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Ricoh BK5010 Installation Manual
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Ricoh BK5010 Installation Manual

Ricoh BK5010 Installation Manual

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INSTALLATION MANUAL
BK5010 SYSTEM
4 Oct, 2007
Subject to change

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Summary of Contents for Ricoh BK5010

  • Page 1 INSTALLATION MANUAL BK5010 SYSTEM 4 Oct, 2007 Subject to change...
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  • Page 3 4 Oct 2007 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.
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  • Page 5 04 October 2007 INSTALLATION REQUIREMENTS INSTALLATION PROCEDURE 1.1 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 6 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. 2. Permissible voltage fluctuation: ± 10% 3. Never place anything on the power cord.
  • Page 7 04 October 2007 INSTALLATION REQUIREMENTS 1.2 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? Install the Trimmer TR5010 Does the user require a Book Folder?
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  • Page 9 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 10 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 11 04 October 2007 BOOKLET MAKER INSTALLATION Exit arm catcher Remove the adhesive backing from the Exit arm catcher. 2. 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. Lift up the Exit paper arm, and set it onto the Exit arm catcher [A].
  • Page 12 BOOKLET MAKER INSTALLATION 04 October 2007 Copier exit tray Make sure that the Exit paper arm is in the upper position [A]. 2. Remove the finisher exit tray by removing screws [B] ( x 4). 3. Remove the plastic deflector [C], on the finisher exit tray.
  • Page 13 04 October 2007 BOOKLET MAKER INSTALLATION 4. Remove the plastic deflector [D] from the shift tray. 5. Install the Shift tray plate [E] on to the finisher ( x 4 counter screws from installation kit) 6. Install the Exit tray plate [F] on to the finisher exit tray ( x 4 from installation kit).
  • Page 14 BOOKLET MAKER INSTALLATION 04 October 2007 Docking assembly Finisher seen from above Finisher seen from front side 1. Remove the finisher rear cover ( x 2). 2. Open the finisher door and pull out the stapling tray. 3. Remove black plastic covers [A] at the bottom of the finisher ( x 2). Install the docking assembly [B] in the holes under the black plastic covers [A]. NOTE: Both nuts [C], installed on the docking assembly, have different diameters on each side of the nut. A big diameter [D] on one side, and a smaller diameter [E] on the other.
  • Page 15 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. NOTE: Make sure to use the communication cable for SR5000 Finisher.
  • Page 16 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. 2. Secure the Communication cable in the finisher [B], with a tie wrap from the installation kit.
  • Page 17 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 18 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. If not, with copier powered on - open and close finisher door.
  • Page 19 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 20 BOOKLET MAKER INSTALLATION 04 October 2007 Place the Multi tool outside the hand feeding paper guides as illustrated [F]. 1-16...
  • Page 21 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 22 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 23 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 24 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 25 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 26 COVER FEEDER INSTALLATION 04 October 2007 1.4 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 27 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 28 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 29 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 30 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 31 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 32 COVER FEEDER INSTALLATION 04 October 2007 Loosen nuts [C] ( x 2). Remove the Cover Feeder dummy [D] by sliding it out. 1-28...
  • Page 33 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 34 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 35 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 36 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 37 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 38 COVER FEEDER INSTALLATION 04 October 2007 Secure the screw [E] ( x 1). 1-34...
  • Page 39 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 40 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 41 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. NOTE: Make sure that the Booklet maker is powered ON before the Copier. Prepare a 15mm high stack of A4/8.5 x 11”...
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  • Page 43 04 October 2007 TRIMMER INSTALLATION 1.5 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. - Trimmer fan is bubble wrapped and located inside the Trimmer.
  • Page 44 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 45 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 46 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 47 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 48 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 49 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 50 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 51 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 52 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 53 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 54 TRIMMER INSTALLATION 04 October 2007 Trimmer with cable protector installed Continued on next page..1-50...
  • Page 55 04 October 2007 TRIMMER INSTALLATION Booklet Maker with Trimmer installed [ I ] Booklet Maker, rear side 1-51...
  • Page 56 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]. Press the Tools button.
  • Page 57 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.
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  • Page 59 04 October 2007 BOOK FOLDER INSTALLATION 1.6 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. Auto set thickness bracket, with spring ....... 1 D.
  • Page 60 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 61 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 62 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 63 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 64 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 65 [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 66 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 67 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 68 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 69 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 70 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 71 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 72 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. Scroll down to Service and press the OK button. Key in the Password.
  • Page 73 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.
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