Oce BLM 500 Operating Information Manual Download Page 52

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Chapter 5 Error Conditions, Problems, and Solutions

General Problems

[25]

Problem

Cause

Solution

The Booklet maker does
not start

The Booklet maker is not
turned on.

Turn ON the Booklet
maker (

see ‘Turn ON the

Booklet maker’ on
page 13

The printer has not sent a
job to the Booklet maker.

Correct the problem at the
printer.

The Booklet maker is not
connected to the power
supply.

Connect to the power
supply of the correct type
and voltage (

see ‘Turn ON

the Booklet maker’ on
page 13

)

A safety cover is open.

Close all safety covers.

The trim bin is not
installed or the trim bin is
not installed correctly.

Install the trim bin.

The Booklet maker is not
connected to the printer
interface.

Check the interface
cables. Connect the
cables.

A fuse has blown on the
power input.

Replace the fuse(s) as
needed (

see ‘Change the

Fuses’ on page 85

)

The stitch head is
jammed.

Clear the stitch head jam
and start the Booklet
maker again.

Clear a

Stitch Head Jam on
page 80

An error condition exists
on the Booklet maker.

Check the error message
on the touch screen.
Correct the fault (

see

‘Error Messages’ on
page 54

)

The START and STOP
buttons do not work

The touch screen is in
power-save mode

Touch the touch screen to
restore normal function

The Touch Screen on
page 20

Summary of Contents for BLM 500

Page 1: ...BLM 500 Bookletmaker 50 User manual Operating information ...

Page 2: ...or warranties with respect to the contents hereof and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose Further Océ reserves the right to revise this publication and to make changes from time to time in the content hereof without obligation to notify any person of such revision or changes Note The contents of this document are subject to copyrig...

Page 3: ...b 18 Chapter 3 The User Interface 19 The Touch Screen 20 The Job Mimic 23 The BASIC Window 25 The LOAD SAVE Window 27 The ADVANCED Window 29 The CONFIGURE Window 30 The MENU Window 31 Chapter 4 Standard Tasks 33 Load and Save the Job Settings 34 Adjust the Stitch Pitch 35 Open the Connecting Bridge Cover 36 Open and Close the Folder Cover 37 Lift and Lower the Clincher Frame 38 Open the Gathering ...

Page 4: ... 84 Change the Fuses 85 Manually park the Shuttle 86 Chapter 6 Maintenance 89 About Maintenance 90 Booklet maker cleaning 91 Clean the Static Elimination Bars 92 Clean the Former Roller 94 Clean the Polyurethane Strips in the Form Clamp 96 Clean the Trimmings Removal Fingers 98 Clean excess grease from the Stitch Head 101 Lubricate the Stitch Head 102 Lubricate the Wire feed Cam 106 Install New St...

Page 5: ...5 Chapter 1 Introduction to the Booklet maker ...

Page 6: ...ncluded in the separate Safety Information Manual Read the safety information before you use your Booklet maker Caution A CAUTION message tells you that a procedure or operation can be dangerous To prevent injury you must follow the instructions Attention An ATTENTION message tells you that a procedure or operation can damage the machine or the product To prevent damage you must follow the instruc...

Page 7: ... 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: ...A The connecting bridge The connecting bridge moves the printed sheets from the printer to the Booklet maker If needed the sheets are rotated into the correct direction Rotation lets the printer operate at optimum print speed Adjustment for the size of the paper and sheet rotation is automatic according to the settings entered on the touch screen B The user interface The user interface has a color...

Page 9: ...2 Right hand side of the Booklet maker Component function table 2 A B 2 Right hand side of the Booklet maker Component Function A The stitch wire cabinet The stitch wire cabinet holds the spool of stitch wire B Trim Bin The trim bin collects the paper that is trimmed from the edge of the book ...

Page 10: ...oklet maker the current settings are stored C Voltage advisory label The voltage advisory label tells the installer to refer to the installation instructions before the Booklet maker is connected to the electrical power supply The Booklet maker can be adjusted for one of several different input voltages D Fuses The fuses make sure the operator and the machine are protected if there is an electrica...

Page 11: ...oklet 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: ...ore you begin a print job Measure the size of the printed paper The paper dimension changes when the paper is printed Measure the set thickness as accurately as possible Use the measuring tool supplied with the machine Enter accurate dimensions via the touch screen If the book is made from several different types of paper make sure the different paper types are all the same size See Book Quality o...

Page 13: ...ocedure 1 Connect the Booklet maker to the power supply 2 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: ...mat of the paper when it enters the Booklet maker Attention Do not operate the touch screen with a sharp object or with too much force These actions can damage the touch screen Before You Begin 4 Note This set can be made into a book see Operate the Booklet maker offline on page 47 Step Action Information 1 Print a set to the stacker 2 Measure the sheet size and the set thickness Measure the set a...

Page 15: ... to turn the sheet rotation ON or OFF Always select the page direction before you change the rotate setting 5 Enter the set thickness Touch SET THICKNESS Enter the measured value 6 Enter the number of stitches Touch STITCHES and enter the number of stitches If needed the stitch pitch can be changed See STITCH PITCH table 9 on page 25 7 Enter the spine form setting The spine form setting is automat...

Page 16: ...16 Chapter 2 How to run the Booklet maker Enter the Job Settings 2 Touch the job name or use the Up arrow or the Down arrow to select the job 3 Touch LOAD 4 Wait until the Booklet maker is ready ...

Page 17: ...17 Stacker adjustment Stacker adjustment Adjust the Stacker Adjust the stacker according to the size and thickness of the finished bookAdjust the Stacker on page 45 ...

Page 18: ...r starts automatically 3 Check the quality of the first book 4 If the quality is not acceptable make adjustments see Book Quality on page 63 Result During the job Unload books from the stacker before the stacker is full The Booklet maker stops and displays a message if the stacker is full Empty the trim bin from time to time The Booklet maker displays a message if the trim bin is full see Empty th...

Page 19: ...19 Chapter 3 The User Interface ...

Page 20: ... use the brightness of the touch screen decreases After several hours the touch screen turns off Touch the screen to restore the normal brightness The touch screen takes two or three minutes to reach full brightness If you hear a beep when you operate the touch screen the selected function is not available Some functions are not available when the machine is in operation Some functions and buttons...

Page 21: ...uttons has a separate window Touch the correct tab to select the window LOAD SAVE BASIC ADVANCED CONFIGURE MENU 2 Window Buttons Each window contains a group of buttons Touch the button to select the function 3 Message List Information and error messages are shown in the MESSAGE LIST To display the information about a message touch HELP then touch the message list 4 Job Mimic The job mimic shows t...

Page 22: ...hen touch any button or tab on the screen Information about that button or tab is displayed Use the Up arrow and the Down arrow to scroll up and down the screen Some text has more than one screen Use the right arrow and left arrow to see the other screens To leave the help text touch HELP or touch X 7 Sheet Counter The sheet counter shows the number of sheets in the gathering area The counter star...

Page 23: ...ormation 1 7 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 the small thick lines show the stitches the arrow shows the original feed edge in the printer 2 Stitch Pitch 8 The stitch pitch is shown only when a non standard setting is selected 3 9 The set thickness in mm is shown ...

Page 24: ...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 5 11 The trim setting is displayed A red X shows that the trim function is not active No Icon Information ...

Page 25: ... 5x11 ROTATE is set to ON automatically PRESETS Touch PRESET to select a standard paper size SET THICKNESS Use the SET THICKNESS window to define the thickness of the set Measure the thickness of the set before you make a book Touch SET THICKNESS and enter the value STITCHES Touch STITCHES to select the number of stitches Available options are 1 6 The machine automatically calculates the position ...

Page 26: ...eases the time taken to form the spine and can decrease the production rate for thin books Alternatively increase the PRESSURE PRESSURE Touch PRESSURE to increase or decrease the pressure used to form the spine Touch to increase the amount of spine form Touch to decrease the amount of spine form The range is 9 to 9 The default setting is 0 THRESHOLD The square spine is formed only on sets thicker ...

Page 27: ... If you change the settings of a saved job touch REPLACE to save the new settings CANCEL Touch CANCEL if you do not need to save a job that you have changed SAVE NEW If you change the settings of a saved job touch SAVE NEW to save the new settings as a new job An on screen keyboard is displayed Enter the new job name Touch OK or CLOSE The original job is not changed If the job name is not changed ...

Page 28: ...e the selection from the job list Touch and hold DELETE A red line appears The red line fills from left to right Hold DELETE until the red line reaches the right hand side VIEW OF JOB LIST VIEW OF JOB LIST changes the order that saved jobs are listed There is a line between Factory Template jobs and jobs saved by the operator The Factory Template jobs are at the top of the list A Z Touch A Z to li...

Page 29: ...e stitch head This action moves the stitch head to the correct position for lubrication PURGE SET When an error occurs a set or part of a set can remain in the gathering area Touch START then touch PURGE SET to clear the set from the machine The book is not stitched or trimmed According to the type of error that occurred there can be a pause of 7 seconds before the PURGE SET button will operate MA...

Page 30: ... unit of measurement Yes STITCH SENSOR There is a sensor that checks for stitches Touch STITCH SENSOR to turn the stitch sensor on or off The default setting is ON Yes PRESET PAPERSIZES The preset paper sizes can be either ISO A sizes or US paper sizes To select which preset paper sizes are available touch the relevant button Yes NETWORK SETTINGS This button is used by the service engineer No SHUT...

Page 31: ...VEL and select the correct level from the list The last three levels are protected by access codes To protect job settings the supervisor level allows jobs to be locked CURRENT LANGUAGE Touch one of the flags to select the language you need AXES Touch AXES to re reference individual axes Supervisor access level is needed for this function Other functions on this button are used by the service engi...

Page 32: ...f sheets that have been processed number of stitches that have been used RESET Touch RESET to reset the book sheet counter and stitch counter Touch and hold RESET A red line appears The red line fills from left to right Hold RESET until the red line reaches the right hand side 13 The MENU Window Buttons 2 2 Button Information ...

Page 33: ...33 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: ...t one REPLACE to over write the previous job with the current job settings SAVE NEW to save the current job with a new name CANCEL to cancel the job save 3 Enter the name for the job on the keyboard 4 Touch OK or CLOSE Load a job 1 Touch LOAD SAVE 2 Touch the job name or use the Up arrow or the Down arrow to select the job 3 Touch LOAD 4 Wait until the Booklet maker has made the adjustments Reset ...

Page 35: ... When to do If you need the Booklet maker to insert the stitches in a non standard position For example to keep the stitches away from the text on the spine of the book Select a non standard stitch pitch 1 Touch BASIC STITCHES 2 Touch AUTO The STITCH PITCH value becomes green 3 Change the stitch pitch value Either use the and or touch the green stitch pitch value to open a numeric keypad 4 Touch S...

Page 36: ... if you open the connecting bridge cover 13 13 Connecting Bridge Cover in the open position 14 When to do If a machine error occurs or for maintenance To clear a paper jam To clean the static elimination bar Caution Keep your hands clothing and hair away from the belts Procedure Lift the connecting bridge cover A A Connecting Bridge Cover ...

Page 37: ... Folder Cover 1 Lift the black locking handle against the spring pressure 2 Turn the handle through 90 to unlock 3 Lift the folder cover carefully to the vertical position Close the Folder Cover Caution Check that the folder cover will not hit the clincher frame locking handle when you close the folder cover If necessary lift and rotate the clincher frame locking handle to a new position figure 16...

Page 38: ...ion 15 15 Folder Cover in the vertical position 15 16 16 Clincher Frame Components 16 When to do If a machine error occurs or for maintenance To clear a paper jam in the stitch area To unlock the Booklet maker main deck A B A Folder Cover B Clincher Frame A B C A Clincher B Locking Handle C Clincher Frame ...

Page 39: ...e Attention You must hold the weight of the clincher frame Do not let the clincher frame fall on your hand 1 Lower the clincher frame 2 Turn the locking handle to the right until the handle is tight 3 Check that the locking handle will not be hit by the folder cover when you close the folder cover The locking handle should point towards the middle of the machine If necessary lift and rotate the lo...

Page 40: ...or 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 Procedure 1 Open the connecting bridge cover 2 Use the gathering area cover handle to lift the gathering area cover A B C A Connecting Bridge Cover open B Gathering Area Cover C Gathering Area Cover Handle ...

Page 41: ...n to do If a machine error occurs or for maintenance To access the stitch head To access the former area To access the trim area Procedure Caution Keep your hands and fingers clear when you lift the main deck A B C E D A Folder Cover open B Connecting Bridge Cover open C Clincher Frame lifted D Gathering Area Cover E Main Deck ...

Page 42: ...older cover see Open the Connecting Bridge Cover on page 36 3 Lift the clincher frame see Lift the Clincher Frame on page 39 4 Open the gathering area cover see Lower the Clincher Frame on page 39 5 Lift the Booklet maker main deck The main deck lifts to approximately 60º The weight of the main deck is supported by a gas strut Let the gas strut control the movement of the main deck ...

Page 43: ...ty and return the trim bin to the Booklet maker as quickly as possible When to do An error message is displayed on the touch screen when the trim bin is full You can empty the trim bin when you choose For example before you start a print job Procedure 1 Use the handle to open the trim bin 2 Use the side handles to lift and remove the trim bin 3 Empty the trim bin 4 Fit the bottom of the trim bin o...

Page 44: ...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 To install a new stitch wire spool see Install New Stitch Wire on page 107 Procedure Open the stitch wire cabinet cover The cover is held closed by a magnetic catch A A Stitch wire cabinet open ...

Page 45: ...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 22 22 22 Collection table position C B A 2 1 A Catch tray adjustment B Collection table C Catch tray A C D B ...

Page 46: ...in window B Collection table C Orange plastic hand screw D Catch tray Step Action Information 1 Set the catch tray angle according to the thickness of the book For books that are 1 5 mm thick or less use position 1 For books that are 1 5 mm thick or less use position 2 figure 21 on page 45 2 Set the collection table position according to the size of the book Read the settings through the window fi...

Page 47: ...n the machine operates Use two hands to push the buttons For safety reasons this task is for a single operator Do not let another person help you Procedure 1 Enter the correct settings on the touch screen according to the size and thickness of the job 2 Touch START 3 Open the connecting bridge cover 4 Open the gathering area cover 5 Put the set in the gathering area with the middle pages of the bo...

Page 48: ...48 Chapter 4 Standard Tasks Operate the Booklet maker offline ...

Page 49: ...49 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: ...occurs in the printer the printer and the Booklet maker stop Procedure 1 Clear the printer error 2 Follow the instructions on the printer If the printer tells you to remove paper from the Booklet maker touch START to start the machine 3 Then touch ADVANCED PURGE SET PURGE SET 4 The partial book is delivered to the stacker 5 Discard the book ...

Page 51: ...the Booklet maker the printer and the Booklet maker stop The type of error is displayed on the touch screen see Error Messages on page 54 Procedure 1 Clear the error The error message on the touch screen tells you about the error 2 Remove all sheets from the Booklet maker 3 Follow the instructions on the printer ...

Page 52: ...safety covers The trim bin is not installed or the trim bin is not installed correctly Install the trim bin The Booklet maker is not connected to the printer interface Check the interface cables Connect the cables A fuse has blown on the power input Replace the fuse s as needed see Change the Fuses on page 85 The stitch head is jammed Clear the stitch head jam and start the Booklet maker again Cle...

Page 53: ...ncorrect The touch screen is in power save mode Touch the touch screen to restore normal function The Touch Screen on page 20 The touch screen calibration is incorrect Calibrate the touch screen see Calibrate the Touch Screen on page 84 Problem Cause Solution ...

Page 54: ...s faster than the books can be made To decrease the book cycle time adjust the machine settings decrease the number of FORMS decrease the number of STITCHES decreasetheTAMPER TIME touch STOP to clear the message from the screen Bridge axis moving The bridge axis is moving This message clears when the adjustment is complete If the message does not clear touchADVANCED RE REF BRIDGE INFEED COVER OPEN...

Page 55: ... cover is closed DRIVE MOTOR STALL There is a paper jam Check the machine and correct the error Touch STOP to clear the message from the screen Endlay axis moving The endlay axis size adjustment is moving This message clears when the adjustment is complete If the message does not clear touchADVANCED RE REF ERROR IN TRIM AREA There is an error at the trimmer Check the trimmer for a paper or book ja...

Page 56: ...ck the outfeed If necessary remove the trim bin and open the trim stop guard to remove the book s Touch STOP to clear the message from the screen If there is paper in the gathering area touch START then touch ADVANCED PURGE SET PURGE SET to clear the set from the machine Jam in the Trim Area on page 74 Fold blade axis moving The fold blade axis book thickness adjustment is moving This message clea...

Page 57: ...INVERTER ERROR Check for a paper jam and clear if necessary Touch STOP to clear the message from the screen If the problem continues contact your service engineer JAM AT BRIDGE INFEED There is a paper jam at the infeed to the connecting bridge Clear the jam and continue see Clear Paper Jams on page 68 JAM AT FORM ROLLER The form roller is jammed Open the folder cover and remove the jam see Jam in ...

Page 58: ... Clear a Stitch Head Jam on page 80 JAM IN TRIMMER There is a book jammed in the trimmer Clear the jam and continue see Jam in the Trim Area on page 74 MANUALLY PARK SHUTTLE The shuttle is not parked correctly Open the folder cover and move the shuttle to the park position Close the folder cover The shuttle will reset When the message list is clear continue operation Manually park the Shuttle on p...

Page 59: ...hADVANCED RE REF SET IN GATHERING AREA There is a set or partial set in the gathering area If the print job has been canceled open the gathering area and remove the sheets Or touch START then touch ADVANCED PURGE SET PURGE SET to clear the set from the machine Shuttle axis moving The shuttle axis is moving This message clears when the adjustment is complete If the message does not clear touchADVAN...

Page 60: ...axis moving The sidelay axis size adjustment is adjusting This message clears when the adjustment is complete If the message does not clear touchADVANCED RE REF STACKER FULL The stacker is full Unload the books from the stacker Stitch axis moving The stitch axis is moving This message clears when the adjustment is complete If the message does not clear touchADVANCED RE REF Stitch position adjustin...

Page 61: ...Area Cover on page 40 TOUCH PAD ERROR There is a fault with the START and STOP touch pads If the problem continues call your service engineer Touch START to clear machine There may be some paper in the machine Touch START to clear the machine before you start a new job Trim axis moving The trim axis size adjustment is moving This message clears when the adjustment is complete If the message does n...

Page 62: ...RIM BLADE NOT PARKED The trim blade is in the 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 Touch START to restart the machine Problem Cause Solution ...

Page 63: ...ook is made from several different types of paper make sure the different paper types are all the same size If the size of the paper is different an accurate book cannot be made The paper must be cut accurately If the sheets are not cut squarely an accurate book cannot be made Adjustments to the FORM settings can be necessary for some types of paper Machine Adjustments Machine adjustments can be m...

Page 64: ...ent axes see table 11 on page 29 The static elimination bars are dirty Clean the static elimination bars see Clean the Static Elimination Bars on page 92 Incorrect function of the static elimination bars Call your service engineer The spine is not formed correctly Incorrect settings see Spine Form Problems on page 66 Turn on the TRIM function See TRIM in table 9 on page 25 The book is not trimmed ...

Page 65: ...xes see table 11 on page 29 The books do not stack on the stacker The collection table is in the wrong position Adjust the position of the collection table to fit the size of the finished book Adjust the Stacker on page 45 The book cover is dirty or marked The former roller is dirty Clean the former roller see Clean the Former Roller on page 94 23 Marks on the spine The former clamp is dirty Clean...

Page 66: ...per may need further adjustment 28 The book cover is dirty or marked The trimmings removal fingers are dirty Clean the Trimmings Removal Fingers on page 98 25 Curved marks on the book There are grease marks around the stitches Clean excess grease from the Stitch Head on page 101 26 Grease marks near the stitches Book Quality Problem Cause Solution Spine Form Condition 27 Correct The spine is squar...

Page 67: ... value See THRESHOLD table 9 on page 25 Does the spine need more form at one end Change NUMBER to 2 or 4 See FORM in table 9 on page 25 Does the spine need more form at each end Increase PRESSURE Then if the spine still needs more form increase NUMBER See FORM in table 9 on page 25 29 Incorrect The spine is damaged or there are creases near the spine Check these settings The SET THICKNESS setting ...

Page 68: ...blems and Solutions Clear Paper Jams Clear Paper Jams Introduction 30 30 Paper Jam Locations 29 31 31 Paper Jam Location Bridge Infeed A B D C E A Connecting Bridge B Gathering Area C Stitch Area D Fold and Forming Areas E Trim Area A ...

Page 69: ...32 32 Trimmer Infeed Conveyor viewed from above Jam before the Trimmer on page 72 31 33 33 Trim Stop Assembly Jam in the Trim Area on page 74 A Bridge Infeed Cover A B A Trimmer Infeed Conveyor B Former clamp mechanism A C B ...

Page 70: ...e message from the screen 5 If there is paper in the gathering area touch START then touch ADVANCED PURGE SET PURGE SET to clear the set from the machine 6 Continue the print job Jam in the Connecting Bridge 1 Open the connecting bridge cover 2 Remove the jammed paper Do not damage or move the belts 3 Close the connecting bridge cover 4 Touch STOP to clear the message from the screen A Orange Plas...

Page 71: ...Jam in the Gathering Area 1 Open the connecting bridge cover 2 Lift the gathering area cover 3 Remove the jammed paper 4 Check the belts are in the correct position Adjust the position of the belts if necessary figure 34 on page 70 5 Close the gathering area cover 6 Close the connecting bridge cover 7 Touch STOP to clear the message from the screen 8 Continue the print job ...

Page 72: ... a book jammed before the trimmer 2 a piece of paper trimming has covered the jam sensor Step Action Information 1 Open the folder cover see Open and Close the Folder Cover on page 37 2 Lift the clincher frame see Lift and Lower the Clincher Frame on page 38 3 Remove the jammed paper 4 Check for broken or damaged stitches in the clincher area Manually operate the clincher to clear any stitches tha...

Page 73: ...t from the drive pin 36 Lift the left hand end clear 4 Remove the book if one is found 5 Remove any paper offcuts from the trimmer infeed conveyor A small piece of paper can cover the jam sensor and cause an error message 6 Install the trimmer infeed conveyor Insert the right hand end of the shaft into the bearing against the spring pressure Insert the left hand end 7 Install the trim bin 8 Close ...

Page 74: ...n rotate to release the trim stop guard 3 Pull the trim stop guard towards you 4 Remove the jammed book Check the trim stop and remove any pieces of trimmed paper 5 Push the trim stop guard into position 6 Hold the locking plates in position and tighten the orange hand screws 7 Attach the trim bin 8 Touch START then touch ADVANCED PURGE SET PURGE SET This action clears any other paper from the Boo...

Page 75: ... 2 Lift the clincher frame Lift and Lower the Clincher Frame on page 38 3 Remove the paper 4 Lower the clincher frame Lift and Lower the Clincher Frame on page 38 5 Close the folder cover 6 If the error message SHUTTLE NOT PARKED is displayed touch START This action moves the shuttle to the correct position 7 Touch STOP and then continue the print job ...

Page 76: ...s finished Load a new spool of stitch wire see Install New Stitch Wire on page 107 The stitch wire is jammed Clear the jammed stitch wire see Clear a Stitch Wire Jam on page 77 The stitches are broken There is stitch wire jammed in the stitch head Inspect and remove the jammed stitch wire see Clear a Stitch Wire Jam on page 77 The stitch wire is jammed on the spool The stitch wire spool is not ins...

Page 77: ...77 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 A B C D ...

Page 78: ...let maker from the power supply 3 Lift the Booklet maker main deck see Lift the Booklet maker Main Deck on page 41 Step Action Information 1 Cut the stitch wire at position A approximately 50mm 2 inches from where the stitch wire leaves the stitch wire guide 38 Detail A Cut stitch wire here 2 Cut the stitch wire at position B between the feed gears and the middle wire tube 39 Detail B Cut stitch w...

Page 79: ...re Jam Remove the middle wire tube figure 37 on page 77 Pull the wire from the stitch head 5 Install the stitch wire into the stitch head see Install the Stitch Wire into the Stitch Head on page 110 Step Action Information ...

Page 80: ...ear 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 If the error message continues do Procedure 2 ...

Page 81: ...or damaged stitches in the clincher area Manually operate the clincher to clear any stitches that are jammed 41 Press to manually operate the clincher 6 Lower the clincher frame Lift and Lower the Clincher Frame on page 38 7 Close the folder cover 8 If there is paper in the gathering area touch START then touchADVANCED PURGE SET MAKE BOOK This action clears paper from the BLM 500 Bookletmaker 50an...

Page 82: ...Tools and Materials 1 Klüber Isoflex NBU 15 Grease 50g 2 Air duster Supplied with the machine 3 Wire cutters Supplied with the machine 4 Flat blade screwdriver B Wire holder C Wire holder retaining spring 43 43 Inspect for stitch wire A Inspect this area for pieces of stitch wire A ...

Page 83: ...e holder for stitch wire figure 43 on page 82 4 Remove any stitches or pieces of stitch wire and clean the area with the air duster Use wire cutters to remove any jammed stitches or pieces of stitch wire 5 Lubricate the stitch head Lubricate the Stitch Head on page 102 6 Fit the wire holder Remember to put the wire holder retaining spring in position 7 Close the Booklet maker 8 Start the Booklet m...

Page 84: ...en 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 Do not use a sharp object Sharp objects damage the screen Procedure 1 Touch the STOP button 5 times 2 Follow the instructions on the touch screen 3 Touch DONE in the centre of the screen ...

Page 85: ...e the fuses This machine uses two fuses in parallel To avoid the risk of fire replace fuses only with the same type and rating Procedure 1 Turn OFF the Booklet maker 2 Disconnect the Booklet maker from the power supply 3 Turn one fuse holder to the left and remove the fuse holder from the Booklet maker 4 Check the fuse 5 If the fuse is blown then replace with a fuse of the correct specification 6 ...

Page 86: ... 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 A ...

Page 87: ... Cover on page 37 2 Push the shuttle assembly to the right figure 45 on page 86 shows the 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 Repeat if necessary 3 Wait until the error message SHUTTLE NOT PARKED is cleared from the screen If the message does not clear check that...

Page 88: ...88 Chapter 5 Error Conditions Problems and Solutions Manually park the Shuttle ...

Page 89: ...89 Chapter 6 Maintenance ...

Page 90: ...r Maintenance Correct maintenance by the operator makes sure that The machine operates correctly The machine makes high quality books The machine is safe to use Small problems can be identified early Operator Maintenance Plan 46 Interval Task Reference Every week Clean the machine see Booklet maker cleaning on page 91 Clean the static elimination bars see Clean the Static Elimination Bars on page ...

Page 91: ...mended 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 Touch screen Clean the touch screen with a clean dry cloth Never use an abrasive material or chemical to clean the touch screen Light pressure with a clean dry cloth is enough to remove fingerprints Do not use too much force ...

Page 92: ...small brush Use the brush to clean the static elimination bars There are three static elimination bars One in the connecting bridge Two in the gathering area 48 48 The Static Elimination Bars in the Gathering Area 49 49 The Static Elimination Bar in the Connecting Bridge 47 Note On the bottom of the static elimination bar there is a row of sharp pins The pins are not dangerous but if you touch the...

Page 93: ...ridge cover Clean the pins on the bottom of the static elimination bar with a small brush 2 Clean the static elimination bars in the gathering area Open the gathering area cover Clean the pins on the bottom of the static elimination bars with a small brush 3 Close the Booklet maker Close the gathering area cover Close the connecting bridge cover ...

Page 94: ... 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 More than one cycle can be needed ...

Page 95: ...rrect settings on the touch screen Set the touch screen to the correct PAPER SIZE Set the SET THICKNESS to 4 0 Set the number of STITCHES to 0 Set the number of FORMS to 4 2 Touch START 3 Open the connecting bridge cover 4 Lift the gathering area cover 5 Put 4mm of clean paper in the gathering area 6 Press the two orange buttons and hold for 9 seconds or until you hear the folder operate ...

Page 96: ... can collect on these parts especially when you make thin books 51 51 Dirty marks beside the spine Required tools Alcohol wipe or A lint free cloth and alcohol isopropanol Caution Only use alcohol to clean this part of the machine Other chemicals can damage the machine Note If you push the eject rollers the rollers can move together against your hand This movement can alarm you but is not dangerou...

Page 97: ...er 2 Use an alcohol wipe or apply a small amount of alcohol to a lint free cloth 3 Reach into the form clamp and clean each of the polyurethane strips There is a polyurethane strip on the face of each side of the clamp Repeat this step until the polyurethane strips are clean 4 Close the folder cover ...

Page 98: ...s 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: ...mings Removal Fingers Illustration 54 51 Illustration 55 52 Illustration 56 A B A Trimmer infeed conveyor B Former clamp mechanism C B A A Trimmer infeed conveyor B Trimmings removal fingers C Former clamp mechanism B A ...

Page 100: ...he parts is through the former clamp mechanism 3 Remove the trim bin 4 Clean the visible trimmings removal fingers with an alcohol wipe 5 Rotate the conveyor shaft by half a turn 1 Hold the shaft and push to the right against the spring pressure to disengage the shaft from the drive pin 57 2 Rotate the shaft by half a turn 3 Align the shaft with the drive pin and release 6 Clean the visible trimmi...

Page 101: ... Action Information 1 On the user interface touch ADVANCED STITCHER UP STITCHER UP The folder cover must be closed This action moves the stitch head to the correct position for lubrication 2 Open the folder cover Open and Close the Folder Cover on page 37 3 Lift the clincher frame Lift and Lower the Clincher Frame on page 38 4 Clean grease from the sides of the stitch head 59 5 Lower the clincher ...

Page 102: ...102 Chapter 6 Maintenance 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 A B C ...

Page 103: ... use the grease shown in this manual Correct lubrication extends the performance and service life of the stitch head Other types of grease do not protect the stitch head Only apply the grease as shown If you apply additional grease the paper gets marked A Stitch Head B Wire Holder C Wire Holder Retaining Spring A B A Driver in upper position B Driver Bar ...

Page 104: ...r interface touch ADVANCED STITCHER UP STITCHER UP The folder cover must be closed This action moves the stitch head to the correct position for lubrication 5 Lift the Booklet maker main deck See Lift the Booklet maker Main Deck on page 41 Step Action Information 1 Use the supplied air duster to remove dust from the stitch head 2 Remove the wire holder from the stitch head Move the wire holder ret...

Page 105: ...se to the visible surface of the driver bar figure 62 on page 103 63 64 4 Re fit the wire holder 5 Lower the Booklet maker main deck 6 Lower the clincher frame see Lower the Clincher Frame on page 39 7 Close all of the covers Step Action Information 1 2 ...

Page 106: ... A B C A Nozzle for the tube of grease B Wire feed cam C Feed lever Step Action Information 1 Lift the PSQ main deck 2 Apply 10 mm of grease from the tube between the bearing surface of the wire feed cam and the feed lever figure 65 66 3 Lower the Booklet maker main deck 4 Lower the clincher frame Lower the Clincher Frame on page 39 5 Close all of the covers 0 4 ...

Page 107: ... 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 See see Lift the Booklet maker Main Deck on page 41 Illustration 67 67 Stitch Wire Guide Block A B C ...

Page 108: ... wire to the right of the stitch wire guide block 68 Detail A Cut here 2 Pull the stitch wire from the stitch wire guide block 3 Fit a new stitch wire spool see Fit a New Stitch Wire Spool A Step Action Information 1 Open the stitch wire cabinet 2 Remove the stitch wire cap and finished stitch wire spool 3 Fit a new stitch wire spool 4 Fit the stitch wire cap 69 5 Loosen the end of the stitch wire...

Page 109: ...end of the stitch wire Remove enough stitch wire to leave the end of the stitch wire clean and straight 7 Feed the stitch wire through the stitch wire guide 70 8 Install the stitch wire see Install the Stitch Wire into the Stitch Head on page 110 Step Action Information ...

Page 110: ... stitch wire between the felt wire cleaning pads 72 Detail A Felt Wire Cleaning Pads 4 Push the stitch wire into the stitch wire guide block 73 Push stitch wire in direction of arrow 5 Push the stitch wire as far as possible 74 Detail A Make sure the stitch wire runs between the wire feed rollers and into the middle wire tube A A Step Action Information 1 Close the stitch wire cabinet 2 Lower the ...

Page 111: ...CHES 4 Hand feed or print an A4 or larger size test job The stitch wire loads automatically during the stitch head cycle 5 Check that the stitch wire is loaded Check that a stitch is made If needed repeat the previous step If a stitch is still not made repeat the procedure Install the stitch wire into the stitch head Install the Stitch Wire into the Stitch Head on page 110 6 Reset the number of st...

Page 112: ...112 Chapter 6 Maintenance Install New Stitch Wire ...

Page 113: ...113 Appendix A Specifications ...

Page 114: ...nimum input size 203 x 203 mm Maximum input size 320 x 488 mm 75 A Stitch fold line B indicates original lead edge from the printer Sheet Rotation Integrated rotator ensures maximum printer productivity Maximum rotation sheet size 320 x 227 mm Minimum rotation sheet size 210 x 203 mm The cross track dimension of the sheet before rotation must be at least 7 mm greater than the in track dimension 76...

Page 115: ... the input sheets Dimensions Footprint 1870 x 1675 mm Height 1330 mm maximum Weight Booklet maker including stitching wire 542kg As per above plus bridge and bridge covers 702kg Power Supply Adjustable to 200 208 220 230 and 240V 50 60Hz single phase Power Consumption stand by 92VA 75W in operation 700VA 500W Noise Emission stand by ambient in operation 66 dB A peak 87 dB A Approvals Complies with...

Page 116: ...116 Appendix A Specifications Specifications ...

Page 117: ...117 Appendix B Declaration of Conformity ...

Page 118: ...umber 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 BS EN 60950 2002 EMC 89 336 EEC Council Directive on the approximation of laws of Member States relating to electromagnetic compatibility EN55022 1998 Class A EN55024 1998 EN61...

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