Ricoh BOOKLET MAKER BK5010 Operating Instructions Manual Download

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6. Troubleshooting

Fault codes

When there is a misfeed or fault condition in the booklet maker system, a message will

be displayed on the Booklet Maker. In case there is a problem that can be rectified by the

operator, a fault code and an explanation will be displayed.

Fault codes that can be rectified by the operator:

Booklet Maker:

BK-201 to BK-21

and BK-401

Trimmer:

TR-201 to TR-204 and TR-401

Cover Feeder:

CF-201 to CF-205, CF-401, CF-501 and CF-502

Book Folder:

BF-201 to BF-206.

BK-201 to BK-210 indicates “Clear Misfeed(s)” in the Booklet maker

BK-211

indicates that the set is too thick to be folded

BK-212 indicates to remove purged set in Booklet maker

BK-401

indicates “Check staple(s)” in the Booklet maker

TR-201 to TR-204 indicates “Clear Misfeed(s)” in the Trimmer

TR-401

indicates “Empty Trim bin” in the Trimmer

CF-201 to CF-205 indicates “Clear Misfeed(s)” in the Cover feeder

CF-401

indicates “Out of covers” when there is no more

cover sheets in the Cover feeder. How to clear,

see Cover feeder fault codes

CF-501

indicates “Cover low” when the Cover feeder is

almost out of Covers. How to clear, see Cover feeder

fault codes

CF-502

indicates that there is a format mismatch between the

cover sheets and the sheets sent from the copier.

BF-201 to BF-206 indicates “Clear Misfeed(s)” in the Book Folder

note

If procedures in this manual do not rectify the problem an authorized technician will be

needed.

General

Summary of Contents for BOOKLET MAKER BK5010

Page 1: ...010 Operating Instruction Stapler Folder Reference Read this manual carefully before you use this product and keep it handy for future reference For safety please follow the instructions in this manual 18 December 2007 ...

Page 2: ...Part no 76436 Doc no x04077 rev 19 April 2006 ...

Page 3: ...1 Emptying the trim bin 22 2 Making Booklets 23 Changing settings 23 General procedure 23 Setting Paper Size 23 Selecting standard paper sizes 23 Custom paper size 24 Stapling 24 Selecting stapling On or Off 24 Trimming 25 Selecting trimming On or Off 25 Adjusting the cutting margin 26 Covers 26 Selecting Cover Feeder Mode 26 Loading covers 27 Book Folding 28 General 28 Setting Mode 28 Procedure 2...

Page 4: ... 44 Close cover s 44 Booklet maker fault codes 45 Check staples 45 Set too thick 45 Trimmer fault codes 45 Trim bin full 45 Cover feeder fault codes 45 Misfeed 45 Double feed 45 Load covers 46 Book Folder fault codes 47 Feed errors 47 7 REMARKS 49 Do s And Don ts 49 Where to put Your Machine 50 Machine environment 50 Power connection 50 Access to machine 51 Maintaining Your Machines 52 Cover Feede...

Page 5: ...n order to rectify creep the TR5010 Trimmer optional can be attached after the Booklet Maker The booklets are then transported from the Booklet Maker into the Trimmer where the trail edge will be cut off If a TR5010 Trimmer is installed to the BK5010 Booklet Maker you can can attach the BF5010 Book Folder optional The printouts which have been stapled folded and trimmed will be fed into the BF5010...

Page 6: ...of each button depends on the information displayed For example Pressing button 3 from the Ready screen takes you to the Tools screen Example 2 In this screen button 3 has no function Button 1 2 3 4 Example 3 Pressing button 3 here will load the stored Job 4 Button 1 2 3 4 Example 4 In this screen pressing button 3 will save the current settings for job No 1 The asterisk on the first row shows tha...

Page 7: ...uide To Components 2 3 6 7 1 1 Top cover 2 Control panel 3 Main power switch 4 Infeed assembly 5 Exit tray storing shelf 4 Booklet Maker 6 Base 7 Docking assembly 8 Belt Stacker 9 Belt Stacker Cover 5 8 9 ...

Page 8: ... 8 9 8 Connections 9 Fold stop gate Booklet Maker continues Main Power Terminator COM TR5010 Terminator Stacker COM Copier POW BF5010 Interlock jumper Interlock jumper POW TR5010 ...

Page 9: ... 1 5 6 1 Stapler heads 2 Staple cartridges 3 Cartridge locking levers 4 Stapler release latches 5 Staple detection leads 6 Hand feeding paper guides Booklet Maker continues 3 4 5 2 ...

Page 10: ...ver Feeder 1 Loading capacity mark 2 Rear side guide 3 Paper orientation label 4 Feed roller assembly 5 2 3 1 4 7 8 6 5 Paper separator pad also see page 52 6 Air nozzle 2x 7 Front side guide 8 Jam clearance baffle ...

Page 11: ...11 COM BK5010 Trimmer 1 2 4 1 Top cover 2 Trim bin 3 Base 4 Connections 3 Stacker COM BK5010 Terminator Com BF5010 Power from BK5010 ...

Page 12: ...mer interior has parts that you will come in contact with if a misfeed occurs 1 Set counter 2 Trimmer stop 3 Outfeed latch 4 Exit compressing brackets 5 Transport belt 6 Infeed roller shaft 7 Trimmer fan 8 Upper knife 9 Infeed latch Trimmer top view ...

Page 13: ...13 1 1 Top cover 2 Trim bin 3 Base 4 Connections 3 Stacker COM BF5010 Terminator POW BF5010 2 Book Folder 4 ...

Page 14: ... 1 Lower feed belts 2 Upper feed belts 1 2 Book Folder top view Upper feed belts in lifted up Book Folder continues The Book Folder interior has parts that you will come in contact with if a misfeed occur ...

Page 15: ...e procedures are described in section 4 Jobs The Tools screen Pressing the Tools button in the Ready screen takes you to the tools screen Here you will find all the necessary tools for a troublefree operation From here you can change the display language set units from millimeters to inches and more See section 3 Tools for how to get around in the Tools screen Changing settings To change or adjust...

Page 16: ...line mode you do not have to wait for the Ready screen before handfeeding the next set The Please wait screen While the machine sometimes needs time to perform changes in settings the Please wait screen will be shown The machine will automatically return to the Ready screen after changes have been implemented ...

Page 17: ...t on the shelf on the Booklet Maker Move the Booklet Maker up to the copier and dock it Note Make sure the Booklet Maker is powered on Turn the Copier on The Copier is now in Booklet maker mode and a staple icon is now present in the Copier display panel 1 Basics Docking Undocking Docking the Booklet Maker 7 6 ON 5 4 3 2 1 7 6 ON 5 4 3 2 1 7 6 ON 5 ...

Page 18: ... Copier Note Be careful not to damage the communication cable Take the Exit tray from the shelf on the Booklet Maker and install it on the Finisher Lift up the Exit arm catcher and move the Exit paper arm to the lower position Turn the Copier on The Copier is now in standard Copier mode Undocking the Booklet Maker Basics 7 6 4 3 2 7 6 4 3 2 7 6 5 ...

Page 19: ...rom the Booklet Maker Open the Top cover 1 Set main power switch 2 on Booklet Maker to ON position Note The main power switch also controls Cover Feeder optional Trimmer optional and Book Folder optional Close the Top cover Turning On Off the Main Power Turning On Off the Main Power Booklet Maker Cover Feeder Trimmer and Book Folder 2 1 ...

Page 20: ...apler head Check staples Staple cartridge and stapler head Basics Open the top cover Remove the set of paper Disconnect the staple indication lead A from the socket Hold the stapler head in place press the release latch B to release the rear end of the stapler head and lift up this end Lift out the head allowing it to rotate around the front end The stapler assembly is spring loaded and will follo...

Page 21: ...rely holding the head actuate the Stapler up and down through full travel Perform this operation with staple cartridge Repeat this a few times to ensure that the staples are ejected at each down movement Reinstall the stapler head by inserting the pin at the top of the stapler head into the stapler retraction swing arm D While rotating the stapler head insert the pin located at the rear end of the...

Page 22: ...1 22 Basics Emptying the trim bin Remove the trim bin by lifting it and pulling it out trim bin no Book Folder installed trim bin with Book Folder installed ...

Page 23: ... permanent changes From the Ready screen press the Jobs button to reach the Jobs screen Select the Job you want to change by pressing the Next button and then press the Change button Note Choose either of the above mentioned procedures when changing size stapling trimming covers or book folding as follows From the Ready screen select Size and press the Change button General procedure Select Auto o...

Page 24: ...he preprogrammed paper sizes Scroll down to Custom sizes by pressing the arrow button and press the OK button Select the custom paper size you want to use and press the OK button If you want to adjust select the custom paper size you want to change and press the Change button Select Width or Length with the arrow button and press the Change button Stapling Selecting stapling On or Off From the Rea...

Page 25: ...h the arrow button and press the OK button Selecting stapling On or Off continues Trimming Selecting trimming On or Off If trimming was On the first choice will be Off and vice versa Select On or Off with the arrow button and press the OK button From the Ready screen select Trim and press the Change button ...

Page 26: ...e fed Select Feed if you want to fold only one sheet in sequence Press the OK button to confirm From the Ready screen select Cover and press the Change button Adjusting the cutting margin Select Trim and press the Change button Select Trim length and press the OK button Press the or buttons to fine adjust in increments of 0 5 mm or 0 02 inches The trimmed booklet size and waste are displayed Press...

Page 27: ...e the Top Cover without removing the cover sheet the cover sheet will be stapled and folded and then fed to the stacker Make sure that the cover sheets are well fanned to avoid misfeeds or double feeds Align the cover sheets well to achieve a reliable feeding operation and good finishing results When using printed covers make sure that the ink has completely dried to avoid smearing Press on top of...

Page 28: ...oklet out to the Belt stacker Use the manual modes to override the auto function There are four different manual modes to select from Mode 1 Approximately 6 to 11 sheets Decreased amount of square forming Mode 2 Approximately 12 to 16 sheets Medium amount of square forming Mode 3 Approximately 17 to 23 sheets Increased amount of square forming Mode 4 Approximately 24 to 30 sheets Maximum amount of...

Page 29: ...pier or off line mode working as a stand alone unit Off line mode Follow Undocking the Booklet maker in section 1 Basics Adjust the hand feeding paper guides to the correct paper size Turn on the Booklet maker The Booklet maker is now in stand by and will start automatically when a set is fed into the Booklet maker If settings need to be changed follow Changing settings earlier in this section ...

Page 30: ... Paper tray A Select Staple icon B Note Make sure correct original orientation C is selected Select Dup Combine Series D Select Book E Select 1 Sided F if your originals are only printed on one side or 2 Sided G if they are printed on both sides Select Magazine H Select Quantity I Press the Start key Begin On line Production Begin On line Production A Paper tray B Staple icon D Dup Combine Series ...

Page 31: ...s From this screen you can change units between millimeters and inches Select Units with the arrow button and press the OK button Select the millimeters or inch units and then press the OK button Select Software version with the arrow button and press the OK button This screen and sub screens show the software version for the different modules in the booklet making system Software version ...

Page 32: ...arrow button and press the OK button Select desired language with the arrow button and press the OK button Select the module in the system for which you want to check the software version and press the OK button This screen will show software version s in the selected module Software version continues Tools ...

Page 33: ...rements of 10 with the or buttons and press the OK button Normal user default setting is 60 The Tools Screen Double Sheet Detection From this screen you can turn the double sheet detection On or Off Select Double sheet det with the arrow button and press the OK button Normally double sheet detection should be set to On However if you experience false double sheet feeds for example when running cov...

Page 34: ...3 34 Tools Service access This screen is for authorized service personnel only and is password protected ...

Page 35: ...ccept the changes you just made Continued on next page The Booklet Maker has a maximum storage capacity of 10 different jobs It is not possible to delete jobs therefore when you need to store a new job an old job must be overwritten To make temporary changes in the actual job settings or temporary changes of a stored job see section 2 Making Booklets Storing a new Job To store a new job or add new...

Page 36: ...e Next button Then press the Load button The booklet maker will then automatically setup that specific job and return to the Ready screen Storing a new Job continues To store the job press the Save button If you want to run the actual job press the Load button The booklet maker will then automatically setup that specific job and return to the Ready screen ...

Page 37: ...ooklet Maker display The message Clear Misfeed s an error code and the location of the misfeed is displayed See examples below General Misfeeds in the Booklet Maker are indicated as area A B or C and by the error code BK XXX Misfeeds in the Book Folder are indicated as area E and by the error code BF XXX ...

Page 38: ...ition remains Switch off the main power Switch on the main power If misfeed condition remains Switch off the main power If a Trimmer is installed first remove the trim bin to get access to the fold stop By hand pull down the fold stop page 8 item 9 Remove misfed sheets Push the fold stop back into the upper position Switch on the main power Clearing misfeed s Booklet Maker Inside the Booklet Maker...

Page 39: ...ed sheets are removed lift up the latch B and place the infeed roller shaft into operating position Clearing misfeed in input area The upper trimmer blade on the trimmer is protected by a knife protection plate that moves away during the cutting stroke Jams can occur in the input area or the exit area WARNING Never put fingers or other parts of the body between the upper and lower trimmer knives A...

Page 40: ...t the exit compressing brackets A Secure them under the latch B Remove the misfed sheets from the exit area After the misfed sheets are removed lift up the latch B and place the compressing brackets in operating position Clearing misfeed in exit area ...

Page 41: ...1 Open the Top Cover Lift the jam clearance baffle A Remove the misfed cover Put the jam clearance baffle back in normal position Clearing Jams Clearing misfeed s in vertical transport area Cover Feeder A ...

Page 42: ...release Remove the misfeeds Place the upper feed belts in normal position Close the top cover Inside the Book Folder Exit area Open the top cover A Lift up the cover B of the Belt stacker Remove the misfeeds Place the cover in normal position Close the top cover A A Clearing misfeed s Book Folder B B B ...

Page 43: ... BK 212 indicates to remove purged set in Booklet maker BK 401 indicates Check staple s in the Booklet maker TR 201 to TR 204 indicates Clear Misfeed s in the Trimmer TR 401 indicates Empty Trim bin in the Trimmer CF 201 to CF 205 indicates Clear Misfeed s in the Cover feeder CF 401 indicates Out of covers when there is no more cover sheets in the Cover feeder How to clear see Cover feeder fault c...

Page 44: ...nd the jam area will be displayed See section 5 Clearing Misfeeds for how to clear a misfeed Close cover s When the message Close Cover s is displayed any of the interlock switches are actuated Check that the top cover is in down position Make sure that the cover of the Belt Stacker is in normal position see section 5 Clearing Misfeeds Exit area ...

Page 45: ...tridges are OK and set is within specifications remove and check stapler head according to section 1 Basics This message will be displayed when the Cover feeder could not feed a cover from the paper bin Check cover loading according to section 2 Making Booklets If problem persists clean separator pad according to section 7 REMARKS This message will be displayed when the Cover Feeder detects that m...

Page 46: ...er will start If you wish to continue production using up the cover sheets that are loaded Press ESC Code CF 501 will extinguish and copier will start Code CF 401 is displayed when covers are empty If you wish to continue production Load more cover sheets according to section 2 Making Booklets If cover job is finished and you wish to run a new job without covers Select Cover Off in the Cover menu ...

Page 47: ...creased To clean the feed belts see section 7 REMARKS Maintaining Your Machine To increase the pressure on the upper feed belts follow this procedure Open the top cover Place both springs in the upper position Close the top cover Book Folder fault codes Feed errors Spring in normal position Spring in upper position ...

Page 48: ...6 48 ...

Page 49: ...Do not override or bypass electrical or mechanical interlock devices Do not operate the equipment if you notice unusual noises or odors Disconnect the powercord from the power source and call your authorized technician to correct the problem Warning Do not put fingers or other parts of the body between the upper and lower trimmer knives Do not switch off the main power switch while machine is runn...

Page 50: ...nect the machine to a power source that lacks a ground connection terminal Always locate the equipment on a solid support surface with adequate strength for the weight of the machine Always keep magnets and all devices with strong magnetic fields away from the machine If the place of installation is air conditioned or heated do not place the machine where it will be Subjected to sudden temperature...

Page 51: ...machine Where to put Your Machine Place the machine near the power source providing clearance as shown 1 Left more than 400 mm 15 3 4 2 Front more than 555 mm 21 7 8 3 Right more than 400 mm 15 3 4 off line use 1 2 3 ...

Page 52: ...g number of misfeeds or double feeds is one indication of the need to clean the Feed Rollers Remove the feed roller assembly by pressing it to the front of unit A The left end of the feed roller assembly will now be released B and the assembly can be removed Clean the Feed rollers and the Paper separator pad with water and a clean lint free cloth Cleaning feed rollers and paper separator pad Cover...

Page 53: ...he feed belts with water and a lint free cloth Open the top cover Clean the upper feed belts A The upper feed belts can easily be rotated in either direction Lift up the upper feed belts to access the lower feed belts Clean the lower feed belts B Rotate the lower feed belts towards the outfeed side for complete cleaning Place the upper feed belts in normal position Close the top cover Book Folder ...

Page 54: ...7 54 ...

Page 55: ...om sizes are available Paper Size Minimum Width 206mm 8 1 Length 275mm 10 8 Paper Size Maximum Width 320mm 12 6 Length 457 2mm 18 Paper Weight Minimum 64gsm 16 lb Bond Paper Weight Maximum 300gsm 172 lb Index 115 lb Cover Engine Duplex 216 gsm Input Output Sheets 1 30 Sheets 80 gsm 20 lb Bond equivalent TBD Stapled Input Output Sheets 1 2 Sheets Non Stapled Folding Off line Use Possible Stitch Fol...

Page 56: ...0 Trimmer TR5010 option Specifications Remarks Speed Same as BK5010 Standard Paper Sizes Same as BK5010 Custom sizes are available Default trim length 4 5 mm 11 64 Adjustable in 0 5 mm steps Minimum trimming 1 mm 0 0394 in Adjustable in 0 5 mm steps Maximum trimming 16 mm 0 63 Adjustable in 0 5 mm steps Paper Weight Minimum Same as BK5010 Paper Weight Maximum Same as BK5010 Engine Duplex 216 gsm I...

Page 57: ...m sizes are available Paper Weight Minimum Same as BK5010 Paper Weight Maximum Same as BK5010 Input Output Sheets Same as BK5010 Input Output Sheets Same as BK5010 Off line Use Possible Together with Booklet maker Trimmer Weight 52 kg 114 6 lb Dimensions 360 x 900 x 620 mm 14 2 x 35 4 x 24 4 Power Source From BK5010 ...

Page 58: ...ing 35 L Language selecting 32 M Turning On Off the Main Power 19 Machine environment 50 specifications 55 Maintaining Your Machines 52 Making Booklets 23 Misfeed s clearing 37 O Options 10 P The Please wait screen 16 The Processing screen 16 Turning On Off the Main Power 19 Paper Size setting 23 Paper size custom 24 Power connection 50 R REMARKS 49 S Service access 34 Setting Paper Size 23 Settin...

Page 59: ...59 ...

Page 60: ......

Page 61: ...7 6 ON 5 4 3 2 1 Part No 76434 X17099 2 3 April 2006 ...

Page 62: ...7 6 5 4 3 2 1 2 3 April 2006 ...

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