Ricoh BOOKLET MAKER BK5010 User manual

INSTALLATION MANUAL
BK5010 SYSTEM
4 Oct, 2007
Subject to change

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4 Oct 2007
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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4 Oct 2007
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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Installation
04 October 2007
1 INSTALLATION PROCEDURE
1.1 INSTALLATION REQUIREMENTS
1.1.1 MINIMUM SPACE REQUIREMENTS
BF5010 TR5010 BK5010
Stacker
CF5010Rail
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
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1-2
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INSTALLATION REQUIREMENTS
1.1.2 POWER REQUIREMENTS
1. Input voltage level:
North America 120V AC, 50-60Hz: More than 4 A.
Europe/Asia 230V AC, 50-60Hz: More than 2 A.
2. Permissiblevoltageuctuation:±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rmlyinsertedintheoutlet.
2. Avoid multi-wiring.
3. Be sure to ground the machine.

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Installation
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1.2 INSTALLATION FLOW CHART
Thefollowingowchartshowshowtoinstalltheoptionalunitsmoreefciently.
TR5010 Trimmer: Enables On-line trimming. Especially thicker sets ( > 4
sheets) look unprofessional because of ”creep”.TR5010
will trim those edges ( up to 16 mm / 5/8”).
CF5010 Cover Feeder: 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 the Book Folder BF5010
Install the Belt Stacker
Yes
Install Trimmer
No
Check the Installation
INSTALLATION REQUIREMENTS

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1-5
Installation
04 October 2007
1.3 BOOKLET MAKER INSTALLATION
1.3.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the following list:
Description Q’ty
A. Exit arm Catcher .................................................................. 1
B. CommunicationCabletoSR5000nisher ........................... 1
C. CommunicationCabletoSR841nisher ............................. 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]
[L] [M] [N]
BOOKLET MAKER INSTALLATION

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04 October 2007
BOOKLET MAKER INSTALLATION
1.3.2 INSTALLATION 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]

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Installation
04 October 2007
Exit arm catcher
1. Remove the adhesive backing from the Exit arm catcher.
2. InstalltheExitarmcatcheronthenisher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gure.
3. Lift up the Exit paper arm, and set it onto the Exit arm catcher [A].
[A]
BOOKLET MAKER INSTALLATION

1-8
04 October 2007
BOOKLET MAKER INSTALLATION
[A]
Copier exit tray
1. Make sure that the Exit paper arm is in the upper position [A].
2. Removethenisherexittraybyremovingscrews[B]( x 4).
3. Removetheplasticdeector[C],onthenisherexittray.
[B]
[C]

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Installation
04 October 2007
4. Removetheplasticdeector[D]fromtheshifttray.
5. InstalltheShifttrayplate[E]ontothenisher( x 4 counter screws from
installation kit)
6. InstalltheExittrayplate[F]ontothenisherexittray( x 4 from installation
kit).
[E]
[F]
[D]
BOOKLET MAKER INSTALLATION

1-10
04 October 2007
BOOKLET MAKER INSTALLATION
1. Removethenisherrearcover( x 2).
2. Openthenisherdoorandpulloutthestaplingtray.
3. Removeblackplasticcovers[A]atthebottomofthenisher( x 2).
4. Install the docking assembly [B] in the holes under the black plastic covers [A].
NOTE: Both nuts [C], installed on the docking assembly, have different
diameters on each side of the nut. A big diameter [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tthenutsinthecorrectposition.Thebiggerdiam-
etershouldtintheholenearesttherearside[F]ofthenisher.
Thesmallerdiametershouldtintheholenearestthefrontside
[G]ofthenisher.
Docking assembly
[A]
[B]
[C]
[D]
[E]
[F]
[G]
Finisher seen from front side
Finisher seen from above

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Installation
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Interface to SR5000 Finisher
Interface between SR5000 Finisher and BK5010
1. Install the Communication cable from the installation kit, to connector
CN138H [A] ( x1)onthenisher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nisher[C],withtwotiewrapsfromtheinstallationkit.
[C] [A]
Finisher Main PCB
[B]
Finisher with rear cover installed
BOOKLET MAKER INSTALLATION

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04 October 2007
BOOKLET MAKER INSTALLATION
Interface to SR841 Finisher
Interface between SR841 Finisher and BK5010
1. Install the Communication cable from the installation kit, to connector
CN132 [A] ( x1)onthenishermainboard.
NOTE: Make sure to use the communication cable for SR841 Finisher.
2. SecuretheCommunicationcableinthenisher[B],withatiewrapfromthe
installation kit.
[B]
[A] Finisher Main PCB

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Installation
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

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04 October 2007
BOOKLET MAKER INSTALLATION
1. If installing a Rail unit, install it now.
NOTE: If the Rail unit is installed later the height adjustment of the Booklet
maker will be incorrect.
2. Dock the Booklet Maker to the Docking assembly.
[C]
[A]
[D]
[B]
Booklet Maker, front view
CAUTION
Before docking, make sure the Jogger Fence [A] is in the upper position. If
not,withcopierpoweredon-openandclosenisher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]ts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 docking pins on
the docking bracket.
5. Hook up the Exit arm catcher to it’s upper position.

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Installation
04 October 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

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04 October 2007
BOOKLET MAKER INSTALLATION
[F]
7. Place the Multi tool outside the hand feeding paper guides as illustrated [F].