Ricoh BOOKLET MAKER BK5010, Installation Manual

Page 1: ...INSTALLATION MANUAL BK5010 SYSTEM 4 Oct 2007 Subject to change ...

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Page 3: ...the equipment grounding conductor can result in electrical shock Always follow all warnings marked on or supplied with the equipment Always locate the equipment on a solid support surface with adequate strength for the weight of the machine Always exercise care in moving or re locating the equipment Always keep magnets and all devices with strong magnetic field away from the ma chine Never use a g...

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Page 5: ...OCEDURE 1 1 INSTALLATION REQUIREMENTS 1 1 1 MINIMUM SPACE REQUIREMENTS BF5010 TR5010 BK5010 Stacker CF5010 Rail 795 mm 31 5 16 360 mm 13 3 4 360 mm 13 3 4 625 mm 24 3 8 400 mm 15 3 4 2140 mm 84 1 4 715 mm 28 1 8 555 mm 21 7 8 INSTALLATION REQUIREMENTS ...

Page 6: ...ore 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 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 ...

Page 7: ...r Enables the possibility to add colour covers to the boolets BF5010 Book Folder Enables the possibility to give the booklets the perfect bound look Yes No Yes No 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 Is a Trimmer installed Yes No Install th...

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Page 9: ...able to SR5000 finisher 1 C Communication Cable to SR841 finisher 1 D Docking assembly 1 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 Interlock Jumper TR5010 1 L Cable protector 1 M Cable protector sticker 1 N Cable holder 1 A E D B F G I H J K C...

Page 10: ...LLATION PROCEDURE Unpacking 1 Remove all parts from the pallet 2 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 A ...

Page 11: ...cher 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 3 Lift up the Exit paper arm and set it onto the Exit arm catcher A A BOOKLET MAKER INSTALLATION ...

Page 12: ...KLET MAKER INSTALLATION A Copier exit tray 1 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 B C ...

Page 13: ...astic 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 E F D BOOKLET MAKER INSTALLATION ...

Page 14: ...meter D on one side and a smaller diameter E on the other 5 Secure the docking assembly with the two nuts C using the multi tool Mounted correctly there shall be less than 1mm play in the Docking assembly NOTE The Multi tool 3 2 is located behind the rear cover of the Book let maker x 5 NOTE Make sure to fit the nuts in the correct position The bigger diam eter should fit in the hole nearest the r...

Page 15: ...stallation kit to connector CN138H A x1 on the finisher main board NOTE Make sure to use the communication cable for SR5000 Finisher 2 Guide the Communication cable through the cable holder B and secure it in the finisher C with two tie wraps from the installation kit C A Finisher Main PCB B Finisher with rear cover installed BOOKLET MAKER INSTALLATION ...

Page 16: ...sher and BK5010 1 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 B A Finisher Main PCB ...

Page 17: ...llation 04 October 2007 1 3 3 ADJUSTMENTS 1 Remove screws A and remove the Bookler maker front cover x5 2 Remove screws B loosen screw C and remove the Bookler maker rear cover x5 A B C BOOKLET MAKER INSTALLATION ...

Page 18: ...ore docking make sure the Jogger Fence A is in the upper position If not with copier powered on open and close finisher door 3 Unhook the Exit paper arm B 4 To align the Booklet Maker side to side turn both front adjustment nuts C until the Exit paper arm B fits in the cut out D on the Booklet Maker NOTE Turn both screws equal amount of turns NOTE Do not adjust the machine sideways by moving the d...

Page 19: ...r 2007 6 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 D E Booklet Maker outfeed view BOOKLET MAKER INSTALLATION ...

Page 20: ...1 16 04 October 2007 BOOKLET MAKER INSTALLATION F 7 Place the Multi tool outside the hand feeding paper guides as illustrated F ...

Page 21: ... Installation 04 October 2007 8 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 G BOOKLET MAKER INSTALLATION ...

Page 22: ...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 Reinstall the Booklet maker front and rear covers x 10 I Booklet Maker rear view Booklet Maker front view ...

Page 23: ... 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 B A Top Cover over Cover Feeder dummy BOOKLET MAKER INSTALLATION ...

Page 24: ...umpers are stored in the installation kit 4 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 5 Connect the powercord E to the Booklet maker x1 6 Mount the cable protector H positioned as shown with two screws in the holes I and route the cables inside the cable ...

Page 25: ...Reinstall the two Stapler heads according to section 3 4 12 6 Power on the Copier NOTE Make sure that the Booklet maker is powered ON before the Copier 7 Set up the Booklet maker to Auto paper size 8 Send one A4 8 5 x 11 job to the Booklet maker 9 Check for the correct feeding of the paper NOTE If paper is not fed correctly check adjustment of the Booklet maker ac cording to section 1 3 3 10 Send ...

Page 26: ...LLATION 1 4 1 ACCESSORY CHECK 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 DSD Calibration strip 1 A B C COVER FEEDER INSTALLATION ...

Page 27: ...N PROCEDURE Unpacking 1 Remove all parts from the box 2 Cut the cable tie A to release the paper bin and DSD Calibration strip B 3 Place the DSD Calibration strip on the cable holder C behind the Booklet Maker rear cover B C A COVER FEEDER INSTALLATION ...

Page 28: ...1 24 04 October 2007 COVER FEEDER INSTALLATION 1 If installed remove the Upper Top Cover by removing the screws A and B x 4 A B Removal of the Upper Top Cover ...

Page 29: ...1 25 Installation 04 October 2007 1 Open the Booklet Maker Top Cover 2 Remove the screw A x 1 A Removal of the Rear Top Cover COVER FEEDER INSTALLATION ...

Page 30: ...1 26 04 October 2007 COVER FEEDER INSTALLATION 3 Remove the screws B and remove the Rear Cover of the Top Cover C x 3 B B C ...

Page 31: ... 1 Remove the nut A x 1 NOTE Nut will be used later when installing the Cover Feeder 2 Remove the screws B x 2 NOTE Screws will be used later when installing the Cover Feeder A B Removal of cover Feeder dummy COVER FEEDER INSTALLATION ...

Page 32: ...1 28 04 October 2007 COVER FEEDER INSTALLATION D C 3 Loosen nuts C x 2 4 Remove the Cover Feeder dummy D by sliding it out ...

Page 33: ...n 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 NOTE The frame of the Cover Feeder C must be on the outside of the bracket B in the Top Cover Cover Feeder outer side view Cover Feeder inner side view A C C A B B COVER FEEDER INSTALLATION ...

Page 34: ...1 30 04 October 2007 COVER FEEDER INSTALLATION 2 Secure the Cover Feeder with the nut D and the screws E x 1 x 2 D E Cover Feeder viewed from Booklet Maker rear side ...

Page 35: ...or harness A x 2 2 Install sensor harness B x 1 3 Install fan harness C x 1 A B C Installation of the Cover Feeder connectors Cover Feeder viewed from Booklet Maker outfeed Cover Feeder viewed from Booklet Maker front side COVER FEEDER INSTALLATION ...

Page 36: ...shing A in the hole in the Cover Feeder front side frame B 2 Press the feed roller against the Cover Feeder front side frame and insert the one way clutch C into the drive clutch D NOTE Make sure that the one way clutch C fully enters the drive clutch D A B C D Installation of Feed roller ...

Page 37: ...r 2007 1 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 C A B D Installation of the Rear Top Cover COVER FEEDER INSTALLATION ...

Page 38: ...1 34 04 October 2007 COVER FEEDER INSTALLATION 2 Secure the screw E x 1 E ...

Page 39: ...Installation 04 October 2007 1 Install the Top Cover by inserting the studs A into the grommets B 2 Secure the Top Cover with screws C x 2 A B C Installation of the Upper Top Cover COVER FEEDER INSTALLATION ...

Page 40: ...OK button 5 Press the CHG button so the Installed is set to YES 6 Press the OK button 7 Perform a Cover Feeder motors Calibration according to section 5 5 8 Perform a Cover Feeder DSD sensor Calibration according to section 5 5 9 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: ...the Cover Feeder will prefeed the first cover to be ready for the set from the copier 11 Set up the Booklet maker to A4 8 5 x 11 paper size 12 Send one A4 8 5 x 11 job to the Booklet maker system 13 Check for the correct feeding of the set from the finisher NOTE The paper should enter in the middle of the infeeder If not adjust the Booklet maker according to section 1 3 3 14 Check that the covers ...

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Page 43: ... trim bin is tie wraped on the rear side Trimmer fan is bubble wrapped and located inside the Trimmer The Rail Extension is located in the packing material Description Q ty A Communication cable between the Booklet maker 1 and the Trimmer B Powercord between the Booklet maker and Trimmer 1 C Trimmer fan assy 1 D Rail extension 1 Plugs and screws 4 E Cable protector 1 F Cable protector sticker 1 G ...

Page 44: ...cking 1 Remove all parts from the pallets 2 Ensure all of the packing material is removed from the outside of the Trimmer 3 Tilt the Trimmer to upright position WARNING 2 persons are required to tilt the Trimmer to the upright position TRIMMER INSTALLATION ...

Page 45: ...October 2007 A Remove the belt stacker 1 Loosen screws A on the Booklet Maker x 2 2 Disconnect the Belt stacker cable x 1 3 Remove belt stacker from the Booklet maker 4 Secure screws A x 2 Booklet Maker TRIMMER INSTALLATION ...

Page 46: ...il under the Boklet Maker 2 Insert the Rail extension A into the Rail under the Booklet Maker B 3 Press the plugs C into the holes in the Rail under the Trimmer and press hammer down the plugs x 4 4 Insert the Rail stop D into the Rail extension 5 Secure the Rail stop with the screws E x 4 A C B D E ...

Page 47: ...1 43 Installation 04 October 2007 1 Remove the Trimmer front cover by removing the screws A x 5 2 Move the Trimmer up to the Booklet maker A 1 5 3 ADJUSTMENTS Height adjustment TRIMMER INSTALLATION ...

Page 48: ...acket 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 NOTE Make sure that the Ground plate on the docking bracket B is ground ed correctly Height adjustment B C D ...

Page 49: ...4 October 2007 4 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 E F TRIMMER INSTALLATION ...

Page 50: ... the Locking bracket B x 2 2 Dock the Trimmer to the Booklet maker 3 Secure the Trimmer by lifting the Locking bracket B and tightening nuts A x 2 NOTE Make sure that the Trimmer locking bracket B locks in the outer slot C on the positioning pin A B C D D Trimmer interior towards Booklet Maker ...

Page 51: ...1 47 Installation 04 October 2007 Install Trimmer fan 1 Install Trimmer fan A by hanging it onto the position pins B inside the Trimmer A B Trimmer interior towards Booklet Maker TRIMMER INSTALLATION ...

Page 52: ... 1 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 2 Install the Belt stacker on to the Trimmer 3 Secure the Belt stacker with the screws A x 2 A Trimmer ...

Page 53: ...ion while the Trimmer is serviced 6 Connect the communication cable to the Trimmer F x1 NOTE The communication cable you received with the Trimmer 7 Connect the other end of the communication cable to the Booklet maker G x1 see next page 8 Connect the powercord to the Trimmer H x1 9 Connect the other end of the powercord to the Booklet maker I x1 see next spread 10 Mount the cable protector J posi...

Page 54: ...1 50 04 October 2007 TRIMMER INSTALLATION COM BK5010 COM BK5010 Continued on next page Trimmer with cable protector installed A C H F L J K ...

Page 55: ...1 51 Installation 04 October 2007 E G I Booklet Maker rear side Booklet Maker with Trimmer installed TRIMMER INSTALLATION ...

Page 56: ... 6 Key in the Password 7 Scroll down to EEPROM Values and press the OK button 8 Scroll to INDEX 16 TR5010 Knife Zero and press the CHG button 9 Key in the value you have in the trimmer 10 Go down to Store and press the OK button 11 Perform a Detailed self diagnostic according to section 5 3 3 12 Restart the system 13 Power on the Copier NOTE Make sure that the Booklet maker is powered ON before th...

Page 57: ...rect feeding of the set from the finisher NOTE The paper should enter in the middle of the infeeder If not adjust the Booklet maker according to section 1 3 3 21 If a Cover Feeder CF5010 is installed check that the covers are correctly fed into the Booklet maker 22 Check if the set has been trimmed correctly 23 If a Cover Feeder CF5010 is installed A Set up the Cover Feeder to Cover OFF and remove...

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Page 59: ...ty A Communication cable 1 B Power cord 1 C Auto set thickness bracket with spring 1 D Sensor bracket with sensor 1 E Spacer pin and screw 2 F 25 mm washer and screw 2 G Extended trim bin two parts 1 Screw and nut 4 H COM BF5010 sticker 1 I Ground strap and screw 1 J Rail extension 1 Plugs and screws 4 K Cable protector 1 L Cable protector sticker 1 M Cable holder 1 COM BF5010 K L M BOOK FOLDER IN...

Page 60: ...Remove all parts from the pallets 2 Ensure all of the packing material is removed from the outside of the Book Folder 3 Tilt the Book Folder to upright position WARNING 2 persons are required to tilt the Book Folder to the upright position BOOK FOLDER INSTALLATION ...

Page 61: ... on the Trimmer 6 Remove the positioning pins from the upper holes B used for the belt stacker x 2 7 Using the lower hole C install the Ground strap to the inside of the position ing pin E using the 25 mm washer and screw provided x 1 x 1 8 Install the other end of the ground strap to the rear frame D x 1 torx 9 Using the second lower hole install the other positioning pin using the 25 mm washer a...

Page 62: ...ALLATION Extended trim bin A 1 Remove the existing trim bin from the Trimmer This trim bin can not be used together with the Book Folder 2 Assemble the new extended trim bin A with the four screws and nuts from the installation kit x 4 x 4 ...

Page 63: ...e Trimmer 2 Insert the Rail extension A into the Rail under the Trimmer B 3 Press the plugs C into the holes in the Rail under the Trimmer and press hammer down the plugs x 4 4 Insert the Rail stop D into the Rail extension 5 Secure the Rail stop with the screws E x 4 A C B D E BOOK FOLDER INSTALLATION ...

Page 64: ...1 60 04 October 2007 BOOK FOLDER INSTALLATION 1 6 3 ADJUSTMENTS Height adjustment 1 Remove the front cover of the Book Folder by removiing the screws A x 5 2 Move the Book Folder up to the Trimmer A ...

Page 65: ...oles C on the Book Folder Adjust by turning the four nuts 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 B C Trimmer Book Folder Book Folder rear view Book Folder front view BOOK FOLDER INSTALLATION ...

Page 66: ...LDER INSTALLATION Parallellity adjustment 4 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 E F ...

Page 67: ... Book folder by lifting the Locking bracket B and tightening nuts A x 2 NOTE Make sure that the Book Folder locking bracket B locks in the outer slot C on the positioning pin D 4 Install the new Extended trim bin A B 1 6 4 DOCKING Docking procedure C D D Book Folder interior view towards Belt Stacker BOOK FOLDER INSTALLATION ...

Page 68: ...OOK FOLDER INSTALLATION Installing Belt stacker 1 Loosen screws A x 2 on the Book Folder 2 Install the Belt stacker on to the Book Folder 3 Secure the Belt stacker by tightening screws A x 2 on the Book Folder A Book Folder ...

Page 69: ...munication cable D between the Trimmer and the Book Folder x 1 5 Connect the power cord from the BK5010 to the BF5010 6 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 7 Attach the sticker Do not lift here G on the cable protector 8 Install the cable holder on the rear side of the Book Folder 9 Route cables through ...

Page 70: ... BK5010 3 3 1 x 5 3 Install the Spacer pin A with the collar out NOTE Install the Spacer pin s on the rear side of the Booklet maker 4 Install the Auto set thickness bracket B and tighten it with the other Spacer pin C with the collar in A B C CAUTION ONLY install spacer pin A and C finger tight Over tightening may break loose the screw from the Fold roller plate Booklet Maker rear side view ...

Page 71: ...cure the Sensor bracket by tightening it with the screws B C x 2 torx NOTE Make sure that the Actuator runs in the sensor slot 3 Connect the sensor harness D to the sensor on bracket E x 1 A B C D E Booklet Maker rear side view Booklet Maker rear side view Booklet Maker rear side view BOOK FOLDER INSTALLATION ...

Page 72: ...16 TR5010 Knife Zero and press the CHG button 8 Key in the value you have in the trimmer 9 Go down to Store and press the OK button 10 Remove the two Stapler heads according to section 3 4 12 11 Perform a detailed self diagnostic according to section 5 3 3 12 Reinstall the two Stapler heads according to section 3 4 12 13 Power on the Copier NOTE Make sure that the Booklet maker is powered ON befor...

Page 73: ... should enter in the middle of the infeeder If not adjust the Booklet maker according to section 1 3 3 21 If a Cover Feeder CF5010 is installed check that the covers are correctly fed into the Booklet maker 22 Check if the sets have been trimmed correctly 23 Check that the booklet not has a Book folded spine 24 If a Cover Feeder CF5010 is installed A Set up the Cover Feeder to Cover OFF and remove...

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