Page 1 BOOKLET MAKER BK5010 SERVICE MANUAL 4 October 2007 Subject to change...
Page 2 Page intentionally blank...
Page 3 IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY Always connect the equipment to a prop- Never use a ground adapter plug to con- erly grounded power source. In doubt, have nect the equipment to a power source that the power source checked by a qualified lacks a ground connection terminal.
Page 4 Page intentionally blank...
Page 5: Table Of Contents
TABLE OF CONTENTS 1 INSTALLATION PROCEDURE 1.1 INSTALLATION REQUIREMENTS ............1-1 1.1.1 MINIMUM SPACE REQUIREMENTS ..........1-1 1.1.2 POWER REQUIREMENTS ............. 1-2 1.2 INSTALLATION FLOW CHART ............... 1-3 1.3 BOOKLET MAKER INSTALLATION ............1-5 1.3.1 ACCESSORY CHECK ..............1-5 1.3.2 INSTALLATION PROCEDURE ............1-6 1.3.3 ADJUSTMENTS ................
Page 6 3.3.5 UPPER TOP COVER ..............3-11 3.3.6 REAR TOP COVER ..............3-12 3.3.7 TOP COVER ASSEMBLY ............. 3-13 3.3.8 INTERLOCK SWITCH S16 &S17 ..........3-16 3.4 AREA A ....................3-17 3.4.1 INFEED MODULE ................. 3-17 3.4.2 PAPER INFEED SENSOR ............3-18 3.4.3 INFEED TRANSPORT MODULE ..........
Page 7 3.7.4 INTERLOCK PCB ”D” ..............3-72 3.7.5 CPU PCB AND COPIER INTERFACE PCB ”A” ......3-73 3.7.6 ADDON PCB ”F” ................3-75 3.7.7 LCD PANEL ................... 3-76 3.8 STACKER ....................3-77 3.8.1 STACKER MODULE ..............3-77 3.8.2 STACKER MOTOR M1 ..............3-78 3.9 BOOKLET QUALITY ADJUSTMENT .............
Page 8 6.1.3 CONNECTOR VIEW ............... 6-5 6.1.4 OUTFEED UPPER VIEW ............... 6-6 6.1.5 OUTFEED LOWER VIEW ............... 6-7 6.1.6 INFEED UPPER VIEW ..............6-8 6.1.7 INFEED LOWER VIEW ..............6-9 6.1.8 INFEED MODULE VIEW .............. 6-10 6.1.9 STACKER MODULE VIEW ............6-11 6.2 BOARD STRUCTURE ................
Page 9 PERIPHERALS COVER FEEDER CF5010 1 INSTALLATION PROCEDURE 1.1 INSTALLATION PROCEDURE ............CF-1-1 2 PREVENTIVE MAINTENANCE SCHEDULE 2.1 PREVENTIVE MAINTENANCE SCHEDULE ........CF-2-1 3. REPLACEMENT AND ADJUSTMENT 3.1 COVER FEEDER ................CF-3-1 3.1.1 REMOVE COMPLETE UNIT ............. CF-3-1 3.2 AREA F ....................CF-3-5 3.2.1 EMPTY BIN SENSOR Q31 ............
Page 10 PERIPHERALS TRIMMER TR5010 1 INSTALLATION PROCEDURE 1.1 INSTALLATION PROCEDURE ............TR-1-1 2 PREVENTIVE MAINTENANCE SCHEDULE 2.1 PREVENTIVE MAINTENANCE SCHEDULE ........TR-2-1 3. REPLACEMENT AND ADJUSTMENT 3.1 COVERS .................... TR-3-1 3.1.1 FRONT AND REAR COVER ............. TR-3-1 3.1.2 TOP COVER ................TR-3-2 3.1.3 BLOWER MOTOR M5 / M6 ............
Page 11 PERIPHERALS 6. DETAILED SECTION DESCRIPTIONS 6.1 ELECTRICAL COMPONENT LIST ............ TR-6-1 6.1.1 REAR VIEW ................TR-6-2 6.1.2 INFEED VIEW ................TR-6-3 6.1.3 OUTFEED VIEW ............... TR-6-4 6.1.4 STOP CARRIAGE VIEW ............TR-6-5 6.2 BOARD STRUCTURE ............... TR-6-7 6.2.1 BLOCK DIAGRAM ..............TR-6-7 6.2.2 CONTROLLER MD6DC ............
Page 12 PERIPHERALS BOOK FOLDER BF5010 Trimmer ....................TR-Wir-1 1 INSTALLATION PROCEDURE 1.1 INSTALLATION PROCEDURE ............BF-1-1 2 PREVENTIVE MAINTENANCE SCHEDULE 2.1 PREVENTIVE MAINTENANCE SCHEDULE ........BF-2-1 3 REPLACEMENT AND ADJUSTMENT 3.1 COVERS .................... BF-3-1 3.1.1 FRONT COVER ................ BF-3-1 3.1.2 REAR COVER ................BF-3-2 3.1.3 INFEED COVER ...............
Page 13 PERIPHERALS 4.3 LED’S ....................BF-4-15 4.4 TEST POINTS ................. BF-4-17 5 SERVICE TABLES 5.1 SERVICE TABLES ................BF-5-1 6. DETAILED SECTION DESCRIPTION 6.1 ELECTRICAL COMPONENT LIST ............ BF-6-1 6.1.1 COMPONENT LAYOUT ............BF-6-2 6.2 BOARD STRUCTURE ............BF-6-5 6.2.1 CONTROLLER MD6DC “D” ............BF-6-5 6.3 PRINCIPLE OF OPERATION ............
Page 14 Page intentionally blank...
Page 15: Installation Requirements
04 October 2007 INSTALLATION REQUIREMENTS INSTALLATION PROCEDURE INSTALLATION REQUIREMENTS 1.1.1 MINIMUM SPACE REQUIREMENTS Rail CF5010 400 mm Stacker ” BF5010 TR5010 BK5010 625 mm 360 mm 360 mm 795 mm ” ” ” ” 2140 mm ”...
Page 16: Power Requirements
INSTALLATION REQUIREMENTS 04 October 2007 1.1.2 POWER REQUIREMENTS WARNING 1. Make sure that the wall outlet is near the main machine and easily accessible. Make sure the plug is firmly inserted in the outlet. 2. Avoid multi-wiring. 3. Be sure to ground the machine. 1. Input voltage level: North America 120V AC, 50-60Hz: More than 4 A. Europe/Asia 230V AC, 50-60Hz: More than 2 A.
Page 17: Installation Flow Chart
INSTALLATION REQUIREMENTS INSTALLATION FLOW CHART The following flow chart shows how to install the optional units more efficiently. Install the Booklet maker BK5010 Does the user require a Cover Feeder? Install the Cover Feeder CF5010 Does the user require a Trimmer?
Page 18 Page intentionally blank...
Page 19: Booklet Maker Installation
E. Shift tray plate ..............1 F. Exit tray plate ............... 1 G. Powercord ................1 H. Terminator plug, will always be installed onto BK5010 ..1 I. Terminator plug TR5010 ............1 J. Interlock Jumper, will always be installed onto BK5010 ..1 K.
Page 20: Installation Procedure
BOOKLET MAKER INSTALLATION 04 October 2007 1.3.2 INSTALLATION PROCEDURE Unpacking Remove all parts from the pallet. Slide the Booklet maker off the pallet by pulling the two cardboard handles [A] underneath the Booklet maker straight out. WARNING 2 persons are required to slide the Booklet Maker off the pallet.
Page 21 04 October 2007 BOOKLET MAKER INSTALLATION Exit arm catcher Remove the adhesive backing from the Exit arm catcher. Install the Exit arm catcher on the finisher so that it will hold the Exit paper arm as high as possible. The nut on the Exit arm catcher should be centered over the Exit paper arm, according to figure.
Page 22 BOOKLET MAKER INSTALLATION 04 October 2007 Copier exit tray Make sure that the Exit paper arm is in the upper position [A]. Remove the finisher exit tray by removing screws [B] ( x 4). Remove the plastic deflector [C], on the finisher exit tray.
Page 23 04 October 2007 BOOKLET MAKER INSTALLATION Remove the plastic deflector [D] from the shift tray. Install the Shift tray plate [E] on to the finisher ( x 4 counter screws from installation kit) Install the Exit tray plate [F] on to the finisher exit tray ( x 4 from installation kit).
Page 24 BOOKLET MAKER INSTALLATION 04 October 2007 Docking assembly Finisher seen from above Finisher seen from front side Remove the finisher rear cover ( x 2). Open the finisher door and pull out the stapling tray. Remove black plastic covers [A] at the bottom of the finisher ( x 2).
Page 25 BOOKLET MAKER INSTALLATION Interface to SR5000 Finisher Finisher Main PCB Finisher with rear cover installed Interface between SR5000 Finisher and BK5010 Install the Communication cable from the installation kit, to connector CN138H [A] ( x1) on the finisher main board.
Page 26 BOOKLET MAKER INSTALLATION 04 October 2007 Interface to SR841 Finisher Finisher Main PCB Interface between SR841 Finisher and BK5010 Install the Communication cable from the installation kit, to connector CN132 [A] ( x1) on the finisher main board. NOTE: Make sure to use the communication cable for SR841 Finisher.
Page 27: Adjustments
04 October 2007 BOOKLET MAKER INSTALLATION 1.3.3 ADJUSTMENTS Remove screws [A] and remove the Bookler maker front cover ( x5). Remove screws [B], loosen screw [C] and remove the Bookler maker rear cover ( x5). 1-13...
Page 28 BOOKLET MAKER INSTALLATION 04 October 2007 Booklet Maker, front view If installing a Rail unit, install it now. NOTE: If the Rail unit is installed later the height adjustment of the Booklet maker will be incorrect. Dock the Booklet Maker to the Docking assembly. CAUTION Before docking, make sure the Jogger Fence [A] is in the upper position.
Page 29 04 October 2007 BOOKLET MAKER INSTALLATION Booklet Maker, outfeed view Turn both outfeed side adjustment nuts [D] until the gap [E] between the Book- let maker and the Finisher is parallell ± 2mm. NOTE: Turn both screws equal amount of turns. 1-15...
Page 30 BOOKLET MAKER INSTALLATION 04 October 2007 Place the Multi tool outside the hand feeding paper guides as illustrated [F]. 1-16...
Page 31 04 October 2007 BOOKLET MAKER INSTALLATION The height adjustment of the Booklet Maker is correct when the lower edge of the Finisher top cover is level with the cut-out [G] in the Multi tool. 1-17...
Page 32 BOOKLET MAKER INSTALLATION 04 October 2007 Booklet Maker, rear view Booklet Maker, front view To adjust the height of the Booklet Maker, turn all four adjustment nuts [I]. One revolution equals 2 mm difference in height. 10. Undock the Booklet maker. 11.
Page 33 04 October 2007 BOOKLET MAKER INSTALLATION Top Cover over Cover Feeder dummy If installting a Cover Feeder CF5010, skip step 2. Insert the two screws mounted on the rear side of the UpperTop Cover into the grommets [A] at the rear side of the Cover Feeder dummy and secure at the front side [B] with screws in plastic bag taped to the inside of the Upper Top Cover( x 2).
Page 34: Connectors
Install the Terminator plug [D] and the Interlock jumper [F]. NOTE: Unless Trimmer TR5010 will be installed. If so, communication cable and power cord between BK5010 and TR5010 will be connected. Connect the powercord [E] to the Booklet maker ( x1).
Page 35: Check The Installation
04 October 2007 BOOKLET MAKER INSTALLATION 1.3.5 CHECK THE INSTALLATION If installing a Cover Feeder CF5010 or Trimmer TR5010, continue to that sec- tion ( 1.4 or 1.5 ) otherwise continue with step 2. Power on the Booklet maker. NOTE: Make sure that the finisher connector is connected to the copier. Remove the two Stapler heads, according to section ( 3.4.12 ).
Page 36: Cover Feeder Installation
COVER FEEDER INSTALLATION 04 October 2007 COVER FEEDER INSTALLATION 1.4.1 ACCESSORY CHECK [C ] Check the quantity and condition of the accessories in the box against the follow- ing list: Description Q’ty A. Cover Feeder module, CF5010 ..........1 B. Feeder roller ................ 1 C.
Page 37: Installation Procedure
04 October 2007 COVER FEEDER INSTALLATION 1.4.2 INSTALLATION PROCEDURE Unpacking Remove all parts from the box. Cut the cable tie [A] to release the paper bin and DSD Calibration strip [B]. Place the DSD Calibration strip on the cable holder [C] behind the Booklet Maker rear cover.
Page 38 COVER FEEDER INSTALLATION 04 October 2007 Removal of the Upper Top Cover If installed, remove the Upper Top Cover by removing the screws [A] and [B] ( x 4). 1-24...
Page 39 04 October 2007 COVER FEEDER INSTALLATION Removal of the Rear Top Cover Open the Booklet Maker Top Cover. Remove the screw [A] ( x 1). 1-25...
Page 40 COVER FEEDER INSTALLATION 04 October 2007 Remove the screws [B] and remove the Rear Cover of the Top Cover [C] x 3). 1-26...
Page 41 04 October 2007 COVER FEEDER INSTALLATION Removal of cover Feeder dummy Remove the nut [A] ( x 1). NOTE: Nut will be used later when installing the Cover Feeder. Remove the screws [B] ( x 2). NOTE: Screws will be used later when installing the Cover Feeder. 1-27...
Page 42 COVER FEEDER INSTALLATION 04 October 2007 Loosen nuts [C] ( x 2). Remove the Cover Feeder dummy [D] by sliding it out. 1-28...
Page 43 04 October 2007 COVER FEEDER INSTALLATION Installing the Cover Feeder Cover Feeder, outer side view Cover Feeder, inner side view Install the Cover Feeder in the exact same position as the Cover Feeder dummy was installed. NOTE: The shaft [A] must be positioned in the cut-out of the bracket [B] in the Top Cover.
Page 44 COVER FEEDER INSTALLATION 04 October 2007 Cover Feeder, viewed from Booklet Maker rear side Secure the Cover Feeder with the nut [D] and the screws [E] ( x 1, x 2). 1-30...
Page 45 04 October 2007 COVER FEEDER INSTALLATION Installation of the Cover Feeder connectors Cover Feeder, viewed from Booklet Maker outfeed Cover Feeder, viewed from Booklet Maker front side Install motor harness [A] ( x 2). Install sensor harness [B] ( x 1). Install fan harness [C] ( x 1).
Page 46 COVER FEEDER INSTALLATION 04 October 2007 Installation of Feed roller Install Feed Roller by inserting the bushing [A] in the hole in the Cover Feeder front side frame [B]. Press the feed roller against the Cover Feeder front side frame and insert the one-way clutch [C] into the drive clutch [D].
Page 47 04 October 2007 COVER FEEDER INSTALLATION Installation of the Rear Top Cover Install the Rear Top Cover [A] of the Top Cover [B] and secure the the screws [C] ( x 3). NOTE: Lift the Jam clearance baffle [D] to get better access to the screw. 1-33...
Page 48 COVER FEEDER INSTALLATION 04 October 2007 Secure the screw [E] ( x 1). 1-34...
Page 49 04 October 2007 COVER FEEDER INSTALLATION Installation of the Upper Top Cover Install the Top Cover by inserting the studs [A] into the grommets [B]. Secure the Top Cover with screws [C] ( x 2). 1-35...
Page 50: Enabling The Cover Feeder
Perform a Cover Feeder DSD sensor Calibration according to section ( 5.5 ). Make sure that the stapler heads are removed, according to section Service Manual BK5010 3.4.12 ). 10. Perform a self diagnosis. - Scroll up to Diagnostic and press the OK button.
Page 51: Check The Installation
04 October 2007 COVER FEEDER INSTALLATION 1.4.4 CHECK THE INSTALLATION If installing a Trimmer TR5010 continue to section ( 1.5 ) otherwise con- tinue with step 2. Power on the Booklet maker. NOTE: Make sure that the finisher connector is connected to the copier. Power on the Copier.
Page 52 Page intentionally blank...
Page 53: Trimmer Installation
04 October 2007 TRIMMER INSTALLATION TRIMMER INSTALLATION 1.5.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the follow- ing list: NOTE: - The Installation Box is located in the trim bin on the Trimmer. - The trim bin is tie wraped on the rear side.
Page 54: Installation Procedure
TRIMMER INSTALLATION 04 October 2007 1.5.2 INSTALLATION PROCEDURE Unpacking Remove all parts from the pallets. Ensure all of the packing material is removed from the outside of the Trimmer. Tilt the Trimmer to upright position. WARNING 2 persons are required to tilt the Trimmer to the upright position. 1-40...
Page 55 04 October 2007 TRIMMER INSTALLATION Remove the belt stacker Booklet Maker Loosen screws [A] on the Booklet Maker ( x 2 ). Disconnect the Belt stacker cable ( x 1). Remove belt stacker from the Booklet maker. Secure screws [A] ( x 2 ).
Page 56 TRIMMER INSTALLATION 04 October 2007 Install Rail Extension Remove the Rail stop from the Rail under the Boklet Maker. Insert the Rail extension [A] into the Rail under the Booklet Maker [B]. Press the plugs [C] into the holes in the Rail under the Trimmer and press/ hammer down the plugs ( x 4).
Page 57: Adjustments
04 October 2007 TRIMMER INSTALLATION 1.5.3 ADJUSTMENTS Height adjustment Remove the Trimmer front cover by removing the screws [A] ( x 5). Move the Trimmer up to the Booklet maker. 1-43...
Page 58 TRIMMER INSTALLATION 04 October 2007 Height adjustment Adjust the height of the Trimmer, so that the docking bracket [B] on the Trim- mer fits in the docking hole [C] on the Booklet maker (one revolution on the nuts is 1.5mm / 1/16” in height). Adjust by turning the four nuts [D] on the Trim- mer with the Multi tool.
Page 59 04 October 2007 TRIMMER INSTALLATION Looking from behind the system, make sure that the Trimmer is parallel with the Booklet Maker [E] ± 2mm. If necessary, adjust by turning the two nuts [F] on the outfeed side of the Trimmer. 1-45...
Page 60: Docking
TRIMMER INSTALLATION 04 October 2007 1.5.4 DOCKING Docking procedure Trimmer interior towards Booklet Maker Loosen nuts [A] to the Locking bracket [B] ( x 2). Dock the Trimmer to the Booklet maker. Secure the Trimmer by lifting the Locking bracket [B] and tightening nuts [A] x 2).
Page 61 04 October 2007 TRIMMER INSTALLATION Install Trimmer fan Trimmer interior towards Booklet Maker Install Trimmer fan [A] by hanging it onto the position pins [B] inside the Trimmer. 1-47...
Page 62 TRIMMER INSTALLATION 04 October 2007 Install Belt stacker Trimmer Loosen screws [A] ( x 2) on the Trimmer. NOTE: Unless the Book folder BF5010 will be installed. If so, the Belt stacker will be installed on to the Book folder instead. Install the Belt stacker on to the Trimmer.
Page 63: Connectors
04 October 2007 TRIMMER INSTALLATION 1.5.5 CONNECTORS Connect the Belt stacker cable [A] to the Trimmer ( x1). NOTE: Unless a Book folder BF5010 also will be installed. If so, the Belt stacker cable will connected to the Book folder instead. Remove the Trimmer Terminator plug from the Booklet maker [B] ( x1).
Page 64 TRIMMER INSTALLATION 04 October 2007 Trimmer with cable protector installed Continued on next page..1-50...
Page 65 04 October 2007 TRIMMER INSTALLATION Booklet Maker with Trimmer installed [ I ] Booklet Maker, rear side 1-51...
Page 66: Check The Installation
TRIMMER INSTALLATION 04 October 2007 1.5.6 CHECK THE INSTALLATION If installing a Book Folder BF5010, continue to section ( 1.6 ) otherwise continue with step 2. Power on the Booklet maker. NOTE: Make sure that the finisher connector is connected to the copier. Trimmer interior towards Booklet Maker In the Trimmer, check the Index 16 value [A].
Page 67 04 October 2007 TRIMMER INSTALLATION 17. If a Cover Feeder CF5010 is installed: A. Prepare a 15mm high stack of A4/8.5 x 11” covers. B. Make sure that the ink has dried out well, to avoid smearing. C. Make sure that the covers are well fanned to avoid misfeeds or double-feeds. D.
Page 68 Page intentionally blank...
Page 69: Book Folder Installation
04 October 2007 BOOK FOLDER INSTALLATION BOOK FOLDER INSTALLATION 1.6.1 ACCESSORY CHECK COM. BF5010 Check the quantity and condition of the accessories in the box against the following list: Description Q’ty A. Communication cable ............1 B. Power cord ................1 C.
Page 70: Installation Procedure
BOOK FOLDER INSTALLATION 04 October 2007 1.6.2 INSTALLATION PROCEDURE Unpacking Remove all parts from the pallets. Ensure all of the packing material is removed from the outside of the Book Folder. Tilt the Book Folder to upright position. WARNING 2 persons are required to tilt the Book Folder to the upright position. 1-56...
Page 71 04 October 2007 BOOK FOLDER INSTALLATION Remove the belt stacker Trimmer Trimmer Trimmer, inside view Disconnect the Power cord to the Booklet Maker ( x 1). Loosen screws [A] ( x 2 ) securing the Belt Stacker on the Trimmer. Disconnect the Belt stacker cable ( x 1) from the Trimmer.
Page 72 BOOK FOLDER INSTALLATION 04 October 2007 Extended trim bin Remove the existing trim bin from the Trimmer. This trim bin can not be used together with the Book Folder. Assemble the new extended trim bin [A] with the four screws and nuts from the installation kit ( x 4, x 4).
Page 73 04 October 2007 BOOK FOLDER INSTALLATION Install Rail Extension Remove the Rail stop from the Rail under the Trimmer. Insert the Rail extension [A] into the Rail under the Trimmer [B]. Press the plugs [C] into the holes in the Rail under the Trimmer and press/ hammer down the plugs ( x 4).
Page 74: Adjustments
BOOK FOLDER INSTALLATION 04 October 2007 1.6.3 ADJUSTMENTS Height adjustment Remove the front cover of the Book Folder by removiing the screws [A] ( x 5). Move the Book Folder up to the Trimmer. 1-60...
Page 75 [D] on the Book Folder with the Multi tool (one revolution on the nuts is 1.5mm in height). Adjust on the front and rear side. NOTE: The Multi Tool is located behind the rear cover of the BK5010 ( x 5).
Page 76 BOOK FOLDER INSTALLATION 04 October 2007 Parallellity adjustment Looking from behind the system, make sure that the Book Folder is parallell with the Trimmer [E] ± 2mm. If necessary, adjust by turning the two nuts [F] on the outfeed side of the Book Folder . 1-62...
Page 77: Docking
04 October 2007 BOOK FOLDER INSTALLATION 1.6.4 DOCKING Docking procedure Book Folder interior, view towards Belt Stacker Loosen nuts [A] to the Locking bracket [B]. Dock the Book folder to the Trimmer. Secure the Book folder by lifting the Locking bracket [B] and tightening nuts [A] ( x 2).
Page 78 BOOK FOLDER INSTALLATION 04 October 2007 Installing Belt stacker Book Folder Loosen screws [A] ( x 2) on the Book Folder. Install the Belt stacker on to the Book Folder. Secure the Belt stacker by tightening screws [A] ( x 2) on the Book Folder. 1-64...
Page 79: Connectors
Install the Communication cable [D] between the Trimmer and the Book Folder x 1). Connect the power cord from the BK5010 to the BF5010 Mount the cable protector [E] positioned as shown with two screws in the holes [F] and route the cables inside the cable protector ( x 2).
Page 80: Auto Set Thickness Bracket
Unplug BK 5010 power cord. Remove the rear cover on the Booklet maker ( Service Manual BK5010 3.3.1) ( x 5 ). Install the Spacer pin [A], with the collar out. NOTE: Install the Spacer pin’s on the rear side of the Booklet maker.
Page 81 04 October 2007 BOOK FOLDER INSTALLATION Sensor bracket Booklet Maker, rear side view Booklet Maker, rear side view Booklet Maker, rear side view Place the spring [A] on the screw on the Sensor bracket. Secure the Sensor bracket by tightening it with the screws [B] & [C] ( torx).
Page 82: Check The Installation
BOOK FOLDER INSTALLATION 04 October 2007 1.6.7 CHECK THE INSTALLATION Power on the Booklet maker. NOTE: Make sure that the finisher connector is connected to the copier. Trimmer interior, view towards Booklet Maker In the Trimmer, check the Index 16 value [A]. Press the Tools button.
Page 83 04 October 2007 BOOK FOLDER INSTALLATION 17. If a Cover Feeder CF5010 is installed: A. Prepare a 15mm/ high stack of A4/8.5 x 11” covers. B. Make sure that the ink has dried out well, to avoid smearing. C. Make sure that the covers are well fanned to avoid misfeeds or double-feeds. D.
Page 84 Page intentionally blank...
Page 85: Preventive Maintenance Schedule
If any of the checkpoints or other parts show indication of wear at any point, replace the part. When lubricating, clean the surface if necessary before applying new lubricant. Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect BK5010 125K 250K 375K 500K NOTE REFERENCE...
Page 86 PM TABLE 19 April 2006 TR5010 125K 250K 375K 500K NOTE REFERENCE Paper paths Blower Brush Sensors Blower Brush Infeed module Infeed belts (4x) Alcohol 3.2.20 Outfeed module Upper outfeed belts C/ I C/ I Alcohol 3.2.15 (2x) Lower outfeed belts C/ I C/ I Alcohol...
Page 87: Replacement And Adjustment
21 August 2006 GENERAL CAUTIONS REPLACEMENT AND ADJUSTMENT GENERAL CAUTIONS WARNING Turn off the main power switch and unplug the machine before attempting any of the procedures in this section. Using the ESD Ground Strap Purpose The purpose of the ESD (Electrostatic Discharge) ground strap is to preserve the inherent reliability and quality of electronic components handled by the Service Representative.
Page 88 Page intentionally blank...
Page 89: Special Tools And Lubricants
SPECIAL TOOLS AND LUBRICANTS SPECIAL TOOLS AND LUBRICANTS 3.2.1 SPECIAL TOOLS In order to facilitate the service of the BK5010 Booklet Making system there are a few special tools needed. Where part number is written it can be purchased from your supplier.
Page 90 21 August 2006 For the BK5010 Booklet Making system not to be interlocked (interlocked=36V interrupted), the Interlock switch must be activated and the Interlock magnet must be blocked with a metal. Use the Cheater to override the interlock for running the system with open top covers.
Page 91: Required Tools
21 August 2006 SPECIAL TOOLS AND LUBRICANTS 3.2.2 REQUIRED TOOLS Open wrenches: 5.5, 7, 8, 10, 13, 17, 19 mm Allen keys: 1.5, 2, 2.5, 3, 4, 5 mm Torx T-20 Circlip pliers Metric Feeler gauge set Metric Sliding calliper 3.2.3 LUBRICANTS Grease: Part number:...
Page 92 Page intentionally blank...
Page 93: Covers
21 August 2006 COVERS COVERS 3.3.1 FRONT AND REAR COVER Open top cover. Remove screws [A] to Front cover ( x5 ). Remove screws [B] to Rear cover ( x4 ). Loosen screw [C] ( x1 ). NOTE: Unhook the Rear cover.
Page 94: Infeed Cover
COVERS 21 August 2006 3.3.2 INFEED COVER Remove Front and Rear cover ( 3.3.1 ). Remove screws [A] ( 2 ). Support Infeed Cover. Remove screws [B] to remove Infeed Cover. NOTE: Remove screws in this order to avoid bending front frame part. WARNING Infeed cover is very heavy and could cause injury if it falls down.
Page 95: Infeeder
21 August 2006 COVERS 3.3.3 INFEEDER Open the Top Cover. Remove screws [A] ( x4 ). Disconnect connector [B]. Lift out the Infeeder.
Page 96: Outfeed Cover
COVERS 21 August 2006 3.3.4 OUTFEED COVER Set the machine to A4. Remove Stacker module ( 3.8.1 ). Remove Front and Rear cover ( 3.3.1 ). Remove screws [A] ( x2 ). Remove screws [B] ( x2 ). Remove screws [C] ( x2 ).
Page 97: Upper Top Cover
21 August 2006 COVERS 3.3.5 UPPER TOP COVER Open the Top Cover. Remove screws [A] ( x2 ). Lift front end of upper Top Cover and pull so that the studs [B] exits the rubber bushings [C] at the rear side of the Cover Feeder or Cover Feeder Dummy. Lift off the Upper Top Cover [D].
Page 98: Rear Top Cover
COVERS 21 August 2006 3.3.6 REAR TOP COVER Remove the nut [A] ( x 1). Remove the screw [B] ( x 1). NOTE: Lift the Jam clearance baffle [C] to get better acces to the screw. Remove the screws [D] ( x 2).
Page 99: Top Cover Assembly
21 August 2006 COVERS 3.3.7 TOP COVER ASSEMBLY Removal Remove Front and Rear cover ( 3.3.1 ). If a Cover Feeder is installed - disconnect connectors [A]. Squeeze the barbs on the sides and remove connectors [B] from Top cover. 3-13...
Page 100 COVERS 21 August 2006 Remove nuts [C] ( x4 ). Remove screw [D] ( x1 ) and [E] ( x1 ). Move Top cover towards the front side. Remove screws [F]( x2 ) and adjustment plates [G] ( x2 ). Lift off the Top cover.
Page 101 21 August 2006 COVERS Adjustment Loosen screw [D] ( x1 ) and screws [F] ( x2 ). Adjust so that the Top cover rests on the rubber supports [H] ( x3 ) when closed. Loosen nuts [C] ( x4 ) and adjust so that the plate [I] holding the upper part of the Top cover lock enters the cut-out in the front frame centered.
Page 102: Interlock Switch S16 &S17
Recheck step 3. WARNING Overriding or cheating the interlock allows the BK5010 system to operate with the top cover open which can result in personal injury. Never give the operator access to the cheater or show how overriding the interlock system is carried out.
Page 103: Area A
21 August 2006 AREA A AREA A 3.4.1 INFEED MODULE Remove Front and Rear cover ( 3.3.1 ). Remove Infeed cover ( 3.3.2 ). Remove connectors [A] ( x2 ). Unhook of the length adjustment strap [B]. Remove screws [C] on the Front side of the Booklet maker ( x2 ).
Page 104: Paper Infeed Sensor
AREA A 21 August 2006 3.4.2 PAPER INFEED SENSOR Remove Infeed Module ( 3.4.1 ). Remove screw [A] ( x1 ). NOTE: You do not have to remove the Infeed module to reach the screw, you are able to reach the screw through the hole in the Infeed module. Remove connector [B] ( x1 ).
Page 105: Infeed Transport Module
21 August 2006 AREA A 3.4.3 INFEED TRANSPORT MODULE Remove connectors [A] ( x2 ). Cut tie wrap [B] . Remove E-clip [C] ( x1 ). Remove pin to the Infeed transport module. 3-19...
Page 106: Infeed Transport Wheel
AREA A 21 August 2006 3.4.4 INFEED TRANSPORT WHEEL Remove Infeed transport module ( 3.4.3 ). Remove nuts [A] ( x3 ). Remove E-clip [B] ( x1 ). 3-20...
Page 107: Infeed Motor M1 & Sensor Q2
21 August 2006 AREA A 3.4.5 INFEED MOTOR M1 & SENSOR Q2 Remove Infeed transport wheel ( 3.4.4 ). Remove screws [A] ( x3 ). Pull out the Infeed motor M1 & sensor Q2. NOTE: The sensor Q2 is located on the motor. 3-21...
Page 108: Side Guides
AREA A 21 August 2006 3.4.6 SIDE GUIDES Removal Front Remove Infeed module ( 3.4.1 ). Remove screw [A] and [B] to the Front side guide [C] ( x2 ). Same procedure on the Rear side guide [D]. Replacement Reverse the removal procedure. NOTE: Make sure that you are using the correct screws (M4 x 8mm) when reinstalling the side guides.
Page 109: Side Jogger Motor M3 & Sensor Q12
21 August 2006 AREA A 3.4.7 SIDE JOGGER MOTOR M3 & SENSOR Q12 Removal Remove Infeed module ( 3.4.1 ). Remove connectors [A] ( x2 ). Loosen allen screw [B] to pulley ( x1 ). Remove screws [C] to motor bracket ( x2 ).
Page 110: Side Guide Transmission &Sensor Q13
AREA A 21 August 2006 3.4.8 SIDE GUIDE TRANSMISSION &SENSOR Q13 Continued on next page..3-24...
Page 111 21 August 2006 AREA A Removal Sensor Q13 Remove Infeed module ( 3.4.1 ). Disconnect connector [A] to sensor Q13 ( x1 ). NOTE: Make sure that the side guides are in there most inner position and move the Back jogger module by hand, to make it easier to get to the sensor. Replacement Reverse the removal procedure.
Page 112: Back Jogger Module & Sensor Q3
AREA A 21 August 2006 3.4.9 BACK JOGGER MODULE & SENSOR Q3 [ H ] Continued on next page..3-26...
Page 113 21 August 2006 AREA A Removal Sensor Q3 Remove Infeed cover ( 3.3.2 ). NOTE: Picture shows Infeed module removed for clarity. It is not necessary to remove Infeed module to replace Sensor Q3. Disconnect connector [A] to Sensor Q3 ( x1 ).
Page 114: Back Jogger Fingers
AREA A 21 August 2006 3.4.10 BACK JOGGER FINGERS [ I ] Continued on next page..3-28...
Page 115 21 August 2006 AREA A Removal Remove Back jogger module ( 3.4.9 ) Loosen spring [A] with a screwdriver [B], by pulling the screwdriver straight out according to the arrows [C] ( x1 ). Remove screws [D] ( x2 ). Remove E-clips [E] ( x4 ).
Page 116: Back Jogger Motor M2
AREA A 21 August 2006 3.4.11 BACK JOGGER MOTOR M2 Removal Remove Back jogger module ( 3.4.9 ). Remove screw [A] and nut [B] ( x1 ). Remove the Bracket [C] from the motor axel. Remove connector [D] ( x1). Remove screws [E] to the motor ( x3 ).
Page 117: Stapler Head
21 August 2006 AREA A 3.4.12 STAPLER HEAD Replacement of staple cartridge Open the booklet maker top cover. Raise the handle (A) on the staple cartridge locking lever. Remove the staple cartridge [B] from the stapler head by sliding it away from the stapler head.
Page 118 AREA A 21 August 2006 Removal of stapler head Open the booklet maker top cover. Disconnect the staple indication lead [D] from the socket. Hold the stapler head in place, press the release lever [E] to release the rear end of the stapler head and lift up this end. Lift out the head, allowing it to rotate around the front end.
Page 119 21 August 2006 AREA A Maintenance of stapler head The stapler head drive post on each stapler head should be lubricated every 20 00 cycles. Put a couple of drops of oil [F] on each side of the drive post [G]. Cycle the stapler head a few times before installing it again.
Page 120: Stapler Head Retraction Distance
AREA A 21 August 2006 3.4.13 STAPLER HEAD RETRACTION DISTANCE 1,0 - 2,0 mm Purpose The purpose is to ensure the staple feed. Removal Remove Infeed cover( 3.3.2 ). Make sure that the Stapler motor linkage is in the top dead center. Adjustment Push down the stapler head [A].
Page 121: Stapler Motor M4
21 August 2006 AREA A 3.4.14 STAPLER MOTOR M4 [ I ] Removal Remove Infeed cover( 3.3.2 ). Disconnect connector [A] ( x1 ). Remove nut [B], brass spacer [C] and screw [D] ( x1 ). Remove Crank journal [E] with an 17 mm open wrench. Remove screw and washer [F] ( x1 ).
Page 122: Stapler Assy Drive Bar & Sensor Q14
AREA A 21 August 2006 3.4.15 STAPLER ASSY DRIVE BAR & SENSOR Q14 0,05 to 0,15 mm Purpose The purpose is to limit the front-to-rear movement of the Stapler assembly drive bars, without causing them to bind. Removal Remove Front and Rear cover ( 3.3.1 ).
Page 123: Clincher Bar Assembly
21 August 2006 AREA A 3.4.16 CLINCHER BAR ASSEMBLY Incorrect, with gap Correct, no gap Removal Set the machine to A3 / 11x17”. Remove Infeed module ( 3.4.1 ). Remove screws and nuts [A] on both sides of the Booklet maker ( x2 ).
Page 124: Cleaning Clincher Points
AREA A 21 August 2006 3.4.17 CLEANING CLINCHER POINTS Removal Remove Clincher bar assembly [A] ( 3.4.16 ). Remove screws [B] to clincher plate [C] ( x3 ). Remove clincher plate [C]. NOTE: The clincher points [D] are not interchangeable. They must be refitted on their original position.
Page 125: Set Transport Drive Alignment
21 August 2006 AREA A 3.4.18 SET TRANSPORT DRIVE ALIGNMENT [ I ] Continued on next page..3-39...
Page 126 AREA A 21 August 2006 Purpose The purpose is to horizontally align the Set transport drive rollers with the Idler wheels, to ensure the correct set transportation into the fold area. Set the machine to A4 / 8.5x11”. Ensure that the tires [A] are centered on the hubs [B] of the drive rollers. Manually move the Drive rollers [C] up against the Pressure rollers [D], by pushing the Staple stop gate down.
Page 127: Pressure Roller
21 August 2006 AREA A 3.4.19 PRESSURE ROLLER 7-10 mm 7-10 mm Purpose The purpose is to position the Pressure rollers for the correct engagement with the Drive rollers. This adjustment interacts with 3.5.1. Adjustment Set the machine to A3 / 11x17”. Check that the distance [A] is 24.5 mm.
Page 128: Set Transport Motor M5
AREA A 21 August 2006 3.4.20 SET TRANSPORT MOTOR M5 Remove Infeed cover ( 3.3.2 ). Remove screw [A] to ground strap ( x1 ). Remove O-ring [B]. Loosen the allen screw underneath the O-ring ( x1 ). Loosen screws [C] and remove the motor ( x2 ).
Page 129: Thick Set Sensor Q36
21 August 2006 AREA A 3.4.21 THICK SET SENSOR Q36 View from infeed View from outfeed Removal Remove the outermost stapler head [A] ( 3.4.12 ). Remove nut [B] ( x1 ). NOTE: In order to maintain distance [C], do not loosen screws [D] or [E]. Disconnect connector [F] ( x1 ).
Page 130 Replacement Reverse the removal procedure. Check Install interlock cheater in order to operate BK5010 with Top Cover open. Set trimming to off. Check sensor Q36 adjustment by hand feeding sets of 80 gsm sheets. A set of 32 sheets should pass but a set of 35 sheets should be stopped in the stapling area with the display showing the message “Set to thick”.
Page 131: Area B
21 August 2006 AREA B AREA B 3.5.1 STAPLE STOP GATE SOLENOID SOL1 Purpose The purpose is to ensure adequate engagement of the pressure rollers. NOTE: This adjustment interacts with 3.4.19. Perform adjustment 3.4.19 before this adjustment 3.5.1. Removal 3.4.19 ). Check/Adjust the Pressure roller ( Set the machine to A3 / 11x17”.
Page 132: Staple Stop Gate Release Solenoid Sol2
AREA B 21 August 2006 3.5.2 STAPLE STOP GATE RELEASE SOLENOID SOL2 Continued on next page..3-46...
Page 133 21 August 2006 AREA B Removal Start Staple / Fold positioning motor M9, in Check motors ( 5.1.1 ). Engage the motor until you can see the screws [A]. Remove Infeed cover ( 3.3.2 ). Cut the tie wrap, securing the cable. Disconnect connector to SOL2 ( x1 ).
Page 134: Saddle Stapling Start Sensor Q4
AREA B 21 August 2006 3.5.3 SADDLE STAPLING START SENSOR Q4 Removal Remove nut [A] ( x1 ). Disconnect connector [B] ( x1 ). Replacement Reverse the removal procedure. NOTE: Make sure that the sleeve of the wire, do not interfere with the paper path. 3-48...
Page 135: Area C
21 August 2006 AREA C AREA C 3.6.1 STAPLE / FOLD POSITION MOTOR M9 & SENSOR Q10 Set the machine to A4 / 8.5x11”. Remove Outfeed cover ( 3.3.4 ). Disconnect connectors [A] ( x2 ). Remove screws [B] to the motor bracket ( x3 ).
Page 136: Length Transmission Shaft & Sensor Q11
AREA C 21 August 2006 3.6.2 LENGTH TRANSMISSION SHAFT & SENSOR Q11 View inside Booklet maker with Infeed cover removed View on Length adjustment shaft with Rear cover removed Continued on next page..3-50...
Page 137 21 August 2006 AREA C Removal Sensor Q11 Remove Rear cover ( 3.3.1 ). Remove Infeed cover ( 3.3.2 ). Disconnect connector [A] ( x1 ). Remove sensor Q11 [B]. Replacement Sensor Q11 Reverse the removal procedure. Lubricate Length transmission shaft Remove Rear cover ( 3.3.1 ).
Page 138: Fold Stop Gate Motor M8 & Sensor Q7
AREA C 21 August 2006 3.6.3 FOLD STOP GATE MOTOR M8 & SENSOR Q7 Removal Set the machine to A3 / 11x17”. Disconnect connector [A] ( x1 ). Loosen allen screw [B] and remove the linkage ( x1 ). Remove screws [C] to the motor ( x3 ).
Page 139: Fold Stop Gate
21 August 2006 AREA C 3.6.4 FOLD STOP GATE Removal Set the machine to A3 / 11x17”. Loosen locknut [A] ( x1 ). Remove screw [B] ( x1 ). Remove the Fold stop gate. Replacement Reinstall the Fold stop gate. NOTE: Make sure that the shaft on the Fold stop gate, is positioned in the linkage.
Page 140: Fold Knife Motor M7 & Sensor Q15
AREA C 21 August 2006 3.6.5 FOLD KNIFE MOTOR M7 & SENSOR Q15 [ I ] Continued on next page..3-54...
Page 141 21 August 2006 AREA C Removal Set the machine to A4 / 8.5x11”. Remove Front and Rear cover ( 3.3.1 ). Remove Infeed cover ( 3.3.2 ). Disconnect connector [A] to motor M7 ( x1 ). Disconnect connector [B] to sensor Q15 ( x1 ).
Page 142: Fold Transmission Module
AREA C 21 August 2006 3.6.6 FOLD TRANSMISSION MODULE Remove Front cover ( 3.3.1 ). Disconnect connector [A] to Fold roller motor M6 ( x1 ). Disconnect connector [B] to Fold roller sensor Q9 ( x1 ). Remove nuts [C] to the Fold transmission module ( x3 ).
Page 143: Fold Transmission Belt & Sensor Q9
21 August 2006 AREA C 3.6.7 FOLD TRANSMISSION BELT & SENSOR Q9 Continued on next page..3-57...
Page 144 AREA C 21 August 2006 Removal Remove Fold transmission module ( 3.6.6 ). Remove screws [A], [B] and [C] to Fold transmission plate ( x3 ). Remove the Fold transmission plate and Fold roller sensor Q9 plate [D]. Loosen screw [E] ( x1 ).
Page 145: Fold Roller Motor M6
21 August 2006 AREA C 3.6.8 FOLD ROLLER MOTOR M6 Continued on next page..3-59...
Page 146 AREA C 21 August 2006 Removal Remove Fold transmission belt ( 3.6.7 ). Remove screw and washer [A] ( x1 ). Remove bearing [B]. Remove the Motor transmission pulley [C]. Remove screws [D] ( x3 ). Replacement Reinstall screws [D] ( x3 ).
Page 147: Fold Transmission Gear Assemblys
21 August 2006 AREA C 3.6.9 FOLD TRANSMISSION GEAR ASSEMBLYS Remove Fold transmission belt ( 3.6.7 ). Remove E-clips ( Remove transmission gears. It is the same Fold transmission coupling assembly [E] on all of the Fold trans- mission gear assembly’s. 3-61...
Page 148: Fold Distance Bracket
AREA C 21 August 2006 3.6.10 FOLD DISTANCE BRACKET Removal Remove Fold transmission module ( 3.6.6 ). Remove nut [A] to the middle bearing bracket ( x1 ). Remove the bearing bracket [B]. Remove Fold distance bracket [C]. NOTE: DO NOT LOOSEN OR REMOVE THE NUT [D] TO THE EXCENTER. Replacement Reverse the removal procedure.
Page 149: Upper Folder Roller
21 August 2006 AREA C 3.6.11 UPPER FOLDER ROLLER [ I ] Continued on next page..3-63...
Page 150 AREA C 21 August 2006 Removal Remove outfeed cover ( 3.3.4 ). Remove the paper guide [A] by pressing it against the rear side of the Booklet maker. Loosen springs [B] to the Cams to the Upper folder rollers ( x2 ).
Page 151: Lower Folder Roller
21 August 2006 AREA C 3.6.12 LOWER FOLDER ROLLER Continued on next page..3-65...
Page 152 AREA C 21 August 2006 Removal Remove outfeed cover ( 3.3.4 ). Remove the paper guide [A] by pressing it against the rear side of the Booklet maker. Remove Fold distance bracket ( 3.6.10 ). Remove nuts [B] and bearing brackets [C] on the front and rear side of the booklet maker ( x2 ).
Page 153: Outfeed Sensor
21 August 2006 AREA C 3.6.13 OUTFEED SENSOR Remove outfeed cover ( 3.3.4 ). Remove nut [A] ( x1 ). Disconnect connector [B] ( x1 ). 3-67...
Page 154 Page intentionally blank Page intentionally blank...
Page 155: Pcb
21 August 2006 3.7.1 MD3DC PCB “H” H.P14 H.P2 H.P5 H.P4 H.P11 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.
Page 156: Upper Md6Dc Pcb "B
21 August 2006 3.7.2 UPPER MD6DC PCB ”B” B.P4 B.P5 B.P12 B.P11 B.P13 B.P3 B.P2 B.P14 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.
Page 157: Lower Md6Dc Pcb "C
21 August 2006 3.7.3 LOWER MD6DC PCB ”C” C.P4 C.P5 C.P12 C.P11 C.P13 C.P3 C.P2 C.P14 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.
Page 158: Interlock Pcb "D
21 August 2006 3.7.4 INTERLOCK PCB ”D” D.P5 D.P6 D.P8 D.P9 D.P13 D.P10 D.P11 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.
Page 159: Cpu Pcb And Copier Interface Pcb "A
21 August 2006 3.7.5 CPU PCB AND COPIER INTERFACE PCB ”A” A.P5 A.P4 A.P3 A.P2 A.P9 A.P1 A.P13 A.P10 A.P8 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs).
Page 160 21 August 2006 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.
Page 161: Addon Pcb "F
21 August 2006 3.7.6 ADDON PCB ”F” F.P1 F.P2 F.P3 F.P6 F.P4 F.P5 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.
Page 162: Lcd Panel
21 August 2006 3.7.7 LCD PANEL CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.
Page 163: Stacker
21 August 2006 STACKER STACKER 3.8.1 STACKER MODULE Loosen screws [A] to the Stacker Module ( x2 ). Disconnect the connector to the Stacker Module ( x1). Lift off the Stacker Module. 3-77...
Page 164: Stacker Motor M1
STACKER 21 August 2006 3.8.2 STACKER MOTOR M1 Removal Remove Stacker Module ( 3.8.1 ). Loosen nuts [A] ( x3 ). Slide the motor bracket [B] and remove. Disconnect connector [C] ( x1 ). Remove screws [D] ( x3 ). Replacement Reverse the removal procedure.
Page 165: Booklet Quality Adjustment
21 August 2006 BOOKLET QUALITY ADJUSTMENT BOOKLET QUALITY ADJUSTMENT 3.9.1 STAPLE STOP GATE PARALLELISM Continued on next page..3-79...
Page 166 BOOKLET QUALITY ADJUSTMENT 21 August 2006 Purpose The purpose is to ensure that the staples are parallel to the edge of the sets. Removal Set the machine to A3 / 11x17”. Open Top cover. Remove the rear stapler head ( 3.4.12 ).
Page 167: Side Guide Parallelism
21 August 2006 BOOKLET QUALITY ADJUSTMENT 3.9.2 SIDE GUIDE PARALLELISM Stapler area seen from above, with the stapler heads removed. Removal Front Check/adjust Staple stop gate parallelism ( 3.9.1). Remove Infeed cover ( 3.3.2 ). Remove screw [A] and [B] to the Front side guide [C] ( x2 ).
Page 168: Staple Position To Clincher
BOOKLET QUALITY ADJUSTMENT 21 August 2006 3.9.3 STAPLE POSITION TO CLINCHER CAUTION Alignment of the stapler head to clincher is carried out at factory. Screws are sealed with red paint to ensure that alignment is maintained and also to indicate if it has been moved.
Page 169 21 August 2006 BOOKLET QUALITY ADJUSTMENT Remove Infeeder ( 3.3.3). Disconnect the Staple detection lead [G]. Push down latch [E] and lift the Stapler head out. Push the plunger [C] slowly so that the legs of the staple comes out about 1-2 mm.
Page 170 BOOKLET QUALITY ADJUSTMENT 21 August 2006 12. Push gently on plunger [C] and check if the staple legs are positioned in the center of the clincher points [K]. Check both sidewise and lengthwise. NOTE: Use a flash light to clearer see the alignment. 13.
Page 171: Stapler Pressure
21 August 2006 BOOKLET QUALITY ADJUSTMENT 3.9.4 STAPLER PRESSURE Removal Front Remove Infeed cover ( 3.3.2 ). Remove Stapler heads ( 3.4.12 ). Check/adjust the Clincher Pressure ( 3.9.6 ). Rotate the motor linkage [A] to the down dead center. NOTE: Use a 17 mm open wrench.
Page 172: Clincher Points Height
BOOKLET QUALITY ADJUSTMENT 21 August 2006 3.9.5 CLINCHER POINTS HEIGHT Purpose The purpose is to achieve the correct, flat form of the staples and to maintain life- time of the clincher points and stapler heads. NOTE: Adjustment of clincher points can be performed with clincher beam in- stalled.
Page 173: Clincher Pressure
21 August 2006 BOOKLET QUALITY ADJUSTMENT 3.9.6 CLINCHER PRESSURE Continued on next page..3-87...
Page 174 BOOKLET QUALITY ADJUSTMENT 21 August 2006 Purpose The purpose is to achieve the correct, flat form of the staples. Removal Front Check/adjust Clincher points height ( 3.9.5 ). Remove Infeed cover ( 3.3.2 ). Remove Stapler heads ( 3.4.12 ). Rotate the motor linkage (see Removal step 4, ( 3.9.4) to the down dead center.
Page 175: Staple And Fold Position
21 August 2006 BOOKLET QUALITY ADJUSTMENT 3.9.7 STAPLE AND FOLD POSITION Purpose The purpose is to ensure that the set is folded in the center of the set, and that the staple is positioned in the center of the set. Shown in tipped position for clarity Initial Action Check/adjust Side Guide Parallelism (...
Page 176 BOOKLET QUALITY ADJUSTMENT 21 August 2006 Staple Adjustment: Check/adjust Paper size reset ( 5.4 ). Set up the Booklet maker for 297x420 mm / 11x17” in Custom size. NOTE: Do NOT use the preset A3 or 11x17” paper sizes. Hand feed a 2-sheet set, using 297x420 mm / 11x17” paper. Run a few sets.
Page 177: Fold Skew
21 August 2006 BOOKLET QUALITY ADJUSTMENT 3.9.8 FOLD SKEW Shown in tipped position for clarity Purpose The purpose is to ensure that the fold is parallel to the edge of the sets. Adjustment Hand feed a 2-sheet set, using A3/ 11x17” paper. Run a few sets.
Page 178: Staple Position On Square Formed Spine
BOOKLET QUALITY ADJUSTMENT 21 August 2006 3.9.9 STAPLE POSITION ON SQUARE FORMED SPINE Purpose The purpose is to position the staples on the square formed spine according to customer preferences. Factory default is within the spine. Shown in tipped position for clarity Adjustment NOTE: This adjustment will affect all types of booklets! If the staple position is adjusted on a 20 sheet booklet with Square formed...
Page 179: Power Requirements
21 August 2006 POWER REQUIREMENTS 3.10 POWER REQUIREMENTS 3.10.1 TAPPING THE TRANSFORMER Transformer in picture tapped for 230V Purpose To be able to change the Transformer setting. Removal Remove screw [A] and renove Transformer cover [B] ( x1 ). Remove Front Cover ( 3.3.1 ).
Page 180 Page intentionally blank Page intentionally blank...
Page 181: Troubleshooting
19 April 2006 FAULT CODE DESCRIPTIONS TROUBLESHOOTING FAULT CODE DESCRIPITIONS Fault Item Fault description Page code BK-001 BK-M1 Infeed motor No displacement pulses ..........4 - 3 BK-002 BK-M1 Infeed motor Short circuit ..............4 - 3 BK-003 BK-M1 Infeed motor Open circuit ..............4 - 3 BK-004 BK-M2 Back jogger motor Cycle time out ............
Page 182 FAULT CODE DESCRIPTIONS 19 April 2006 Fault Item Fault description Page code BK-040 BK-M19/Q34 Pre-Infeed Motor No displacement pulses ......... 4 - 19 BK-041 BK-M19 Pre-Infeed Motor Short circuit ............. 4 - 20 BK-042 BK-M19 Pre-Infeed Motor Open circuit ............. 4 - 20 BK-043 BK-Q35 Docking Position Sensor Faulty ............
Page 183 19 April 2006 FAULT CODE DESCRIPTIONS BK-001 Fault Code BK-001, indicates that the Infeed motor (BK-M1) does not receive any displacement pulses. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Infeed motor (BK-M1) in check motors. Procedure Disconnect the sensor plug Q2 to motor BK-M1.
Page 184 FAULT CODE DESCRIPTIONS 19 April 2006 BK-004 Fault Code BK-004, indicates that the Back jogger motor (BK-M2) had a Cycle time out. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Back jogger motor (BK-M2) in check motors. Make sure that the Back jogger home position sensor (BK-Q3) is installed correctly.
Page 185 19 April 2006 FAULT CODE DESCRIPTIONS BK-006 Fault Code BK-006, indicates that the Back jogger motor (BK-M2) has an Open circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M2. Enter Service mode and start Back jogger motor (BK-M2) in check motors. Measure between the orange wire M2 and the violet wire M2 (PWM 36V and ground).
Page 186 FAULT CODE DESCRIPTIONS 19 April 2006 BK-008 Fault Code BK-008, indicates that the Side jogger motor (BK-M3) had a Cycle time out. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Side jogger motor (BK-M3) in check motors. Make sure that the Side jogger home position sensor (BK-Q13) is installed correctly.
Page 187 19 April 2006 FAULT CODE DESCRIPTIONS BK-010 Fault Code BK-010, indicates that the Side jogger motor (BK-M3) has an Open circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M3. Enter Service mode and start Side jogger motor (BK-M3) in check motors. Measure between the orange wire M3 and the violet wire M3 (PWM 36V and ground).
Page 188 FAULT CODE DESCRIPTIONS 19 April 2006 BK-011 Fault Code BK-011, indicates that the Stapler motor (BK-M4) had a Cycle time out. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Stapler motor (BK-M4) in check motors. Make sure that the Stapler home position sensor (BK-Q14) is installed correctly.
Page 189 19 April 2006 FAULT CODE DESCRIPTIONS BK-012 Fault Code BK-012, indicates that the Stapler motor (BK-M4) has a Short circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M4. Run the Diagnostics again. Fault code BK-013 (Open circuit) is displayed? Disconnect plug C.P3 from PCB “C”.
Page 190 FAULT CODE DESCRIPTIONS 19 April 2006 BK-015 Fault Code BK-015, indicates that the Set transport motor (BK-M5) has an Open circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M5. Enter Service mode and Set transport motor (BK-M5) in check motors. Measure between the orange wire M5 and the violet wire M5 (PWM 36V and ground).
Page 191 19 April 2006 FAULT CODE DESCRIPTIONS BK-017 Fault Code BK-017, indicates that the Fold roller motor (BK-M6) has a Short circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M6. Run the Diagnostics again. Fault code BK-018 (Open circuit) is displayed? Disconnect plug C.P3 from PCB “C”.
Page 192 FAULT CODE DESCRIPTIONS 19 April 2006 BK-019 Fault Code BK-019, indicates that the Fold knife motor (BK-M7) had a Cycle time out. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Fold knife motor (BK-M7) in check motors. Make sure that the Fold knife home position sensor (BK-Q15) is installed correctly.
Page 193 19 April 2006 FAULT CODE DESCRIPTIONS BK-021 Fault Code BK-021, indicates that the Fold knife motor (BK-M7) has an Open circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M7. Enter Service mode and start Fold knife motor (BK-M7) in check motors. Meas- ure between the orange wire M7 and the violet wire M7 (PWM 36V and ground).
Page 194 FAULT CODE DESCRIPTIONS 19 April 2006 BK-024 Fault Code BK-024, indicates that the Staple / Fold positioning motor (BK-M9) does not receive any displacement pulses. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Staple / Fold positioning motor (BK-M9) in check mo- tors.
Page 195 19 April 2006 FAULT CODE DESCRIPTIONS BK-025 Fault Code BK-025, indicates that the Staple / Fold positioning motor (BK-M9) had a Cycle time out. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Staple / Fold positioning motor (BK-M9) in check motors. Make sure that the Staple / Fold home position sensor (BK-Q11) is installed correctly.
Page 196 FAULT CODE DESCRIPTIONS 19 April 2006 BK-027 Fault Code BK-027, indicates that the Staple / Fold positioning motor (BK-M9) has an Open circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M9. Enter Service mode and start Staple / Fold positioning motor (BK-M9) in check motors. Measure between the orange wire M9 and the violet wire M9 (PWM 36V and ground).
Page 197 19 April 2006 FAULT CODE DESCRIPTIONS BK-033 Fault Code BK-033, indicates that the stopgate release solenoid has an Open circuit Initial Actions Make sure that the connectors are properly connected to the Solenoid. Check fuse F3 Procedure Power off the machine. Remove connectors from solenoid SOL2. Measure on the contacts on the Solenoid. Is there an open circuit? Reinstall connectors.
Page 198 FAULT CODE DESCRIPTIONS 19 April 2006 BK-035 Fault Code BK-035, indicates that the Start sensor, Saddle stapling sensor (BK-Q4) is faulty. Initial Actions Make sure that the Start sensor, Saddle stapling sensor (BK-Q4) is installed correctly. Procedure 1. Replace sensor BK-Q4. 2.
Page 199 19 April 2006 FAULT CODE DESCRIPTIONS BK-039 Fault Code BK-039, indicates that the Outfeed sensor Booklet maker (BK-Q8) is faulty. Initial Actions Make sure that the Outfeed sensor Booklet maker (BK-Q8) is installed correctly. Procedure 1. Replace sensor BK-Q8. 2. Disconnect plug A.P1 from CPU PCB. Measure between J1-17 and J1-19 (5V and ground). The voltage is approximately 5 VDC? Replace CPU PCB.
Page 200 FAULT CODE DESCRIPTIONS 19 April 2006 BK-041 Fault Code BK-041, indicates that the Pre-Infeed Motor (BK-M19) has a Short circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M19. Run the Diagnostics again. Fault code BK-042 (Open circuit) is displayed? Disconnect plug H.P2 from PCB “H”.
Page 201 19 April 2006 FAULT CODE DESCRIPTIONS BK-043 Fault Code BK-043, indicates that the Docking Position Sensor (BK-Q35) is faulty. Initial Actions Make sure that the Docking Position Sensor (BK-Q35) is installed correctly. Procedure 1. Replace sensor BK-Q35. 2. Disconnect plug F.P6 from Addon PCB. Measure between J6-1 and J6-3 (5V and ground). The voltage is approximately 5 VDC? Replace Addon PCB.
Page 202 FAULT CODE DESCRIPTIONS 19 April 2006 BK-045 Fault Code BK-045, indicates that the Fold Gap Sensor (BK-Q37) is faulty. Initial Actions Make sure that the Fold Gap Sensor (BK-Q37) is installed correctly. Procedure 1. Replace sensor BK-Q37. 2. Disconnect plug F.P3 from Addon PCB. Measure between J3-2 and J3-4 (5V and ground). The voltage is approximately 5 VDC? Replace Addon PCB.
Page 203 19 April 2006 FAULT CODE DESCRIPTIONS BK-151 Fault Code BK-151, indicates that the 36V input is low. Initial Actions Check fuse F3. Check the Voltage protection plug P7 on the interlock PCB. The resistance must be grater than MOhm. Make sure that contact P8 on interlock PCB is correctly installed. Make sure that contact P12 on controller PCB is correctly installed Make sure that the transformer in the machine is wired correctly.
Page 204 Fault Code BK-154, indicates that the 24V output is high. Initial Actions Make sure that all the connectors are properly installed on the BK5010 interlock PCB. Enter Service mode, and run Trimmer motors M5/6, make sure that they run correctly.
Page 205 Make sure that all the connectors to the interlock switches are properly installed. Procedure Use interlock cheaters to close all covers. Measure between P1-1 and P1-2 on the BK5010 Interlock PCB. Is there conti- nuity? Replace the BK5010 interlock switch.
Page 206 Fault Code BK-158, indicates that there is a communication lost problem. Initial Actions Make sure that the communication cable between the BK5010 and the TR5010 is properly connected. Make sure that the communication cable between the BK5010 and the CF5010 is properly connected.
Page 207 19 April 2006 FAULT CODE DESCRIPTIONS BK-159 Fault Code BK-159, indicates that the PCB MD6DC B is not connected. Initial Actions Make sure that all connectors are properly connected to PCB MD6DC B. Make sure that the dipswitches on the PCB are set correctly ( 5.2.1).
Page 208 FAULT CODE DESCRIPTIONS 19 April 2006 BK-201 Fault Code BK-201, indicates that during a run, the Paper infeed sensor (BK-Q1), was not blocked within timeout after the start signal from the copier was detected. Initial Actions Check fuse F2 on Transformer. Make sure that the Paper infeed sensor (BK-Q1) is installed correctly.
Page 209 19 April 2006 FAULT CODE DESCRIPTIONS BK-204 Fault Code BK-204, indicates that at “initialization” or during a run, the Start sensor Saddle stapling (BK-Q4), was blocked, exceeding timeout. Initial Actions Check fuse F2 on Transformer. Make sure that the Start sensor Saddle stapling (BK-Q4) is installed correctly. Ensure that the Start sensor Saddle stapling (BK-Q4) is clean.
Page 210 FAULT CODE DESCRIPTIONS 19 April 2006 BK-209 Fault Code BK-209, indicates that during a run, the Outfeed sensor Booklet maker (BK-Q8), was not blocked within timeout. Initial Actions Check fuse F2 on Transformer. Make sure that the Outfeed sensor Booklet maker (BK-Q8) is installed correctly. Ensure that the Outfeed sensor Booklet maker (BK-Q8) is clean.
Page 211 19 April 2006 FAULT CODE DESCRIPTIONS BK-401 Fault Code BK-401, indicates that the stapler head is faulty. Initial Actions Check stapler head ( 3.4.12 ). Procedure Disconnect the connectors to the stapler heads. Disconnect plug A.P1 from CPU PCB. Check wire for Continuity / Short circuit from the rear stapler head lead to the A.P1-24 and the front stapler head lead to the A.P1-15.
Page 212 FAULT CODE DESCRIPTIONS 19 April 2006 ST-001 Fault Code ST-001, indicates that the Stacker motor (ST-M1) has a Short circuit. Initial Actions Make sure that the connectors are properly installed on the stacker motor. Procedure Disconnect the motor plug M1. Run the Diagnostics again. Fault code ST-002 (Open circuit) is displayed? Disconnect plug P2 from PCB “B”.
Page 213: Blown Fuse Conditions
19 April 2006 BLOWN FUSE CONDITIONS BLOWN FUSE CONDITIONS WARNING ONLY USE SLOW BLOW FUSES. Fuse Sec. Rating Symptom at power on 6.1.3 No response 6.1.1 Normal display function but no operations in the machine are possible 6.1.1 No response 6.1.1 Not in use 4-33...
Page 214 Page intentionally blank...
Page 215: Leds
19 April 2006 LEDS LEDS Motor Drive PCB (MD6DC) in Booklet Maker & Trimmer D1: Yellow LED flashes when power is on. The flashing indicates that a program is present and functioning. Should a download fail or the 5V is missing, LED would be OFF. D2: Red LED flashes whenever information is sent or received on the Internal CAN. If power is switched on but no operations are performed, LED is OFF.
Page 216 LEDS 19 April 2006 Motor Drive PCB (MD3DC) in Booklet Maker D1 (B) D2 (A) D1: Red LED flashes when power is on. The flashing indicates that a program is present and functioning. Should a download fail or the 5V is missing, LED would be OFF. D2: Yellow LED flashes whenever information is sent or received on the Internal CAN.
Page 217 19 April 2006 LEDS CPU PCB in Booklet Maker D5: Yellow LED flashes when power is on. The flashing indicates that a program is present and functioning. Should a download fail or the 5V is missing, Yellow LED would be OFF. 4-37...
Page 218 LEDS 19 April 2006 Interlock PCB in Booklet Maker Green By PGND (TP2) +UNREG +24V D6: Red LED is ON when unregulated 36V is present. If machine is interlocked (i.e. the top cover is open and 36V is cut off) or 36V is missing, LED is OFF. The unregulated 36V can be measured between +UNREG Test Point and PGND Test Point.
Page 219 D4: Hard stop from BK5010. Copier stops immediately (such as when top cover opens). D5: Soft stop from BK5010. Copier cycles out (such as when stacker is full). D9: Start signal from copier. Papers are exiting Copier entering BK5010 D10-D12: Paper size indicators. A binary pattern between the three LEDs shows the paper size sent from the copier.
Page 220 Page intentionally blank...
Page 221: Test Points
19 April 2006 TEST POINTS TEST POINTS Motor Drive PCB (MD6DC) in Booklet Maker & Trimmer +UNREG GND/ PGND +UNREG: Outgoing unregulated 36V, after interlock relay. Measure between Test Point +UNREG and Test Point GND/PGND using a voltmeter. The voltage will be shown on the voltmeter unless: - Voltage is outside allowed range 29-43V. Voltage will be 0V. - Machine is interlocked (i.e.
Page 222 TEST POINTS 19 April 2006 Motor Drive PCB (MD3DC) in Booklet Maker GND/ PGND VCC: Stabilized and rectified 5V made from incoming 10V AC from transformer. Measure between Test Point VCC and Test Point GND/PGND using a voltmeter. The voltage will be shown on the voltmeter. Range 4.9-5.1V. GND / PGND: Ground /Power Ground is the minus when measuring 5V (VCC).
Page 223 19 April 2006 TEST POINTS CPU PCB in Booklet Maker GND / PGND VCC: Stabilized and rectified 5V made from incoming 10V AC from transformer. Measure between Test Point VCC and Test Point GND/PGND using a voltmeter. The voltage will be shown on the voltmeter. Range 4.9-5.1V. GND: Ground is the minus when measuring 5V (VCC).
Page 224 TEST POINTS 19 April 2006 Interlock PCB in Booklet Maker PGND (TP2) Green By +UNREG +24V TP1: Incoming unregulated 36V, before interlock relay. Measure between Test Point TP1 and Test Point PGND using a voltmeter. The voltage will be shown on the volt- meter regardless of the voltage being outside allowed range 29-43V. +UNREG: Outgoing unregulated 36V, after interlock relay.
Page 225 19 April 2006 TEST POINTS Addon PCB in Booklet Maker GND / PGND: Ground /Power Ground is the minus 4-45...
Page 226 Page intentionally blank...
Page 227: Service Tables
21 August 2006 SERVICE PROGRAM MODE SERVICE TABLES CAUTION Never turn off the main power when motors are cycling. To avoid damaging the circuitry, stop the motor/motors running under the Check Motors menu, and then switch the main power off. SERVICE PROGRAM MODE 5.1.1 SERVICE PROGRAM MODE OPERATIONS The Service Program (SP) mode is used to check electrical data, check electrical...
Page 228 SERVICE PROGRAM MODE 21 August 2006 Checking Motors and Solenoids 1. Go to Check Motors or Check Solenoids. Press OK. 2. Go to the unit in which the motor/solenoid to be checked is located. Press OK. 3. Go to the motor/solenoid to be checked. Press OK. 4.
Page 229 21 August 2006 SERVICE PROGRAM MODE Interface Under Interface you adapt the BK5010 interface to the correct host machine. 1. Go to Interface. Press OK. 2. Press Arrow to select correct host machine. Press OK. Changing EEPROM Values 1. Go to EEPROM values. Press OK.
Page 230: Service Program Mode Tables
SERVICE PROGRAM MODE 21 August 2006 5.1.2 SERVICE PROGRAM MODE TABLES Check Motors and function Booklet Maker Motor Normal Reading Function BK-M1 14V ±2V, ≈0.90m/s Infeed Motor transports the set to the stapling section. BK-M2 9V ±2V Back Jogger Motor jogs the sheets together lengthwise.
Page 231 21 August 2006 SERVICE PROGRAM MODE Trimmer Motor Normal Reading Function TR-M1 22V ±2V, ≈0.70m/s Transport/Knife Motor transports the booklet in and out ≈0.70m/s of the Trimmer unit. It also functions as a second Trim Knife Motor when reversed. In Service mode, only transport direc- tion can be run.
Page 232 SERVICE PROGRAM MODE 21 August 2006 Check Solenoids and function Booklet Maker Solenoid Normal Reading Function BK-SOL1 Will be actuated Stop Gate Solenoid moves the staple stop down for appr. 30 sec. and the set transport rollers up/down. BK-SOL2 Will be actuated Stop Gate Release Solenoid releases the staple for appr.
Page 233 21 August 2006 SERVICE PROGRAM MODE Check Sensors/Switches and function Booklet Maker Sensor Normal State Function BK-Q1 0 = Unblocked Paper Infeed Sensor BK-Q3 0 = Unblocked Back Jogger Home Position Sensor BK-Q4 0 = Unblocked Start Sensor, Saddle Stapling BK-Q7 0 = Unblocked Fold Stop Sensor BK-Q8 0 = Unblocked...
Page 234 SERVICE PROGRAM MODE 21 August 2006 Trimmer Sensor Normal State Function TR-S2/S3 0 = Unactuated Infeed Switch / Control Switch Infeed / Control Switch Out feed TR-Q5 1 = Blocked Trim Knife Home Position Sensor TR-Q6 1 = Unblocked Outfeed Sensor TR-Q7 0 = Blocked Stop Gate Home Position Sensor...
Page 235 21 August 2006 SERVICE PROGRAM MODE Voltmeter Voltage at Range MD3DC (H) 29-43V Unregulated 36V (after interlock relay) distributed from Interlock PCB in Booklet maker. Voltage supplies: BK-M19 Pre Infeed motor CF-M15 Feed motor CF-M17/18 Blower motors MD6DC (B) 29-43V Unregulated 36V (after interlock relay) distributed from Interlock PCB in Booklet maker.
Page 236 SERVICE PROGRAM MODE 21 August 2006 EEPROM Values Index Default Function Password The password to enter service mode can be changed here. STD Trim 004.50 Standard trim margin that is default pre- sented in the user menu. Value reflects how many millimetres that will be trimmed off from the longest sheet (centre fold) in the booklet.
Page 237 21 August 2006 SERVICE PROGRAM MODE EEPROM Values Index Default Function Zero Trim Offset ≈3.0 Fine tuning of trim margin. Value reflects deviation from real trim margin and STD trim margin. TR-M1 Speed ≈01800 The value reflect calibration of Transport motor M1. CF-M16 Speed ≈00500 The values reflect calibration of Drive motor...
Page 238: Eeprom Reset
SERVICE PROGRAM MODE 21 August 2006 5.1.3 EEPROM RESET If minor logic problems arise the EEPROM reset procedure can be initiated. All data in the EEPROM will be cleared including jobs, jam history etc. The only data not cleared are: Counters: - Staple - Fold...
Page 239: Software Download
3. Make sure all DIP-switches 1 - 4 is set to OFF (down) position. 4. Run the BK5010 MD6DC v1.00.exe* file (* v1.00 is an example - use latest version) and follow the instruction in the program, or according to the latest bulletin.
Page 240: Downloading To Lower Pcb Md6Dc C In The Booklet Maker
Make sure DIP-switches 2 and 3 is set to OFF (down) position. 4. Run the BK5010 MD6DC v1.00.exe* file (* v1.00 is an example - use latest version) and follow the instruction in the program, or according to the latest bulletin.
Page 241: Downloading To Pcb Cpu In Booklet Maker
2. Remove the Front Cover on the BK5010 ( 3.3.1). 3. Run the BK5010 CPU v1.00.exe* file (* v1.00 is an example - use latest version) and follow the instruction in the program, or according to the latest bulletin. 4. When the download is complete, set the contrast of the LCD by turning the potentiometer R 41 ( 4.4).
Page 242: Downloading To Lower Pcb Md3Dc H In The Booklet Maker
Make sure DIP-switches 1, 3 and 4 is set to OFF (up) position. 4. Run the BK5010 MD3DC v1.00.exe* file (* v1.00 is an example - use latest version) and follow the instruction in the program, or according to the latest bulletin.
Page 243: Downloading To Pcb Md6Dc A In Trimmer
21 August 2006 SERVICE PROGRAM MODE 5.2.5 Downloading to PCB MD6DC A in Trimmer. CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.
Page 244: Downloading To Pcb Md6Dc D In Book Folder
SERVICE PROGRAM MODE 21 August 2006 5.2.6 Downloading to PCB MD6DC D in Book Folder. CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.
Page 245: Self-Diagnostic Mode
21 August 2006 SELF-DIAGNOSTIC MODE SELF-DIAGNOSTIC MODE 5.3.1 RUN TIME DIAGNOSTICS Throughout the operation of the machine all functions and components are moni- tored. Should an error occur, a fault code is displayed. Many faults can simply be corrected by the operator. In that case a picture shows the location of the fault with a text message, such as ”Clear Misfeed(s)”.
Page 246: Detailed Self-Diagnostic Mode
Executing Diagnostics Follow this procedure to execute the diagnostics. 1. Undock the BK5010 from the copier. 2. Enter the service program mode ( 5.1.1). 3. Remove the two stapler heads ( 3.4.12).
Page 247: Paper Size Reset
21 August 2006 PAPER SIZE RESET PAPER SIZE RESET If any mechanical adjustments have been carried out that effects the positio- ning of side guides, staple stop or fold stop, this procedure must be performed. If the EEPROM or the CPU PCB has been replaced, this procedure must be performed.
Page 248 PAPER SIZE RESET 21 August 2006 Executing Paper Size Reset The side guides and stop gate must be parallel and square before this procedure is carried out ( 3.8.1, 3.8.2 ). 1. Remove the two stapler heads ( 3.4.12 ). 2. Insert a Interlock cheater. 3.
Page 249 21 August 2006 PAPER SIZE RESET If the purpose of performing the paper size reset procedure is strictly a result of an electronical or logical operation, such as replacement of CPU PCB, the procedure can be ended her by pressing ESC. If any changes has been made that effects the geometry regarding the paper size, such as mechanically adjusted stop gate, back jogger or replaced/moved home position sensor, the procedure must be continued to the end.
Page 250 Page intentionally blank...
Page 251: Cf Service
Booklet Maker, this procedure must also be performed. Enable the Cover Feeder At installation of the Cover Feeder you have to Enable the Cover Feeder, other wise the BK5010 system do not recognise the machine. 1. Enter the Service Program mode. 2. Go to CF5010 Service. Press the OK button.
Page 252 CF SERVICE 21 August 2006 Executing Cover Feeder DSD sensor Calibration 1. Enter the Service Program Mode. 2. Go to CF5010 SERVICE. Press OK. 3. Select Calibrations. Press OK. 4. Select Double Sheet Det. Press OK. 5. Place the DSD calibration strip, located behind the rear cover of the Booklet Maker, as illustrated [A].
Page 253: Bf Service
21 August 2006 BF SERVICE BF SERVICE In the Book Folder Service menu, you are able to set up the Book folder to Adjust- ment mode. Use the Adjustment mode when adjusting the Square folding quality. When the Adjustment mode is set to ON, the Home position of the Stop gate is changed.
Page 254 Page intentionally blank...
Page 255: Detailed Section Descriptions
5 May 2006 ELECTRICAL COMPONENT LIST DETAILED SECTION DESCRIPTIONS ELECTRICAL COMPONENT LIST Page Grid code BK-M1 Infeed motor ....................6-8 ..E2 BK-M2 Back Jogger motor ................... 6-10 ..D2 BK-M3 Side jogger motor ..................6-10 ..F2 BK-M4 Stapler motor ....................6-9 ..H20 BK-M5 Set transport motor ..................
Page 256 ELECTRICAL COMPONENT LIST 5 May 2006 Page Grid code Communication Copier ....................6-5 ..L10 Stacker Receptacle......................6-5 ..A18 Terminator ........................6-5 ..N5 Interlock jumper......................6-5 ..M15 Terminator / Communication Trimmer ................. 6-5 ..N4 Interlock jumper / Power supply Trimmer ..............6-5 ..M18 Power supply Book Folder ...................
Page 257: Front View
5 May 2006 ELECTRICAL COMPONENT LIST 6.1.1 FRONT VIEW Main Power SW Panel Switches Addon PCB Interlock switch PCB Set Counter Softstart PCB CPU PCB BK-Q9 BK-M6 Rectifier BK-M4 Transformer Capacitor...
Page 258: Rear View
ELECTRICAL COMPONENT LIST 5 May 2006 6.1.2 REAR VIEW BK-M19 MD3DC PCB “H” MD6DC PCB “B” BK-Q11 MD6DC PCB “C” Interlock PCB BK-Q35 BK-Q37 Copier Interface PCB...
Page 259: Connector View
5 May 2006 ELECTRICAL COMPONENT LIST 6.1.3 CONNECTOR VIEW Terminator Terminator/ Stacker COM. TR5010 Power Receptacle / Receptacle Line Filter Copier Interlock jumper Interlock jumper/ Power Supply Power Supply Trimmer Book Folder...
Page 260: Outfeed Upper View
ELECTRICAL COMPONENT LIST 5 May 2006 6.1.4 OUTFEED UPPER VIEW Staple Detection Lead Interlock Switch BK-Q19 / BK-Q20 BK-S16 / S17 BK-Q36 Set Counter Outfeed cover removed BK-Q4 BK-Q8...
Page 261: Outfeed Lower View
5 May 2006 ELECTRICAL COMPONENT LIST 6.1.5 OUTFEED LOWER VIEW BK-Q8 Outfeed cover removed BK-M9 / BK-Q7 BK-M8 BK-Q10...
Page 262: Infeed Upper View
ELECTRICAL COMPONENT LIST 5 May 2006 6.1.6 INFEED UPPER VIEW BK-M1/ BK-Q2 BK-Q1...
Page 263: Infeed Lower View
5 May 2006 ELECTRICAL COMPONENT LIST 6.1.7 INFEED LOWER VIEW BM-SOL2 BM-M5 BM-SOL1 BM-Q14 BK-Q15 BK-M4 BK-M7...
Page 264: Infeed Module View
ELECTRICAL COMPONENT LIST 5 May 2006 6.1.8 INFEED MODULE VIEW Bottom view BK-M3 / BK-Q13 BK-Q3 BK-M2 BK-Q12 6-10...
Page 265: Stacker Module View
5 May 2006 ELECTRICAL COMPONENT LIST 6.1.9 STACKER MODULE VIEW ST-M1 6-11...
Page 266 Page intentionally blank...
Page 267: Board Structure
Interlock Interlock Lead The electronics in the BK5010 is distributed and divided in four different PCBs, one CPU board (CPU PCB PL76) and three motor drive boards (two PCB MD6DC and one MD3DC) . Each PCB has their own processor, they are communicating via internal CAN (iCAN).
Page 268: Controller Cpu
BOARD STRUCTURE 19 April 2006 6.2.2 CONTROLLER CPU GPIO / AD CAN2 LPC2292 xCAN Interlock Expansion 1 Start/Exit ARM CPU 16 KB / 256 KB GPIO iCAN CAN1 128KB Expansion 2 Atmega48 Flash download Support UART0 GPIO 2 MB Data Debug UART1 Expansion...
Page 269: Controller Md6Dc
19 April 2006 BOARD STRUCTURE 6.2.3 CONTROLLER MD6DC The MD6DC PCB is present in Booklet maker (x2), Trimmer (x1) and Book Folder (x1). The xCAN portion on MD6DC is not used in the Booklet maker as the external communication is handled by the xCAN portion on the CPU PCB. In the Trimmer and the Book Folder the xCAN portion on MD6DC is used for exter- nal communication.
Page 270 BOARD STRUCTURE 19 April 2006 6.2.3 CONTROLLER MD6DC, CONTINUES BK-M1 BK-M8 BK-M7 BK-M9 ST-M1 BK-M6 BK-M4 BK-M2 BK-SOL1 BK-M3 BK-SOL2 Booklet maker Set counter CF-M16 BK-M5 6-16...
Page 271: Controller Md3Dc
19 April 2006 6.2.4 CONTROLLER MD3DC The MD3DC PCB is present in Booklet maker (x1). 6-17...
Page 272: Controller Md3Dc, Continues
19 April 2006 6.2.4 CONTROLLER MD3DC, CONTINUES BK-M19 CF-M17, CF-M18 CF-M15 6-18...
Page 273: Booklet Making Process
19 April 2006 BOOKLET MAKING PROCESS BOOKLET MAKING PROCESS 6.3.1 PRINCIPLE OF OPERATION Compiling Copier sends a start signal. The pre infeed motor (BK-M19) and infeed motor (BK- M1) start. The set enters the infeed module. Infeed sensor (BK-Q1) activates. Side guides moves half way in (BK-M3).
Page 274 BOOKLET MAKING PROCESS 19 April 2006 M3 & Q12 Jogging and Stapling When start sensor (BK-Q4) is activated and infeed sensor (BK-Q1) deactivated back jogger motor (BK-M2) moves the back jogger up to knock the trail edge of the set. At the same time the side jogger motor (BK-M3) moves the side guides against the paper plus a few millimeters to over jog the set by about 5mm, depend- ing on the set stiffness.
Page 275 19 April 2006 BOOKLET MAKING PROCESS Pre-fold transport When staples are detected (BK-Q19/Q20) the back jogger motor (BK-M2 - see page 6-20) moves the back jogger down to release the trail edge of the set. The side guides (BK-M3) move out slightly. Just enough to release the grip of the set but still to guide the set straight to the fold stop.
Page 276 BOOKLET MAKING PROCESS 19 April 2006 Folding Folder roller motor (BK-M6) that drives the first and second pair of fold rollers starts about the time when the start sensor (BK-Q4) is activated. Also the fold stop gate motor (BK-M8) moves the fold stop away a bit at that time. Slightly after the fold stop sensor (BK-Q7) is activated, the fold stop gate motor (BK-M8) jogs the set upwards into position.
Page 277: Size Adjustment
19 April 2006 BOOKLET MAKING PROCESS 6.3.2 SIZE ADJUSTMENT Initialization cycle Main power is switched on Staple/fold positioning motor (BK-M9) and side jogger motor (BK-M3) starts. Staple/fold positioning motor (BK-M9) moves staple stop and fold stop to the short- est sheets size. Side jogger motor (BK-M3) moves side guides to the widest paper size.
Page 278 BOOKLET MAKING PROCESS 19 April 2006 Changing paper size New paper size is selected on the UI. Staple/fold positioning motor (BK-M9) and side jogger motor (BK-M3) starts. Side jogger motor (BK-M3) runs in the direction towards the new paper size. Side jogger motor sensor (BK-Q12) counts pulses from the previous paper size to the new paper size and stops the motor (BK-M3) when the correct amount of pulses are received.
Page 279: Major Specifications
18 April 2006 SPECIFICATIONS SPECIFICATIONS MAJOR SPECIFICATIONS Specifications Remarks Speed (Online usage) Maintain engine speed (actual depends if Actual speed in number of engine is 90, 110 or 135 ppm version). booklets (per min / hour) depends on number of sheets per booklet.
Page 280: Attachement To Bellini
Jam signal to stop Bellini (Soft stop) Seven types of paper size Jam signal to stop Bellini (Hard stop) information: A3SEF / A4SEF / Start Signal from Bellini to start BK5010 DLTSEF / LTSEF / LGSEF / Paper size information from Bellini B4SEF...
Page 281: Peripherals Specification
18 April 2006 SPECIFICATIONS PERIPHERALS SPECIFICATION COVER FEEDER CF5010 Specifications Remarks Maximum Speed Same as BK5010 Standard Paper Sizes Same as BK5010 Paper Weight (Minimum) 70 gsm/ 18 lb. Bond Paper Weight (Maximum) Same as BK5010 Cover Feeder Capacity 20 mm (approx 200 sheets of 80gr/m2 paper)
Page 282: Book Folder Bf5010
SPECIFICATIONS 18 April 2006 BOOK FOLDER BF5010 Specifications Remarks Speed Same as BK5010 Standard Paper Sizes Same as BK5010 Custom sizes are available Paper Weight (Minimum) Same as BK5010 Paper Weight (Maximum) Same as BK5010 Input / Output Sheets Same as BK5010...
Page 283: Booklet Maker
19 April 2006 WIRING Booklet Maker See pocket at rear of manual for wiring diagrams. Cover Feeder See pocket at rear of manual for wiring diagrams. Trimmer See pocket at rear of manual for wiring diagrams. Book Folder See pocket at rear of manual for wiring diagrams. Wir-1...
Page 284 Page intentionally blank...

Ricoh bk5010 Service Manual

1 Installation Procedure

2 Preventive Maintenance Schedule

3 Replacement and Adjustment

4 Troubleshooting

5 Service Tables

6 Detailed Section Descriptions

Quick Links

Related Manuals for Ricoh bk5010

Summary of Contents for Ricoh bk5010

Table of Contents