Ricoh BOOKLET MAKER BK5010 User manual

BOOKLET MAKER BK5010
SERVICE MANUAL
4 October 2007
Subject to change

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III
IMPORTANT SAFETY NOTICES
1. Before disassembling or assembling parts of the Booklet maker and peripherals.
make sure that the Booklet maker power cord is unplugged,
2. The wall outlet should be near the Booklet maker and easily accessible.
3. Note that some components of the Booklet maker and peripherals are supplied
with electrical voltage even if the main power switch is turned off.
4. If any adjustment or operation check has to be made with exterior covers off or
open while the main switch is turned on, keep hands away from electrical or
mechanically driven components.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The Booklet maker and its peripherals must be installed and maintained by a
customer service representative who has completed the training course on those
models.
Always connect the equipment to a prop-
erly grounded power source. In doubt, have
the power source checked by a qualied
electrician.
WARNING: Improper connection of 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 eld away from the ma-
chine.
Never use a ground adapter plug to con-
nect the equipment to a power source that
lacks a ground connection terminal.
Never attempt any maintenance function
that is not specifically described in this
documentation.
Never remove the covers or guards that
are fastened with screws, unless you are a
trained Service representative.
Never install the unit near a radiator or any
other heat source.
Never override or “cheat” electrical or me-
chanical interlock devices.
Never operate the equipment if you notice
unusual noises or odors. Disconnect the
power cord from the power source and call
your customer service engineer to correct
the problem.
PREVENTION OF PHYSICAL INJURY
SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
1. Dispose of replaced parts in accordance with local regulations.

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V
TABLE OF CONTENTS
1 INSTALLATION PROCEDURE
1.1 INSTALLATION REQUIREMENTS.......................................................... 1-1
1.1.1 MINIMUM SPACE REQUIREMENTS ............................................. 1-1
1.1.2 POWER REQUIREMENTS............................................................. 1-2
1.2 INSTALLATION FLOW CHART ............................................................... 1-3
1.3 BOOKLET MAKER INSTALLATION ........................................................ 1-5
1.3.1 ACCESSORY CHECK .................................................................... 1-5
1.3.2 INSTALLATION PROCEDURE ....................................................... 1-6
1.3.3 ADJUSTMENTS............................................................................ 1-13
1.3.4 CONNECTORS............................................................................. 1-20
1.3.5 CHECK THE INSTALLATION ....................................................... 1-21
1.4 COVER FEEDER INSTALLATION ........................................................ 1-22
1.4.1 ACCESSORY CHECK .................................................................. 1-22
1.4.2 INSTALLATION PROCEDURE ..................................................... 1-23
1.4.3 ENABLING THE COVER FEEDER............................................... 1-36
1.4.4 CHECK THE INSTALLATION ....................................................... 1-37
1.5 TRIMMER INSTALLATION.................................................................... 1-39
1.5.1 ACCESSORY CHECK .................................................................. 1-39
1.5.2 INSTALLATION PROCEDURE ..................................................... 1-40
1.5.3 ADJUSTMENTS............................................................................ 1-43
1.5.4 DOCKING....................................................................................... 1-46
1.5.5 CONNECTORS............................................................................. 1-49
1.5.6 CHECK THE INSTALLATION ....................................................... 1-52
1.6 BOOK FOLDER INSTALLATION........................................................... 1-55
1.6.1 ACCESSORY CHECK .................................................................. 1-55
1.6.2 INSTALLATION PROCEDURE ..................................................... 1-56
1.6.3 ADJUSTMENTS............................................................................ 1-60
1.6.4 DOCKING....................................................................................... 1-63
1.6.5 CONNECTORS............................................................................. 1-65
1.6.6 AUTO SET THICKNESS BRACKET............................................. 1-66
1.6.7 CHECK THE INSTALLATION ....................................................... 1-68
2. PREVENTIVE MAINTENANCE SCHEDULE
2.1 PM TABLE ............................................................................................... 2-1
3. REPLACEMENT AND ADJUSTMENT
3.1 GENERAL CAUTIONS ............................................................................ 3-1
3.2 SPECIAL TOOLS AND LUBRICANTS .................................................... 3-3
3.2.1 SPECIAL TOOLS ............................................................................ 3-3
3.2.2 REQUIRED TOOLS ........................................................................ 3-5
3.2.3 LUBRICANTS ................................................................................. 3-5
3.2.4 SYMBOLS USED IN TEXT ............................................................. 3-5
3.3 COVERS.................................................................................................. 3-7
3.3.1 FRONT AND REAR COVER........................................................... 3-7
3.3.2 INFEED COVER ............................................................................. 3-8
3.3.3 INFEEDER ...................................................................................... 3-9
3.3.4 OUTFEED COVER ....................................................................... 3-10

VI
3.3.5 UPPER TOP COVER.................................................................... 3-11
3.3.6 REAR TOP COVER ...................................................................... 3-12
3.3.7 TOP COVER ASSEMBLY ............................................................. 3-13
3.3.8 INTERLOCK SWITCH S16 &S17 ................................................. 3-16
3.4 AREA A .................................................................................................. 3-17
3.4.1 INFEED MODULE......................................................................... 3-17
3.4.2 PAPER INFEED SENSOR............................................................ 3-18
3.4.3 INFEED TRANSPORT MODULE.................................................. 3-19
3.4.4 INFEED TRANSPORT WHEEL .................................................... 3-20
3.4.5 INFEED MOTOR M1 & SENSOR Q2 ........................................... 3-21
3.4.6 SIDE GUIDES ............................................................................... 3-22
3.4.7 SIDE JOGGER MOTOR M3 & SENSOR Q12.............................. 3-23
3.4.8 SIDE GUIDE TRANSMISSION &SENSOR Q13........................... 3-24
3.4.9 BACK JOGGER MODULE & SENSOR Q3 .................................. 3-26
3.4.10 BACK JOGGER FINGERS ........................................................... 3-28
3.4.11 BACK JOGGER MOTOR M2........................................................ 3-30
3.4.12 STAPLER HEAD ........................................................................... 3-31
3.4.13 STAPLER HEAD RETRACTION DISTANCE................................ 3-34
3.4.14 STAPLER MOTOR M4.................................................................. 3-35
3.4.15 STAPLER ASSY DRIVE BAR & SENSOR Q14............................ 3-36
3.4.16 CLINCHER BAR ASSEMBLY........................................................ 3-37
3.4.17 CLEANING CLINCHER POINTS .................................................. 3-38
3.4.18 SET TRANSPORT DRIVE ALIGNMENT....................................... 3-39
3.4.19 PRESSURE ROLLER ................................................................... 3-41
3.4.20 SET TRANSPORT MOTOR M5 .................................................... 3-42
3.4.21 THICK SET SENSOR Q36............................................................ 3-43
3.5 AREA B.................................................................................................. 3-45
3.5.1 STAPLE STOP GATE SOLENOID SOL1...................................... 3-45
3.5.2 STAPLE STOP GATE RELEASE SOLENOID SOL2 .................... 3-46
3.5.3 SADDLE STAPLING START SENSOR Q4................................... 3-48
3.6 AREA C.................................................................................................. 3-49
3.6.1 STAPLE / FOLD POSITION MOTOR M9 & SENSOR Q10 .......... 3-49
3.6.2 LENGTH TRANSMISSION SHAFT & SENSOR Q11 ................... 3-50
3.6.3 FOLD STOP GATE MOTOR M8 & SENSOR Q7.......................... 3-52
3.6.4 FOLD STOP GATE ....................................................................... 3-53
3.6.5 FOLD KNIFE MOTOR M7 & SENSOR Q15 ................................. 3-54
3.6.6 FOLD TRANSMISSION MODULE................................................ 3-56
3.6.7 FOLD TRANSMISSION BELT & SENSOR Q9 ............................. 3-57
3.6.8 FOLD ROLLER MOTOR M6......................................................... 3-59
3.6.9 FOLD TRANSMISSION GEAR ASSEMBLYS............................... 3-61
3.6.10 FOLD DISTANCE BRACKET........................................................ 3-62
3.6.11 UPPER FOLDER ROLLER........................................................... 3-63
3.6.12 LOWER FOLDER ROLLER .......................................................... 3-65
3.6.13 OUTFEED SENSOR..................................................................... 3-67
3.7 PCB ....................................................................................................... 3-69
3.7.1 MD3DC PCB “H” ........................................................................... 3-69
3.7.2 UPPER MD6DC PCB ”B”.............................................................. 3-70
3.7.3 LOWER MD6DC PCB ”C”............................................................. 3-71

VII
3.7.4 INTERLOCK PCB ”D” ................................................................... 3-72
3.7.5 CPU PCB AND COPIER INTERFACE PCB ”A”............................ 3-73
3.7.6 ADDON PCB ”F” ........................................................................... 3-75
3.7.7 LCD PANEL................................................................................... 3-76
3.8 STACKER .............................................................................................. 3-77
3.8.1 STACKER MODULE ..................................................................... 3-77
3.8.2 STACKER MOTOR M1 ................................................................. 3-78
3.9 BOOKLET QUALITY ADJUSTMENT..................................................... 3-79
3.9.1 STAPLE STOP GATE PARALLELISM .......................................... 3-79
3.9.2 SIDE GUIDE PARALLELISM ........................................................ 3-81
3.9.3 STAPLE POSITION TO CLINCHER ............................................. 3-82
3.9.4 STAPLER PRESSURE ................................................................. 3-85
3.9.5 CLINCHER POINTS HEIGHT....................................................... 3-86
3.9.6 CLINCHER PRESSURE ............................................................... 3-87
3.9.7 STAPLE AND FOLD POSITION.................................................... 3-89
3.9.8 FOLD SKEW ................................................................................. 3-91
3.9.9 STAPLE POSITION ON SQUARE FORMED SPINE.................... 3-92
3.10 POWER REQUIREMENTS ................................................................... 3-93
3.10.1 TAPPING THE TRANSFORMER.................................................. 3-93
4. TROUBLESHOOTING
4.1 FAULT CODE DESCRIPITIONS.............................................................. 4-1
4.2 BLOWN FUSE CONDITIONS ............................................................... 4-33
4.3 LEDS ..................................................................................................... 4-35
4.4 TEST POINTS ....................................................................................... 4-41
5. SERVICE TABLES
5.1 SERVICE PROGRAM MODE.................................................................. 5-1
5.1.1 SERVICE PROGRAM MODE OPERATIONS................................. 5-1
5.1.2 SERVICE PROGRAM MODE TABLES........................................... 5-4
Check Motors and function......................................................................... 5-4
5.1.3 EEPROM RESET.......................................................................... 5-12
5.2 SOFTWARE DOWNLOAD .................................................................... 5-13
5.2.1 Downloading to upper PCB MD6DC B in Booklet maker. ............. 5-13
5.2.2 Downloading to lower PCB MD6DC C in the Booklet maker. ....... 5-14
5.2.3 Downloading to PCB CPU in Booklet maker................................. 5-15
5.2.4 Downloading to lower PCB MD3DC H in the Booklet maker. ....... 5-16
5.2.5 Downloading to PCB MD6DC A in Trimmer. ................................. 5-17
5.2.6 Downloading to PCB MD6DC D in Book Folder............................ 5-18
5.3 SELF-DIAGNOSTIC MODE .................................................................. 5-19
5.3.1 RUN TIME DIAGNOSTICS ........................................................... 5-19
5.3.2 POWER ON SELF TEST .............................................................. 5-19
5.3.3 DETAILED SELF-DIAGNOSTIC MODE........................................ 5-20
5.4 PAPER SIZE RESET .................................................................... 5-21
5.5 CF SERVICE ......................................................................................... 5-25
5.6 BF SERVICE ......................................................................................... 5-27
6. DETAILED SECTION DESCRIPTIONS
6.1 ELECTRICAL COMPONENT LIST.......................................................... 6-1
6.1.1 FRONT VIEW.................................................................................. 6-3
6.1.2 REAR VIEW .................................................................................... 6-4

VIII
6.1.3 CONNECTOR VIEW ....................................................................... 6-5
6.1.4 OUTFEED UPPER VIEW ............................................................... 6-6
6.1.5 OUTFEED LOWER VIEW............................................................... 6-7
6.1.6 INFEED UPPER VIEW ................................................................... 6-8
6.1.7 INFEED LOWER VIEW................................................................... 6-9
6.1.8 INFEED MODULE VIEW .............................................................. 6-10
6.1.9 STACKER MODULE VIEW........................................................... 6-11
6.2 BOARD STRUCTURE........................................................................... 6-13
6.2.1 BLOCK DIAGRAM ........................................................................ 6-13
6.2.2 CONTROLLER CPU ..................................................................... 6-14
6.2.3 CONTROLLER MD6DC................................................................ 6-15
6.2.4 CONTROLLER MD3DC................................................................ 6-17
6.2.4 CONTROLLER MD3DC, CONTINUES......................................... 6-18
6.3 BOOKLET MAKING PROCESS ............................................................ 6-19
6.3.1 PRINCIPLE OF OPERATION ....................................................... 6-19
6.3.2 SIZE ADJUSTMENT ..................................................................... 6-23
SPECIFICATIONS
MAJOR SPECIFICATIONS........................................................................Spec-1
QUALITY SPECIFICATIONS.....................................................................Spec-1
ATTACHEMENT TO BELLINI ....................................................................Spec-2
PERIPHERALS SPECIFICATION .............................................................Spec-3
COVER FEEDER CF5010....................................................................Spec-3
TRIMMER TR5010 ...............................................................................Spec-3
BOOK FOLDER BF5010 ......................................................................Spec-4
WIRING
Booklet Maker...............................................................................................Wir-1
Cover Feeder................................................................................................Wir-1
Trimmer.........................................................................................................Wir-1
Book Folder ..................................................................................................Wir-1

IX
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE.......................................................... CF-1-1
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE .................................... CF-2-1
3. REPLACEMENT AND ADJUSTMENT
3.1 COVER FEEDER .............................................................................. CF-3-1
3.1.1 REMOVE COMPLETE UNIT..................................................... CF-3-1
3.2 AREA F .............................................................................................. CF-3-5
3.2.1 EMPTY BIN SENSOR Q31....................................................... CF-3-5
3.2.2 PAPER WIDTH SENSOR Q38.................................................. CF-3-6
3.2.3 FEED ROLLER ASSY AND PAPER SEPARATOR PAD........... CF-3-7
3.2.4 FEED MOTOR M15 .................................................................. CF-3-8
3.2.5 PAPER BIN LOW SENSOR Q33 .............................................. CF-3-9
3.2.6 DRIVE MOTOR M16 ASSEMBLY ........................................... CF-3-10
3.2.7 DRIVE SHAFT ASSEMBLY..................................................... CF-3-11
3.2.8 PINCH ROLL SHAFT ASSEMBLY .......................................... CF-3-12
3.2.9 PAPER PATH / DSD DETECTION SENSOR Q30.................. CF-3-13
3.2.9 PAPER POSITIONING SENSOR Q32.................................... CF-3-14
3.2.10 UPPER PAPER PATH............................................................. CF-3-15
3.2.11 BLOWER MOTOR M17 / M18 ................................................ CF-3-16
4. TROUBLESHOOTING
4.1 FAULT CODE DESCRIPTIONS......................................................... CF-4-1
5 SERVICE TABLES
5.1 SERVICE TABLES............................................................................. CF-5-1
6. DETAILED SECTION DESCRIPTIONS
6.1 ELECTRICAL COMPONENT LIST.................................................... CF-6-1
6.1.1 REAR VIEW .............................................................................. CF-6-2
6.1.2 OUTFEED VIEW....................................................................... CF-6-3
6.2 COVER FEEDING PROCESS .......................................................... CF-6-5
6.2.1 PRINCIPLE OF OPERATION ................................................... CF-6-5
SPECIFICATIONS
SPECIFICATIONS ...............................................................................CF-Spec-1
WIRING
Cover Feeder..........................................................................................CF-Wir-1
PERIPHERALS
COVER FEEDER CF5010

X
PERIPHERALS
TRIMMER TR5010
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE.......................................................... TR-1-1
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE .................................... TR-2-1
3. REPLACEMENT AND ADJUSTMENT
3.1 COVERS............................................................................................ TR-3-1
3.1.1 FRONT AND REAR COVER..................................................... TR-3-1
3.1.2 TOP COVER ............................................................................. TR-3-2
3.1.3 BLOWER MOTOR M5 / M6 ...................................................... TR-3-3
3.1.4 INFEED COVER ....................................................................... TR-3-4
3.1.5 LOCKING BRACKET ................................................................ TR-3-5
3.1.6 UPPER OUTFEED COVER...................................................... TR-3-6
3.1.7 INTERLOCK SWITCH S9 &S10 ............................................... TR-3-7
3.1.8 LOWER OUTFEED COVER ..................................................... TR-3-8
3.1.9 PROTECTION COVER............................................................. TR-3-9
3.2 AREA C............................................................................................ TR-3-11
3.2.1 INFEED SENSOR Q13 ........................................................... TR-3-11
3.2.2 CONTROL SWITCH S2 .......................................................... TR-3-12
3.2.3 CONTROL SWITCH S3 .......................................................... TR-3-13
3.2.4 TRANSPORT MOTOR M1...................................................... TR-3-14
3.2.5 TRANSPORT BELT SENSOR Q4........................................... TR-3-15
3.2.6 TRIM KNIFE MOTOR M2........................................................ TR-3-16
3.2.7 TRIM KNIFE HOME POSTITON SENSOR Q5....................... TR-3-17
3.2.8 TRIM KNIFE............................................................................ TR-3-18
3.2.9 PAPER PATH & OUTFEED SENSOR Q6............................... TR-3-22
3.2.10 STOP GATE CARRIAGE ........................................................ TR-3-23
3.2.11 STOP GATE MOTOR M3 & SENSOR Q7 ............................... TR-3-24
3.2.12 LENGTH ADJUSTMENT MOTOR M4 & SENSOR Q12 ......... TR-3-25
3.2.13 LENGTH ADJUSTMENT HOME POSITION SWITCH S11 .... TR-3-26
3.2.14 LOWER OUTFEED BELTS..................................................... TR-3-27
3.2.15 UPPER OUTFEED BELTS ...................................................... TR-3-28
3.2.16 TRIM BIN FULL SENSOR Q8................................................. TR-3-29
3.2.17 TRANSMISSION CHAIN......................................................... TR-3-30
3.2.18 KNIFE SUPPORT CHAIN ....................................................... TR-3-31
3.2.19 KNIFE CHAIN ......................................................................... TR-3-32
3.2.20 INFEED BELTS....................................................................... TR-3-33
3.3 PCB ................................................................................................. TR-3-35
3.3.1 MD6DC PCB ”A” ..................................................................... TR-3-35
4. TROUBLESHOOTING
4.1 FAULT CODE DESCRIPTIONS......................................................... TR-4-1
5 SERVICE TABLES
5.1 SERVICE TABLES............................................................................. TR-5-1