Ricoh BOOKLET MAKER BK5010 User manual

BOOKLET MAKER BK5010
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

Part no: 76436
Doc no: x04077
rev , 19 April 2006

3
TABLE OF CONTENTS
What You Can Do With This Machine ............................................................................................ 5
Guide To Components .................................................................................................................... 7
Booklet Maker .............................................................................................................................................. 7
Options........................................................................................................................................... 10
Cover Feeder ............................................................................................................................................. 10
Trimmer ...................................................................................................................................................... 11
Book Folder ................................................................................................................................................13
Control Panel ................................................................................................................................. 15
1. Basics............................................................................................... 17
Docking / Undocking..................................................................................................................... 17
Docking the Booklet Maker ........................................................................................................................ 17
Undocking the Booklet Maker .................................................................................................................... 18
Turning On / Off the Main Power.................................................................................................. 19
Booklet Maker, Cover Feeder, Trimmer and Book Folder ..........................................................................19
Check staples, Staple cartridge and stapler head...................................................................... 20
Removing stapler head .............................................................................................................................. 20
Removing staple cartridge..........................................................................................................................20
Installing stapler head / clearing staple jam ............................................................................................... 21
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 ............................................................................................................................. 28
On-line/Off-line............................................................................................................................... 29
Off-line mode.............................................................................................................................................. 29
On-line mode.............................................................................................................................................. 29
Begin On-line Production ............................................................................................................. 30
3. Tools ................................................................................................. 31
The Tools Screen........................................................................................................................... 31
Units ...........................................................................................................................................................31
Software version.........................................................................................................................................31
Language ...................................................................................................................................................32
Air Separation.............................................................................................................................................33
Double Sheet Detection ............................................................................................................................. 33
Service access ...........................................................................................................................................34
4. Jobs .................................................................................................. 35
Storing and deleting jobs ............................................................................................................. 35
Storing a new Job.......................................................................................................................................35
Recalling a Job........................................................................................................................................... 36

4
5. Clearing Misfeed(s) ......................................................................... 37
Clearing misfeed(s) ....................................................................................................................... 37
General.......................................................................................................................................................37
Booklet Maker................................................................................................................................ 38
Clearing misfeed(s) ....................................................................................................................................38
Inside the Booklet Maker..................................................................................................... 38
Trimmer .......................................................................................................................................... 39
Clearing misfeed(s) ....................................................................................................................................39
Clearing misfeed in input area............................................................................................ 39
Clearing misfeed in exit area .............................................................................................. 40
Cover Feeder.................................................................................................................................. 41
Clearing misfeed(s) in vertical transport area.............................................................................................41
Book Folder.................................................................................................................................... 42
Clearing misfeed(s) ....................................................................................................................................42
Inside the Book Folder ........................................................................................................ 42
Exit area ................................................................................................................................ 42
6. Troubleshooting .............................................................................. 43
Fault codes..................................................................................................................................... 43
General.......................................................................................................................................................43
General fault codes ....................................................................................................................................44
Clear Misfeed(s) ................................................................................................................... 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 Feeder ............................................................................................................................................. 52
Cleaning feed rollers and paper separator pad................................................................. 52
Book Folder ................................................................................................................................................53
Cleaning feed belts .............................................................................................................. 53
8. Specication ................................................................................... 55
Machine Specications................................................................................................................. 55
Booklet Maker BK5010...............................................................................................................................55
Cover Feeder CF5010 (option) ..................................................................................................................56
Trimmer TR5010 (option) ...........................................................................................................................56
Book Folder BF5010 (option) ..................................................................................................................... 57
INDEX.................................................................................................... 59

5
What You Can Do With This Machine
The Booklet Maker BK5010, Trimmer TR5010, Book Folder BF5010 and Cover Feeder CF5010
forms a booklet making system that works online with the Copier.
The print-outs from the Copier are collected in the nisher and then transported into the BK5010
Booklet Maker to the staple area. From the CF5010 Cover Feeder (optional), if present, any
type of covers, colored or black and whites, can be added to the printed set. The Booklet
Maker now jogs and then staples the set. The set is then transported further to the folding
area where the set is folded into a booklet and then fed out to the belt stacker. When a larger
number of sheets are folded an effect called creeping occurs. In 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. The BF5010 will atten the spine of the booklet square. The booklets
will, after passing the BF5010, have the look of a perfect bound book. The booklets are then
fed out to the Belt Stacker.
To facilitate undocking, a BK5010 Rail unit (optional) can be installed under the Booklet
Maker. Undocked or off-line, the Booklet Maker can be used as a stand-alone unit for hand
feeding.
CF5010 Cover Feeder (option)TR5010 Trimmer (option)
BK5010 Booklet MakerBK5010 Rail unit(option)
BF5010 Book Folder (option)
Belt Stacker

6
The BK5010 Booklet making system is controlled from a single control panel on the Booklet
Maker. The control panel has only four buttons which will allow you to easily set up, adjust
and operate the complete system.
The buttons are multi functional, meaning that the
function 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
rst row shows that the settings for Job (1) has been
changed, but not yet saved.
Button: 1 2 3 4

7
Guide 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
89

8
89
8 Connections
9 Fold stop gate
Booklet Maker, continues
Main Power
Terminator/
COM TR5010TerminatorStacker
COM Copier POW BF5010
Interlock jumper
Interlock jumper/
POW TR5010

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

10
Options
Cover Feeder
1 Loading capacity mark
2 Rear side guide
3 Paper orientation label
4 Feed roller assembly
5
2
3
1
47
8
6
5 Paper separator pad (also see
page 52)
6 Air nozzle (2x)
7 Front side guide
8 Jam clearance bafe

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

12
Trimmer, continues
5
1
2
3
4
6
7
8
9
The Trimmer 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

13
1
1 Top cover
2 Trim bin
3 Base
4 Connections
3
StackerCOM BF5010
Terminator
POW BF5010
2
Book Folder
4

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.

15
Control Panel
The Ready screen.
When the system power is switched on the Ready
screen will be shown. Here you will nd information
showing the actual set up. From this screen you can
also access other screens, that will help you operate
the complete BK5010 Booklet making system.
arrow button
change button
tools button
jobs button
The Jobs screen.
Pressing the [Jobs] button in the Ready screen opens
the Jobs screen. From here you can load, customize
and save job settings. These 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 nd 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 settings; Select an item in the
Ready screen with the [arrow] button and press the
[Change] button. For example you can ne adjust the
trimming, turn off the cover feeder or set the Book
Folder to the correct mode. Explore all settings more
thoroughly in section 2. Making Booklets.

16
The Processing screen.
This screen is shown when the machine is busy working.
If the machine is used in off-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.

17
Turn the Copier off.
Lift up the Exit arm catcher and set the Exit paper
arm in the upper position.
Remove the Exit tray from the Finisher and put it 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
6ON
5
4
3
2
1
7
6ON
5
4
3
2
1
7
6ON
5
4
3
2
1

1
18
Turn the Copier off.
Note
Keep the Booklet Maker powered on.
Push in the latch on the docking assembly and
move the Booklet Maker away from the 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
5
4
3
2
1
7
6
5
4
3
2
1
7
6
5
4
3
2
1

1
19
Plug the Booklet Maker powercord into the wall
outlet.
Cover Feeder (optional), Trimmer (optional) and
Book Folder (optional) are powered from 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

1
20
The staple cartridges, containing approximately 5000
staples per cartridge. Cartridge may be removed either
for renewal or for jam clearance.
Raise the handle (C) on the staple cartridge locking
lever.
Remove the staple cartridge from the stapler head
by sliding it away from the stapler 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 follow the rotation of the stapler.
Removing stapler head
AB
C
Removing staple cartridge