Plockmatic BK5030 Installation Manual v2012.11

INSTALLATION MANUAL
BK5030 SYSTEM
including CT5010e and CT5030
Part no:122-106962
Doc no: X17138
Date: November 2012
Warning:
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
Note
The domestic environment is an environment where the use of broadcast radio and
television receivers may be expected within a distance of 10 m of the apparatus
concerned.
Introduction
This installaion manual contains instructions how to install this machine. To make sure that
this machine is properly installed, carefully read and follow the instructions in this manual.
Keep this manual in a handy place near the machine while installing.
Please read the Safety Information before installing this machine. It contains information
related 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.
Safety Information
When using this machine, following safety precautions should always be followed.
Safety during operation

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 specified 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:
• Before disassembling or assembling parts of the System and peripherals.
• 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 specifically instructed).
• If any adjustment or operation check has to made with exterior covers off or open
while the main switch is turned on, keep hand away from electrical or mechanically
driven components.
• Note that components of the System and peripherals can be supplied with electric
voltage even if the mail power switch is turned off and the power cord is disconnected.
• 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.
General safety
WARNING:
• Always connect the equipment to a properly grounded power source (wall outlet). Wall
outlet should be located near the system and easily accessible. If in doubt, have the
power source checked by a qualified 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 specific purpose only. Any use going beyond this specific 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 modifications to the machine. The manufacturer will
not be liable for modifications 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 fingers or other parts of the body to moving, rotating or cutting devices
such as for instance between upper and lower trimmer knives.
• Always locate the equipment on a solid support surface with adequate strength tor the
weight of the machine.
General safety, continued
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.
• Always follow all warnings marked on, or supplied with, the equipment.
• When you disconnect the power plug from the wall outlet, always pull the plug (not the cable).
• Turn off the power and disconnect the power cord before you move the machine. While mov-
ing the machine, always exercise care and make sure that the power cord will not be damaged
under the machine.
• Always 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 off 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 maintenance function that is not specifically described in this documenta-
tion.
• 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:
• 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.
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
specifications without prior notice!
• Dispose of replaced parts and consumables in accordance with local regulations.
TABLE OF CONTENTS
1. INSTALLATION PROCEDURE............................ 1-1
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............................................................................1-14
1.3.4 CONNECTORS.............................................................................1-18
1.3.5 CHECK THE INSTALLATION........................................................1-19
1.4 COVER FEEDER INSTALLATION...........................................1-21

1.4.1 ACCESSORY CHECK...................................................................1-21
1.4.2 INSTALLATION PROCEDURE......................................................1-22
1.4.3 ENABLING THE COVER FEEDER...............................................1-28
1.5 TRIMMER INSTALLATION......................................................1-33

1.5.1 ACCESSORY CHECK...................................................................1-33
1.5.3 ADJUSTMENTS............................................................................1-37
1.5.4 DOCKING......................................................................................1-40
1.5.5 CONNECTORS.............................................................................1-42

1.6 BOOK FOLDER INSTALLATION.............................................1-49
1.6.1 ACCESSORY CHECK...................................................................1-49
1.6.3 ADJUSTMENTS............................................................................1-54
1.6.4 DOCKING......................................................................................1-57
1.6.5 INSTALLING STACKER SAFETY BRACKET................................1-59
1.6.6 CONNECTORS.............................................................................1-60
1.7 CREASER TRIMMER INSTALLATION....................................1-66

1.7.1 ACCESSORY CHECK...................................................................1-66
1.7.3 DOCKING......................................................................................1-91
1.7.4 CONNECTORS.............................................................................1-93
1.7.5 ADJUSTMENT...............................................................................1-95

November 2012 INSTALLATION REQUIREMENTS
1 INSTALLATION PROCEDURE
requirements
Installation
1.1 INSTALLATION REQUIREMENTS
1.1.1 MINIMUM SPACE REQUIREMENTS
760 mm
400 mm
29.9”
15.8”
500 mm
21.8”
4 2 0 - 6 3 0 m m 360 mm 360 mm 810 mm 700 mm
16.5-24.8” 14.2” 14.2” 31.9” 27.6”
1-1
INSTALLATION REQUIREMENTS November 2012
1.1.2 POWER REQUIREMENTS
WARNING
1. Make sure that the wall outlet is near the main machine and easily
accessible. Make sure the plug is firmly inserted in the outlet.
2. Avoid multi-wiring.
3. Be sure to ground the machine.
1. Input voltage level:

100 - 240 V AC, 50 - 60 Hz, 4 - 2 A.
2. Never place anything on the power cord.
1-2
November 2012 INSTALLATION REQUIREMENTS
1.2 INSTALLATION FLOW CHART
requirements
Installation
The following flow chart shows how to install the optional units more efficiently.
Install the Booklet maker BK5030
Does the user require a Cover Feeder?

Yes No
Install the Cover Feeder CF5030
Does the user require a Trimmer?

Yes No
Install the Trimmer TR5030
Does the user require a Book Folder?

Yes No
Is a Trimmer installed?
Yes No
Install Trimmer
Install the Book Folder BF5030
Install the Belt Stacker
Install CT5030/ CT5010 if applicable
Check the Installation
1-3
INSTALLATION November 2012
TR5030 Trimmer: Enables On-line trimming. Especially thicker sets

( > 4 sheets) look unprofessional because of ”creep”.
TR5030 will trim those edges ( up to 16 mm / 5/8”).
CF5030 Cover Feeder: Enables the possibility to add colour covers to the book-
lets.
BF5030 Book Folder: Enables the possibility to give the booklets the perfect
bound look.
CT5030 Creaser trimmer
Enables Creasing to avoid toner cracking at the Spine of

the Booklet.
Enables Bleed Trimming for for state of the art looking

Booklets.
Enables Rotation of small media to enhance Productivity.

(Optional)
1-4
November 2012 BOOKLET MAKER INSTALLATION
1.3 BOOKLET MAKER INSTALLATION
Booklet Maker
Installation
1.3.1 ACCESSORY CHECK
[A] [B] [C] [D] [E]
[F] [G] [H] [I]
[J] [K] [L]
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 SR5030 finisher............................ 1
C. Docking assembly (incl. 4 M4 nuts and 4 washers).............. 1
D. Shift tray plate....................................................................... 1
E. Exit tray plate........................................................................ 1
F. Powercords .......................................................................... 3
G. Terminator plug, will always be installed onto BK5030......... 1
H. Terminator plug TR5030........................................................ 1
I. Interlock Jumper TR5030...................................................... 1
J. Cable protector...................................................................... 1
K. Cable holder.......................................................................... 2
L. Cable ties, 100 mm............................................................... 3
1-5
BOOKLET MAKER INSTALLATION November 2012
1.3.2 INSTALLATION PROCEDURE

Unpacking
[A]
1. Remove all packaging material.

2. Carefully pull out the foam blocks [A] (x2) from underneath the BK5030.
WARNING
Two persons are required to remove the foam blocks.
1-6
Booklet Maker
Installation
[B]
[C]
3. Mount Ramp Support [B] according to top picture.

4. Place Ramp [C] according to lower picture.
5. Carefully roll BK5030 off the pallet.
1-7
Exit arm catcher
[A]
[B]
1. Remove the adhesive backing from the Exit Arm Catcher [A].
2. Install the Exit arm catcher on the finisher as shown in picture.
The nut on the Exit arm catcher should be centered over the Exit paper arm,
according to lower picture.
3. Lift up the Exit paper arm, and set it onto the Exit Arm Catcher [B].
1-8
Printer exit tray
Booklet Maker
Installation
[A]
[B]
[C]
1. Make sure that the Exit Paper Arm [A] is in the upper position.
2. Remove the finisher exit tray by removing screws [B] ( x 4).
3. Remove the plastic deflector [C], on the finisher exit tray.
1-9
[E]
[F]

4. Install the Shift Tray Plate [E] on to the finisher ( use x 4 counter screws
from installation kit).
5. Install the Exit Tray Plate [F] on to the finisher exit tray (use x 4 from instal-
lation kit).
1-10
Docking assembly
Booklet Maker
Installation
DS5030 Finisher
[A] ( x 4)
[B]
1. Remove the four screws on Finisher Rear Cover [A].

2. Using the screws Install the Docking Assembly [B] as shown in second picture.
1-11
Rail Unit
Select this hole if CT5010 /CT5030

is installed
[B]
[C]
Select this hole if CT5010 /CT5030

[A] is NOT installed
1. If installing a Rail Unit [A], install it according to picture.

Select correct rail hole[C].
NOTE: If the Rail unit is installed at a later time the height adjustment of the
Booklet maker has to be redone.
2. Hook up the Exit arm catcher to it’s upper position.
CAUTION
Before docking, make sure the Jogger Fence [B] is in the upper position.
If not, with printer powered on - open and close finisher door.
3. Push the Booklet maker onto the rail but leave it undocked with the finisher at
this time.
1-12
Interface to SR5030 Finisher
Booklet Maker
Installation
[A]
[C] [B]
[D]
Finisher Main PCB

1. Remove Finisher Back Cover [A] ( x 5).
2. Guide the communication cable through opening [B] on back cover (The cable
is part of the installation kit).
3. Make a loop on the cable [C] and attach a Cable tie.
4. Install the communication cable, to connector CN2 [D] ( x1) on the finisher
main board.
1-13
1.3.3 ADJUSTMENTS
Front and Back cover removal
[A]
[C]
[B]
1. Remove screws [A] ( x6) and remove Bookler maker front cover .
2. Remove screws [B] ( x2), loosen screws [C] ( x3) and remove Booklet
maker rear cover ( x5).
1-14
Docking the BK5030 to the SR5030 finisher
Booklet Maker
Installation
[B]
[A]
[C]
[D]
1. If installing a Rail unit, install it now.

NOTE: If the Rail unit is installed at a later time the height adjustment of the
Booklet maker has to be redone.
CAUTION
Before docking, make sure the Jogger Fence [A] is in the upper position.
If not, with printer powered on - open and close finisher door.
2. Dock the Booklet maker to the Docking assembly.
3. The covers of the Booklet maker and the finisher should line up.
Pay attention to vertical and horizontal referens points [B], [C] and [D].
1-15
Booklet Maker, rear view
[I]
Booklet Maker, front view

4. To adjust the position of the Booklet Maker use the four adjustment nuts [I].
5. To move the Booklet Maker upwards/downvards turn all four adjustment nuts
the same amount. One revolution equals 2 mm difference in height.
6. To adjust the Booklet Maker side to side turn only the two adjustment nuts on
the front side or the two on the rear side.
1-16
Booklet Maker
Installation
Booklet Maker, outfeed view
7. To adjust the position of the Booklet Maker in the infeed / outfeed direction,
turn only the two adjustment nuts on the infeed side or the two on the outfeed
side.
8. Repeat adjustments 5, 6 and 7 until the position of the Booklet Maker is
correct.
9. Undock the Booklet Maker.
10. Reinstall the Booklet Maker front and rear covers.
NOTE: Not necessary if the next moment is installation of a cover feeder
CF5030.
1-17
1.3.4 CONNECTORS
1. Connect the Communication cable [A] from the finisher ( x1), to the Book-
let Maker.
2. Connect the Belt Stacker cable [B] ( x1).
NOTE: Unless Trimmer TR5030 and/or Book Folder BF5030 will be installed.
If so, Belt Stacker cable will be connected to the last module in the system.
3. Install the Terminator plug [C].
NOTE: The Terminators and Interlock jumpers are included in the installation
kit.
4. Install the Terminator plug [D] and the Interlock jumper [E] .
NOTE: Unless Trimmer TR5030 will be installed. If so, communication cable
and power cord between BK5030 and TR5030 will be connected.
5. Connect the Power cord [F] to the Booklet Maker ( x1).
6. Mount the cable protector [G] positioned as shown with two screws in the
holes [H] and route the cables inside the cable protector ( x 2).
7. Install the cable holders [I] to the holes on the rear side of the Booklet Maker
base and route the cables through them.
[A] [B] [C] [E] [D] [F]
[G]
Only Booklet Maker installed [I]
[H]
1-18
1.3.5 CHECK THE INSTALLATION
Booklet Maker
Installation
1. If installing a Cover Feeder CF5030 or Trimmer TR5030, continue to that sec-
tion ( 1.4 or 1.5 ) otherwise continue with step 2.
2. Turn on the power for the Booklet maker.
NOTE: Make sure that the finisher connector is connected to the copier.
[A]
3. Pull out both staple cartridges [A] and close the top cover.
4. Undock the BK5030 from the copier.
5. Press the [Tools] button and then the [Service] button.
6. Key in password 107 and press the [OK] button.
7. Select BK5030 and press the [Enter] button.
8. Go to Diagnostics and press the [OK] button then press the [Start] button.
9. If you should receive a fault code after performing a Detailed self diagnostic, a
service manual and trained technician is required to solve the problem.
10. IMPORTANT:
ALWAYS POWER OFF THE SYSTEM WHEN EXITING THE DIAGNOSTIC
MODE.
11. Reinstall the two Stapler cartridges and close the top cover.
12. Dock the BK5030 to the copier.
13. Turn on the power to the Booklet maker and the copier.
NOTE: Make sure that the Booklet maker is powered ON before the copier.
1-19
14. Open the Booklet maker top cover and install an interlock cheater to be able
to run the Booklet maker with the top cover open.
WARNING:
• To avoid hazardous situations, please read and follow the safety information
in the beginning of this manual.
15. Set up the Booklet maker to Auto paper size and Staple On.
16. Check that the Booklet maker is set to “Staple On”.
17. Send one A4/8.5 x 11” job to the Booklet maker.
18. Check for the correct feeding of the sheets.
NOTE: The sheets should enter in the middle of the infeeder. If not, adjust the
Booklet maker according to section ( 1.3.3 on page 1-14).
19. Send one A3/11 x 17” job to the Booklet maker.
Use an interlock cheater and run the machine

with the top cover open.
Verify that the sheet enters the Booklet Maker
centered between the side guides.
1-20
November 2012 COVER FEEDER INSTALLATION
1.4 COVER FEEDER INSTALLATION
Cover Feeder
Installation
[A ]
[B ]
[D] [C]
Check the quantity and condition of the accessories in the box against the follow-
ing list:
Description Q’ty
A. DSD Calibration strip............................................................. 1
B. Self adhesive label, not used in CF5030............................. 1
C. Feeder roller ......................................................................... 1
D. Cover Feeder module, CF5030............................................. 1
1-21
COVER FEEDER INSTALLATION November 2012

Unpacking
[C]
[A]
[B]
[C]
1. Remove all parts from the box.

2. Cut the cable tie [A] to release the paper bin, self adhesive label [B] and DSD
Calibration strip [C].
3. Discard the self adhesive label [B].
4. Place the DSD Calibration strip on the cable holder [C] behind the Booklet
Maker rear cover.
1-22
Cover Feeder
Installation
[B]
[A]
[C]
1. Install the Feed roller assembly [A] by pressing it to the front side and lifting it
into position according to arrows [B].
2. Make sure that the Feed roller locks into position [C].
1-23
Removal of Booklet Maker Top Cover
[A] [B]
[C] [D]
[E]
1. Remove screws [A] ( x 4).

2. Remove screws [B] ( x 2).
3. Remove screws [C] ( x 2).
4. Remove screws [D] ( x 3).
5. Remove top cover [E].
1-24
Cover Feeder Dummy
Cover Feeder
Installation
[A]
[B]
1. Remove screws [A] ( x 2).

2. Remove the Cover Feeder dummy [B].
1-25
Installing the Cover Feeder
1. Install the Cover Feeder in the exact same position as the Cover Feeder
dummy was installed.
Fasten with screws ( x 2).
1-26
Cover Feeder
Installation
]A[ [B] [C] [D]
2. Install motor harness [A] ( x 1).

3. Install sensor harness [B] ( x 1).
4. Install fan harness [C] ( x 2) on PCB [D], located under the Top Cover.
5. Install Top Cover ( x 11).
1-27
1.4.3 ENABLING THE COVER FEEDER
1. Turn on the power for the Booklet Maker.

5. Scroll to “CF5030 installed: No”.
6. Press the [CHG] button, so that it reads “CF5030 installed: Yes”.
7. Press [OK] button.
8. Scroll to [Sensors] and press the [OK] button.
9. Scroll to “CF-Q30 paper/dsd sensor”.
10. Place the DSD calibration strip, located behind the rear cover of the Booklet
Maker, as illustrated [A]. The calibration strip must be positioned between the
CF-Q30 (DSD sensor) LED and phototransistor [B] ( Service Manual
CF5010 6.1.2 ).
11. The value should be +4.7 ± 0.05. If not, turn the potentiometer [C] on the Ad-
don PCB until you reach the correct value.
12. Press the [Exit] button when adjustment is done.
13. Press [Exit] button once to go back to Service Program mode or twice to leave
Service Program mode.
[B]
[A]
[C]
Upper Top Cover removed for clarity
1-28
Cover Feeder
Installation
1. If installing a Trimmer TR5030 continue to section ( 1.5 on page 1-32 )
otherwise continue with step 2.
[A]
10. IMPORTANT:
MODE.
1-29
WARNING:
15. Set up the Booklet maker to Auto paper size and Staple On.
16. Check that the Booklet maker is set to “Staple On”.

21. Remove the interlock cheater and close the top cover.
22. A. Prepare a 15mm high stack of A4/8.5 x 11” covers.
B. Make sure that the ink has dried out well, to avoid smearing.
C. Make sure that the covers are well fanned to avoid misfeeds or double-
feeds.
D. Align the covers well to achieve a reliable collating operation and good fin-
ishing result.
1-30
Cover Feeder
Installation
E. Press down the green marks on Paper bin and load the covers.
F. Move the adjustable side guides up against the covers, until there is no clear-
ance.
G. Set up the Cover Feeder to Cover ON, the fan will start and the Cover
Feeder will prefeed the first cover to be ready for the set from the copier.
23. Set up the Booklet maker to A4/8.5 x 11” paper size.
24. Send one A4/8.5 x 11” job to the Booklet maker system.
25. Check that the covers are correctly fed into the Booklet maker.
26. A. Set up the Cover Feeder to Cover OFF and remove all covers from the bin.
Use the Purge mode to completely empty the Cover Feeder from covers.
B. Prepare a 15mm high stack of A3/11 x 17” covers.
C. Repeat step 22 B to 22 G.
27. Set up the Booklet maker to A3/11 x 17” paper size.
28. Send one A3/11 x 17” job to the Booklet maker system.
1-31
November 2012 TRIMMER INSTALLATION
1.5 TRIMMER INSTALLATION
Installation
Trimmer
[C]
[A] [B]
[D] [E]
Check the quantity and condition of the accessories in the box against the follow-
ing list:
NOTE: - The Installation Box is located in the trim bin on the Trimmer.
- The trim bin is tie wrapped on the rear.
- Trimmer fan is bubble wrapped and located inside the Trimmer.
- The Rail Extension is located in the packing material
Description Q’ty
A. Communication cable between the Booklet maker............... 1
and the Trimmer
B. Powercord between the Booklet maker and Trimmer........... 1
C. Rail extension ....................................................................... 1
Plugs and screws ................................................................. 4
D. Cable protector...................................................................... 1
E. Cable holder.......................................................................... 1
1-32
TRIMMER INSTALLATION November 2012

Unpacking
1. Remove all parts from the pallets.

2. Ensure all of the packing material is removed from the outside of the Trimmer.
3. Tilt the Trimmer to upright position.
WARNING
Two persons are required to tilt the Trimmer to the upright position.
1-33
Remove the belt stacker
Installation
Trimmer
[A] Booklet Maker
1. Loosen screws [A] on the Booklet Maker ( x 2 ).

2. Disconnect the Belt stacker cable ( x 1).
3. Remove belt stacker from the Booklet maker.
4. Secure screws [A] ( x 2 ).
1-34
Install Rail Extension
[C]
[A] [B]
[D] [E]
1. Remove the Rail stop from the Rail under the Boklet Maker.
2. Insert the Rail extension [A] into the Rail under the Booklet Maker [B].
3. Press the plugs [C] into the holes in the Rail under the Trimmer and press/
hammer down the plugs ( x 4).
4. Insert the Rail stop [D] into the Rail extension.
5. Secure the Rail stop with the screws [E] ( x 4).
1-35
1.5.3 ADJUSTMENTS
Installation
Height adjustment
Trimmer
[A]
1. Remove the Trimmer front cover by removing the screws [A] ( x 4).
2. Move the Trimmer up to the Booklet maker.
1-36
Height adjustment
[B] [C]
[D]
3. Adjust the height of the Trimmer, so that the docking bracket [B] on the Trim-
mer fits in the docking hole [C] on the Booklet maker (one revolution on the
nuts is 1.5mm / 1/16” in height). Adjust by turning the four nuts [D] on the Trim-
mer with the Multi tool.
NOTE: Make sure that the Ground plate on the docking bracket [B], is ground-
ed correctly.
1-37
Installation
Trimmer
[E]
[F]
4. Seen from the rear of the system, make sure that the Trimmer is parallel with
the Booklet Maker [E] ± 2mm. If necessary, adjust by turning the two nuts [F]
on the outfeed side of the Trimmer.
1-38
1.5.4 DOCKING
Docking procedure
[B]
Trimmer interior towards

[D] [A] [D] Booklet Maker
[C]
1. Loosen nuts [A] to the Locking bracket [B] ( x 2).

2. Dock the Trimmer to the Booklet maker.
3. Secure the Trimmer by lifting the Locking bracket [B] and tightening nuts [A]
( x 2).
NOTE: Make sure that the Trimmer locking bracket [B] locks in the outer slot
[C] on the positioning pin.
1-39
Install Belt stacker
Installation
Trimmer
Trimmer
[A]
1. Loosen screws [A] ( x 2) on the Trimmer.

NOTE: Unless the Book folder BF5030 will be installed. If so, the Belt stacker
will be installed on to the Book folder instead.
2. Install the Belt stacker on to the Trimmer.
3. Secure the Belt stacker with the screws [A] ( x 2).
1-40
1.5.5 CONNECTORS
1. Connect the Belt stacker cable [A] to the Trimmer ( x1).

NOTE: Unless a Book folder BF5030 also will be installed. If so, the Belt
stacker cable will be connected to the Book folder instead.
2. Remove the Trimmer Terminator plug from the Booklet maker [B] ( x1).
3. Connect the Trimmer Terminator plug on the Trimmer [C] ( x1).
4. Remove the Interlock jumper [D] from the Booklet maker ( x1).
5. Connect the Interlock jumper to the Booklet maker frame [E] ( x1) (see
next spread). This jumper will be stored in this area, it will be needed later on
to allow the Booklet maker to function while the Trimmer is serviced.
6. Connect the communication cable to the Trimmer [F] ( x1).
NOTE: The communication cable you received with the Trimmer.
7. Connect, the other end of the communication cable, to the Booklet maker [G]
( x1).
8. Connect the powercord to the Trimmer [H] ( x1).
9. Connect, the other end of the powercord, to the Booklet maker [ I ] ( x1).
10. Mount the cable protector [J] positioned as shown with two screws in the holes
[K] and route the cables inside the cable protector ( x 2).
11. Install the cable holder [L] to the hole [M] on the rear side of the Trimmer base.
12. Route cables through the cable holders on the rear of the Booklet Maker and
Trimmer.
[B]
[D]
Booklet Maker without Trimmer installed

Continued on next page....
1-41
Installation
Trimmer
[A] Com. Booklet maker Com. SQF/BF
[C]
[H]
[F] [E]
[K] [G] [I] [J]
Com.
Bookle
t maker
Com.
SQF/BF
Booklet Maker with Trimmer installed
[M]
Trimmer with cable protector installed
[L]
1-42
1. If installing a Book Folder BF5030 continue to section ( 1.6 on page

1-48) otherwise continue with step 2.
[A]
Trimmer interior towards Booklet Maker
3. In the Trimmer, check the Index 16 value [A].

7. Select NVM and press enter.
8. Scroll to INDEX 16. TRKnife Zero.
9. Press the [+] or [-] buttons to enter value [A].
10. Press the [OK] button.
11. Press the [Exit] button once.
1-43
Installation
[A]
Trimmer
16. IMPORTANT:
MODE.
WARNING:
21. Set up the Booklet maker to Auto paper size, Staple On, Cover Off and Trim
On.
1-44


If a Cover Feeder CF 5030 is installed, proceed with step 27 and onwards. If not,
the installation check is finished.
feeds.
ishing result.
ance.
G. Set up the Cover Feeder to Cover ON, the fan will start and the Cover
1-45
Installation
31. A. Set up the Cover Feeder to Cover OFF and remove all covers from the bin.
Trimmer
1-46
Page intentionally blank
November 2012 BOOK FOLDER INSTALLATION
1.6 BOOK FOLDER INSTALLATION
Book Folder
Installation
[A] [B] [C]
[D] [E] [F]
[G] [H]
Description Q’ty
A. Communication cable ........................................................... 1
B. Power cord ........................................................................... 1
C. Extended trim bin (two parts) ............................................... 1
Screw and nut ...................................................................... 4
D. Rail extension ....................................................................... 1
Plugs and screws ................................................................. 4
E. Cable protector...................................................................... 1
F. Cable holder.......................................................................... 1
G. Safety bracket....................................................................... 2
H. Safety bracket nut and screw................................................ 2
1-48
BOOK FOLDER INSTALLATION November 2012

Unpacking
1. Remove all parts from the pallet.

2. Ensure all of the packing material is removed from the outside of the Book
Folder.
3. Tilt the Book Folder to upright position.
WARNING
Two persons are required to tilt the Book Folder to the upright position.
1-49
Remove the belt stacker
Book Folder
Installation
Trimmer Trimmer
[A]
[B]
1. Disconnect the power cord to the Booklet Maker ( x 1).

2. Loosen screws [A] ( x 2 ) securing the Belt Stacker on the Trimmer.
3. Disconnect the Belt stacker cable ( x 1) from the Trimmer.
4. Remove the Belt stacker from the Trimmer.
5. Secure screws [A] on the Trimmer.
6. Remove the positioning pins from the upper holes [B], used for the belt stacker ( x 2).
7. Using the second lower hole, install the other positioning pin, using the 25 mm
washer and screw provided ( x 1, x 1).
1-50
Extended trim bin
[A]
1. Remove the existing trim bin from the Trimmer. This trim bin can not be used
together with the Book Folder.
2. Assemble the new extended trim bin [A] with the four screws and nuts
from the installation kit ( x 4, x 4).
1-51
Book Folder
Installation
[C]
[A] [B]
[D] [E]
1. Remove the Rail stop from the Rail under the Trimmer.
2. Insert the Rail extension [A] into the Rail under the Trimmer [B].
1-52
1.6.3 ADJUSTMENTS
Height adjustment
[A]
1. Remove the front cover of the Book Folder by removing the screws [A] ( x 4).
2. Move the Book Folder up to the Trimmer.
1-53
Book Folder
Installation
Book Folder Trimmer
[C] [B]
[D]
Book Folder, rear view

Book Folder, front view
3. Adjust the height of the Book Folder, so that the positioning pins [B] on the
Trimmer fits in the docking holes [C] on the Book Folder. Adjust by turning the
four nuts [D] on the Book Folder with the Multi tool (one revolution on the nuts
is 1.5mm in height). Adjust on the front and rear.
NOTE: The Multi Tool is located behind the rear cover of the BK5030 ( x 4).
1-54
Parallellity adjustment
[E]
[F]
4. Seen from the rear of the system, make sure that the Book Folder is parallell
with the Trimmer [E] ± 2mm. If necessary, adjust by turning the two nuts [F] on
the outfeed side of the Book Folder .
1-55
1.6.4 DOCKING
Book Folder
Installation
Docking procedure [B]
Book Folder interior, view

towards Belt Stacker
[D] [A] [D]
[C]
1. Loosen nuts [A] to the Locking bracket [B].

2. Dock the Book folder to the Trimmer.
3. Secure the Book folder by lifting the Locking bracket [B] and tightening nuts
[A] ( x 2).
NOTE: Make sure that the Book Folder locking bracket [B] locks in the outer
slot [C] on the positioning pin [D].
4. Install the new Extended trim bin.
1-56
Installing Belt stacker
Book Folder
[A]
1. Loosen screws [A] ( x 2) on the Book Folder.

2. Install the Belt stacker on to the Book Folder.
3. Secure the Belt stacker by tightening screws [A] ( x 2) on the Book Folder.
1-57
1.6.5 INSTALLING STACKER SAFETY BRACKET
Book Folder
Installation
[B]
[C]
[A] Nuts not shown in picture
1. Mount safety brackets [A] on stacker.

2. Fasten screws [B] ( x 2) with nuts [C] ( x 2) (nuts is to be placed on the
inside).
NOTE: Make sure the belt stacker cable does not interfere with the safety
bracket.
1-58
1.6.6 CONNECTORS
Com.
Booklet
maker
[A]
Com.
SQF/BF
[B]
Trimmer without Book Folder installed
[C]
[E]
Com.
Booklet
Book Folder
maker
Com.
SQF/BF
[D]
Trimmer with Book Folder installed
1. Move the Belt stacker cable [A] to the Book Folder ( x 1).
NOTE: Do not connect the Belt stacker cable [A] to the Trimmer.
2. Move the Terminator plug [B] from the Trimmer to the Book Folder ( x 1).
3. Install the communication cable [C] between the Trimmer and the Book Folder
( x 1).
4. Connect the power cord from the BK5030 to the BF5030
5. Mount the cable protector [D] positioned as shown with two screws in the
holes [E] and route the cables inside the cable protector ( x 2).
6. Install the cable holder [F] to the hole [G] on the rear side of the Book Folder
base.
1-59
Book Folder
Installation
[F] [G]
7. Route cables through the cable holders on the rear of the Booklet Maker, Trim-
mer and Book Folder.
1-60

[A]
Trimmer interior towards Booklet Maker
2. In the Trimmer, check the Index 16 value [A].

6. Select NVM and press enter.
7. Scroll to INDEX 16. TRKnife Zero.
8. Press the [+] or [-] buttons to enter value [A].
9. Press the [OK] button.
10. Press the [Exit] button once.
1-61
[A]
Book Folder
Installation
15. IMPORTANT:
MODE.
WARNING:
20. Set up the Booklet maker to Auto paper size, Staple On, Cover Off, Trim On
and Book fold unit Auto.
21. Send five 2 sheet booklets of A4/8.5 x 11” (8 pages of A5/8.5 x 5.5 = a booklet
containing 2 sheets of A4/8.5 x 11”) to the Booklet maker system.
23. Check that the booklets have been trimmed correctly and that they not have a
Book folded spine.
1-62
24. Send five 10 sheet booklets of A3 / 11x17” (40 pages of A4/8.5 x 11 = a book-
let containing 10 sheets of A3 / 11x17”) to the Booklet maker system.

Verify that the sheets enters the Booklet
Maker centered between the side guides.
26. Check that the booklets have been trimmed correctly and that they have a
Book folded spine.
If a Cover Feeder CF 5030 is installed, proceed with step 28 and onwards. If not,
the installation check is finished.
feeds.
ishing result.
ance.
G. Set up the Booklet maker to Cover On, the fan will start and the Cover
1-63
32. A. Set up the Booklet maker to Cover Off and remove all covers from the bin.
Book Folder
Installation
1-64
ROTATOR CREASER TRIMMER INSTALLATION November 2012
1.7 CREASER TRIMMER INSTALLATION
[D]
[B] [C]
[A]
[I]
[E]
[F] [G]
[H] [J]
Description Q’ty
A. Communication cable between the Booklet maker...............................
and the CT5010 / CT5030.....................................................................1
B. Powercords to the CT5010 /CT5030.....................................................3
C. Rail extension .......................................................................................3
Plugs and screws .................................................................................12
D. Cable protector......................................................................................1
E. Infeed Paper Path..................................................................................1
F. Waste Box.............................................................................................1
G. Infeed docket bracket............................................................................1
H Outfeed docket bracket.........................................................................1
I. Intermediate Cover................................................................................1
J. Uncurved Top Cover (CT5010 only)......................................................1
1-65
November 2012 ROTATOR CREASER TRIMMER INSTALLATION
Installation
Preparations
RCT
1. Install BK5030. ( 1.3 on page 1-5)
2. Ensure that sofware in BK5030 is of version 2.00 or higher.
Download the latest software from http://www.plockmatic.se/customer-centre using
your personal log-in information.
3. Turn off the Booklet Makers power.
4. Disconnect the Communication cable from the finisher from the Booklet Maker,
the Communication cable will later be connected to the CT 5030.
CAN Termination plug CAN to Trimmer

Communication cable from the finisher
5. Undock Booklet Maker and make space for the CT 5030.

Install 2pcs. of Rail extensions (Step 6-10), if applicable.
If not applicable proceed to step 11.
1-66
[C]
[A] [B] [D]
[E]
[F]
Select this hole Select this hole

if CT 5010/CT 5030 is installed if CT 5010 /CT 5030 is NOT installed
6. Remove the Rail stop from the Rail under the CT5030.
7. Insert the Rail extension [A] into the Rail under the Trimmer [B].
11. Select correct hole [F].
1-67
Install Top Cover for Finisher ( Applicable only for CT5010)
Installation
1. Remove curved Top Cover [A], by removing screws ( x 4) [B].
RCT
2. Unhook the Top Cover.
[A]
[B]
1-68
3. Secure uncurved Top Cover [C] with screws and nuts ( x 4, x4) [D]
[D]
[C]
1-69
Installation
RCT
Unpack
[B]
[A]
[A]
1. Remove the straps [A]

2. Remove the lid [B].
1-70
[C]
CAUTION!
Ensure that the waste
box is saved.
3. Remove the Waste Box and ensure the box is saved [C].
1-71
Installation
RCT
[D] [E]
4. Remove the Ramp Support [D] .

5. Remove the Protection Foam Blocks (x2) [E].
1-72
[F]
6. Remove Ramp Support Foam (x2) [F].
1-73
[G]
Installation
RCT
7. Remove from the Corners the Protection Foam Blocks (x4) [G].
1-74
[H]
[I]
8. Remove the Paper Box [H].
9. Remove the Plastic Cover [I].

10. Remove Accessories Box [J]
[J]
1-75
Installation
RCT
[K]
[L]
[M]
11. Open the bottom corners of the box [K].

Remove the Protection Foam [L].
Remove Front and Rear Cover ( x 2) ( CT5030 Servicemanual REP 3.3.1 ) [M].
1-76
Installation
RCT
X
x
12. Adjust the height of the casters (x4).

The height, X should be equal 44 mm when installing CT5030
and equal 32 mm when installing CT5010e.
1-77
13. Pull out the foam blocks (x2) underneath the BK5030.
WARNING
Two persons are required to remove the foam blocks.
1-78
Installation
RCT
[N]
14. Mount Ramp Support Foam according to picture [N].
1-79
15. Place Ramp according to picture.
1-80
Installation
RCT
16. Carefully roll CT5030 off the pallet.
WARNING
Two persons are required to carefully roll CT5030 off the pallet.
1-81
[O]
17. Remove packaging Operator Manual from the CT5030 [O].

18. Open and unpack the Accessories Box.
1-82
19. Position the Docking Bracket Outfeed and secure with screws [P] ( x 2)
Installation
RCT
[P]
20. Position Docking Bracket Infeed and secure with screws [Q] ( x 2)
[Q]
1-83
[R]
21. Position the Paper Path Bracket and secure with screws [R] ( x 2).
1-84
Installation
RCT
[S]
22. Position the Cable Protector [S]

23. Secure with screws ( x 2).
1-85
[T]
24. Remove the screw to Docking Sensor bracket [T] ( x 1).
[U]
25. Route Sensor cable through the hole in the docking infeed [U].
1-86
Installation
RCT
[V]
[W]
26. Connect the connector [V] and secure it with a cable retainer [W].
[X]
27. Re-assemble the Docking Sensor bracket by re-tighten the screw [X].
1-87
[Z]
27. Position the Side Front Cover and secure with screws and nuts [Z] ( x 4, x 4).
1-88
Installation
RCT
29. Re-attach the Front and Rear Cover ( x 2)
CT5030 Servicemanual REP 3.3.1 )
30. Assemble Waste Box
31. Place the box under the waste transporter and against the Cable Protector.
1-89
1.7.3 DOCKING
1. Position the CT5030 in front of the Rail edge and the Printer.
2. Push the the CT5030 towards the Printer.
3. Dock the CT5030 with the Printer.

1-90
Installation
RCT
4. Position the BK5030 in front of the edge of the Rail and CT5030.
5. Push the the BK5030 towards the CT5030 until docked.
1-91
1.7.4 CONNECTORS
[Communication cable]
[CAN to Trimmer]
[CAN Termination plug]
1. Remove the CAN-termination plug from the BK5030 and install it in the CT 5030.
[CAN to CT5030]
[Communication cable]
2. Install CAN-cable from (Booklet Maker)Termination plug terminal to CT 5030 terminal “COM
Booklet Maker”.
3. Install the Communication cable from the finisher to the CT5030.
1-92
CAN Termination Plug CAN TO BK5030
Installation
RCT
Main cord
Communication cable
from the finisher
4. Ensure that the CT5030 is switched off and install the main cord.
1-93
ADJUSTMENT November 2012
1.7.5 ADJUSTMENT
1. Adjust Infeed and Outfeed height before docking CT5030 to Printer and Booklet Maker. Turn
casters Rear (x2) and Front (x2) [A].
Adjust casters using the Multi tool.
Turn Clockwise to raise CT5030 and CCW to lower.Ensure that gaps in-between covers are paral-
lel after docking. (Docking Latch(es)) ( CT5030 Servicemanual REP 3.4).
Note: When adjusting the casters on the CT 5030 do not turn each caster more than 2 full revolu-
tions before adjusting the other casters.
[A]
2. Check that there is no interference between the CT 5030 infeed baffle and the finisher outfeed.
3. Check that the alignment between the CT5030 Exit Baffle and the Booklet Maker Infeed Baffle
is adequate. This can be done with the help of a ruler or a piece of paper. Raise or lower rear and
/ or front set of casters as needed. Raise / lower casters equally.
4. Perform Front / Rear adjustment of Infeed docking bracket.

The center of sheets entering from the printer should hit 232 ± 3 (9.1”±0.12”) mm from inner side
of Out Board Frame. ( CT5030 Servicemanual REP 3.4.2 Docking bracket Infeed).
5. Perform Front / Rear adjustment of Outfeed Docking bracket.

The sheets should hit symmetrical in-between side jogger rails in the Booklet Makers compiler
section. ( CT5030 Servicemanual REP 3.4.3 Docking bracket Outfeed. )
6. Make sure that the CT 5030 Front Covers are aligned and parallell with the Finisher.
1-94
November 2012 CHECK INSTALLATION
1. Switch on the CT5030’s power.
Note: CT 5010 / 5030 are identified and installed in the system upon Power On.
To uninstall CT 5010:
- Enter the Service Program Mode
- Select CT 5010 Services
- Set Installed to No
To uninstall CT 5030:
- Enter BK 5030 Servce Components chapter BK5030 chapter 5.5.1.
- Change CT 5030 Installed from Yes to No

2. Refer to the s/w release Document and ensure that the CT s/w is at appropriate level.
3. Run test jobs according to below Table, save all the Boklets.
Paper Size # of sheets # of sets Paper Weight Size Image Crease Crease SQF
Offset Tool Offset
SRA3 / 1 10 120 gsm SRA3T / 0 Fine 0 Auto
12x18 12x18T
SRA3 / 1 10 220 gsm SRA3T / 0 Coarse 0 Auto
12x18 12x18T
SRA4 / 4 10 90 gsm SRA4T / 0 Fine 0 Auto
9x12 9x12T
SRA4 / 1 10 280 gsm SRA4T / 9x12T 0 Coarse 0 Auto
9x12
4. Inspect the output. To correct any issues CT5030 Service manual section 3.
Re-run jobs jobs after adjustments and check output Quality.
1-95

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INSTALLATION MANUAL

The product (System) which is connected to this machine will be class A

How to read this manual

Safety during operation

1.1.2 POWER REQUIREMENTS.............................................................1-2

1.2 INSTALLATION FLOW CHART..................................................1-3

1.3 BOOKLET MAKER INSTALLATION..........................................1-5

1.3.2 INSTALLATION PROCEDURE........................................................1-6

1.3.5 CHECK THE INSTALLATION........................................................1-19

1.4 COVER FEEDER INSTALLATION...........................................1-21

1.4.2 INSTALLATION PROCEDURE......................................................1-22

1.4.3 ENABLING THE COVER FEEDER...............................................1-28

1.4.4 CHECK THE INSTALLATION........................................................1-29

1.5 TRIMMER INSTALLATION......................................................1-33

1.5.2 INSTALLATION PROCEDURE......................................................1-34

1.5.6 CHECK THE INSTALLATION........................................................1-44

1.6.2 INSTALLATION PROCEDURE......................................................1-50

1.6.5 INSTALLING STACKER SAFETY BRACKET................................1-59

1.6.7 CHECK THE INSTALLATION........................................................1-62

1.7 CREASER TRIMMER INSTALLATION....................................1-66

1.7.2 INSTALLATION PROCEDURE......................................................1-67

1.7.6 CHECK THE INSTALLATION........................................................1-96

16.5-24.8” 14.2” 14.2” 31.9” 27.6”

1.1.2 POWER REQUIREMENTS

1. Input voltage level:

1.2 INSTALLATION FLOW CHART

Install the Booklet maker BK5030

Does the user require a Cover Feeder?

Install the Cover Feeder CF5030

Does the user require a Trimmer?

Install the Trimmer TR5030

Does the user require a Book Folder?

Install the Book Folder BF5030

Install the Belt Stacker

Install CT5030/ CT5010 if applicable

Check the Installation

TR5030 Trimmer: Enables On-line trimming. Especially thicker sets

CT5030 Creaser trimmer

Enables Creasing to avoid toner cracking at the Spine of

Enables Bleed Trimming for for state of the art looking

Enables Rotation of small media to enhance Productivity.

1.3 BOOKLET MAKER INSTALLATION

[A] [B] [C] [D] [E]

[F] [G] [H] [I]

[J] [K] [L]

1.3.2 INSTALLATION PROCEDURE

1. Remove all packaging material.

3. Mount Ramp Support [B] according to top picture.

Exit arm catcher

Printer exit tray

1. Remove the four screws on Finisher Rear Cover [A].

Select this hole if CT5010 /CT5030

Select this hole if CT5010 /CT5030

1. If installing a Rail Unit [A], install it according to picture.

Interface to SR5030 Finisher

Finisher Main PCB

Docking the BK5030 to the SR5030 finisher

1. If installing a Rail unit, install it now.

2. Dock the Booklet maker to the Docking assembly.

Booklet Maker, rear view

Booklet Maker, front view

[A] [B] [C] [E] [D] [F]

1.3.5 CHECK THE INSTALLATION