Ricoh BOOKLET MAKER BK5010 Operating Instructions Manual
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Also See for BOOKLET MAKER BK5010:
- Service manual (284 pages) ,
- Installation manual (74 pages) ,
- Technical bulletin (3 pages)
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Summary of Contents for Ricoh BOOKLET MAKER BK5010
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Page 1: Booklet Maker Bk5010
BOOKLET MAKER BK5010 Operating Instruction Stapler Folder Reference Read this manual carefully before you use this product and keep it handy for future reference. For safety, please follow the instructions in this manual. 18 December 2007... - Page 2 Part no: 76436 Doc no: x04077 rev , 19 April 2006...
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Page 3: Table Of Contents
TABLE OF COnTEnTS What You Can Do With This Machine .................... 5 Guide To Components ........................7 Booklet Maker ..............................7 Options ............................10 Cover Feeder .............................10 Trimmer ..............................11 Book Folder ..............................13 Control Panel ..........................15 1. Basics ....................17 Docking / Undocking ........................ - Page 4 Book Folder ..............................53 Cleaning feed belts ......................53 8. Specification ................... 55 Machine Specifications ......................... 55 Booklet Maker BK5010 ..........................55 Cover Feeder CF5010 (option) ........................56 Trimmer TR5010 (option) ........................... 56 Book Folder BF5010 (option) ........................57 InDEx....................59...
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Page 5: What You Can Do With This Machine
BK5010 Rail unit(option) BK5010 Booklet Maker The Booklet Maker BK5010, Trimmer TR5010, Book Folder BF5010 and Cover Feeder CF5010 forms a booklet making system that works online with the Copier. The print-outs from the Copier are collected in the finisher and then transported into the BK5010 Booklet Maker to the staple area. - Page 6 The BK5010 Booklet making system is controlled from a single control panel on the Booklet Maker. The control panel has only four buttons which will allow you to easily set up, adjust and operate the complete system. The buttons are multi functional, meaning that the function of each button depends on the information displayed.
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Page 7: Guide To Components
Guide To Components Booklet Maker Top cover Base Control panel Docking assembly Main power switch Belt Stacker Infeed assembly Belt Stacker Cover Exit tray storing shelf... - Page 8 Booklet Maker, continues Connections Fold stop gate COM Copier POW BF5010 Terminator/ Stacker Terminator COM TR5010 Main Power Interlock jumper Interlock jumper/ POW TR5010...
- Page 9 Booklet Maker, continues Stapler heads Stapler release latches Staple cartridges Staple detection leads Cartridge locking levers Hand feeding paper guides...
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Page 10: Options
Options Cover Feeder Loading capacity mark Paper separator pad (also see page 52) Rear side guide Air nozzle (2x) Paper orientation label Front side guide Feed roller assembly Jam clearance baffle... -
Page 11: Trimmer
Trimmer Top cover Trim bin Base Connections Stacker COM BK5010 Power from Terminator/ BK5010 Com BF5010... - Page 12 Trimmer, continues The Trimmer interior has parts that you will come in contact with if a misfeed occurs. Trimmer, top view Set counter Infeed roller shaft Trimmer stop Trimmer fan Outfeed latch Upper knife Exit compressing brackets Infeed latch Transport belt...
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Page 13: Book Folder
Book Folder Top cover Trim bin Base Connections Terminator COM BF5010 Stacker POW BF5010... - Page 14 Book Folder, continues The Book Folder interior has parts that you will come in contact with if a misfeed occur. Book Folder, top view, Upper feed belts in lifted up Lower feed belts Upper feed belts...
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Page 15: Control Panel
Control Panel The Ready screen. When the system power is switched on the Ready screen will be shown. Here you will find information showing the actual set up. From this screen you can also access other screens, that will help you operate the complete BK5010 Booklet making system. - Page 16 The Processing screen. This screen is shown when the machine is busy working. If the machine is used in off-line mode you do not have to wait for the Ready screen before handfeeding the next set. The Please wait screen. While the machine sometimes needs time to perform changes in settings, the Please wait screen will be shown.
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Page 17: Basics
1. Basics Docking / Undocking Docking the Booklet Maker Turn the Copier off. Lift up the Exit arm catcher and set the Exit paper arm in the upper position. Remove the Exit tray from the Finisher and put it on the shelf on the Booklet Maker Move the Booklet Maker up to the copier and dock it. -
Page 18: Undocking The Booklet Maker
Basics Undocking the Booklet Maker Turn the Copier off. note Keep the Booklet Maker powered on. Push in the latch on the docking assembly and move the Booklet Maker away from the Copier. note Be careful not to damage the communication cable Take the Exit tray from the shelf on the Booklet Maker, and install it on the Finisher. -
Page 19: Turning On / Off The Main Power
Turning On / Off the Main Power Turning On / Off the Main Power Booklet Maker, Cover Feeder, Trimmer and Book Folder Plug the Booklet Maker powercord into the wall outlet. Cover Feeder (optional), Trimmer (optional) and Book Folder (optional) are powered from the Booklet Maker. -
Page 20: Check Staples, Staple Cartridge And Stapler Head
Basics Check staples, Staple cartridge and stapler head Removing stapler head Open the top cover. Remove the set of paper. Disconnect the staple indication lead (A) from the socket. Hold the stapler head in place, press the release latch (B) to release the rear end of the stapler head and lift up this end. -
Page 21: Installing Stapler Head / Clearing Staple Jam
Staple Cartrigde and Stapler Head Installing stapler head, staple cartridge / clearing staple jam Look inside stapler head for jammed staples in the area of the staple actuator. Remove staples if any. Position the stapler head on the edge of a firm surface (for example the top of a table). -
Page 22: Emptying The Trim Bin
Basics Emptying the trim bin Remove the trim bin by lifting it and pulling it out. trim bin, no Book Folder installed trim bin, with Book Folder installed... -
Page 23: Making Booklets
2. Making Booklets Changing settings General procedure Changing of settings can be performed in two ways. Temporary, which means that the changes will remain until a new job is loaded or permanent, which means that the changes will be stored as a job. This job can later be recalled. Procedure for temporary changes: From the Ready screen, select the option you wish to change and press the [Change] button. -
Page 24: Custom Paper Size
Making Booklets Custom paper size Select Size and press the [Change] button to display the preprogrammed paper sizes. Scroll down to Custom sizes, by pressing the [arrow] button, and press the [OK] button. Select the custom paper size you want to use and press the [OK] button. -
Page 25: Trimming
Changing settings Selecting stapling On or Off, continues If stapling was On, the first choice will be Off and vice versa. Select On or Off with the [arrow] button and press the [OK] button. Trimming Selecting trimming On or Off From the Ready screen, select Trim and press the [Change] button. -
Page 26: Adjusting The Cutting Margin
Making Booklets Adjusting the cutting margin Select Trim and press the [Change] button. Select Trim length and press the [OK] button. Press the [+] or [-] buttons to fine adjust in increments of 0.5 mm or 0.02 inches. The trimmed booklet size and waste are displayed. -
Page 27: Loading Covers
Changing settings Selecting Cover Feeder Mode, continues The Purge mode is used when you want to completely empty the Cover Feeder from covers. Remove all cover sheets from the bin. Select Purge and press the [Run] button. The prefed cover sheet will now be fed into the Booklet Maker to the stapling area, but without being stapled. -
Page 28: Book Folding
Book Folding General The Book Folder has six different settings. It can be set to [Auto], [Mode 1], [Mode 2], [Mode 3], [Mode 4] or [Off]. In [Auto] mode, the Booklet Maker detects how may sheets there are in the booklet, and automatically set the Book Folder to the correct mode. -
Page 29: On-Line/Off-Line
Making Booklets On-line/Off-line The Booklet maker can be operated in two modes. On-line mode, when used together with the copier, or off-line mode, working as a stand-alone unit. Off-line mode Follow “Undocking the Booklet maker” in section 1. Basics. Adjust the hand feeding paper guides to the correct paper size. Turn on the Booklet maker. -
Page 30: Begin On-Line Production
Begin On-line Production Begin On-line Production Make sure that the [staple icon] is present on the copier control panel. If not, turn off the Copier and Booklet Maker. First turn the Bookklet Maker ON and then turn the Copier Make sure that the Booklet maker system is set according to your job specification. Select [Paper tray] (A). -
Page 31: Tools
3. Tools The Tools Screen The Tools screen. From the Ready screen, press the [Tools] button to get to the Tools screen. Here you will find all the necessary tools for troublefree operation. Units From this screen you can change units, between millimeters and inches. -
Page 32: Language
Tools Software version, continues Select the module in the system for which you want to check the software version and press the [OK] button. This screen will show software version(s) in the selected module. Language From this screen you can change the language in the user interface. -
Page 33: Air Separation
The Tools Screen Air Separation From this screen you can increase or decrease the Air separation. This screen will only be shown if a Cover Feeder is present. Select Air separation with the [arrow] button and press the [OK] button. You might want to increase the Air flow when running thick, heavy covers. -
Page 34: Service Access
Tools Service access This screen is for authorized service personnel only and is password protected. -
Page 35: Jobs
4. Jobs Storing and deleting jobs The Booklet Maker has a maximum storage capacity of 10 different jobs. It is not possible to delete jobs, therefore when you need to store a new job, an old job must be overwritten. To make temporary changes in the actual job settings or temporary changes of a stored job, see section 2. -
Page 36: Recalling A Job
Jobs Storing a new Job, continues To store the job, press the [Save] button. If you want to run the actual job, press the [Load] button. The booklet maker will then automatically setup that specific job and return to the Ready screen. Recalling a Job To recall a stored job press the [Jobs] button from the Ready screen to enter the Jobs screen. -
Page 37: Clearing Misfeed(S)
5. Clearing Misfeed(s) Clearing misfeed(s) General If a misfeed condition should occur, it is indicated on the Booklet Maker display. The message “Clear Misfeed(s)”, an error code and the location of the misfeed is displayed. See examples below. Misfeeds in the Booklet Maker are indicated as area A, B or C and by the error code BK- XXX. -
Page 38: Booklet Maker
Booklet Maker Clearing misfeed(s) Inside the Booklet Maker To clear a misfeed indicated in Area A or B Open the top cover. Remove misfed sheets. Close the top cover. To clear a misfeed indicated in Area C Open the top cover. Close top cover. -
Page 39: Trimmer
Clearing Jams Trimmer Clearing misfeed(s) The upper trimmer blade on the trimmer is protected by a knife protection plate that moves away during the cutting stroke. Jams can occur in the input area or the exit area. WARNING: Never put fingers or other parts of the body between the upper and lower trimmer knives. Clearing misfeed in input area Remove the Trimmer fan (see page 12, item 7). -
Page 40: Clearing Misfeed In Exit Area
Trimmer Clearing misfeed(s), continues Clearing misfeed in exit area Lift the exit compressing brackets (A). Secure them under the latch (B). Remove the misfed sheets from the exit area. After the misfed sheets are removed, lift up the latch (B) and place the compressing brackets in operating position. -
Page 41: Cover Feeder
Clearing Jams Cover Feeder Clearing misfeed(s) in vertical transport area Open the Top Cover. Lift the jam clearance baffle (A). Remove the misfed cover. Put the jam clearance baffle back in normal position. -
Page 42: Book Folder
Book Folder Clearing misfeed(s) Inside the Book Folder Open the top cover. Lift up both upper feed belts (A). note Press the green dots (B) on the latches to release. Remove the misfeeds. Place the upper feed belts in normal position. Close the top cover. -
Page 43: Troubleshooting
6. Troubleshooting Fault codes General When there is a misfeed or fault condition in the booklet maker system, a message will be displayed on the Booklet Maker. In case there is a problem that can be rectified by the operator, a fault code and an explanation will be displayed. Fault codes that can be rectified by the operator: Booklet Maker: BK-201 to BK-212 and BK-401... -
Page 44: General Fault Codes
General fault codes Clear Misfeed(s) In general, fault codes indicate a misfeed condition. When a misfeed occurs, the message “Clear Misfeed(s)”, a code and the jam area will be displayed. See section 5. Clearing Misfeeds, for how to clear a misfeed. Close cover(s) When the message “Close Cover(s)”... -
Page 45: Booklet Maker Fault Codes
Booklet maker fault codes Check staples This message will be displayed when a staple cartridge is empty or when stapling could not be performed. Check in the following order: – If a staple cartridge is empty, replace according to section 1. Basics. –... -
Page 46: Load Covers
Cover feeder fault codes, continues Load covers Code CF-501 is displayed when covers run low. If you wish to continue production: Load more cover sheets according to section 2. Making Booklets. Code CF-501 will extinguish and copier will start. If you wish to continue production, using up the cover sheets that are loaded: Press ESC. -
Page 47: Book Folder Fault Codes
Book Folder fault codes Feed errors If feed errors occur, the feed belts needs to be cleaned or the pressure on the upper feed belts needs to be increased. To clean the feed belts, see section 7, REMARKS Maintaining Your Machine. To increase the pressure on the upper feed belts follow this procedure. Open the top cover. -
Page 49: Remarks
7. REMARKS Do’s And Don’ts • Always follow all warnings marked on, or supplied with, the equipment. • Always exercise care in moving or relocating the equipment. Caution: • Unplug the powercord from the wall outlet and machine before you move or relocate the equipment. -
Page 50: Where To Put Your Machine
REMARKS Where to put Your Machine Machine environment • Always locate the equipment on a solid support surface with adequate strength for the weight of the machine. • Always keep magnets and all devices with strong magnetic fields away from the machine. -
Page 51: Access To Machine
Where to put Your Machine Access to machine Place the machine near the power source, providing clearance as shown. 1. Left: more than 400 mm / 15 3/4”. 2. Front: more than 555 mm / 21 7/8” 3. Right: more than 400 mm / 15 3/4” (off-line use). -
Page 52: Maintaining Your Machines
REMARKS Maintaining Your Machines never attempt any maintenance function that is not specifically described in this documentation. Cover Feeder Cleaning feed rollers and paper separator pad The Feed rollers need to be cleaned regularly when in use, and if the unit has not been used for a period of time. -
Page 53: Book Folder
Book Folder Cleaning feed belts The Feed belts need to be cleaned regularly when in use, and if the unit has not been used for a period of time. How often this should be done, depends on the paper type and print quality. -
Page 55: Specification
8. Specification Machine Specifications Booklet Maker BK5010 Major Specifications Specifications Remarks Speed (Online usage) Maintain engine speed (actual depends if Actual speed in number of book- engine is 90, 110 or 135 ppm version). lets (per min / hour) depends on number of sheets per booklet. -
Page 56: Cover Feeder Cf5010 (Option)
Specification Cover Feeder CF5010 (option) Specifications Remarks Maximum Speed Same as BK5010 A3/11x17” or bigger paper sizes, need two sheet sets as inlet at least Standard Paper Sizes Same as BK5010 Paper Weight (Minimum) 70 gsm / 18 lb. Bond Paper Weight (Maximum) Same as BK5010 Cover Feeder Capacity... -
Page 57: Book Folder Bf5010 (Option)
Book Folder BF5010 (option) 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 Input / Output Sheets Same as BK5010 Off-line Use Possible... -
Page 58: Index
InDEx Maintaining Your Machines 52 Making Booklets 23 Misfeed(s) clearing 37 Access to machine 51 Air Separation, adjusting 33 Options 10 Docking the Booklet Maker 17 Undocking the Booklet Maker 18 The Please wait screen 16 Basics 17 The Processing screen 16 Begin On-line Production 30 Turning On / Off the Main Power 19 Book Folder 13... - Page 61 X17099 (2) 3 April 2006 Part No: 76434...
- Page 62 2(2) 3 April 2006...