Oce BLM 500 Operating Information Manual
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Oce BLM 500 Operating Information Manual

Oce BLM 500 Operating Information Manual

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Summary of Contents for Oce BLM 500

  • Page 1 User manual BLM 500 / Bookletmaker 50 Operating information...
  • Page 2 Copyright Copyright  2008 Océ All rights reserved. No part of this work may be reproduced, copied, adapted, or transmitted in any form or by any means without written permission from Océ. Océ makes no representation or warranties with respect to the contents hereof and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose.

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Chapter 1 Introduction to the Booklet maker ........5 Introduction .
  • Page 4 Table of Contents Chapter 5 Error Conditions, Problems, and Solutions ......49 Clear a Printer Error ......... 50 Clear a Booklet maker error .

  • Page 5: Introduction To The Booklet Maker

    Chapter 1 Introduction to the Booklet maker...

  • Page 6: Introduction

    Introduction Introduction Introduction Thank you for choosing the Booklet maker. Your Manual The User Manual for the Booklet maker describes how to perform these tasks: Operate the Booklet maker Find and correct error conditions Perform normal maintenance tasks Operator training is given when the Booklet maker is installed. To make sure you use your Booklet maker correctly, read your manual.
  • Page 7 Introduction How to Get Help If you have any questions or problems, refer to the problem-solving section in this manual (see the chapter “Error Conditions, Problems, and Solutions”). Contact your Booklet maker supplier for further help.

  • Page 8: Description Of The Booklet Maker

    Description of the Booklet maker Description of the Booklet maker Introduction The Booklet maker operates online with digital printers to process sets of printed pages into stitched books. The main parts are shown below. Illustration [1] Operator Side of the Booklet maker Component - function table [1] Operator Side of the Booklet maker Component...

  • Page 9: Right-Hand Side Of The Booklet Maker

    Right-Hand Side of the Booklet maker Right-Hand Side of the Booklet maker Illustration [2] Right-hand side of the Booklet maker Component - function table [2] Right-hand side of the Booklet maker Component Function The stitch-wire The stitch-wire cabinet holds the spool of cabinet stitch-wire.

  • Page 10: The Rear Panel Of The Booklet Maker

    The Rear Panel of the Booklet maker The Rear Panel of the Booklet maker Illustration [3] The Rear Panel of the Booklet maker Component - function table [3] The Rear Panel of the Booklet maker Component Function Rating and serial The rating label displays the type of machine, serial label number, power use, and fuse information.

  • Page 11: How To Run The Booklet Maker

    Chapter 2 How to run the Booklet maker This chapter gives information on how to run a job on the Booklet maker. For information on how to operate the printer, refer to the printer documentation. Information about the user interface is included in the chapter “The User Interface.” Information about standard procedures, for example opening covers to clear a paper jam, is included in the chapter “Standard Tasks.”...

  • Page 12: Before You Begin

    Before You Begin Before You Begin Paper and Book Quality Instructions The size of paper and the thickness of the set must be measured. These measurements are entered via the touch screen before you begin a print job. Measure the size of the printed paper. The paper dimension changes when the paper is printed.

  • Page 13: Turn On The Booklet Maker

    Turn ON the Booklet maker Turn ON the Booklet maker Procedure Connect the Booklet maker to the power supply. Use the ON/OFF switch to turn ON the Booklet maker. Result The machine makes this sequence of beeps: 'beep__beep beep beep beep_____ beep beep'. The touch screen illuminates and the machine is ready for use.

  • Page 14: Enter The Job Settings

    Enter the Job Settings Enter the Job Settings Introduction Enter the settings for a new job in the BASIC window on the touch screen. See the chapter “The User Interface” for more information. The PAPER SIZE and PAGE DIRECTION settings are entered on the touch screen. These dimensions refer to the format of the paper when it enters the Booklet maker.
  • Page 15 Enter the Job Settings Procedure for a New Job Step Action Information Touch BASIC Enter the paper Touch PAPER SIZE. Enter the dimensions of the size paper. The job setting is easier if you first select a preset paper size, then adjust the settings as necessary Touch PAPER SIZE >...
  • Page 16 Enter the Job Settings Touch the job name or use the Up arrow or the Down arrow to select the job. Touch LOAD. Wait until the Booklet maker is ready Chapter 2 How to run the Booklet maker...

  • Page 17: Stacker Adjustment

    Stacker adjustment Stacker adjustment Adjust the Stacker Adjust the stacker according to the size and thickness of the finished bookAdjust the Stacker on page...

  • Page 18: Run The Job

    Run the Job Run the Job Make sure the adjustments on the Booklet maker are complete before you release the print job from the print queue. Start the print job. The Booklet maker starts automatically. Check the quality of the first book. If the quality is not acceptable, make adjustments (see ‘Book Quality’...

  • Page 19: Chapter 3 The User Interface

    Chapter 3 The User Interface...

  • Page 20: The Touch Screen

    The Touch Screen The Touch Screen Introduction [4] The User Interface START Button STOP Button Touch Screen The user interface includes a color touch screen and START/STOP buttons. Operate the touch screen with your fingertip. You can touch the screen with a blunt item, for example a palm-top 'wand' or the blunt end of a pen.
  • Page 21 The Touch Screen Illustration [5] The Touch Screen Component - function table Component Function Window Tabs The touch screen buttons are divided into groups that have related functions. Each group of buttons has a separate window. Touch the correct tab to select the window. LOAD &...
  • Page 22 The Touch Screen Component Function Status The STATUS line shows the machine status. - GREEN The Booklet maker is READY or RUNNING. - ORANGE PLEASE WAIT - wait until the Booklet maker is ready. ATTENTION - the Booklet maker needs intervention by the operator. - RED The Booklet maker is in an ERROR condition.

  • Page 23: The Job Mimic

    The Job Mimic The Job Mimic Introduction The job mimic shows the current machine status. Illustration [6] The Job Mimic Component - function table Icon Information The following items are shown the size of paper the format of the paper in the gathering area the broken line shows the fold line...
  • Page 24 The Job Mimic Icon Information [10] The number of forms is shown. If the pressure is adjusted, the setting is shown in brackets. A red X shows that the form function is not active. [11] The trim setting is displayed. A red X shows that the trim function is not active.

  • Page 25: The Basic Window

    The BASIC Window The BASIC Window Introduction The BASIC window gives you access to frequently-changed machine settings. Button overview [9] The BASIC Window Buttons (1 – 2) Button Information PAPER SIZE Measure the accurate size of the paper before you make a book.
  • Page 26 The BASIC Window [9] The BASIC Window Buttons (2 – 2) Button Information FORM To make the square spine of the book, pressure is applied to the spine. This process is called forming. Touch FORM to specify the amount of spine form. To make a good spine on different paper types, the amount of spine form can be changed.

  • Page 27: The Load & Save Window

    The LOAD & SAVE Window The LOAD & SAVE Window Introduction The LOAD & SAVE window lets you save and reload job settings. Each job is given a name. The jobs are displayed in a list on the screen. Touch the job name or use the Up arrow or Down arrow to make the selection.
  • Page 28 The LOAD & SAVE Window [10] The LOAD & SAVE Window Buttons (2 – 2) Button Information PADLOCK The padlock symbol shows when a saved job is locked or SYMBOL unlocked. There is a small padlock symbol next to each locked job.

  • Page 29: The Advanced Window

    The ADVANCED Window The ADVANCED Window Introduction The ADVANCED window gives you access to special machine functions. [11] [11] Button overview Button Information RE-REF If the machine calibration appears incorrect or if an 'axis moving' error message remains on the screen, touch RE-REF to re-reference the adjustment axes.

  • Page 30: The Configure Window

    The CONFIGURE Window The CONFIGURE Window Introduction The CONFIGURE window lets you make changes to the configuration of the machine. Some functions and buttons are only available at certain access levels, see 'ACCESS LEVEL' table 13 on page CONFIGURE Window Buttons [12] [12] Button overview Button...

  • Page 31: The Menu Window

    The MENU Window The MENU Window Introduction MENU shows the settings that are not changed during day-to-day operation. These settings include Change the Access Level Change the display language Advanced machine settings that are accessed by a person who has the correct access-code.
  • Page 32 The MENU Window [13] The MENU Window Buttons (2 – 2) Button Information COUNTERS The counters display the number of books that have been made number of sheets that have been processed number of stitches that have been used -RESET Touch RESET to reset the book, sheet counter, and stitch counter.

  • Page 33: Chapter 4 Standard Tasks

    Chapter 4 Standard Tasks This chapter describes the standard tasks that are needed in the day-to-day operation of your Booklet maker.

  • Page 34: Load And Save The Job Settings

    Load and Save the Job Settings Load and Save the Job Settings Introduction The current job settings can be saved to memory and reloaded for use again at a later date. Load the 'Default Job Template' to reset the Booklet maker to normal settings. Save a job Touch LOAD &...

  • Page 35: Adjust The Stitch Pitch

    Adjust the Stitch Pitch Adjust the Stitch Pitch Introduction The stitch pitch is the space between the stitches. The machine automatically calculates the stitch pitch according to the size of the paper and the number of stitches. The stitches are inserted symmetrically on the spine of the book. If a non-standard stitch pitch is needed, use STITCH PITCH to make the adjustment.

  • Page 36: Open The Connecting Bridge Cover

    Open the Connecting Bridge Cover Open the Connecting Bridge Cover Introduction The Booklet maker will not stop if you open the connecting bridge cover. [13] [13] Connecting Bridge Cover in the open position. [14] Connecting Bridge Cover When to do If a machine error occurs, or for maintenance.

  • Page 37: Open And Close The Folder Cover

    Open and Close the Folder Cover Open and Close the Folder Cover Introduction If a machine error occurs, or for maintenance. To access the stitch area To access the folder area Note: The folder cover has an interlock switch. The Booklet maker stops if you open the folder cover.

  • Page 38: Lift And Lower The Clincher Frame

    Lift and Lower the Clincher Frame Lift and Lower the Clincher Frame Introduction [15] [15] Folder Cover in the vertical position. [15] Folder Cover Clincher Frame [16] [16] Clincher Frame Components [16] Clincher Locking Handle Clincher Frame When to do If a machine error occurs, or for maintenance.
  • Page 39 Lift and Lower the Clincher Frame Lift the Clincher Frame Open the folder cover. Turn the locking handle to the left , until the thread is disengaged. Lift the clincher frame to the vertical position. Lower the Clincher Frame Attention: You must hold the weight of the clincher frame. Do not let the clincher frame fall on your hand.

  • Page 40: Open The Gathering Area Cover

    Open the Gathering Area Cover Open the Gathering Area Cover Introduction [17] [17] Gathering Area Cover. [17] Connecting Bridge Cover open Gathering Area Cover Gathering Area Cover Handle When to do If a machine error occurs, or for maintenance. To access the gathering area To access the static elimination bar in the gathering area The Booklet maker will stop if you open the gathering area cover.

  • Page 41: Lift The Booklet Maker Main Deck

    Lift the Booklet maker Main Deck Lift the Booklet maker Main Deck Introduction [18] [18] Lift the Booklet maker Main Deck [18] Folder Cover open Connecting Bridge Cover open Clincher Frame lifted Gathering Area Cover Main Deck When to do If a machine error occurs, or for maintenance.
  • Page 42 Lift the Booklet maker Main Deck [19] Step Action Information Open the connecting bridge (see ‘Open the Connecting Bridge cover. Cover’ on page Open the folder cover. (see ‘Open the Connecting Bridge Cover’ on page Lift the clincher frame. (see ‘Lift the Clincher Frame’ on page Open the gathering area cover.

  • Page 43: Empty The Trim Bin

    Empty the Trim Bin Empty the Trim Bin Introduction [19] [19] Trim Bin Open. [20] Trim Bin Side Handle Trim Bin open Note: The Booklet maker operates with the trim bin removed for a short period of time. The printer waits while the trim bin is removed, then continues when the trim bin is replaced.

  • Page 44: Open The Stitch Wire Cabinet

    Open the Stitch Wire Cabinet Open the Stitch Wire Cabinet Introduction [20] [20] Stitch Wire Cabinet. [21] Stitch wire cabinet open When to do To see if the stitch wire is jammed or finished. An error message is displayed on the touch screen when the stitch wire is jammed or finished.

  • Page 45: Adjust The Stacker

    Adjust the Stacker Adjust the Stacker Introduction The collection table must be in the correct position for the stacker to operate. The position of the collection table depends on the finished size of the job. When you start a new job If the books do not stack correctly [21] [21] The Stacker...
  • Page 46 Adjust the Stacker [23] Book size in window Collection table Orange plastic hand screw Catch tray Procedure [24] Step Action Information Set the catch tray angle according For books that are 1.5 mm thick or to the thickness of the book. less, use position 1.

  • Page 47: Operate The Booklet Maker Offline

    Operate the Booklet maker offline Operate the Booklet maker offline Introduction You can hand feed sets into the Booklet maker if offline operation is needed. The machine operates when you push the two buttons. When to do To check the settings are correct To make a small number of books offline Attention: Do not put your hands in the gathering area when the machine operates.
  • Page 48 Operate the Booklet maker offline Chapter 4 Standard Tasks...

  • Page 49: Error Conditions, Problems, And Solutions

    Chapter 5 Error Conditions, Problems, and Solutions This chapter describes how to correct problems that can occur with your Booklet maker. If a problem persists, contact your service engineer.

  • Page 50: Clear A Printer Error

    Clear a Printer Error Clear a Printer Error Introduction If a paper jam or other error occurs in the printer, the printer and the Booklet maker stop. Procedure Clear the printer error. Follow the instructions on the printer. If the printer tells you to remove paper from the Booklet maker, touch START to start the machine.

  • Page 51: Clear A Booklet Maker Error

    Clear a Booklet maker error Clear a Booklet maker error Introduction If a paper jam or other error occurs in the Booklet maker, the printer and the Booklet maker stop. The type of error is displayed on the touch screen (see ‘Error Messages’...

  • Page 52: General Problems

    General Problems General Problems [25] Problem Cause Solution The Booklet maker does The Booklet maker is not Turn ON the Booklet not start turned on. maker (see ‘Turn ON the Booklet maker’ on page 13). The printer has not sent a Correct the problem at the job to the Booklet maker.
  • Page 53 General Problems Problem Cause Solution The operation of the The touch screen is in Touch the touch screen to touch screen is incorrect power-save mode restore normal function The Touch Screen on page The touch screen Calibrate the touch screen calibration is incorrect (see ‘Calibrate the Touch Screen’...

  • Page 54: Error Messages

    Error Messages Error Messages [26] Problem Cause Solution AXES MOVING Some of the machine axes are moving. This message clears when the adjustment is complete. If the message does not clear, touch ADVANCED > RE REF BOOK CYCLE TIME The printer has delivered TOO LONG the sets faster than the books can be made.
  • Page 55 Error Messages Problem Cause Solution BRIDGE MOTOR Check for a paper jam in (see ‘Clear Paper Jams’ STALL the connecting bridge. on page Touch STOP to stop the Booklet maker. Clear the paper jam. Touch STOP to clear the message from the screen.
  • Page 56 Error Messages Problem Cause Solution FLOW ERROR - There is an error at the Jam in the Folder or FORMER former. Open the folder Former Area on page 72 cover and remove the book(s). If necessary, open the main deck to remove the book(s).
  • Page 57 Error Messages Problem Cause Solution FORM CLAMP The form clamp is in the CLOSED wrong position. Touch START to reset the position. Follow the instructions on the screen. FORM ROLLER ERROR The form roller is (see ‘Jam in the Trim jammed.
  • Page 58 Error Messages Problem Cause Solution JAM IN GATHERING There is a paper jam in the (see ‘Jam in the AREA gathering area. Open the Gathering Area’ on connecting bridge cover, page lift the connecting bridge and remove the paper jam. JAM IN STACKER There is a paper jam at the AREA...
  • Page 59 Error Messages Problem Cause Solution REMOVE SET FROM Open the folder cover and FOLD AREA remove the set. REMOVE SET - Open the gathering area GATHERING AREA and remove the sheets. Or touch START, then touch ADVANCED > PURGE SET > PURGE SET to clear the set from the machine.
  • Page 60 Error Messages Problem Cause Solution SHUTTLE MOTOR Use the ON/OFF switch. ERROR Turn the machine OFF, then turn the machine ON. If the problem continues, call your service engineer. SHUTTLE NOT The shuttle is in the PARKED wrong position. Touch START to reset the position.
  • Page 61 Error Messages Problem Cause Solution STITCH TIMEOUT There is an error at the Stitch Timeout Error on stitcher. page 75 If the problem continues, call your service engineer. TOO MANY PAGES The printer has delivered (see ‘Open the Gathering more than 55 sheets into Area Cover’...
  • Page 62 Error Messages Problem Cause Solution TRIM BLADE NOT The trim blade is in the PARKED wrong position. Touch START to reset the position. Follow the instructions on the screen. USER STOP The user has touched the STOP button while the machine is in operation.

  • Page 63: Book Quality

    Book Quality Book Quality Paper Size and Book Quality Instructions Careful measurement of the paper size and set thickness is important. To make an accurate book you must enter accurate paper dimensions into the touch screen. Measure the size of the printed paper. The paper dimension changes when the paper is printed.
  • Page 64 Book Quality [27] Book Quality Cause Solution Problem The finished book The wrong paper size was Measure the paper and enter is not neat and tidy entered on the touch screen. the correct dimensions (see ‘Enter the Job Settings’ on The sheets are not page 14).
  • Page 65 Book Quality Book Quality Cause Solution Problem The stitch is not on The wrong paper size was Measure the paper and enter the center-line of entered on the touch screen. the correct dimensions. the spine The Booklet maker Touch RE-REF in the adjustment system is not ADVANCED window to calibrated correctly.
  • Page 66 Book Quality Book Quality Cause Solution Problem The book cover is The trimmings-removal Clean the Trimmings Removal dirty or marked fingers are dirty. Fingers on page 98 [25] Curved marks on the book There are grease marks Clean excess grease from the around the stitches.
  • Page 67 Book Quality Spine Form Condition [28] Incorrect - The spine needs more form. Check these settings: The SET THICKNESS Measure the set thickness setting is incorrect and enter the correct dimension. Enter the Job Settings on page 14 The folder cover is not Close the folder securely closed? cover.Close the Folder...

  • Page 68: Clear Paper Jams

    Clear Paper Jams Clear Paper Jams Introduction [30] [30] Paper Jam Locations [29] Connecting Bridge Gathering Area Stitch Area Fold and Forming Areas Trim Area [31] [31] Paper Jam Location - Bridge Infeed Chapter 5 Error Conditions, Problems, and Solutions...
  • Page 69 Clear Paper Jams [30] Bridge Infeed Cover [32] [32] Trimmer Infeed Conveyor viewed from above. Jam before the Trimmer on page 72 [31] Trimmer Infeed Conveyor Former-clamp mechanism [33] [33] Trim Stop Assembly Jam in the Trim Area on page 74...
  • Page 70 Clear Paper Jams [32] Orange Plastic Hand Screw Locking Plate Trim Stop Guard [34] [34] Gathering Area Belt Positions Jam in the Bridge Infeed Open the bridge infeed cover. Remove the jammed paper. Close the bridge infeed cover. Touch STOP to clear the message from the screen.
  • Page 71 Clear Paper Jams If there is paper in the gathering area, touch START , then touch ADVANCED > PURGE SET > PURGE SET to clear the set from the machine. Continue the print job. Jam in the Gathering Area Open the connecting bridge cover. Lift the gathering area cover.
  • Page 72 Frame’ on page Close the folder cover. If there is paper in the This action clears paper from the gathering area, touch START, BLM 500 / Bookletmaker 50. then touch ADVANCED > PURGE SET > PURGE SET. Continue the print job.
  • Page 73 Clear Paper Jams [34] Step Action Information Open the Booklet maker main deck Remove the trim bin. Loosen the trimmer infeed The procedure can be seen from conveyor. the top of the machine. Access to the parts is through the former-clamp mechanism.
  • Page 74 Clear Paper Jams Jam in the Trim Area [35] Step Action Information Remove the trim bin. Loosen the 2 orange plastic The locking plates can rotate to hand screws to release the release the trim stop guard. locking plates. Pull the trim stop guard towards you.

  • Page 75: Stitch Timeout Error

    Stitch Timeout Error Stitch Timeout Error Introduction [36] Step Action Information Open the folder cover. Open and Close the Folder Cover on page 37 Lift the clincher frame. Lift and Lower the Clincher Frame on page 38 Remove the paper. Lower the clincher frame.

  • Page 76: Stitch Head Problems

    Stitch Head Problems Stitch Head Problems [37] Problem Cause Solution The stitch head does not The STITCH function is Make sure STITCH is set operate not selected. to 1 or more (see ‘The BASIC Window’ on page 25). The stitch wire is Load a new spool of finished.

  • Page 77: Clear A Stitch Wire Jam

    Clear a Stitch Wire Jam Clear a Stitch Wire Jam Introduction Before you begin: Lift the Booklet maker main deck. See Lift the Booklet maker Main Deck on page 41 [37] [37] Stitch Head.
  • Page 78 Clear a Stitch Wire Jam [38] Top location of Middle Wire Tube Middle Wire Tube Metal Spring Clip Feed Gears Before You Begin [39] Step Action Information Turn off the Booklet maker Use the ON/OFF switch. Disconnect the Booklet maker from the power supply.
  • Page 79 Clear a Stitch Wire Jam Step Action Information Remove the middle wire figure 37 on page 77 tube. Pull the wire from the stitch head. Install the stitch wire into the (see ‘Install the Stitch Wire into the stitch head. Stitch Head’...

  • Page 80: Clear A Stitch Head Jam

    Clear a Stitch Head Jam Clear a Stitch Head Jam Introduction The error message JAM IN STITCH HEAD is displayed. This may be caused by the SET THICKNESS setting is incorrect the stitch head is jammed by broken wire the stitch head needs lubrication Do Procedure 1.
  • Page 81 38 Close the folder cover. If there is paper in the This action clears paper from the gathering area, touch START, BLM 500 / Bookletmaker 50and then touchADVANCED > resets the stitch head. PURGE SET > MAKE BOOK.
  • Page 82 Clear a Stitch Head Jam Wire holder Wire holder retaining spring [43] [43] [43] Inspect for stitch wire Inspect this area for pieces of stitch wire Tools and Materials: Klüber Isoflex NBU 15 Grease, 50g. Air duster. Supplied with the machine Wire cutters.
  • Page 83 Clear a Stitch Head Jam [44] Step Action Information Lift the Booklet maker main Lift the Booklet maker Main Deck deck. on page 41 Remove the wire-holder Move the wire-holder retaining from the stitch head. spring to the right. figure 42 on page 81 Remove the wire-holder If the wire-holder is held in position,...

  • Page 84: Calibrate The Touch Screen

    Calibrate the Touch Screen Calibrate the Touch Screen When to do Calibrate the touch screen if the buttons do not operate or the buttons do not operate correctly. Attention: Use a pencil, the blunt end of a pen or a palm top wand for this procedure.

  • Page 85: Change The Fuses

    Change the Fuses Change the Fuses Introduction The Booklet maker has two fuses at the power input. If either fuse is blown, the Booklet maker will not operate. Required tool Fuse description: 7A, HRC Quick Acting, F Attention: Turn OFF the machine and remove the power supply cable before you change the fuses.

  • Page 86: Manually Park The Shuttle

    Manually park the Shuttle Manually park the Shuttle When to do The error messages ‘MANUALLY PARK SHUTTLE’ and ‘SHUTTLE NOT PARKED’ are displayed. Illustration [45] [45] Shuttle Assembly Position - CORRECT [46] [46] Shuttle Assembly Position - NOT CORRECT [47] [47] Detail A: Pick-up fingers Chapter 5 Error Conditions, Problems, and Solutions...
  • Page 87 Manually park the Shuttle [45] Step Open the folder cover. Open and Close the Folder Cover on page 37 Push the shuttle-assembly to figure 45 on page 86 shows the the right. correct position for the shuttle assembly. If the shuttle assembly does not move to the correct position, push the pick-up fingers away from each other by 2-3mm and try again.
  • Page 88 Manually park the Shuttle Chapter 5 Error Conditions, Problems, and Solutions...

  • Page 89: Maintenance

    Chapter 6 Maintenance...

  • Page 90: About Maintenance

    About Maintenance About Maintenance Service Interval The Booklet maker needs service every four months. After every one million stitches, the stitch head needs service. This interval is every third spool of stitch-wire. Only a service engineer can service the Booklet maker. Contact your supplier for further information.

  • Page 91: Booklet Maker Cleaning

    Booklet maker cleaning Booklet maker cleaning Introduction Clean the Booklet maker every week to remove surface dust. Attention: Only clean the machine with materials that are recommended in this manual. Do not use other chemicals or abrasive material. Outside of the Booklet maker Use a moist cloth to clean the outside of the Booklet maker.

  • Page 92: Clean The Static Elimination Bars

    Clean the Static Elimination Bars Clean the Static Elimination Bars Introduction Clean the static elimination bars every week. This action extends the performance and service life of the static elimination bars. The Booklet maker is supplied with a small brush. Use the brush to clean the static elimination bars.
  • Page 93 Clean the Static Elimination Bars [48] Step Action Information Clean the static elimination bar Open the connecting bridge in the connecting bridge. cover. Clean the pins on the bottom of the static elimination bar with a small brush Clean the static elimination Open the gathering area cover.

  • Page 94: Clean The Former Roller

    Clean the Former Roller Clean the Former Roller Introduction Clean the former roller if the spines of the books are dirty. Ink and toner can collect on the former roller. [50] [50] Dirty marks on the spine Required tool Clean, plain paper that is not printed. A3 size (USA: 11 x 17”) is recommended. 4mm thickness is needed for each cycle.
  • Page 95 Clean the Former Roller Procedure [49] Step Action Information Enter the correct settings on Set the touch screen to the the touch screen. correct PAPER SIZE Set the SET THICKNESS to Set the number of STITCHES to 0. Set the number of FORMS to Touch START Open the connecting bridge cover.

  • Page 96: Clean The Polyurethane Strips In The Form Clamp

    Clean the Polyurethane Strips in the Form Clamp Clean the Polyurethane Strips in the Form Clamp Introduction Follow this procedure if there are dirty marks near the spine on the front and back cover of the book. Ink and toner can collect on these parts, especially when you make thin books.
  • Page 97 Clean the Polyurethane Strips in the Form Clamp [50] Step Action Information Open the folder cover Use an alcohol wipe, or apply a small amount of alcohol to a lint free cloth. Reach into the form clamp and There is a polyurethane strip on the clean each of the polyurethane face of each side of the clamp.

  • Page 98: Clean The Trimmings Removal Fingers

    Clean the Trimmings Removal Fingers Clean the Trimmings Removal Fingers Introduction Follow this procedure if there are small, dirty marks on the book. Ink and toner can collect on the trimmings removal fingers and cause marks on the book. [53] [53] Curved marks on the book Required tool Alcohol wipe...
  • Page 99 Clean the Trimmings Removal Fingers Illustration [54] [51] Trimmer infeed conveyor Former clamp mechanism Illustration [55] [52] Trimmer infeed conveyor Trimmings removal fingers Former clamp mechanism Illustration [56]...
  • Page 100 Clean the Trimmings Removal Fingers [53] Trimmings removal fingers Drive end of the conveyor shaft Procedure [54] Step Action Information Turn off the Booklet maker Lift the Booklet maker main The procedure can be seen from the deck. top of the machine. Access to the parts is through the former-clamp mechanism.

  • Page 101: Clean Excess Grease From The Stitch Head

    Clean excess grease from the Stitch Head Clean excess grease from the Stitch Head Introduction Follow this procedure if there are grease marks around the stitches on the book. [58] Required tool Lint free cloth Procedure [55] Step Action Information On the user interface, touch The folder cover must be closed.

  • Page 102: Lubricate The Stitch Head

    Lubricate the Stitch Head Lubricate the Stitch Head Introduction [60] [60] Trim the nozzle of the tube of grease [61] [61] Stitch Head Wire Holder Chapter 6 Maintenance...
  • Page 103 Lubricate the Stitch Head [56] Stitch Head Wire Holder Wire Holder Retaining Spring [62] [62] Driver Bar [57] Driver, in upper position Driver Bar Required tools Klüber Isoflex NBU15 Grease, 50g Air duster - is supplied with the machine Attention: - Only use the grease shown in this manual. Correct lubrication extends the performance and service life of the stitch head.
  • Page 104 Lubricate the Stitch Head Before You Begin [58] Step Action Information Trim the first part from the figure 60 on page 102 nozzle. Remove the cap from the tube of grease. Fit the nozzle to the tube of grease. On the user interface, touch The folder cover must be ADVANCED >...
  • Page 105 Lubricate the Stitch Head Step Action Information Apply 30 mm of grease to the figure 62 on page 103 visible surface of the driver [63] 1.2" [64] Re-fit the wire-holder. Lower the Booklet maker main deck. Lower the clincher frame. (see ‘Lower the Clincher Frame’...

  • Page 106: Lubricate The Wire-Feed Cam

    Lubricate the Wire-feed Cam Lubricate the Wire-feed Cam Introduction [65] [65] Lubricate the wire-feed cam [60] Nozzle for the tube of grease Wire-feed cam Feed lever Lubricate the wire-feed cam [61] Step Action Information Lift the PSQ main deck. Apply 10 mm of grease from figure 65 the tube between the bearing [66]...

  • Page 107: Install New Stitch Wire

    Install New Stitch Wire Install New Stitch Wire Introduction Only use stitch-wire that is approved by your supplier. Stitch-wire that is not approved by your supplier can cause poor performance and voids the warranty. Stitch-wire Description: Stitcher wire S33. Before you begin Lift the Booklet maker main deck.
  • Page 108 Install New Stitch Wire [62] Stitch Wire Guide Block Stitch wire Felt wire-cleaning pads Remove the Stitch Wire from the Stitch Head [63] Step Action Information [68] Cut the stitch wire to the right of the stitch wire guide block. Detail A: Cut here Pull the stitch wire from the stitch wire guide block.
  • Page 109 Install New Stitch Wire Step Action Information Use wire cutters to remove the Remove enough stitch wire to leave damaged end of the stitch the end of the stitch wire clean and wire. straight. [70] Feed the stitch wire through the stitch wire guide.
  • Page 110 Install New Stitch Wire Install the Stitch Wire into the Stitch Head [65] Step Action Information Pull the stitch wire from the end of the stitch wire guide. [71] Make sure the stitch wire runs behind the gas-strut. [72] Feed the end of the stitch wire between the felt wire-cleaning pads.
  • Page 111 Install New Stitch Wire Step Action Information Close the folder cover. Close the connecting bridge cover. Feed the Stitch-wire [67] Step Action Information Touch START. Set the number of stitches to 6 Touch BASIC > STITCHES. Hand-feed or print an A4 or The stitch-wire loads automatically larger size test job.
  • Page 112 Install New Stitch Wire Chapter 6 Maintenance...

  • Page 113: Appendix A Specifications

    Appendix A Specifications...

  • Page 114: Specifications

    Specifications Specifications [68] Operating 10-35°C at 35-85% relative humidity Conditions Production Cycle time: Printer dependent Interset gap: 2 seconds (if printer has DFD2, then 1.5 or 2 seconds, depending on job settings) Minimum set time: 7.5 seconds (if printer has DFD2, then 5.5 or 7.8 seconds, depending on job settings) Maximum set time: 12.5 seconds Stock Sizes...
  • Page 115 Specifications Book Thickness Maximum finished book thickness: 10 mm (approximately 200 pages 80gsm) Maximum set thickness: 5 mm (approximately 50 sheets 80gsm) Stitching 1 - 6 stitches, evenly spaced on the spine of the book Stitches/spool: up to 291,500 Books*/spool: approximately 127,000 Trimming Maximum fore-edge trim: 28 mm Minimum trimmed book size: 80 mm...
  • Page 116 Specifications Appendix A Specifications...

  • Page 117: Declaration Of Conformity

    Appendix B Declaration of Conformity...

  • Page 118: Declaration Of Conformity

    Blaydon Road Sandy, Bedfordshire SG19 1RZ United Kingdom Declares that the product: Name of Product: BLM 500 / Bookletmaker 50 serial Number: WA/PSQ/---/010 onwards Conforms to the following Directives: Safety: 290/95/EEC Council Directive 'on the approximation of laws of Member States relating to electrical equipment designed for use within certain voltage limits'.

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