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
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

 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. Specification .................................................................................... 55
Machine Specifications.................................................................................................................. 55
Booklet Maker BK5010................................................................................................................................ 55
Cover Feeder CF5010 (option)................................................................................................................... 56
Trimmer TR5010 (option)............................................................................................................................ 56
Book Folder BF5010 (option)...................................................................................................................... 57

Index.................................................................................................... 59


What You Can Do With This Machine

BF5010 Book Folder (option) TR5010 Trimmer (option) CF5010 Cover Feeder (option)

Belt Stacker BK5010 Rail unit(option) BK5010 Booklet Maker

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 finisher 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 flatten 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.

 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
first row shows that the settings for Job (1) has been
changed, but not yet saved.

Button: 1 2 3 4


Guide To Components
Booklet Maker

2 4
3

8 9

1 Top cover 6 Base

2 Control panel 7 Docking assembly
3 Main power switch 8 Belt Stacker
4 Infeed assembly 9 Belt Stacker Cover
5 Exit tray storing shelf


 Booklet Maker, continues

8 9

8 Connections
9 Fold stop gate

COM Copier Terminator/ POW BF5010

Stacker Terminator COM TR5010 Main Power

Interlock jumper

Interlock jumper/
POW TR5010


Booklet Maker, continues

5 4 5

1 Stapler heads 4 Stapler release latches

2 Staple cartridges 5 Staple detection leads
3 Cartridge locking levers 6 Hand feeding paper guides

 Options
Cover Feeder

1 5

2 6

7
4

1 Loading capacity mark 5 Paper separator pad (also see

page 52)
2 Rear side guide 6 Air nozzle (2x)
3 Paper orientation label 7 Front side guide
4 Feed roller assembly 8 Jam clearance baffle

10
Trimmer

4
1 Top cover
2 Trim bin
3 Base
4 Connections
COM B
K5010

Stacker COM BK5010 Power from Terminator/

BK5010 Com BF5010

11
 Trimmer, continues

The Trimmer interior has parts that you will come in contact with if a misfeed occurs.

2
7

3
8
4

5
9

Trimmer, top view

1 Set counter 6 Infeed roller shaft

2 Trimmer stop 7 Trimmer fan
3 Outfeed latch 8 Upper knife
4 Exit compressing brackets 9 Infeed latch
5 Transport belt

12
Book Folder

1 Top cover 4
2 Trim bin
3 Base
4 Connections

Terminator

COM BF5010 Stacker POW BF5010

13
 Book Folder, continues

The Book Folder interior has parts that you will come in contact with if a misfeed occur.

1 2

Book Folder, top view,

Upper feed belts in lifted up

1 Lower feed belts

2 Upper feed belts

14
Control Panel

The Ready screen.

When the system power is switched on the Ready
screen will be shown. Here you will find 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 tools button

change button jobs button

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 fine 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.

The Tools screen.

Pressing the [Tools] button in the Ready screen takes
you to the tools screen. Here you will find 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.

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.

15
 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.

16
1 5
11. Basics 5

2 Docking / Undocking 6 ON
2 6 ON
Docking the Booklet Maker

Turn the Copier off.

3 7
3 7the Exit arm catcher and set the Exit paper
Lift up
arm in the upper position.

4
4
Remove the Exit tray from the Finisher and put it on
the shelf on the Booklet Maker

5 Move the Booklet Maker up to the copier and dock it.

Note
Make sure the Booklet Maker is powered on.

6 ON
Turn the Copier on.

7 The Copier is now in Booklet maker mode and a staple

icon is now present in the Copier display panel.

17
 Basics

22 66
Undocking the Booklet Maker

Turn the Copier off.

Note
1 Keep the Booklet Maker powered on.

33 77
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

44
5

6 Take the Exit tray from the shelf on the Booklet

Maker, and install it on the Finisher.

7
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.

18
Turning On / Off the Main Power

Turning On / Off the Main Power

Booklet Maker, Cover Feeder, Trimmer and Book Folder
1
1 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.

19
 Basics

Check staples, Staple cartridge and stapler head

Removing stapler head
1
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.

B A

Removing staple cartridge

The staple cartridges, containing approximately 5000

C 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.

20
Staple Cartrigde and Stapler Head

Installing stapler head, staple cartridge / clearing staple jam

Look inside stapler head for jammed staples in the area

of the staple actuator. Remove staples if any.
Position the stapler head on the edge of a firm surface 1
(for example the top of a table).
While securely holding the head, actuate the Stapler
up and down through full travel. Perform this operation
without staple cartridge
Renewing or reinstalling the staple cartridge, pull 25
mm (1 inch) of staples out of the cartridge and tear the
staples downward starting at one side pulling away
from you. The staple tear line is indicated by an arrow
on the side of the cartridge.
Insert the cartridge into the stapler head with the end
of the staples facing toward the head of the stapler
mechanism. Push it firmly ahead.
Hold the staple cartridge firmly in place and push down
the cartridge locking lever.
Note
Keep holding (pushing) the staple cartridge into place while
pushing down the cartridge locking lever.
While securely holding the head, actuate the Stapler up
and down through full travel. Perform this operation with
staple cartridge. Repeat this a few times to ensure that
the staples are ejected at each down movement.
Reinstall the stapler head by inserting the pin at the top of
the stapler head into the stapler retraction swing arm (D).
While rotating the stapler head, insert the pin located
at the rear end of the stapler head into the slots in the
frame of the stapler head assembly. Press down the
rear end of the stapler head until the release lever snaps
into place, locking the stapler head in position.
Press down the front end of the stapler head until it
snaps in position under the frame assembly.
Reconnect the staple indication lead (A), see previous
page.
Close the top cover and press the [Esc] button. The
booklet maker will automatically go to Ready mode. If
not and/or error message persists, hand feed a four
sheet set of paper. The booklet maker will automatically
cycle and advance staples until both stapler heads are
driving staples. The booklet maker will automatically go
D to Ready mode.
21
 Basics

Emptying the trim bin

Remove the trim bin by lifting it and pulling it out.

trim bin, no Book Folder installed

trim bin, with Book Folder installed

22
2. Making Booklets

Changing settings
General procedure

Changing of settings can be performed in two ways. Temporary, which means that the changes
will remain until a new job is loaded or permanent, which means that the changes will be
stored as a job. This job can later be recalled.

Procedure for temporary changes:

From the Ready screen, select the option you wish to change and press the [Change] button.
Confirm changes by pressing the [OK] button.

Procedure for permanent changes:

From the Ready screen, press the [Jobs] button to reach the Jobs screen. Select the Job you
want to change by pressing the [Next] button and then press the [Change] button.

Note
Choose either of the above mentioned procedures when changing size, stapling, trimming,
covers or book folding as follows.

Setting Paper Size

Selecting standard paper sizes

From the Ready screen, select Size and press the

[Change] button.

Select Auto or any standard paper size with the [arrow]

button and press the [OK] button. Selecting Auto means
that the booklet maker will automatically adjust to the
same paper size (A4, A3, 8.5”x11”, 8.5”x14”, 11”x17”
or B4) as the copier.
For other paper sizes, follow “Custom paper size” as
described on the next page.

23
 Making Booklets

Custom paper size

Select Size and press the [Change] button to display

the preprogrammed paper sizes.
Scroll down to Custom sizes, by pressing the [arrow]
button, and press the [OK] button. Select the custom
2 paper size you want to use and press the [OK]
button.

If you want to adjust, select the custom paper size you

want to change and press the [Change] button. Select
Width or Length with the [arrow] button and press the
[Change] button.

The paper size can now be changed in increments of

0.1 mm or approx.. 0.01 inches. Press the [OK] button
to confirm.

Four different custom paper sizes can be stored.

Stapling
Selecting stapling On or Off

From the Ready screen, select Staple and press the

[Change] button.

24
Changing settings

Selecting stapling On or Off, continues

If stapling was On, the first choice will be Off and vice
versa.
Select On or Off with the [arrow] button and press the
[OK] button.
2

Trimming

Selecting trimming On or Off

From the Ready screen, select Trim and press the

[Change] button.

If trimming was On, the first choice will be Off and vice
versa.
Select On or Off with the [arrow] button and press the
[OK] button.

25
 Making Booklets

Adjusting the cutting margin

Select Trim and press the [Change] button. Select

Trim length and press the [OK] button. Press the [+]
or [-] buttons to fine adjust in increments of 0.5 mm or
0.02 inches. The trimmed booklet size and waste are
displayed. Press the [OK] button to confirm.
2

Covers

Selecting Cover Feeder Mode

From the Ready screen, select Cover and press the

[Change] button.

Select On if you want the cover feeder to automatically

feed one cover to each set from the copier, or if you
are manually feeding a set.
Select Off if no covers are to be fed.
Select Feed if you want to fold only one sheet in
sequence.
Press the [OK] button to confirm.

26
Changing settings

Selecting Cover Feeder Mode, continues

The Purge mode is used when you want to completely

empty the Cover Feeder from covers.

Remove all cover sheets from the bin.

Select Purge and press the [Run] button. The prefed 2
cover sheet will now be fed into the Booklet Maker
to the stapling area, but without being stapled.

Open the Top Cover and remove the cover sheet.

Note
If you open and close the Top Cover without removing
the cover sheet, the cover sheet will be stapled and
folded and then fed to the stacker.

Loading covers

A Make sure that the cover sheets are well fanned to

avoid misfeeds or double-feeds.

Align the cover sheets well to achieve a reliable

feeding operation and good finishing results.

When using printed covers make sure that the ink

has completely dried, to avoid smearing.

Press on top of either air nozzle (A) to lower the

paper bin. Load the covers facing downwards into
the paper bin.

Move the adjustable side guides (B) up against the

cover sheets until there is no clearance.
B

27
 Book Folding

General

The Book Folder has six different settings. It can be set to [Auto], [Mode 1], [Mode 2],
[Mode 3], [Mode 4] or [Off].

2 In [Auto] mode, the Booklet Maker detects how may sheets there are in the booklet, and
automatically set the Book Folder to the correct mode.
Note
When the Book Folder is set to [Auto] and the booklet has less than approximately 6 sheets/
booklet, the Book Folder will bypass the Square folding action, transporting the booklet out
to the Belt stacker.
Use the manual modes to override the auto function. There are four different manual modes
to select from.

Mode 1: Approximately 6 to 11 sheets. Decreased amount of square forming.

Mode 2: Approximately 12 to 16 sheets. Medium amount of square forming.
Mode 3: Approximately 17 to 23 sheets. Increased amount of square forming.
Mode 4: Approximately 24 to 30 sheets. Maximum amount of square forming.

Select [Off] to bypass the Book Folder

Setting Mode

Procedure

From the Ready screen, scroll down to BF5010 and

press the [Change] button.

Select [Auto], [Mode 1], [Mode 2], [Mode 3], [Mode

4] or [Off] with the [arrow] button and press the [OK]
button.

28
Making Booklets

On-line/Off-line
The Booklet maker can be operated in two modes. On-line mode, when used together with
the copier, or off-line mode, working as a stand-alone unit.

Off-line mode
2
Follow “Undocking the Booklet maker” in section 1. Basics.

Adjust the hand feeding paper guides to the correct paper size.

Turn on the Booklet maker.

The Booklet maker is now in stand-by and will start automatically when a set is fed into the
Booklet maker. If settings need to be changed, follow “Changing settings” earlier in this
section.

On-line mode

Follow “Docking the Booklet maker” in section 1. Basics.

29
 Begin On-line Production

Begin On-line Production

Make sure that the [staple icon] is present on the copier control panel. If not, turn off the
Copier and Booklet Maker. First turn the Bookklet Maker ON and then turn the Copier
ON.

Make sure that the Booklet maker system is set according to your job specification.
2 Select [Paper tray] (A).

Select [Staple icon] (B).

Note
Make sure correct original orientation (C) is selected.

Select [Dup / Combine / Series] (D).

Select [Book] (E).

Select [1 Sided] (F) if your originals are only printed on one side or [2 Sided] (G) if they
are printed on both sides.

Select [Magazine] (H).

Select [Quantity] (I).

Press the Start key .

A. Paper tray

B. Staple icon

D. Dup. / Combine /
Series

C. Original orientation

E. Book F. 1 Sided G. 2 Sided H. Magazine I. Quantity

30
3. Tools

The Tools Screen

The Tools screen.

From the Ready screen, press the [Tools] button to get to the Tools screen. Here you will find
all the necessary tools for troublefree operation.

Units

From this screen you can change units, between

millimeters and inches. Select Units with the [arrow]
button and press the [OK] button.

Select the millimeters or inch units and then press the

[OK] button.

Software version

Select Software version with the [arrow] button and

press the [OK] button. This screen, and sub screens
show the software version for the different modules in
the booklet making system.

31
 Tools

Software version, continues

Select the module in the system for which you want

to check the software version and press the [OK]
button.

This screen will show software version(s) in the selected

module.

Language

From this screen you can change the language in the

user interface.
Select Language with the [arrow] button and press the
[OK] button.

Select desired language with the [arrow] button and

press the [OK] button.

32
The Tools Screen

Air Separation

From this screen you can increase or decrease the Air

separation. This screen will only be shown if a Cover
Feeder is present. Select Air separation with the [arrow]
button and press the [OK] button.

You might want to increase the Air flow when running

thick, heavy covers.
Set the desired speed in increments of 10% with the [+]
or [-] buttons and press the [OK] button. Normal user
(default) setting is 60%.

Double Sheet Detection

From this screen you can turn the double sheet

detection On or Off. Select Double sheet det. with the
[arrow] button and press the [OK] button.

Normally double sheet detection should be set to On.

However, if you experience “false double sheet feeds”,
for example when running covers that are thick, with
dark print or with mixed prints on the covers, the double
sheet detection can be set to Off.

33
 Tools

Service access

This screen is for authorized service personnel only

and is password protected.

34
4. Jobs

Storing and deleting jobs

The Booklet Maker has a maximum storage capacity of 10 different jobs. It is not possible
to delete jobs, therefore when you need to store a new job, an old job must be overwritten.
To make temporary changes in the actual job settings or temporary changes of a stored job,
see section 2. Making Booklets.

Storing a new Job

To store a new job or add new settings to an existing

job you need to start from the Jobs screen. From the
Ready screen press the [Jobs] button to enter the Jobs
screen.

Select an already stored job by pressing the [Next]

button. Then press the [Change] button.

Select the option you want to change with the [arrow]

button and then press the [Change] button. See section
2. Making Booklets for how to set up each separate
option.
After changing the options press the [OK] button to
accept the changes you just made.

Continued on next page.

35
 Jobs

Storing a new Job, continues

To store the job, press the [Save] button.

4 If you want to run the actual job, press the [Load] button.
The booklet maker will then automatically setup that
specific job and return to the Ready screen.

Recalling a Job

To recall a stored job press the [Jobs] button from the

Ready screen to enter the Jobs screen.
Select the desired job by pressing the [Next] button.
Then press the [Load] button. The booklet maker will
then automatically setup that specific job and return to
the Ready screen.

36
5. Clearing Misfeed(s)

Clearing misfeed(s)

General

If a misfeed condition should occur, it is indicated on the Booklet Maker display. The message
“Clear Misfeed(s)”, an error code and the location of the misfeed is displayed.
See examples below.

Misfeeds in the Booklet Maker are indicated

as area A, B or C and by the error code BK-
XXX.

Misfeeds in the Book Folder are indicated as

area E and by the error code BF-XXX.

37
 Booklet Maker
Clearing misfeed(s)

Inside the Booklet Maker

To clear a misfeed indicated in Area A or B

Open the top cover.

Remove misfed sheets.

Close the top cover.

To clear a misfeed indicated in Area C

Open the top cover.

Close top cover.

If misfeed condition remains:

Switch off the main power.

Switch on the main power.

If misfeed condition remains:

Switch off the main power.

If a Trimmer is installed, first remove the trim bin to

get access to the fold stop. By hand, pull down the
fold stop (page 8, item 9).

Remove misfed sheets.

Push the fold stop back into the upper position.

Switch on the main power.

38
Clearing Jams

Trimmer
Clearing misfeed(s)

The upper trimmer blade on the trimmer is protected by a knife protection plate that moves
away during the cutting stroke. Jams can occur in the input area or the exit area.

WARNING:
Never put fingers or other parts of the body between the upper and lower trimmer knives.

Clearing misfeed in input area

Remove the Trimmer fan (see page 12, item 7).

5
Lift up the infeed roller shaft (A).

Secure under latch (B)

Remove the misfed sheets in the infeed area.

After the misfed sheets are removed, lift up the latch (B) and place the infeed roller shaft
into operating position.

39
 Trimmer

Clearing misfeed(s), continues

Clearing misfeed in exit area

Lift the exit compressing brackets (A).

Secure them under the latch (B).

Remove the misfed sheets from the exit area.

After the misfed sheets are removed, lift up the latch (B) and place the compressing
brackets in operating position.

40
Clearing Jams

Cover Feeder
Clearing misfeed(s) in vertical transport area

Open the Top Cover.

Lift the jam clearance baffle (A).

Remove the misfed cover.

Put the jam clearance baffle back in normal position.

41
 Book Folder
Clearing misfeed(s)
Inside the Book Folder

Open the top cover.

B
Lift up both upper feed belts (A).
Note
A Press the green dots (B) on the latches to release.

Remove the misfeeds.

B
Place the upper feed belts in normal position.
5 Close the top cover.

Exit area

Open the top cover (A).

Lift up the cover (B) of the Belt stacker.

A
Remove the misfeeds.

Place the cover in normal position.

Close the top cover.

42
6. Troubleshooting

Fault codes
General

When there is a misfeed or fault condition in the booklet maker system, a message will
be displayed on the Booklet Maker. In case there is a problem that can be rectified by the
operator, a fault code and an explanation will be displayed.

Fault codes that can be rectified by the operator:

Booklet Maker: BK-201 to BK-212 and BK-401

Trimmer: TR-201 to TR-204 and TR-401
Cover Feeder: CF-201 to CF-205, CF-401, CF-501 and CF-502
Book Folder: BF-201 to BF-206.

BK-201 to BK-210 indicates “Clear Misfeed(s)” in the Booklet maker

BK-211 indicates that the set is too thick to be folded
BK-212 indicates to remove purged set in Booklet maker
BK-401 indicates “Check staple(s)” in the Booklet maker

TR-201 to TR-204 indicates “Clear Misfeed(s)” in the Trimmer
TR-401 indicates “Empty Trim bin” in the Trimmer

CF-201 to CF-205 indicates “Clear Misfeed(s)” in the Cover feeder
CF-401 indicates “Out of covers” when there is no more
cover sheets in the Cover feeder. How to clear,
see Cover feeder fault codes
CF-501 indicates “Cover low” when the Cover feeder is
almost out of Covers. How to clear, see Cover feeder
fault codes
CF-502 indicates that there is a format mismatch between the
cover sheets and the sheets sent from the copier.

BF-201 to BF-206 indicates “Clear Misfeed(s)” in the Book Folder
Note
If procedures in this manual do not rectify the problem an authorized technician will be
needed.

43
 General fault codes

Clear Misfeed(s)

In general, fault codes indicate a misfeed condition.

When a misfeed occurs, the message “Clear Misfeed(s)”,
a code and the jam area will be displayed. See section
5. Clearing Misfeeds, for how to clear a misfeed.

Close cover(s)

6 When the message “Close Cover(s)” is displayed any

of the interlock switches are actuated.

Check that the top cover is in down position.

Make sure that the cover of the Belt Stacker is in

normal position, see section 5, Clearing Misfeeds,
Exit area.

44
Booklet maker fault codes

Check staples

This message will be displayed when a staple cartridge is empty or when stapling could not
be performed. Check in the following order:
– If a staple cartridge is empty, replace according to section 1. Basics.
– If staple cartridges are OK; remove the set and check that the number of sheets is within
specifications.
– If staple cartridges are OK and set is within specifications; remove and check stapler head
according to section 1. Basics.

Set too thick

This message will be displayed when the set sent from the copier is outside Booklet Maker
specifications. Open the top cover, remove the set and close the top cover.

Trimmer fault codes 6

Trim bin full

This message will be displayed when the trim bin is full or when a trim strip, due to static
electricity, is prevented from falling down into the trim bin. Empty the trim bin and remove loose
trim strips from inside the Trimmer. See section 1. Basics for how to remove the trim bin.

Cover feeder fault codes

Misfeed

This message will be displayed when the Cover feeder could not feed a cover from the paper
bin. Check cover loading according to section 2. Making Booklets. If problem persists, clean
separator pad according to section 7. REMARKS.

Double feed

This message will be displayed when the Cover Feeder detects that more than one cover
was fed from the cover bin. If more than one cover was fed, check cover loading according to
section 2. Making Booklets. If the covers that are fed are thick, with dark print or with mixed
prints on the covers, double feeding may be displayed even if that is not the case. Turn off
double sheet detection according to section 3. Tools.
45
 Cover feeder fault codes, continues

Load covers

Code CF-501 is displayed when covers run low.

If you wish to continue production:

Load more cover sheets according to section 2. Making Booklets.

Code CF-501 will extinguish and copier will start.

If you wish to continue production, using up the cover sheets that are loaded:

Press ESC. Code CF-501 will extinguish and copier will start.

Code CF-401 is displayed when covers are empty.

6
If you wish to continue production:

Load more cover sheets according to section 2. Making Booklets.

If cover job is finished and you wish to run a new job without covers:

Select Cover Off in the Cover menu.

Open and Close BK5010 Top Cover.

46
Book Folder fault codes

Feed errors

If feed errors occur, the feed belts needs to be cleaned or the pressure on the upper feed
belts needs to be increased. To clean the feed belts, see section 7, REMARKS Maintaining
Your Machine. To increase the pressure on the upper feed belts follow this procedure.

Open the top cover.

Place both springs in the upper position.

Close the top cover.

Spring in normal position Spring in upper position

47
6

48
7. REMARKS

Do’s And Don’ts

• Always follow all warnings marked on, or supplied with, the equipment.

• Always exercise care in moving or relocating the equipment.

Caution:
• Unplug the powercord from the wall outlet and machine before you move or relocate
the equipment.

• Do not remove the covers or guards that are fastened with screws.

• Do not override or bypass electrical or mechanical interlock devices.

• Do not operate the equipment if you notice unusual noises or odors. Disconnect the
powercord from the power source and call your authorized technician to
correct the problem.

Warning:
• Do not put fingers or other parts of the body between the upper and lower trimmer
knives.

• Do not switch off the main power switch while machine is running. Make sure machine
cycle has ended.

• Do not open covers while machine is running.

• Do not move machine while machine is running.

49
 REMARKS

Where to put Your Machine

Machine environment

• Always locate the equipment on a solid support surface with adequate strength for the
weight of the machine.

• Always keep magnets and all devices with strong magnetic fields away from the
machine.

If the place of installation is air-conditioned or heated, do not place the machine where it
will be:

• Subjected to sudden temperature changes.

• Directly exposed to cool air from air-conditioner.

• Directly exposed to heat from heater.

7 Power connection

• Always connect the equipment to a properly grounded power source. If in

doubt, have the power source checked by a qualified electrician.

• WARNING: Improper grounding of the equipment can result in electrical shock.

• Never connect the machine to a power source that lacks a ground connection
terminal.

50
Where to put Your Machine

Access to machine

Place the machine near the power source, providing clearance as shown.

1 3

1. Left: more than 400 mm / 15 3/4”.

2. Front: more than 555 mm / 21 7/8”
7
3. Right: more than 400 mm / 15 3/4” (off-line use).

51
 REMARKS

Maintaining Your Machines

Never attempt any maintenance function that is not specifically described in this
documentation.

Cover Feeder

Cleaning feed rollers and paper separator pad

The Feed rollers need to be cleaned regularly when in use, and if the unit has not been used
for a period of time. How often this should be done, depends on the paper type and print
quality.
An increasing number of misfeeds, or double feeds, is one indication of the need to clean
the Feed Rollers.

Remove the feed roller assembly by pressing it to the front of unit (A). The left end of the
feed roller assembly will now be released (B) and the assembly can be removed.

Clean the Feed rollers and the Paper separator pad with water and a clean lint free
cloth.

7 Press toward front. Paper separator pad

Lift out this

side

Showed with Top cover upper part

Feed rollers removed for clarity.
52
Book Folder

Cleaning feed belts

The Feed belts need to be cleaned regularly when in use, and if the unit has not been used
for a period of time. How often this should be done, depends on the paper type and print
quality.
An increasing number of misfeeds is one indication of the need to clean the Feed belts. Clean
the feed belts with water and a lint free cloth.

Open the top cover.

Clean the upper feed belts (A). The upper feed belts can easily be rotated in either
direction.

Lift up the upper feed belts to access the lower feed belts.

Clean the lower feed belts (B). Rotate the lower feed belts towards the outfeed side for
complete cleaning.

Place the upper feed belts in normal position. 7

Close the top cover.

Upper feed belts in normal position. Upper feed belts lifted up.

53
7

54
8. Specification

Machine Specifications
Booklet Maker BK5010

Major Specifications
Specifications Remarks
Speed (Online usage) Maintain engine speed (actual depends if Actual speed in number of book-
engine is 90, 110 or 135 ppm version). lets (per min / hour) depends on
number of sheets per booklet.
Maximum Speed 1800 booklets / hour (A4 / 8.5x11”)
1800 booklets / hour (A3 / 11x17”)
Standard Paper Sizes A4, A3, B4, 8.5x11”, 8.5x14”, 11x17 Custom sizes are available
Paper Size (Minimum) Width 206mm / 8.1”
Length 275mm / 10.8”
Paper Size (Maximum) Width 320mm / 12.6”
Length 457.2mm / 18”
Paper Weight (Minimum) 64gsm/16 lb. Bond
Paper Weight (Maximum) 300gsm / 172 lb. Index / 115 lb. Cover Engine Duplex: 216 gsm
Input / Output Sheets 1 – 30 Sheets (80 gsm / 20 lb. Bond, Stapled
equivalent) TBD
Input / Output Sheets 1 – 2 Sheets Non Stapled Folding
Off-line Use Possible Stitch / Fold (2 staples)
Weight 130 kg / 286.6 lb
Dimensions (L x H x D) 1420 x 970 x 700 mm / 55.9 x 38.2 x 27.6” Incl. Base and Stacker
Power Source 100 / 110 / 115 / 127 / 220 / 230 50-60Hz + - 10%
Power consumption 200 W or less Continuous Operations

55
 Specification

Cover Feeder CF5010 (option)

Specifications Remarks
Maximum Speed Same as BK5010 A3/11x17” or bigger paper
sizes, need two sheet sets as
inlet at least
Standard Paper Sizes Same as BK5010
Paper Weight (Minimum) 70 gsm / 18 lb. Bond
Paper Weight (Maximum) Same as BK5010
Cover Feeder Capacity 20 mm (approx 200 sheets of 80 gsm paper)
13/16” (approx 200 sheets of 20 lb. Bond paper)
Off-line Use Possible (Together with Booklet maker)
Weight 7 kg / 15.4 lb or less
Dimensions (L x H x D) 310 x 190 x 530 mm / 12.2 x 7.5 x 20.9”
Power Source From BK5010

Trimmer TR5010 (option)

8 Specifications Remarks
Speed Same as BK5010
Standard Paper Sizes Same as BK5010 Custom sizes are available
Default trim length 4.5 mm / (11/64”) Adjustable in 0.5 mm steps
Minimum trimming 1 mm / (0.0394 in)* Adjustable in 0.5 mm steps
Maximum trimming 16 mm (0.63”) Adjustable in 0.5 mm steps
Paper Weight (Minimum) Same as BK5010
Paper Weight (Maximum) Same as BK5010 Engine Duplex: 216 gsm
Input / Output Sheets Same as BK5010
Input / Output Sheets Same as BK5010
Off-line Use Possible (Together with Booklet maker)
Weight 65 kg / 143.3 lb or less
Dimensions (L x H x D) 360 x 900 x 620 mm / 14.2 x 35.4 x 24.4”
Power Source From BK5010
* When trimming SRA3 (450 mm) Booklets minimum trimming is 5 mm, when trimming 18” Booklets mini-
mum trimming is 9 mm.

56
Book Folder BF5010 (option)

Specifications Remarks
Speed Same as BK5010
Standard Paper Sizes Same as BK5010 Custom sizes are available
Paper Weight (Minimum) Same as BK5010
Paper Weight (Maximum) Same as BK5010
Input / Output Sheets Same as BK5010
Input / Output Sheets Same as BK5010
Off-line Use Possible (Together with Booklet maker &
Trimmer)
Weight 52 kg / 114.6 lb
Dimensions 360 x 900 x 620 mm / 14.2 x 35.4 x 24.4”
Power Source From BK5010

57
 Index Maintaining Your Machines 52
Making Booklets 23
Misfeed(s)
A clearing 37
Access to machine 51 O
Air Separation, adjusting 33
Options 10
B
P
Docking the Booklet Maker 17
Undocking the Booklet Maker 18 The Please wait screen 16
Basics 17 The Processing screen 16
Begin On-line Production 30 Turning On / Off the Main Power 19
Book Folder 13 Paper Size
cleaning feed belts 53 setting 23
fault codes 47 Paper size
Book Folding, setting mode 28 custom 24
Booklet Maker 7 Power connection 50
fault codes 45
Booklets, making 23 R

C REMARKS 49

Changing settings 23 S
Clearing Misfeed(s) 37
Service access 34
Control Panel 15
Setting Paper Size 23
Cover Feeder 10
Settings, changing 23
Cleaning feed rollers and paper separator pad 52
Software version 31
fault codes 45
Specification 55
selecting mode 26
Staple cartridge
Covers 26
install 21
loading 27
remove 20
Custom paper size 24
Stapler head
Cutting margin
install 21
adjusting 26
remove 20
D Staples
check 20
Do’s And Don’ts 49 clearing jam 21
Docking 17 Stapling
Double Sheet Detection 33 on / off 24

F T
Fault codes 43 Turning On / Off the Main Power 19
Book Folder 47 The Jobs screen 15
Booklet Maker 45 The Ready screen 15
Cover Feeder 45 The Tools screen 15
general 44 Tools 31
Trimmer 45 Trim bin
emptying 22
G Trimmer 11
Trimmer fault codes 45
General fault codes 44
Guide To Components 7 Trimming.See also Cutting margin
on / off 25
J Troubleshooting 43
Turning Off the Main Power 19
The Jobs screen 15 Turning On the Main Power 19
Jobs
storing & deleting 35 U
L Undocking 17
Units
Language selecting 31
selecting 32
W
M
What You Can Do with This Machine 5
Turning On / Off the Main Power 19 Where to put Your Machine 50
Machine
environment 50
specifications 55
58
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 X17099

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2 6 ON

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Part No: 76434 (2) 3 April 2006

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2 6

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(2) 3 April 2006