 0.1 FLASH sec.
Page 353 Output Checks Check Point Check Method • No glue pellets in the glue hopper • Confirms whether the A/D input value at the receptor sensor does not detect glue when D/A 1. Glue Vat Empty Sensor output value of the emitter sensor is set at standard value.
Page 354 4. Troubleshooting Check Point Check Method • Confirms that the blade moves and that there is no limit sensor error. If the self-diagnostic check Blade Limit Sensor (Movement to succeeds, turn the bookbinder off and move the Front/Rear) cutter blade to the limit position manually so the unit is out of the error position.
Page 355 Output Checks 5. Perform cover transport from the inserter unit (or bookbinder entrance): 1) Signature transport, 2) Start cover transport after signature has been stacked. 6. Perform book output: 1) Start binding operation, 2) Glue application, 3) Book trimming Once the stacking tray returns to the signature turnover position, stacking in the tray can resume.
Page 356: Inserter D391 Output Check
4. Troubleshooting Signature Size Cover Size Finished Size Note: "LEF" in the table above denotes standard size paper longer in main scan direction than sub scan direction. SW2 Bank SW5: Signature and Cover Size Speeds Signature Speed Cover Speed 651mm/s 651mm/s 434mm/s 434mm/s...
Page 357 Output Checks Inserter Control Board (Rear Cover Removed) Inserter control board DIP switches (Default OFF: Standby Mode) LEDs 1, 2, 3 SW2 (a push-switch) CPU (IC7)
Page 358 4. Troubleshooting Stand-by Mode, Service Mode Mode LED3 LED2 LED1 Standby Mode Nothing Open Top Cover Open Flashing: 0.5 sec. Inserter Open Service Mode Flashing: 1 sec. Note: To set the inserter in the Service Mode, set the Perfect Binder in the Service Mode. Error Display If a problem is detected in the inserter, the LEDs display changes in the order described below.
Page 359 Output Checks LED 3 LED 2 LED 1 Problem Location Lag paper jam Tray A Lift Motor (M3 (INS)) At power on Drive Switch Motor (M2 (INS)) Firmware error CPU flash memory Cover open jam Top cover Paper size mismatch Paper tray fences on Tray A, B (c) Sensor where jam detected One or more LED goes ON for 0.5 sec, then OFF for 0.25 sec.
Page 360 4. Troubleshooting 3. Remove the Service Board cover of the bookbinder. 4. On the SW1 bank set DIP SW1 to ON. 1. Remove the rear cover of the inserter ( x2). 2. On the inserter control board set the DIP SWs as shown above. 3.
Page 361 Output Checks Press What Happens Push [SW2]. Starts Tray A Lift Motor (M3 (INS)), lifts Tray A, then stops. Push [SW2]. Starts Tray A Lift Motor (M3 (INS)), lowers Tray A, then stops. Push [SW2]. Starts Tray B Lift Motor (M4 (INS)), lifts Tray B, then stops. Push [SW2].
Page 362 4. Troubleshooting Press What Happens Turns on motors for 50-sheet feed. Lowers Tray B. Loops to "1" above. Note: • The first execution runs paper separation at 500 mm/s, paper feed at 1100 mm/s. • The second execution runs paper separation at 250 mm/s, paper feed at 325 mm/s. •...
Page 363 Output Checks 6. Set the DIP SWs as shown above. 7. Turn on the host machine. 8. Set the DIP SWs and do the procedures as shown in the table below. DIP SW Procedure Sensor Check 1 1. Set the DIP SWs as shown on the left. 2.
Page 364 4. Troubleshooting DIP SW Procedure Sensor Check 3 1. Set the DIP SWs as shown on the left. 2. Push [SW2] three times. 3. After each switch press check the status of each LED in this order: LED1, LED2, LED3. •...
Page 365 Output Checks DIP SW Procedure Sensor Check 5 1. Set the DIP SWs as shown on the left. 2. Push [SW2] three times. 3. After each switch press check the status of each LED in this order: LED1, LED2, LED3. •...
Page 366 4. Troubleshooting...
Page 367: Service Tables
5. Service Tables Service Program Mode For details about "Service Program Mode" for this peripheral, see the main service manual.
Page 368 5. Service Tables...
Page 369: Details
6. Details Basics Overview The bookbinder is divided into two parts: the binding unit (top half) and trimming/stacking unit (bottom half). In the binding unit paper sent from the host machine is stacked and aligned (jogged) to form the...
Page 370: General Board Layout
6. Details signature, and then the signature is glued on one edge and joined with the cover. In the trimming unit the book is trimmed, stacked, and output. The binding unit is comprised of eight distinct units: • Vertical Transport •...
Page 371: Basic Operation
Basics Every control board shares these common points in their configurations: • The CPU of each board has a built-in ROM that contains the firmware for the control of operation sequences. • The boards control and drive motors using commands sent from the host machine. •...
Page 372 6. Details and signature by gluing them together. Without commands for creation of a bound book, the bookbinder feeds paper straight through the horizontal transport path for downstream delivery. Once the commands are received for binding sheets into a book, the operational control passes to the master control board, slave control board, and cutter control board.
Page 373: Exit Paths
Basics The glued spine of the signature is set in the center of the cover below and then pushed down so the halves of the cover wrap up around the signature to form the book. The book (cover and signature now glued together) is moved to the trimming unit. The book is rotated three times for trimming on the bottom, top, and fore edge.
Page 374 6. Details Downstream Delivery Exit Paper from the host machine enters the bookbinder at the entrance rollers [1]. The entrance junction gate solenoid at [2] remains OFF so the entrance junction gate remains UP so paper can pass through the horizontal transport rollers [3].
Page 375 Basics Bookbinding Delivery Exit Paper sent from the host machine enters the bookbinder at the entrance rollers [1]. The entrance junction gate solenoid turns ON and lowers the entrance junction gate [2] to guide paper to the signature path [3]. As each sheet arrives on the stacking tray [4], the sides and trailing/leading edges are jogged by side fences and positioning rollers to align the signature (stack) for binding.
Page 376: Downstream Delivery
6. Details Downstream Delivery Paper Entrance Roller Signature Transport Roller 1 Horizontal Transport Roller 1 Horizontal Transport Roller 2 Buffer Roller Horizontal Transport Roller 3 Horizontal Transport Roller 4 Horizontal Transport Roller 5 [10] Exit Roller 1 [11] Exit Roller 2 [12] Horizontal Exit Sensor (S25) [13]...
Page 377: Blank Paper Handling
Basics The following motors switch on just before the sheet arrives at the entrance roller: • Entrance motor (M10). Drives the entrance roller [2] and signature transport roller [3]. • Cover motor (right) (M12). Drives transport roller 2 [5], transport roller 3 [7], and buffer roller [6]. •...
Page 378 6. Details When the bookbinder is turned on again, or after the front doors are closed, if the master control board, slave control board or cutter control board detect a signature in the sub grip, main grip, or trimming unit, the bookbinder enters the automatic exit mode.
Page 379: Book Binding
Book Binding Book Binding Overview After paper sent from the host machine is aligned for binding in the stacking tray, the stack (signature) is aligned for gluing. Glue is applied to the spine of the signature and then the signature is joined with the cover.
Page 380 6. Details After the last sheet feeds the sub grip unit [D] with the aligned stack (signature) firmly clamped lowers away from the bottom of the stacking tray and passes the signature to the main grip unit [E]. The main grip unit rotates the signature clockwise until it is vertical with its spine pointing down and then lowers it to the spine alignment plate.
Page 381: Cover Transport: Vertical Path
Book Binding Cover Transport: Vertical Path Vertical Transport Roller 1 Vertical Transport Roller 2 Vertical Transport Roller 3 Vertical Transport Roller 4 Vertical Transport Motor (M5 (INS)) Vertical Transport Sensor 1 (S19 (INS)) Vertical Transport Sensor 2 (S18 (INS)) The vertical path rollers feed paper from the inserter as far as the signature transport roller 1. Covers fed from the inserter enter the vertical path at vertical transport roller [1].
Page 382: Paper/Signature Transport
6. Details Paper/Signature Transport Signature Path Transport Operation Entrance Roller Signature Transport Roller 1 Entrance Junction Gate Signature Transport Roller 2 Signature Transport Roller 3 Signature Transport Roller 4 Signature Transport Roller 5 Signature Exit Roller...
Page 383 Book Binding Entrance Motor Signature Transport Motor SOL2 Entrance JG Solenoid Entrance Sensor Signature Path Sensor 1 Signature Path Sensor 2 The signature path rollers transport paper from the host machine to the stacking tray. The master control board controls the operation of the entrance motor (M10) and signature transport motor (M11).
Page 384 6. Details Signature Path Exit Signature Exit Roller Stacking Roller TE Press Lever...
Page 385 Book Binding Stacking Roller Motor TE Press Lever Motor Paper Detection Sensor (Front) Paper Detection Sensor (Rear) TE Press Lever HP Sensor Timing Sensor The signature path exit unit (located at the top of the signature path unit): • Feeds paper onto the stacking tray •...
Page 386 6. Details The timing sensor (S5) detects the leading and trailing edge of each sheet and signals a jam if the paper stops or fails to arrive within the prescribed time. Also, when the timing sensor (S5) detects the trailing edge of the sheet, the TE press lever motor (M2) turns on and lowers the TE press lever which presses down the trailing edge of the sheet as soon as it enters the stacking tray.
Page 387 Book Binding Stacking Roller Motor Stacking Tray Lift Motor Jog Motor (Front) Jog Motor (Rear) Stacking Weight Motor Switchback Roller Lift Motor Switchback Flapper Motor Stacking Tray Motor Top Cover Sensor Stacking Tray Overflow Sensor Stacking Tray Lower Limit Sensor Tray Empty Sensor Stacking Tray HP Sensor Switchback Flapper HP Sensor...
Page 388 6. Details Switchback Roller HP Sensor Jog Fence HP Sensor (Front: Small) Jog Fence HP Sensor (Rear: Small) Jog Fence HP Sensor (Front: Large) Jog Fence HP Sensor (Rear: Large) Stacking Weight HP Sensor At the start of a job and before the leading edge of the first sheet of paper enters the bookbinder, the following motors turn on and start rotating at the same speed of the host machine exit rollers: entrance motor (M10), signature transport motor (M11), stacking roller motor (M1).
Page 389 Book Binding After the leading edge of the paper [1] is detected by the timing sensor (S5) and after the paper has traveled the prescribed distance, the switchback roller lift motor (M7) turns on. This lowers the switchback roller [2] to the transport position and the paper feeds into the nip of the switchback roller.
Page 390 6. Details After the side fences have jogged and aligned the sides of the stack, the switchback roller lift motor (M7) turns on and lowers the switchback roller [1] until it contacts the paper [2]. Next, the jog motor (front) (M4) and jog motor (rear) (M5) reverse and retract the front and rear jog fences [3] to their home positions.
Page 391 Book Binding Front Jog Fence Rear Jog Fence Paper Jog Fence HP Sensor: Front: Large Jog Fence HP Sensor: Rear: Large Sub Grip Operation The sub grip unit [1] takes the aligned stack (signature) from the stacking tray unit and passes it to the main grip [2].
Page 392 6. Details Sub Grip Lift Motor Signature Move Motor Sub Grip Size Motor Sub Grip Motor Signature HP Sensor Signature Main Grip Position Sensor Main Grip Rotate Enable Sensor Sub Grip HP Sensor Size HP Sensor Sub Grip Signature Sensor Sub Grip Open Sensor Sub Grip Close Sensor...
Page 393 Book Binding After all the sheets have been stacked and aligned in the stacking tray to form the signature, the sub grip size motor (M19) turns on and rotates the size move gear [1] (a pinion) which starts driving both sides of the sub gripper [2] toward the edges of the signature [3].
Page 394 6. Details With the signature [1] firmly clamped, the stacking tray lift motor (M2) and sub grip lift motor (M17) switch on and lower both the stacking tray [2] and sub grip unit [3] as far as the stacking tray lower limit sensor (S7) and then stop.
Page 395 Book Binding The grip motor: front (M24) and grip motor: rear (M23) switch on and close the main gripper [1] to clamp the signature tightly at the spine. Next, the sub grip motor (M20) turns on and opens the sub gripper [2] to release the signature in the sub grip unit.
Page 396 6. Details Mini-Gripper Main Gripper Grip Unit Rotation Motor Main Grip Lift Motor Gripper Motor: Rear Gripper Motor: Rear Grip Motor: Front Rotate-to-Binding Position Sensor Main Grip Rotate HP Sensor Main Grip HP Sensor Main Grip HP Sensor: H Main Grip Encoder: Rear Main Grip Open Sensor: Rear Main Grip Press Sensor 1...
Page 397 Book Binding Main Grip Press Sensor 2 Signature Thickness Sensor Main Grip Open Sensor: Front Main Grip Encoder: Front Main Grip Close Sensor: Front Main Grip Close Sensor: Rear Main Grip Signature Sensor The gripper motor: front (M24) the gripper motor: rear (M23) switch on and close the main grip [1], securely clamping the signature [2] passed from the sub grip to the main grip.
Page 398 6. Details The grip unit rotation motor (M21) turns on and rotates the main grip unit [1] with the signature [2] clamped by the mini-gripper [3] and main gripper [4]. The main grip lift motor (M22) turns on and lowers the main grip unit [1] and signature [2] as far as the signature guide plate [3].
Page 399 Book Binding The gripper motor: front (M24) and gripper motor: rear (M23) switch on, close the main gripper [1], and clamp the signature [2]. The main grip lift motor (M22) turns on raises the grip unit and signature to the gluing position The signature thickness sensor (S50) measures the thickness of the signature the first time the grip unit closes onto the signature.
Page 400: Cover Transport And Registration
6. Details Cover Transport and Registration Horizontal Transport Roller 1 Horizontal Transport Roller 2 Horizontal Transport Roller 3 Horizontal Transport Roller 4 Horizontal Transport Roller 5 Buffer Roller Cover Transport Guide: Right Cover Transport Guide: Left Cover Gripper [10] Cover Registration Unit...
Page 401 Book Binding Cover Motor: Right Cover Motor: Left Cover Guide Motor: Left Cover Guide Motor: Right Cover Horizontal Registration Motor SOL1 Cover Grip Solenoid Cover Path Sensor 1 Cover Registration Sensor Cover Guide HP Sensor: Right Cover Guide Open Sensor: Right Cover Guide HP Sensor: Left Cover Guide Open Sensor: Left Registration Unit HP Sensor (S70)
Page 402 6. Details Before paper from the host machine arrives at the entrance of the bookbinder the following motors turn on and start rotating at the same speed as the host machine exit rollers: • Entrance motor (M10) • Signature transport motor (M11) •...
Page 403 Book Binding The spine fold motor: left (M28) turns on and lowers the transport rollers 1, 2 on the left side of the cover, releasing the cover from the nip. The cover grip solenoid (SOL1) energizes and opens the cover gripper [3].
Page 404 6. Details Cover The cover horizontal registration motor (M31) turns on and positions the cover at the horizontal position as shown by the arrow. The size of the cover determines which sensor is used to position the cover: • Cover registration sensor (S) (S71). Used for small paper sizes up to 297 mm wide. •...
Page 405 Book Binding • The cover horizontal registration motor (M31) turns on and moves the cover registration unit [1] and cover [2] until the sensor turns on, continues to move the cover the prescribed distance and then turns off. • Next, the cover horizontal registration motor (M31) reverses and moves the cover the prescribed distance away from the sensor after the sensor turns off.
Page 406: Gluing
6. Details Gluing Gluing Unit Operation The gluing unit applies glue to the spine of the signature that will be joined with the cover to form the book. Glue Hopper Glue Dispenser Glue Feeder Gluing Unit Glue Vat...
Page 407 Book Binding Glue Vat Motor Glue Supply Motor Glue Vat Empty Sensor (S31E/S31R) Glue Vat Empty Sensor (S32E/S32R) Glue Supply Cover Sensor Glue Temperature Thermistor Glue Abnormal Temperature Thermistor Glue Level Thermistor Glue Vat Roller Rotation Sensor Glue Vat HP Sensor: Rear Glue Vat HP Sensor: Front Glue Roller HP Sensor Thermostat...
Page 408 6. Details Glue Vat Roller Glue Vat Main Gripper Unit Signature Signature Spine Once the glue has been heated long enough to melt it and has reached the optimum temperature for application, the glue vat roller motor (M25) turns on and rotates the glue vat roller [1] to start stirring the glue.
Page 409 Book Binding The main grip lift motor (M22) turns on, raises the main grip unit [1] and signature [2] slightly higher. Also, the glue vat roller motor (M25) turns on and reverses the rotation of the glue vat roller [3]. The glue vat move motor (M32) turns on and moves glue vat [4] from the front to the rear.
Page 410 6. Details Glue Bin (holds the glue pellets) Glue Feeder Glue Vat (holds after it has melted) The operator pours glue pellets into the glue hopper [1]. When the operator closes the hopper, the shutter [2] opens the dry glue pellets fall down into the bin [3] where they are stored.
Page 411 Book Binding • The heater remains on to maintain the target temperature. If the glue temperature is between 100°C and 120°C: • The slave board turns on the heater and sets the target temperature for 152°C. • When the glue temperature thermistor (S56) detects a glue temperature of 150°C±5°C, the slave control board turns on the glue vat roller motor (M25) which starts rotating the glue vat roller at 82.5 mm/s •...
Page 412 6. Details Spine Plate Motor Spine Fold Motor: Left Spine Fold Motor: Right Spine Fold HP Sensor: Left Spine Fold Close Sensor: Left Spine Plate Open Sensor Spine Plate Closed Sensor Spine Fold HP Sensor: Right Spine Fold Closed Sensor: Right...
Page 413 Book Binding Spine Fold Plate: Left Spine Fold Plate: Right Signature Cover Glued Spine Left Cover Transport Guide Main Grip Unit Spine Plate The spine fold motor: left (M28) and spine fold motor: right (M29) switch on and move the left spine fold plate [1] and right spine fold plate [2] to their home positions from the spine fold close positions.
Page 414 6. Details Cover Transport Guide: Right Cover Spine Fold Plate: Left Spine Fold Plate: Right Signature Main Gripper The cover guide motor: right (M16) turns on, opens the right cover transport guide [1] , and releases the cover [2] from the nips of the transfer rollers. The spine fold motor: left (M28) and spine fold motor: right (M29) turn on and close the left and right spine fold plates [3], [4] which clamp the signature [5] near its glued spine.
Page 415 Book Binding The main grip lift motor (M22) turns on and raises the main grip unit [1] where it can grip the signature [2] at a higher point, then the motor stops. The joined signature and cover [3] do not move. After the main gripper [4] moves to the higher grip position, the grip motor: front (M24) and grip motor: rear (M23) turn on and clamp the signature again.
Page 416 6. Details Signature Transport Signature Exit Roller Signature Path Guide Signature Exit Roller Motor Signature Path Exit Motor Book Exit Sensors (S64E: Emitter/S64R: Receptor) Leading Edge Sensors (S65E: Emitter/S65R: Receptor) Signature Exit Path HP Sensor Signature Exit Path Press Sensor...
Page 417 Book Binding Now the cover is ready to be folded up around the joined signature to complete the formation of the book and the book is passed to the trimming unit. The main grip lift motor (M22) turns on and lowers the main grip unit [1] as far as the signature exit rollers [2].
Page 418 6. Details The signature path exit motor (M30) turns on, pushes the signature exit guide [1] to the left and lamps the signature and cover [2] in the nip of the signature exit rollers [3]. After the signature is firmly clamped in the nip of the signature exit rollers the grip motor: front (M24) and grip motor: rear (M23) turn on and retract the main gripper [4] away from the sides of the signature.
Page 419: Trimming Unit
Book Binding After the signature has been clamped in the trimming unit the signature path exit motor (M30) switches on and retracts the signature exit guide [1] which opens the nip of the signature exit rollers [2] and releases the signature [3]. After the signature rollers have opened, the slide motor (M44) turns on and lowers the signature (clamped between the rotation plates) into the trimming unit to align the signature for trimming.
Page 420 6. Details Book Rotation Plate: Right Book Rotation Motor 2 Book Rotation Motor 2 Book Rotation Motor 1 Book Grip Motor Slide Motor Slide HP Sensor Book Rotation HP Sensor 1 Trim Unit Entrance Sensors (S92R, S92E) Grip HP Sensor Grip End Sensor Book Rotation HP Sensor 2...
Page 421 Book Binding Blade Blade Cradle Edge Press Plate Cutter Motor Edge Press Plate Motor Blade Cradle Motor SOL4 Trimmings Plunger Solenoid Blade Cradle HP Sensor Blade Sensor 1 Blade Sensor 2...
Page 422 6. Details Trimmer Limit Sensor Press End Sensor Book Registration Sensors (S88R/S88E) Press Limit Sensor Edge Press Plate HP Sensor Trimming the Book The book grip motor (M43) turns on, retracts the right rotation plate [1] and releases the book [2]. The book falls on top of the blade [3] so the spine of the book is perfectly horizontal against the top of the blade.
Page 423 Book Binding The slide motor (M44) turns on and raises the book rotation grip unit [1] and the book [2] until the leading edge sensor pair (S65R/S65E) (or book registration sensor pair (S88R/S88E)) detects the edge of the book and stops the motor. The slide motor (M44) turns on and lowers or raises the book to the proper trimming position.
Page 424 6. Details The edge press plate motor (M36) turns on and retracts the edge press plate which releases the book edge. Book rotation motors 1 and 2 (M42, M41) both switch on and turn the book rotation plates [4] and the book counter-clockwise 180 degrees (front to rear).
Page 425 Book Binding The edge press plate motor (M36) turns on and retracts the edge press plate which releases the book edge . Book rotation motors 1 and 2 (M42, M41) both switch on and turn the book rotation plates [4] and the book counter-clockwise 90 degrees (front to rear).
Page 426 6. Details • The first cut is done at the mid-point of the area to be removed. • The blade and edge press plate are retracted. • The edge press plate is pushed against the book edge then the blade does the final cut. The cutter motor (M35) turns on and retracts the blade .
Page 427 Book Binding Blade Operation Retracted toward front before cutting Cutting Retracts to rear after cutting The blade [1] is attached to a base plate [2] connected to the cutter motor (M35). After each cut against the blade cradle [3] the cutter motor alternately retracts the base plate and blade to the front or rear. As the blade starts the cut at a slight angle and is pulled away to either the front or rear, this creates a slight rocking motion of the blade along the line of the cut so the blade can cut more efficiently and be pulled away smoothly from the cut edges.
Page 428 6. Details Blade Sn 2 Blade Sn 1 (S84) Blade Position (S85) Retracted to rear Trimmings Collection and Disposal Normally, the trimmings should smoothly fall away from the blade after an edge is trimmed. However, trimmings can frequently stick to the blade after the first and second cuts at the top and bottom of the book. There may be an especially strong tendency for trimmings to adhere to the blade where it cuts into the glue on the end of the spine.
Page 429 Book Binding The cutter motor (M35) turns on and drives the blade [1] against the edge of the book [2] to perform the cut. The trimmings catcher [3] and the trimmings seat [4] move with the blade when it performs the cut. After the cut is done the cutter motor (M35) retracts the blade and trimmings catcher mechanism.
Page 430 6. Details After every 550 cuts the blade cradle is lowered 1 mm to change the position where the blade repeatedly impacts the blade cradle. This reduces wear on the blade cradle and extends its service life. The blade does not move. The blade cradle motor (M40) lowers the blade cradle to change the cutting position. •...
Page 431 Book Binding Book Press Plate Trimmings Buffer Motor Trimmings Buffer Full Sensors (S96R, S96E) Trimmings Box Full Sensor S100 Trimmings Buffer HP Sensor: Left S101 Trimmings Buffer Clock Sensor S103 Trimmings Buffer HP Sensor: Right S104 Book Press Plate Sensor...
Page 432 6. Details First Cut The trimmings sub buffer [1] is linked to the trimmings buffer [2] and moves together with the down stroke of the book press plate [3]. • The trimmings buffer motor (M37) turns on at the start of the trimming operation and moves the trimmings sub buffer to the left to catch the strips trimmed form the signature by the blade.
Page 433 Book Binding The trimmings buffer motor (M37) turns on and moves the trimmings buffer [3] slightly to the left by a prescribed distance and stops. The trimmings sub buffer disengages from the hook that links it to the book press plate [4] and returns to its home position, allowing the trimmings to fall into the trimmings buffer . 2nd Cut This operation cycle for the 2nd cut is the same as 1st cut.
Page 434 6. Details The trimmings box full sensor (S97) and its actuator, and the trimmings buffer full sensor pair (S96E, S96R), check the level of the trimmings accumulated in the trimmings box [1] and the trimmings buffer [2]. At power on and during machine operation: •...
Page 435 Book Binding Book Lift Tray Book Buffer Tray Book Output Tray Book Output Belt Motor Book Lift Tray Motor Book Buffer Tray Motor SOL5 Book Door Lock Solenoid...
Page 436 6. Details Book Arrival Sensor Book Buffer Tray HP Sensor Book Lift Tray HP Sensor Book Collection Tray HP Sensor Stacking Tray Book Sensor Book Door Sensor Trimmings Box Sensor S102 Book Lift Tray Lock Sensor The trimmings buffer motor (M37) turns on and retracts the book press plate [1] in the transport path. The operations described below are done while the next book is being trimmed.
Page 437 Book Binding The book lift tray motor (M38) turns on and lowers the book lift tray [1] and the book [2] into the book buffer. The trailing edge of the book falls against the book press plate [3]. Book handling and trimming pause while the trimming unit above collects and disposes of trimmings. Next, the book output belt motor (M34) turns on and moves the book output tray [4] to the left.
Page 438 6. Details The trimmings buffer motor (M37) turns on and returns the trimmings buffer [3] to its home position.
Page 439: Jam Detection
Jam Detection Jam Detection Overview The shown and listed below are used to monitor the transport of paper and covers through the bookbinder. They confirm that the paper and covers feed smoothly and detect jams when they occur. • Each sensor confirms that the leading and trailing edges of each sheet as it passes the sensor location. •...
Page 440: Jams
6. Details Signature Path Sensor 2 Cover Path Sensor 1 Cover Registration Sensor Horizontal Exit Sensor Cover Path Sensor 2 Sub Grip Signature Sensor Cover Horizontal Sensor (Small) Cover Horizontal Sensor (Large) Jams Lag Jams (Paper Late Jam) A late jam occurs when the sensor does not detect the leading edge (LE) or trailing edge (TE) within the prescribed time because the paper failed to arrive.
Page 441 Jam Detection Failed to detect the LE within the prescribed time after entrance sensor (S17) detected the paper. 1018: S26 Cover Path Sensor 2 Failed to detect the LE within the prescribed time after cover path sensor 1 (S20) detected the paper. 1019: S25 Horizontal Exit Sensor Failed to detect the LE within the prescribed time after cover path sensor 2 (S26) detected the paper.
Page 442 6. Details 1124: S5 Timing Sensor Detected LE but failed to detect TE within the prescribed time. 1125: S8 Tray Empty Sensor Failed to detect signature TE within the prescribed time while the signature was being sent from the sub grip unit to the main grip unit.
Page 443 Jam Detection 1300: S5, S8, S17, S18, S19, S20, S21, S25, S26 One or more of these sensors detected a sheet of paper in the paper path when the bookbinder was turned • Timing Sensor (S5) • Tray Empty Sensor (S8) •...
Page 444 6. Details • The bookbinder received a command to stack over 200 sheets in the stacking tray 1FA1: Job Specification Error The bookbinder received a command to stack fewer than 9 sheets of paper in the stacking tray. 1FA2: Book Jam 1 The book jammed in the trimming unit because the width of the third cut on the fore edge was wider than 40 mm (1.6").
Page 445: Power Supply
Power Supply Power Supply Overview The bookbinder is driven by two DC power units, power supply units 1 and 2. Power Supply Components...
Page 446: Electrical Circuit Protection Features
6. Details Name Function Supplies DC power to the master control board, inserter control Power Supply Unit 1 board: DC 5V, 24V Power Supply Unit 2 Supplies DC power to the slave control board, cutter control board Power Switch Turns power supply units 1, 2 on/off Microswitch Turns the DC 24V, 36V circuits on/off Trips the breaker and cuts power supply to the bookbinder if a power...
Page 447 Power Supply • Switching on the host machine (after switching off the host machine sent the bookbinder into the energy save mode) Here are some more details about these energy save modes. 1. Idle time to trigger energy save mode automatically The bookbinder enters the energy save mode automatically after it has remained idle for a specified time.
Page 448: Inserter-C1 (D391)
6. Details Inserter-C1 (D391) Overview The Inserter-C1 (D391) (hereafter "inserter") is mounted on top of the bookbinder and feeds the book covers that the bookbinder binds to signatures. Cross Section Tray A Tray B Tray A Pickup Roller Tray B Pickup Roller Tray A Feed Roller Tray B Feed Roller Tray A Separation Roller...
Page 449: Basic Operation
Inserter-C1 (D391) The inserter control board and its CPU (IC7) control the operation of the inserter unit. The CPU reads and interprets the input signals from the bookbinder and the inserter sensors. The CPU uses this information to run the inserter motors and clutches according to pre-set timings. The inserter is supplied with DC 24V power from the bookbinder.
Page 450: Motors And Sensors
6. Details Motors and Sensors S1 (INS) Paper Set Sensor: Tray A S14 (INS) Inserter Transport Sensor S3 (INS) Paper Out Sensor: Tray A S19 (INS) Vertical Transport Sensor 1 S4 (INS) Paper Feed Sensor: Tray A M1 (INS) Tray Feed Motor S5 (INS) Registration Sensor: Tray A M2 (INS)
Page 451: Paper Feed And Transport
Inserter-C1 (D391) S12 (INS) Lower Limit Sensor: Tray B CL2 (INS) Registration Clutch: Tray S13 (INS) Registration Sensor: Tray B Paper Feed and Transport The section describes what happens during paper feed from Tray A (essentially the same as what happens with Tray B).
Page 452 6. Details Drive Selection Drive gear [1] drives the rollers for Tray A, and drive gear [2] drives the rollers for Tray B. One tray feed motor (M1 (INS)) engages the drive gear of whichever tray is selected for the job. The switching gear [3] of the tray feed motor (M1 (INS)) is mounted on a rack [4] that is moved forward and back by pinion gear [5] driven by drive switch motor (M2 (INS)).
Page 453 Inserter-C1 (D391) Paper Pickup and Feed The tray lift motor (M4) turns on and lifts Tray A until the paper feed sensor (S4 (INS)) detects the top of the paper stack and stops the motor with the pickup roller [1] resting on top of the stack. The feed mechanism is the standard FRR design.
Page 454 6. Details to keep the registration roller disengaged slightly longer than normal to allow more time for the paper to buckle against the registration roller and correct skew. Transport 1: Feed to Standby Position The tray feed motor (M1 (INS)) turns on again and starts rotating the registration roller [1] and transport roller [2] that feed the paper to the standby position [3].
Page 455: Paper Detection
Inserter-C1 (D391) Next Cover Feed Once the sheet in the feed path has fed 20 mm past transport rollers 1 [1], the tray feed motor (M1 (INS)) stops and then reverses to start feeding the next sheet. If another sheet is not available, the tray is lowered. When vertical transport sensor 1 (S19 (INS)) detects the passage of the trailing edge feeding into the vertical transport roller 1 [2] this signals the vertical transport motor (M5 (INS)) to turn off.
Page 456 6. Details Paper Size Detection The inserter can detect only the width of the paper loaded in the tray. Neither tray is long enough to measure the paper length in the direction of paper feed. A pinion gear [1] engaging two opposing racks [2] and [3], one attached to each side fence [4] and [5], ensures that both fences move exactly the same distance from the center of the tray when the operator sets the fences for the paper loaded in the tray.
Page 457 Inserter-C1 (D391) Paper Out Sensor: Tray A (S3 (INS)) Paper Feed Sensor: Tray A (S4 (INS)) Registration Sensor: Tray A (S5 (INS)) Paper Set Sensor: Tray B (S6 (INS)) Paper Out Sensor: Tray B (S8 (INS)) Paper Feed Sensor: Tray B (S10 (INS)) Registration Sensor: Tray B (S13 (INS)) Inserter Transport Sensor (S4 (INS)) Vertical Transport Sensor 1 (S19 (INS))
Page 458: Motor, Sensor Locations
6. Details Motor, Sensor Locations Inserter Inserter Vertical Path Motor and Sensors (Inserter) M5 (INS) Vertical Transport Motor Drives all the rollers in the vertical feed path of the perfect binder. S18 (INS) Vertical Transport Sensor 2 Detects the leading and trailing edge of every sheet that passes through the second transport roller (delivery roller) past the registration roller and signals a jam if either edge fails to pass within the prescribed time.
Page 459 Motor, Sensor Locations Inserter Motors and Sensors S1 (INS) Paper Set Sensor: Tray A Detects paper on Tray A and signals that Tray A is ready to feed paper. S2 (INS) Paper Width Sensor Tray A Detects the position of the rear side fence. This signals the width of the paper loaded in Tray A.
Page 460 6. Details Detects the leading and trailing edge of every sheet that passes through the Tray A feed roller and signals a jam if either edge fails to pass within the prescribed time. S5 (INS) Registration Sensor: Tray A Detects the leading and trailing edge of every sheet that passes through the Tray A registration roller and signals a jam if either edge fails to pass within the prescribed time.
Page 461 Motor, Sensor Locations M1 (INS) Tray Feed Motor Drives the rollers in Tray A or Tray B, whichever tray is selected for the jog. The drive gear of the motor is mounted on a rack is moved forward to engage the Tray A drive roller or moved to the rear to engage the Tray B drive roller.
Page 462: Bookbinder
6. Details Bookbinder Signature Output, Transport, Stacking Tray Sensors Paper Detection Sensor (Front) Detects the sheet of paper. Paper Detection Sensor (Rear) Detects the sheet of paper. TE Press Lever HP Sensor Detects the home position of the TE press lever that compresses the trailing edge of the stack in the stacking tray.
Page 463 Motor, Sensor Locations Detects the leading and trailing edge of each sheet of paper as it enters the stacking tray. When it detects the trailing edge, this turns on the TE press lever motor which lowers the press lever onto the trailing edge of the stack. Stacking Tray Overflow Sensor Detects when the number of sheets on the stacking tray has exceeded the capacity of the tray.
Page 464 6. Details Entrance sensor Detects the leading and trailing edge of each sheet of paper as it enters the perfect binder from the host machine. Signature Path Sensor 1 Detects the leading and trailing edge of each sheet of paper in the path to the stacking tray and triggers jam alerts if the paper stops or fails to arrive.
Page 465 Motor, Sensor Locations Stacking Roller Motor Drives the signature exit roller and stacking roller that feed each sheet out of the signature path into the stacking tray. Stacking Tray Lift Motor Lowers the stacking tray to where the signature is delivered to the sub grip unit. Raises the stacking roller after the signature is passed to the sub grip unit.
Page 466 6. Details Signature Transport Motor Drives the four transport rollers in the signature path that feeds paper from the entrance roller to the stacking tray. Sub Grip Motors and Sensors Signature HP Sensor Detects when the main grip unit is at its lowest position (tilted ccw to the left) where it can receive the signature from the sub grip on the left.
Page 467 Motor, Sensor Locations Detects when the sub grip unit is at the correct home position for the width of the selected paper size. Sub Grip Signature Sensor Detects the signature in the sub grip unit. Sub Grip Open Sensor Detects when the sub grip unit is open. Sub Grip Close Sensor Detects when the sub grip unit is closed.
Page 468 6. Details Main Grip Motors and Sensors Rotate-to-Binding Position Sensor Detects when the main grip unit has rotated to the binding position. Main Grip Rotate HP Sensor Detects when the main grip unit is at the home position. Main Grip HP Sensor: Low Detects when the main grip unit can be rotated.
Page 469 Motor, Sensor Locations Detects the press position of the main gripper during signature alignment. Main Grip Press Sensor 2 Detects the press position of the main gripper when the main unit is ready to press the signature into the center of the cover. Signature Thickness Sensor Detects the thickness of the signature as soon as the signature has passed from the sub grip unit to the main grip unit.
Page 470 6. Details Opens and closes the front half of the main gripper that grips the spine of the signature in the main grip unit. Gluing Unit Motors, Sensors, Heater, Thermostat S31E Glue Vat Empty Sensor: Emitter Detects presence of glue in the vat (the emitter sensor of an Emitter/Receptor pair). S31R Glue Vat Empty Sensor: Receptor Detects presence of glue in the vat (the receptor sensor of an Emitter/Receptor pair).
Page 471 Motor, Sensor Locations Reads the temperature of the glue in the vat (this sensor is inside the glue unit). If temperature exceeds upper range, triggers an alert and cuts off power to the bookbinder. Glue Level Thermistor Monitors the amount of glue in the vat (this sensor is inside the glue unit). Glue Vat Roller Rotation Sensor Detects rotation of the glue roller to confirm that the motor and roller are operating.
Page 472 6. Details Cover Transport Motors and Sensors Spine Plate HP Sensor: Left Detects the home position of the left spine fold plate. Spine Fold Close Sensor: Left Detects when the left spine fold plate is at its closed position. Spine Plate Open Sensor Detects when the spine plate is open.
Page 473 Motor, Sensor Locations Detects the leading edge of the book during binding and release of the book to the trimming unit (the emitter of an Emitter/Receptor pair). S65R Leading Edge Sensor: Receptor Detects the leading edge of the book during binding and release of the book to the trimming unit (the receptor of an Emitter/Receptor pair).
Page 474 6. Details Spine Plate Motor Retracts the spine plate to the right to open the well through which the main grip unit pushes the joined signature and cover so the sides of the cover can fold up around the sides of the signature.
Page 475 Motor, Sensor Locations Cover Horizontal Registration Motor Moves the cover in the cover registration unit to the front or back to position the cover for binding to the signature. Cover Path: Sensor 1 Detects the cover in the paper path during transport and spine folding. Cover Registration Sensor Detects the cover only during cover gripping.
Page 476 6. Details Detects the rear edge of a small size cover (larger than 297 mm) during cover registration in the cover registration unit. SOL1 Cover Grip Solenoid Opens and closes to control operation of the cover gripper in the cover registration unit. The cover gripper clamps the cover so the cover registration guide can move the cover front/rear to position the cover for binding to the signature.
Page 477 Motor, Sensor Locations Grip HP Sensor Detects the home position of the gripper in the main grip unit. Grip End Sensor Detects when the signature grip operation in the main grip unit has ended. Book Rotation HP Sensor 1 Detects the position of rotate motor rotation motor 1 (M42) after it has been rotated to rotate the book for trimming Book Rotation Motor 2 After the right book rotation plate is pushed against the right side of the book to clamp it for...
Page 478 6. Details Trimming Unit Motor, Sensors, and Solenoid Cutter Motor Pushes the cutting blade against the edges of the signature to trim away the bottom, top, and fore edges, then retracts the blade away so the trimmings can be retrieved. Edge Press Plate Motor Pushes the edge press plate against the edge of the book to compress before the blade does the cut.
Page 479 Motor, Sensor Locations Blade Sensor 2 Detects the left/right positions of the cutter blade and the cutter end (cutter area sensor is inside the base plate) as the blade moves slightly from one side to the other during cutting. Trimmer Limit Sensor Detects any abnormal amount of movement in the trimming blade (cutter area inside base plate).
Page 480 6. Details Trimmings Collection Unit Motor and Sensors Trimmings Buffer Motor Moves the trimmings buffer to the left and right. (1) Moves it to the left to gather the trimmed strips from the cutter, moves it to the right to dump the strips into the trimmings box below.
Page 481 Motor, Sensor Locations Detects rotation of the trimmings buffer motor (M37) which moves the trimmings buffer left and right across the top of the trimmings box. S103 Trimmings Buffer HP Sensor (Left Detects the home position (left) of the trimmings buffer above the trimmings box. S104 Book Press Plate Sensor Detects the position of the book press plate.
Page 482 6. Details Book Arrival Sensor Detects the arrival of the bound book in the book buffer below the trimming unit. Book Buffer Tray HP Sensor Detects the home position (forward) of the book collection buffer tray. The book buffer tray retracts to the rear to allow the book to fall onto the output tray.
Page 483 Motor, Sensor Locations Other Switches, Sensors, and Solenoids MSW1 Left Front Door Switch: Upper Detects when the left front door is open and closed MSW2 Right Front Door Switch (Upper) Detects when the right front door is open and closed MSW3 Top Cover Switch Detects when the top cover is open and closed...
Page 484 6. Details Detects when the left front door is open and closed MSW7 Right Front Door Switch (36V) Detects when the right front door is open and closed PSW1 Glue Heater Button Starts heating the glue. Right Front Door Sensor Detects when the right front door is opened and closed.
Page 485 Motor, Sensor Locations Cools power supply unit 1. FM02 Power Supply Fan: Center Cools both power supply units 1, 2. FM03 Power Supply Fan: Left Cools power supply unit 2. FM04 Glue Supply Fan :Upper Cools the area around the top of the gluing unit. FM05 Glue Supply Fan :Lower Cools the area round the bottom of the gluing unit.
Page 486 6. Details Mounted beside FM13 cools the area around the spine plate where the signature is pressed onto the cover. FM13 Spine Plate Fan :Upper Rear Mounted beside FM12 cools the area around the spine plate where the signature is pressed onto the cover.
Page 487 Motor, Sensor Locations Controls sub grip, main grip, gluing unit, cover feed in the cover registration unit, and interfaces with the master, cutter, and inserter control boards. Draws power directly from PSU2. PCB3 Cutter Control Board Controls signature rotation for trimming, trimming, trimmings collection, and book stacking. PCB4 Main Grip Relay Board 1 PCB5...
Page 488 6. Details Stacker Button Standby, nothing on tray FLASH Stacking, cannot press and open door Book on tray, press button to open door and remove book. Binding Status Lamp No binding in progress Binding in progress PCB17 Glue Heater Button/LED Press this button to start heating the glue before a job starts.
Page 489: Specifications
7. Specifications Specifications For details about "Specifications" for this peripheral, see the main service manual.
Page 490 MEMO...

This manual is also suitable for:

D391

Ricoh Perfect Binder GB5000 Service Manual

Safety, Conventions, Trademarks

Field Service Manual Revision History

1 Installation

Installation Requirements

Perfect Binder (D391) Installation

Inserter-C1 (D391-18) Installation

Transit Pass Unit (D391-19) Installation

Docking, Completing the Installation

Preparing the Bookbinder for Moving

2 Preventive Maintenance

PM Tables

3 Replacement and Adjustment

Basics

Common Procedures

Path Entrance Motors

Signature Path Exit Unit

Stacking Tray

Main Grip Unit

Gluing Unit

Cover Transport Unit

Trimming Unit

Horizontal Path Rollers

Perfect Binder Boards

Inserter

4 Troubleshooting

Service Call Tables

Jams

Service Board Basics

Service Mode

Output Checks

5 Service Tables

Service Program Mode

6 Details

Basics

Book Binding

Jam Detection

Power Supply

Inserter-C1 (D391)

Motor, Sensor Locations

7 Specifications

Quick Links

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Summary of Contents for Ricoh Perfect Binder GB5000