Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

[jdkeeley]

I need to hire a tech who can help me via skype or even telephone. I have one of these booklet makers, but live in a rural location and don't have a tech in my area who will touch this thing. So I'm reading through the service manuals myself and need someone to bounce things off of before I start getting too crazy.

At this point I have it running offline and can handfeed it and it makes booklets (exciting!). However, it staples but not on the center fold line on 11x17. For 8.5x11 it seems to hit the mark. It folds off-center (in a straight line, but off-center - after its folded it ). I tried doing a paper reset, but have no idea where and how the multi tool is supposed to go in to set the paper size so this step keeps failing. I reset the EEPROM values as the thing is new to me but that didn't seem to make any difference.

Is there any resource out there for this kind of thing? Can I hire one of you and pay you via paypal or something to skype in and walk me through things?

Thanks!

[Rorschach]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

It appears that you've got the service manual in hand, since you mentioned a paper reset, and EEPROM reset.

First, I'd try setting it up for 11x17 as a custom size. Sometimes these Plocks give wonky output if you use the preset sizes.

If it still doesn't staple or fold properly with the custom size, then I'd go into service mode (instructions are in the service manual), and you should be able to adjust the staple stop and fold stop for each paper size individually. This would seem to be your fix, as you said that LT staples and folds correctly, but DLT does not. I've had this on a Plock in the past, and I'm pretty sure that's where I made the adjustments. Concentrate on the fold stop first to get it folding on center, and then work on the staple stop to get the staples to match the fold. It may be called something other than staple stop/fold stop in service mode, but it should be labeled something close to that.

Additionally, because you say that LT folds and staples perfectly, I would probably stay away from some of the hardware-based fold adjustments that are in the manual. Those physically move the stop plates, and will likely affect every size of booklet across the board.

We only have a few of the BK5010 left in the field down here; most have refreshed and now have the PBM 350/500. I can try and run by one of them to take a peek in a day or two to see the settings, if you still can't get it.

[jdkeeley]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

We only have a few of the BK5010 left in the field down here; most have refreshed and now have the PBM 350/500. I can try and run by one of them to take a peek in a day or two to see the settings, if you still can't get it.

Thank you Rorschch so much for your response!! I have a small graphic design company and bought a Ricoh C901 and the 5010e booklet system 3 years ago to try and cut down on some of my printing costs. Today was the first day the C901 printed a damn thing - a whopping 1200 pages for a magazine that I now have in spreads in my car to take to a print house tomorrow to bind and trim for me (because problematic still isn't working right!!). There are lines on all the pages as well because the fuser that was just rebuilt is apparently still having problems too (but whatever, actual printed pages is amazing)!! My husband calls the whole thing a boat anchor and I can't help but agree with him.

Anyway - before waving the white flag completely I'm going to see if I can figure this 5010 out and see if it can't fold a few books. Seems I have you on the hook I will explain with a little more detail and maybe you can help me out (or ask someone you know who knows):

1. I have tried every size setting from auto to custom. I have burned through a box of paper thinking that I could outwizard it on user settings. Nada. Just to clarify - it staples on the fold at LT, but doesn't fold on center - one side is slightly longer than the other. This is just exaggerated on the DLT and the staples are not on the center of the fold (out about 1/2 inch).

2. I Service Mode, but I don't see any fold stop or staple stop settings. This is where I reset the EEPROM settings (again, this was a new machine to me, so thought it might be that). Nope.

3. In the service manual it says

"5.4 PAPER SIZE RESETIf any mechanical adjustments have been carried out that effects the positioning
of side guides, staple stop or fold stop, this procedure must be performed.
If the EEPROM or the CPU PCB has been replaced, this procedure must be
performed.
During the procedure, the side jogger motor and staple/fold positioning motor moves
between given positions to calculate this specific motors characteristics in conjunction
with this specific machines mechanics. The paper size reset procedure results
in variables used when calculating the different positions for different paper sizes."

So this is where I am bamboozled and why I need someone on Skype to walk me through this: From the manual on how to reset the paper size...


Remove the two stapler heads ( 3.4.12 ).
2. Insert a Interlock cheater.
3. Enter the Service Program Mode.
4. Go to Paper Size Reset. Press OK.
5. The text READY will be shown on the LCD display. Press Run.
The text SIDE JOGGERS will be shown.
The side joggers moves in and out.
NOTE: If this fails, switch OFF and ON the main power switch and go to
step 1.
6. The text INSERT TOOL will be shown.
7. Insert the Multi tool [A], according to picture below.
Push the Multi tool gently up against the side guide to make sure it is in contact.
8. Press OK.
The text FOLD POSITION will be shown on the LCD.
The stop gate moves the Multi tool upwards [B] so the top of the Multi tool
catches the clincher bar.
IMPORTANT: If this fails, the procedure must be done all over again!
The text REMOVE TOOL will be shown.
9. Remove the tool. Press OK.

STEP 7 is a nightmare. I have the multi tool in my hand and a very non-descript picture from the manual. I can't even get the damn tool in anywhere near the side guide. This is why I need someone to phone/Skype walk me through it.

I thought about starting the manual adjustments, but this seems like a bad idea at this point when it's likely a setting. I read somewhere else that if I docked it to the 901 I could do the adjustments through the 901 interface - is this true?

Help...anyone...help.

Thanks!!

[Coptech]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

I think they are actually designed to staple just off center to keep the folding knife from interfering with the staples. I think it also helps the fine "square edge" process. I had one plockmatic line-up in a print shop. I outlived it but it was touch and go for awhile. Parts are a killer on those things. The larger dealers called them "revenue killers". I found Ricoh badly overcharged for parts (at least on the scream punch) If you find Canon's part numbers, and double the suggested retail, you will find a Ricoh dealer's cost.

[slimslob]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

If this machine has been setting for any length of time, you might need to remove as much of the old congealed grease and oil that you can. Pay special atttention to the clincher bar and the individual clinchers as they can get sticky and cause stapling problems.

[jdkeeley]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

If this machine has been setting for any length of time, you might need to remove as much of the old congealed grease and oil that you can. Pay special atttention to the clincher bar and the individual clinchers as they can get sticky and cause stapling problems.

Thank you slimslob. The clincher bar doesn't seem to be an issue as far as having any dirt or grease (but I did double check, so thanks!). The staples are folding correctly and are parallel - they just don't sit on the fold, and the fold is off center. So aggravating...

[jdkeeley]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

I think they are actually designed to staple just off center to keep the folding knife from interfering with the staples. I think it also helps the fine "square edge" process. I had one plockmatic line-up in a print shop. I outlived it but it was touch and go for awhile. Parts are a killer on those things. The larger dealers called them "revenue killers". I found Ricoh badly overcharged for parts (at least on the scream punch) If you find Canon's part numbers, and double the suggested retail, you will find a Ricoh dealer's cost.

Oh I know this thing is a POS. It has been sitting in my shop for 3 years now and hasn't stapled a single book (and I paid a pretty decent penny for it).

Again - I think my biggest problem is doing the paper reset at the step where the multi tool is supposed to be inserted snug against the side bar. Then when you press 'OK" the top of the tool is supposed to catch on the clincher bar and have set the paper dimensions correctly. But I can't see how this is even possible to get the tool inserted like it is the photo provided. paperreset.jpg

The manual doesn't show removing the bars or anything - and yet how did they wedge the tool down in there?? Help!!

Thanks!

[jdkeeley]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

Thank you everyone for your suggestions. I finally figured out the paper size reset - I had to disconnect the booklet maker from the face trimmer and was then able to fish the tool in properly to run that service module.

After that, I messed around with every setting of paper size and EEPROMS and any other combination I could think of and still not folding/stapling on center for the 11x17 (but perfect for 8.5x11). So I'm going to suck it up and do the manual adjustment on the fold stop gate so that at least it works with 11x17 (and will just manually adjust it back if we are going to do any 8.5x11 booklets).

This forum is a great resource!! Thank you so much for your help!

[WHW]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

I need to hire a tech who can help me via skype or even telephone. I have one of these booklet makers, but live in a rural location and don't have a tech in my area who will touch this thing. So I'm reading through the service manuals myself and need someone to bounce things off of before I start getting too crazy.

At this point I have it running offline and can handfeed it and it makes booklets (exciting!). However, it staples but not on the center fold line on 11x17. For 8.5x11 it seems to hit the mark. It folds off-center (in a straight line, but off-center - after its folded it ). I tried doing a paper reset, but have no idea where and how the multi tool is supposed to go in to set the paper size so this step keeps failing. I reset the EEPROM values as the thing is new to me but that didn't seem to make any difference.

Is there any resource out there for this kind of thing? Can I hire one of you and pay you via paypal or something to skype in and walk me through things?

Thanks!

May I ask where/how you got the a copy of the service manual for the BK5010e? I recently purchased a used BK5010e and am trying to avoid having the only service tech I know with experience with the machine from driving two hours to my location if it's something I might be able to adjust.

I'll thank you in advance for your response.

[slimslob]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

May I ask where/how you got the a copy of the service manual for the BK5010e? I recently purchased a used BK5010e and am trying to avoid having the only service tech I know with experience with the machine from driving two hours to my location if it's something I might be able to adjust.

I'll thank you in advance for your response.

If you are an authorized Ricoh dealer, download it from Ricoh. That's how I got mine, rfg-esource, use the expanded search form, enter BK5010 as the product code. Brings up everything they have for the Plockmatic, both 5010 and 5010e.

[TayTayTheTechnician]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

Is anyone on this thread willing to chat with me in regards to BK5010? No one in my area touches these anymore and was given the task to repair one but I'm running into issues that seem to be caused by my lack of familiarity. I cannot get past error bk156 and as far as I know, I have all of the proper jumpers. The machine is standing alone with trimmers attached but without a copier. The manual keeps instructing me to use service mode, but I cannot without the copier attached. Or that is my understanding at least. I would be so grateful for the help.

[slimslob]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

It is referring to the Plockmatic service mode. If you don't have a service manual, get one. everything you need to know is in the manual, except you might have your regional support rep for the password.

[WHW]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

Is anyone on this thread willing to chat with me in regards to BK5010? No one in my area touches these anymore and was given the task to repair one but I'm running into issues that seem to be caused by my lack of familiarity. I cannot get past error bk156 and as far as I know, I have all of the proper jumpers. The machine is standing alone with trimmers attached but without a copier. The manual keeps instructing me to use service mode, but I cannot without the copier attached. Or that is my understanding at least. I would be so grateful for the help.

For what it's worth, my BK5010e is used offline and I've accessed the service mode on several occasions. As I recall it's TOOLS > SERVICE > 107

[TayTayTheTechnician]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

For what it's worth, my BK5010e is used offline and I've accessed the service mode on several occasions. As I recall it's TOOLS > SERVICE > 107

Thank you for this information. I have the service manual, but I was assuming that the '107' service mode was corresponding to the copier service mode. there are only three buttons on the plock itself so I was at a loss as to how I would input the numbers. I am also having trouble because once the machine errors out, it will not let me click tools. I will keep playing with it and see what I can find with this new info. Do you have any experience with the 156 error? I'm starting to believe that it is a configuration error and has nothing to do with the switch. I swapped the switch from another down machine and had the same result. and prior to me detaching the booklet maker from the trimmer and conveyer belt, I was experiencing BK024 error. Thank you very much for your input, I'm aware that I may be overthinking a lot of this lol so it is nice to have a point of reference.

[slimslob]

Re: Ricoh Pro C901 booklet maker (plockmatic/problematic BK5010e)

For what it's worth, my BK5010e is used offline and I've accessed the service mode on several occasions. As I recall it's TOOLS > SERVICE > 107

Sounds right to me. Still needs the service to know how to trouble shoot BK156.