Ricoh FT9101 Quick start guide

RICOH FT9101
FIELD SERVICE MANUAL
LARGE CAPACITY TRAY RT32
FINISHER SR500
PRINTER CONNECTOR UNIT PCU10
KEY COUNTER/PRINTER
CONNECTOR BRACKET KP10
COMPANY, LTD.

Read This First
A few simple symbols and notations are used to help you read faster and find the information you
need. Before you use this guide, glance over this list of special notations and be sure you
understand what they mean.
NOTE
Information under this heading describes helpful hints, restric-
tions, and how to avoid difficulties.
CAUTION
Failure to pay attention to CAUTION notices can
result in damage to the equipment.
WARNING
Warnings are for your safety. Failure to pay
attention to WARNING information can be
dangerous to you and others.

IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the copier and peripherals,
make sure that the copier power cord is unplugged.
2. The wall outlet should be near the copier and easily accessible.
3. Note that some components of the copier are supplied with electrical
voltage even if the main switch is turned off.
4. If any adjustment or operation check has to be made with exterior covers
off or open while the main switch is turned on, keep hands away from
electrified or mechanically driven components.
5. The inside and the metal parts of the fusing unit become extremely hot
while the copier is operating. Be careful to avoid touching those
components with your bare hands.
HEALTH SAFETY CONDITIONS
1. Never operate the copier without the ozone filter installed.
2. Always replace the ozone filter with the specified one at the specified
interval.
3. Toner and developer are non-toxic, but if you get either of them in your
eyes by accident, it may cause temporary eye discomfort. Try to remove
with eye drops or flush with water as first aid. If unsuccessful, get medical
attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The copier and its peripherals must be installed and maintained by a
customer service representative who has completed the training course
on those models.
2. The main control board has a lithium battery which can explode if handled
incorrectly. Do not replace the battery. Do not recharge, or burn this
battery. Used batteries must be handled in accordance with local
regulations.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
1. Do not incinerate the toner cartridge or the used toner. Toner dust may
ignite suddenly when exposed to open flame.
2. Dispose of used toner, developer, and organic photoconductors
according to local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
4. When keeping used lithium batteries (main control boards) in order to
dispose of them later, do not put more than 100 batteries (main control
boards) per sealed box. Storing larger numbers or not sealing them apart
may lead to chemical reactions and heat build-up.

SECTION 1
OVERALL MACHINE INFORMATION

1. INSTALLATION
1.1 Installation Requirements
1.1.1 Delivery and installation work flow
Installation environment, floor strength
Installation
condition check
Operation check as far as the
machine stand-by condition
Machine power on
Delivery
Clamp removal
Main body setup
Installation of peripherals
Machine operation check
User guidance
Space around machine, delivery route
Power supply
The user’s acceptance of the limited items
for using the machine (See User Guidance
Items section for the limited items.)
Supply developer
Supply cleaning carrier
Set OPC belt
Supply silicon oil
Install power plug and cord
Leveling
Installing original stacker
Installing sub-tray
Installing toner cartridge
Setting copy paper
1 July 1994 Installation Requirements
1-1

1.1.2 Environment
Select the conditions which fully satisfy the following items at installation.
1. Avoid a place exposed to direct sunlight or other strong light (should be below 1500 lux).
2. Avoid locations with high temperatures or high humidity, or low temperatures and low
humidity. (Standard range of temperature and humidity: 10oC to 30oC, 15% to 90%)
3. Avoid places with hot air or strong heat sources.
4. Avoid locations subject to abrupt temperature changes.
5. Avoid small or dusty rooms.
6. Avoid poorly ventilated locations. (Air turnover should be 3 times or more per hour per
person.)
7. Install the machine flat on the floor. It must be level within 5 mm front to rear and 5 mm left
to right. This is mainly to prevent affecting the tracking operation of the OPC belt.
8. Align the position of the LCT and finisher with the copier. First, adjust the height of
peripherals on the basis of the exterior covers position. Finally, align the paper transport
guide plate height between each unit. This is to prevent paper misfeeds where each unit
connects.
9. The unit must be installed on a floor which can support its total weight: copier including ADF
482 kg, finisher 77 kg, and LCT 75 kg.
10. Provide enough space, 100 cm in front, 60 cm in rear and 30 cm on both sides for operation
and service. No fluorescent lights should be installed above the operation unit. (This is to
make it easier to see the operation display.)
1.1.3 Power connection (For the European version machine only)
1. Plug
The plug must be approved under the TÜV safety standard and for a three-phase power supply.
2. Power supply cord
The cord must be approved under the TÜV safety standard and have five wires inside. The
cross-sectional area of each wire must be 2.5 mm2, and the outside diameter of the cord must
be 14 to 18 mm. (The capacity must be over 600 volts and 16 A for each phase.) The length
must be 5 m or less even if an extension cord is used.
1.1.4 Transportation
Remove the operation unit before
transporting the copier if the copier cannot
get into the elevator or copy room. This
reduces depth to 775 mm from 830 mm.
Remove the cardboard packing in advance.
1. Remove four screws (M4 x 6) from the operation
unit.
2. Remove the connector for the operation unit and
remove the operation unit.
CAUTION
Never carry the copier side down.
Connector
4 screws (M4 x 6) Operation unit
Installation Requirements 1 July 1994
1-2

1.2 Copier Installation
1.2.1 Accessory list
Name Diagram Quantity Use
Developer vessel
Cleaning carrier vessel
Cleaning carrier magnet
1 of each To collect the developer and cleaning carrier.
Vessel rail 2 To set the developer vessel.
Original stacker 1 To receive originals from the ADF.
OPC belt 1
Leveling shoe 4 For the docking position adjustment.
Original back fence 1 To install on the original stacker.
Development unit
grounding harness
1 To avoid damage of the image density sensor board
when a vacuum cleaner is used.
Tray fences fixing plate 3 To fix the paper tray side fences.
Syringe 1 To apply silicon oil in the fusing unit.
Plated screw M 4 x 8 4 To secure the vessel rails.
Counter reset key 1 To reset the total counter to 0.
Printer interface board 1 To connect a printer using service tool [6]. These
parts are needed when the optional printer
connector unit is installed. Keep these parts for
future use.
Short printer harness 1
Long printer harness 1 To connect a printer using service tool [6].
NOTE
When the optional finisher is not used, the sub-tray (P/N-A0291460) must be ordered and used.
Sub-tray 1 To receive copies fed out. (Not required when the
sorter is used.)
1 July 1994 Copier Installation
1-3

1.2.2 Removing the clamps
1. Remove the cushions from the paper feed tray, the
cushion from the copy tray, and the strips of
filament tape from the exterior.
2. Open the center door and remove the 7 strips of
filament tape and a cushion from the transport unit.
3. Remove the right cover (2 screws). Then, remove
the clamps from tray 1, tray 2 and tray 3 using a
slot head screwdriver.
ADF
Cushions (2)
Cushion Cushions (3)
Center door Cushion
Clamp
Right cover
Copier Installation 1 July 1994
1-4

4. Take off the left cover and remove the red bracket
holding the second mirror.
5. Remove the protective sheets of the exposure
glass and copy tray.
6. Remove the strips of filament tape from the duplex
unit.
Protective sheet Copy tray
Filament tape
Holder bracket
1 July 1994 Copier Installation
1-5

7. To remove the inner cover, remove the left door
fixing screw (2 screws), and disconnect the cooling
fan connector.
8. Remove the first mirror bracket (red bracket).
9. To enable accessing the service tool password,
turn on DIPSW101-2.
10. Remove the OPC cleaning unit fixing screw to pull
out the unit, and cut the unit fastener.
11. To pull out the fusing unit, remove the front fusing
cover (2 screws) and one unit fixing screw.
12. Remove the cover from the right side of the unit (4
screws).
13. Loosen the pressure fixing screws to remove the
wedges on the front and far side. Re-tighten the
pressure fixing screws.
14. Install the fusing right side cover.
NOTE
Install the front fusing cover after pouring silicon oil.
15. Peel off the plain sheet behind the fusing oil pan.
Sheet
Left door
Inner cover
Cooling fan
connector
Mirror
bracket
Unit fixing screw
Unit fastener
Unit fixing screw
(before removal) Wedges
Pressure
fixing screw
Wedge
Pressure fixing screw
Unit fixing screw
Front fusing cover
Copier Installation 1 July 1994
1-6

1.2.3 Setting up the copier
1. Release the development backup rollers by the
lever, and remove the development unit fixing
bracket. Then, slide out the unit.
2. Remove the filter cover from the developer supply
port (2 screws). While turning the development
knob in the direction opposite to the arrow, put in 4
bags (1 kg/bag) of developer from the supply port.
CAUTION
•Clean off the developer on the unit casing.
It may touch the OPC surface.
•Do not put in another compound (cleaning
carrier, etc.) by mistake.
3. Reinstall the filter cover.
4. Turn the development knob in the direction of the
arrow and return the developer from the
development roller to the unit inside.
Development
backup lever
Fixing bracket
Filter cover
Developer
Developer
supply port
Casing
Development knobDevelopment knob
Filter cover
Development knob
1 July 1994 Copier Installation
1-7

5. Slide in the development unit, and fix it with the
fixing bracket.
6. Release the cleaning backup roller by the lever,
and remove the cleaning fixing screw to pull out
the cleaning unit.
7. Remove the upper cover from the cleaning unit (4
screws). Put in one bag of cleaning carrier (700 g)
on the cleaning roller (right side of the unit).
CAUTION
•Be sure that the carrier is not in the
scavenging roller side.
•Do not put in another compound by
mistake, such as developer, etc.
•Distribute the carrier evenly by turning the
knob. This unit has no agitation mechanism
as the development unit does.
8. Close the upper cover, set the unit in the main
body, and secure it with the fixing screw.
Fixing bracket
Cleaning fixing screw
Cleaning
backup lever
Upper cover
Cleaning carrier
Cleaning roller
Fixing screw
Copier Installation 1 July 1994
1-8

9. Pull out the charge corona unit, and release the
transport unit.
10. Release the development and cleaning back-up
levers, and turn the development knob in the
direction of the arrow. Then, remove the OPC unit
stay to pull out the OPC unit.
CAUTION
Be sure to return the developer from the
development roller to the inside of the unit
before pulling out the OPC unit. Do this by
turning the development knob.
11. Insert two paper tubes (OPC belt accessories) in
the two guide holders of the OPC unit. Then,
release the pressure release lever to loosen the
tension, and pull the OPC belt out of the case.
12. Use the paper tubes as guides to fit the OPC belt
to the unit.
CAUTION
•As you fit the OPC belt, be sure to prevent
folds and contact between the side plate of
the OPC unit and the belt end. Do not
touch the OPC surface directly.
•Set the OPC belt so that the OPC home
mark is on the rear side of the machine.
•The rear side of the OPC belt must be under
the OPC sensor.
Charge corona unit
Development back-up lever
Cleaning
back-up lever
Transport unit
OPC unit stay
OPC belt case
Pressure
release lever
Paper tube
Guide holder
OPC home
mark side
OPC belt
1 July 1994 Copier Installation
1-9

13. Set the OPC belt in the center of the unit and
restore tension to the belt with the pressure
release lever.
14. Set the OPC unit in the main body and install the
OPC unit stay.
15. Set two backup levers, and position the charge
corona unit, its connector, and transport unit.
16. Install the inner cover (2 screws and a connector)
and left door (2 screws).
OPC unit stay
Transport unit
Charge corona unit Backup levers
Inner cover
Left door
Pressure release lever
OPC sensor
Copier Installation 1 July 1994
1-10

17. Pull out the fusing unit and remove the front fusing
cover.
18. Put silicon oil in the oil sump. About 80 g of oil is
sufficient.
19. Install the front cover and set the unit in the main
body.
20. Put two cans of silicon oil in the oil tank. (2/3 of
capacity makes about 200,000 copies.)
CAUTION
Never removethe oil supplyunit fromthefusing
unit to prevent oil marks on copies. It can be
removed only when the oil blade, metering
blade, and oil supply felt are replaced with new
ones.
21. Tighten the screw (M4 x 8 plated screw:
accessory) on the rear of the vessel rails
(accessories). Put the screws in the hole at the
bottom rear of the machine frame.
22. Fit the vessel rails on the bottom of the machine,
and secure each of them with the screw (M4 x 8
plated screw) from the front of the machine. Set
the developer vessel (accessory) on the rail. Put
the cleaning carrier vessel and magnet (both
accessories) in the developer vessel.
Oil tank
Cleaning
carrier vessel
Cleaning
carrier magnet
Developer vessel
Vessel rail
1 July 1994 Copier Installation
1-11

European version machine only (Steps 23 to 27)
CAUTION
The power supply cord and plug for the
European version machine must meet the
following requirements:
•The plug must be approved under the TÜV
safety standard and for a three-phase
power supply.
•The cord must be approved under the TÜV
safety standard and have five wires inside.
The cross-sectional area of each wire must
be 2.5 mm2, and the outside diameter of the
cord must be 14 to 18 mm. (The capacity
must be over 600 volts and 16 A for each
phase.) The length must be 5 m or less
even if an extension cord is used.
23. Remove the rear left cover (2 screw).
24. Remove the power supply cord bracket (2 screws).
Then, pass the power supply cord through the cord
bushing.
25. Connect the five wires of the power supply cord to
the appropriate terminals as shown.
CAUTION
•Secure each wire to the terminals firmly
with screws.
•The grounding wire is green and yellow.
26. Reinstall the power supply cord bracket. Then,
tighten the nut to secure the bushing with the cord.
CAUTION
Be sure that the cord bushing secures the cord
firmly.
27. Install a plug on the other end of the power supply
cord.
CAUTION
•Connect five wires to each of the terminals
’L1’, ’L2’, ’L3’, ’N’, and "Grounding" in the
same order as on the machine.
•Secure each wire to the plug firmly with
screws.
The machine is set up for a 400 volts 3-phase
power supply (European version) or 240 volts
single phase power supply (U.S.A. version) at
the production line. To install the machine in
areas wherethepowersupplyis380or415volts
(220 or 230 volts single phase), follow the steps
below:
28. Loose the screw and disconnect the wire from the
400 volts (or 240 volts) terminal.
29. Connect the wire to an appropriate terminal and
tighten the screw. The terminal to be connected
depends on the power supply from the wall outlet.
CAUTION
The200voltsterminalneverbeused.Thecopier
requires 380 volts (or 220 volts single phase) at
least.
Cord fixing nut Cord bushing Power supply cord bracket
220 or
380V
230 or
400V
240 or
415V
Copier Installation 1 July 1994
1-12

30. Remove the rear right cover (2 screws).
31. Be sure that the proper connector of the harness
from the timer board is set. The color of each
connector means the following:
Black: for 380 or 220V power supply
Red: for 400 or 230V power supply
Yellow: for 415 or 240V power supply
32. If the connector setting does not meet the power
supply, connect an appropriate connector.
33. Set the leveling shoes (accessories) to level the
machine.
STANDARD
Difference, front to rear Within 5 mm
Difference, left to right Within 5 mm
CAUTION
Using a level gauge, level the machine flat on
the floor. This is mainly to prevent affecting the
tracking operation of the OPC belt.
34. Install the exterior covers.
NOTE
Do not install the exterior covers at this stage if the
finisher or LCT is to be installed.
35. Fit the original stacker (accessory) and sub-tray
(must be ordered separately if necessary). To fit
the original stacker, use screws which secured the
upper left cove (M4 x 12 plated screw).
36. Put the original back fence (accessory) on the
original stacker.
NOTE
The sub-tray is not required if the finisher is used.
It is installed in the LCT if the LCT is used and the
finisher is not.
Timer board
transformer
Red
connector
Black
connector
Yellow
connector
Original stacker
Sub-tray
Leveling shoe
Screws securing
upper left cover
1 July 1994 Copier Installation
1-13

37. When inch size originals are used, make a slot as
shown to stop the original stopper at the 81/2 inch
position.
CAUTION
When the slot is made, operating cautions must
be instructed to operators, so that operators
can adjust the original stopper position
correctly according to the original size set in the
ADF. The A4 position and 81/2 inch position are
very close. If the original stopper position is not
proper, original misfeeds will occur.
38. Set the toner cartridge.
CAUTION
Shake the toner cartridge well before you set it.
39. Set paper in each paper tray.
CAUTION
Do not block the fan filter windows of the left
and rear exterior covers.
Original stopper
Copier Installation 1 July 1994
1-14

1.3 Machine Operation Check
1.3.1 Stand-by operation check
1.3.2 Copier operation check
CAUTION
Before making copies, carry out forming for the developer, OPC belt, and cleaning
carrier (in this order) using service tool [3-04].
1. Check the stand-by operation referring the above. Connect the power plug, then turn on the
main switch.
2. Access the service tool, and do all formings.
3. Check that all the keys on the operation panel and paper tray down keys work properly.
4. Check that safety switches of the center door, upper right door, and copy tray work properly.
5. Place a sheet on the original table of the ADF and check that the ADF mode is selected.
Also, insert a sheet in the SADF table and check that the SADF mode is selected.
The cleaning coil
cooling fan, two
ozone exhaust fans
(behind the rear left
cover), and
cleaning unit
cooling fan (behind
the left cover) start
turning.
1. Configuring the first and
second mirrors.
2. The fusing heater ON.
3. The OPC belt ON (2 turns).
4. The Tracking motor ON .
5. All the fans ON except for
the duplex and ADF blowers.
The idling mode starts (30 seconds).
The main motor repeats turning on and
off four times during this period.
The Start key
turns green.
200
Approx.
30 sec.
Fusing Temp.
[° C]
Power
connection Main switch
ON
175 ° C 175 to 180 ° C
100
1 July 1994 Machine Operation Check
1-15