Ricoh BK5010e User manual

BOOKLET MAKER BK5010e
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.
16 April 2009

Part no: 76543
Doc no: x04083
rev , 16 April 2009
Warning:
This is a ClassAproduct. In a domestic environment this product may cause radio interference
in which case the user may be required to take adequate measures.
The product (System) which is connected to this machine will be class A
Note
The domestic environment is an environment where the use of broadcast radio and television
recievers may be expected within a distance of 10 m of the apparatus concerned.

Introduction
This manual contains instructions on the operation and maitenance of this machine. To get
the maximum versatility from this machine all operators should carefully read and follow
the instructions in this manual. Keep this manual in a handy place near the machine.
Please read the Safety Information before using this machine. It contains information re-
lated to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS.
How to read this manual
Notation conventions
Whenever necessary, the following points for attention are indicated in this manual.
WARNING:
Indicates a potentially hazardous situation which, if instructions are not followed, could
result in death or serious injury.
CAUTION:
Indicates a potentiality hazardous situation which, if instructions are not followed, may
result in minor or moderate injury or damage to machine or property.
Note
This sign refers to:
Remarks for making the operation much easier. You get practical hints or knowledge to
assist you in the machine operation such as:
Preparations required before operating
How to prevent papers from being misfed or damaged
Precautions required or actions to take after misoperation
Limitations like numerical limits, functions that cannot be used together or conditions,
under which a particular function cannot be used or obtained.
Information.
[ ]
Keys that appear on the machine’s display panel.
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WARNING:
To avoid hazardous situations like for instance electric shock or danger while exposed
to moving, rotating or cutting devices, do not remove any covers, guards or screws
other than those specied in this manual.
Turn off the power and disconnect the power plug (by pulling the plug, not the cable) if
any of the following conditions exists:
You drop objects or spill something into the equipment.
You suspect that your equipment needs service or repair.
Your equipment’s covers has been damaged.
You notice unusual noises or odours when operating the equipment.
If the power cable or plug becomes worn out or otherwise damaged.
Before cleaning and care (unless otherwise specically instructed).
Electromagnetic compliance:
This is a Class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.
The product (System) which is connected to this machine will be class A.
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Safety Information
When using this machine, following safety precautions should always be followed.
Safety during operation
General safety
WARNING:
Always connect the equipment to a properly grounded power source (wall outlet). If in
doubt, have the power source checked by a qualied electrician.
Improper grounding of the equipment can result in electrical shock. Never connect the
machine to a power source that lacks a ground connection terminal. This machine is
destined for specic purpose only. Any use going beyond this specic purpose is re-
garded as beyond the determination. The manufacturer will not be liable for damages
resulting from any use beyond the determination, unallowed operation, respectively.
The user alone bears the risk.
Do not make arbitrary changes or modications to the machine. The manufacturer will
not be liable for modications made at the machine on your own and damages result-
ing thereof. EC declaration of conformity and the mark CE will be invalidated, if you
make changes at the machine or at the individual components.
Do not override or bypass electrical or mechanical interlock devices.
The machine is to be used only by authorized and instructed persons. The responsibil-
ities on operating the machine have to be strictly laid down and observed so that there
are no unclear competences regarding safety aspects.
Vent holes serve for air circulation to protect the machine from overheating. Make sure
that the holes are not covered.
Do not expose ngers or other parts of the body to moving, rotating or cutting devices
such as for instance between upper and lower trimmer knives.
Allways locate the equipment on a solid support surface with adequate strength tor
the weight of the machine.
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Note
The indications like front and rear, left and right refer to the paper transport direction.
The operator manual always has to be available at the place of use of the machine.
In the interest of technical development the company reserves the right to make alterations to
specications without prior notice!
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CAUTION:
The machine and its peripherals must be installed and maintained by a customer service repre-
sentative who has completed the training course on those models.
Allways follow all warnings marked on, or supplied with, the equipment.
When you disconnect the power plug from the wall outlet, allways pull the plug (not the cable).
Disconnect the power cord before you move the machine. While moving the machine, allways
exercise care and make sure that the power cord will not be damaged under the machine.
Allways contact service if relocating the equipment.
Do not move the machine while the machine is running.
Do not open covers while the machine is running.
Do not switch of the power while the machine is running. Make sure the machine cycle has
ended.
Lay the power cord in a way that nobody will stumble over it. Do not place things on the cord.
Never attempt any maintenace function that is not specically described in this documentation.
Always keep magnets and all devices with strong magnetic elds away from the machine.
If the place of installation is air-conditioned or heated, do not place the the machine where it
will be:
Subject to sudden temperature changes.
Directly exposed to cool air from an air-conditioner.
Directly exposed to heat from a heater.
If the machine is not used over an extended period of time it should be unplugged to prevent
damage in the case of overload.
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General safety, continued

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TABLE OF CONTENTS
What You Can Do With This Machine ............................................................................................ 9
Guide To Components .................................................................................................................. 11
Booklet Maker ............................................................................................................................................ 11
Options ...........................................................................................................................................13
Cover Feeder .............................................................................................................................................14
Trimmer ......................................................................................................................................................15
Book Folder................................................................................................................................................17
Control Panel .................................................................................................................................19
1. Basics ...............................................................................................21
Docking / Undocking ..................................................................................................................... 21
Docking the Booklet Maker ........................................................................................................................21
Undocking the Booklet Maker ....................................................................................................................22
Turning On / Off the Main Power .................................................................................................. 23
Booklet Maker, Cover Feeder, Trimmer and Book Folder ..........................................................................23
Check staples, Staple cartridge and stapler head...................................................................... 24
Removing stapler head ..............................................................................................................................24
Removing staple cartridge..........................................................................................................................24
Installing stapler head, staple cartridge / clearing staple jam.....................................................................25
Emptying the trim bin ....................................................................................................................26
2. Making Booklets ..............................................................................27
Changing settings .........................................................................................................................27
General procedure .....................................................................................................................................27
Setting Paper Size......................................................................................................................................27
Selecting standard paper sizes .......................................................................................... 27
Custom paper size ...............................................................................................................28
Stapling ......................................................................................................................................................28
Selecting stapling On or Off ................................................................................................28
Trimming.....................................................................................................................................................29
Selecting trimming On or Off .............................................................................................. 29
Adjusting the cutting margin ..............................................................................................30
Covers........................................................................................................................................................30
Selecting Cover Feeder Mode .............................................................................................30
Loading covers .....................................................................................................................31
Book Folding ..............................................................................................................................................31
General ..................................................................................................................................31
Setting Mode ..............................................................................................................................................32
Procedure .............................................................................................................................32
On-line/Off-line ...............................................................................................................................33
Off-line mode..............................................................................................................................................33
On-line mode..............................................................................................................................................33
Begin On-line Production .............................................................................................................34
3. Tools .................................................................................................35
The Tools Screen ........................................................................................................................... 35
Units ...........................................................................................................................................................35
Software version.........................................................................................................................................35
Language ...................................................................................................................................................36
Air Separation.............................................................................................................................................37
Double Sheet Detection .............................................................................................................................37
Service access ...........................................................................................................................................38
4. Jobs ..................................................................................................39
Storing and deleting jobs ............................................................................................................. 39
Storing a new Job.......................................................................................................................................39
Recalling a Job...........................................................................................................................................40

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5. Clearing Misfeed(s) .........................................................................41
Clearing misfeed(s) .......................................................................................................................................................... 41
General ......................................................................................................................................................................... 41
Booklet Maker ...................................................................................................................................................................42
Clearing misfeed(s)....................................................................................................................................................... 42
Inside the Booklet Maker ...................................................................................................................................... 42
Trimmer ............................................................................................................................................................................. 43
Clearing misfeed(s)....................................................................................................................................................... 43
Clearing misfeed in input area ............................................................................................................................. 43
Clearing misfeed in exit area ............................................................................................................................... 44
Cover Feeder.....................................................................................................................................................................45
Clearing misfeed(s) in vertical transport area............................................................................................................... 45
Book Folder ....................................................................................................................................................................... 46
Clearing misfeed(s)....................................................................................................................................................... 46
Inside the Book Folder ......................................................................................................................................... 46
Exit area .................................................................................................................................................................46
6. Troubleshooting ..............................................................................47
Fault codes........................................................................................................................................................................47
General ......................................................................................................................................................................... 47
General fault codes....................................................................................................................................................... 48
Clear Misfeed(s) .................................................................................................................................................... 48
Close cover(s) ....................................................................................................................................................... 48
Booklet maker fault codes ............................................................................................................................................49
Check staples ........................................................................................................................................................ 49
Set too thick ........................................................................................................................................................... 49
Oil clinchers ........................................................................................................................................................... 49
Remove purged sets ............................................................................................................................................. 49
Illegal feed mode ................................................................................................................................................... 49
Stacker full .............................................................................................................................................................49
Trimmer fault codes ...................................................................................................................................................... 49
Trim bin full ............................................................................................................................................................ 50
Close trimmer belts ............................................................................................................................................... 50
Cover feeder fault codes............................................................................................................................................... 50
Misfeed ...................................................................................................................................................................50
Double feed ............................................................................................................................................................ 50
Load covers ........................................................................................................................................................... 50
Book Folder fault codes................................................................................................................................................51
Feed errors ............................................................................................................................................................ 51
7. REMARKS ........................................................................................53
Do’s And Don’ts ................................................................................................................................................................ 53
Where to put Your Machine ............................................................................................................................................. 54
Machine environment ................................................................................................................................................... 54
Power connection ......................................................................................................................................................... 54
Access to machine........................................................................................................................................................ 55
Maintaining Your Machines ............................................................................................................................................. 56
Booklet Maker............................................................................................................................................................... 56
Oil Clinchers and Stapler heads .......................................................................................................................... 56
Cover Feeder................................................................................................................................................................ 58
Cleaning feed rollers and paper separator pad .................................................................................................. 58
Book Folder .................................................................................................................................................................. 59
Cleaning feed belts ...............................................................................................................................................59
8. Specication ...................................................................................61
Machine Specications ....................................................................................................................................................61
Booklet Maker BK5010e............................................................................................................................................... 61
Cover Feeder CF5010 (option)..................................................................................................................................... 62
Trimmer TR5010e (option)............................................................................................................................................ 62
Book Folder BF5010e (option)...................................................................................................................................... 63
System Certications.................................................................................................................................................... 63
Set Size Guide.............................................................................................................................................................. 64
INDEX....................................................................................................65

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What You Can Do With This Machine
The Booklet Maker BK5010e, Trimmer TR5010e, Book Folder BF5010e 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
BK5010e 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 TR5010e 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 TR5010e Trimmer is installed to the BK5010e Booklet Maker, you can can
attach the BF5010e Book Folder (optional). The printouts, which have been stapled, folded
and trimmed will be fed into the BF5010e. The BF5010e will atten the spine of the booklet
square. The booklets will, after passing the BF5010e, 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)TR5010e Trimmer (option)
BK5010e Booklet MakerBK5010 Rail unit(option)
BF5010e Book Folder (option)
Belt Stacker

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The BK5010e 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