Ricoh Pro C900 User manual

Colour High Volume Production System
Installation Guide
Pro C900 / Pro C900s and Peripherals
This document is to be used in conjunction with the relevant mainframe and peripheral
service manuals.

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Pro C900 Page 2 of 24
Document Revision Table
Revision Table
This table shows all the revisions made to this document.
Revision No. Revision Date Reason
1 June 2009 First revision
Author: Roger Harvey
Authorised: Ajith Manadeniya

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Pro C900 Page 3 of 24
Table of contents
Introduction ...........................................................................................................4
Machine Run-up and Installation Requirements ................................................5
Special Service Tools Requirements...................................................................7
Machine Weight Distribution................................................................................8
Machine Dimensions.............................................................................................9
Pro C900/ Pro C900s Recommended Space Requirements ............................10
Paper Feed Combinations..................................................................................11
Finishing Combinations .....................................................................................12
Stage 1: Workshop Run-Up Procedure.............................................................13
Stage 2: Transporting the machine ...................................................................15
Stage 3: On-Site Installation Procedure............................................................16
Configuring the Machine................................................................................................17
Copy Quality Checks......................................................................................................19
Machine and Peripheral Checks....................................................................................20
Stage 4: Documentation.....................................................................................22
Checklist of documents to remain on site ......................................................................22
Checklist of documents to be returned to National Technical Support ..........................23
Production Solution Consultant (PSC) installation responsibilities...............23
Customer machine training information...........................................................23

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Pro C900 Page 4 of 24
Introduction
It is very important to follow the steps in the relevant service manuals
each time a high volume production system is to be installed. As the high
volume production customer is more proficient in the machine’s
operation, a higher level of expectation must be met.
This document has been created to assist service technicians in setting
the machine to the expected standard so all installations are completed
and consistent.
This document is not intended to be used as a service manual but as a
reference to emphasise the areas of the service manuals which require
attention at installation. All steps in the run-up procedure and the on-site
installation procedure are detailed in the mainframe and peripheral
service manuals.
There are some settings that may need to be evaluated case by case to
ensure they will suit your client.
The main steps involved when installing the Pro C900/ Pro C900s can be
summarised in the following steps:
1. Workshop run-up procedure
2. Transporting the machine
3. On-site installation procedure
a. Configuring the machine
b. Copy quality checks
c. Machine and peripheral checks
4. Documentation
a. Checklist for documents to remain on site
b. Checklist for documents to be returned to National
Technical Support.

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Pro C900 Page 5 of 24
Machine Run-up and Installation Requirements
The following items are required to run up and install the Pro C900/ Pro
C900s mainframe:
Qty Item Notes
6 Silicon Oil
Type SS
A257 9550
Three bottles of silicon oil for the machine (when on-site) and three
bottles for the customer. The Pro C900 / Pro C900s models are
shipped with enough silicon oil in the oil tank to complete the
workshop run-up procedure.
1 Mainframe
32 Amp
single
phase male
plug
Two types of plugs are recommended. The type of plug that needs to
be purchased will depend on the customer’s 32 amp female socket
location and type:
Clipsal Product Number 56PA332, 3 Round Pins, Angled Plug
Clipsal Product Number 56P332, 3 Round Pins, Straight.
1 Trained
Customer
Replaceable
Units
(TCRU) Kit
This kit will be delivered with every order. Ideally the TCRU items will
remain at the customer’s site.
1 Customer
Replaceable
Units (CRU)
Toner, finishing consumables, waste toner bottle (G178 6973). These
items will remain at the customer’s office.
1 Field
Replaceable
Unit (FRU)
Fusing unit (G178 4142). This item will remain at the customer’s
office.
1 Silicon Oil
Catcher
Tray
This tray will be required for the FRU fusing unit. The silicon oil
Catcher Tray is not available as a spare part. Please source a local
solution.
4 100gsm A4
non coated Four reams of 100gsm A4 non-coated paper
2 100gsm A3
non-coated Two reams of 100gsm A3 non-coated paper.
1 64mb
Machine SD
Card
NVRAM data, address book data and Fiery settings back-up. At
installation all address book information, NVRAM data and Fiery
settings will be backed up to an SD card. This item will remain at the
customer’s office.
1 19mm
Yellow
Tongue
Flooring
When flooring is required, Yellow Tongue flooring is the
recommended flooring type. It comes in various shapes and sizes.
Chosen sizes will need to suit the machine and finishing option
configuration so that the join between each floor board does not
coincide with the wheels of the mainframe or finishing option.
Please refer to the Production Range Dimension Calculator xls file to
determine flooring dimensions.
This calculator can be downloaded from the Technical Website/
Documents/ Pro C900 - Pro C900s / Installation Documents section.
Please use the following link;
http://partners.ricoh.com.au/web/aubase/technical/documents.nsf/
allbymodel/B1EF3252E8A986B8CA2575D00080D6C3?OpenDocument

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Pro C900 Page 6 of 24
1 Stacker
Ramp When floor boards are used, install a ramp at the edge of the flooring to allow the stacker trolley to move in and out of the stacker. At this
stage this is a locally sourced solution.
1 Particle
Board for
the Rear
Controller
Box
If Yellow Tongue Flooring is required for the mainframe and options,
please install one sheet of 1200mm x 1500mm x 19mm (D x W x H)
particle board for the rear controller box to open out on too.

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Pro C900 Page 7 of 24
Special Service Tools Requirements
The following special tools need to be carried by each technician to
complete run-up/ installation and to service the Pro C900/ Pro C900s
mainframe and options.
Qty Item Notes
1 Small Spirit
Level No larger than 30cm in length to ensure the machine is level.
1 Large Spirit
Level About 1m in length to ensure the floor surface is level.
1 Barrieta Grease A257 9300
1 Silicon Grease
G501 5203 9502
1 Launa Oil
1 Drum Setting
Powder B132 9700
1 64MB SD Card B645 5010 This is the recommended size
SD card for updating firmware on this
model.
Important: Unless stated otherwise please
load one firmware module at a time.
1 Latex gloves Image transfer belt replacement
1 Magnification
Scope C401 9503
1 C4 Colour Test
Chart A092 9503 (Pro C900s Only)
2 Bottles of
Silicon Oil Type
SS
A257 9550
1 Ream of
100gsm A4
non-coated.
Recommended paper type for auto colour
calibration (ACC) of the Pro C900s model.
See RTB RD016009 for details.
1 Ream of
100gsm A3
non-coated.
Recommended paper type for producing
installation copy quality samples.
1 8GB USB drive Note: Current system software V3.0 can be
fitted to both the Pro C900 and the Pro
C900s. Earlier copier and printer system
software versions were different requiring
two USB drives.
1 GBC Special
Tools Refer to the GBC Steam Punch Service Manual
1 Plockmatic Tools Refer to the Plockmatic Service Manual

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Pro C900 Page 8 of 24
Machine Weight Distribution
Due to the weight distribution of the engine, the installation-site should
be checked to ensure that the weight of the engine has been considered.
The diagrams below show the machine’s weight distribution.
Location Weight (kg) No. Location Weight (kg)
a 202 1 d+c 245
b 202 2 a+b 405
c 123 3 b+c 325
d 123 4 a+d 325
5 a+b+c+d 650

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Pro C900 Page 9 of 24
Machine Dimensions
The diagrams below show the machine’s dimensions.
Pro C900 with SR5000
Pro C900s with LCT, Cover Interposer, Z-Fold, Booklet Finisher
and SR5000

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Pro C900 Page 10 of 24
Pro C900/ Pro C900s Recommended Space Requirements
A: Front: Greater than 140cm
B: Left: Greater than 100cm
C: Back: Greater than 92cm (from the rear of the Fiery enclosure)
D: Right: Greater than 100cm
Note: This machine has a 32 amp power requirement and requires 2 x
network port connections.
It should be noted that the side clearance dimensions provided should be
from the furthest point of the machine or accessory.
Please refer to Ricoh Document Q355: Recommended Work Area for a
Ricoh Technician on Floor Equipment.
This file can be located in the Technical Website/ Documents/ Pro C900 -
Pro C900s / Installation Documents section. Please use the following link:
http://partners.ricoh.com.au/web/aubase/technical/documents.nsf/allby
model/38651E30152D3A3ECA2575D000812A17?OpenDocument

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Pro C900 Page 11 of 24
Paper Feed Combinations
Pro C900
Pro C900s

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Pro C900 Page 12 of 24
Finishing Combinations
Minimum Configuration
Maximum Configuration

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Pro C900 Page 13 of 24
Stage 1: Workshop Run-Up Procedure
Important:
Do not include the Perfect Binder in the run-up procedure.
All Pro C900/ Pro C900s models require a basic run-up procedure in the
workshop prior to moving the machine to the customer’s site.
It is recommended to allow two days for one technician to complete the
workshop run-up procedure. This should allow sufficient time to ensure
the machine performance prior to the on-site installation.
The following items need be completed in the listed order.
Please always refer to the Pro C900/ Pro C900s and Peripheral Service
Manuals for full details:
1. Remove the mainframe from the pallet and remove all external
tape and packaging material from mainframe
2. Install the 32 amp plug: Before installing the 32 amp plug to the
mainframe, ensure that the style of plug meets the customer’s site
requirements—that is, straight or angled style.
3. Level the mainframe: This is only required if the workshop floor is
very uneven.
4. Remove the internal packaging and tape
5. Install silicon oil into the fusing unit.
Important:
Do not fill the oil tank with silicon oil. This will be performed
at the customer’s site. The mainframe is shipped with enough
silicon oil in the oil tank to complete the basic run-up
procedure.
6. Install the toner bottles
7. Install the operation panel unit
8. The following steps should be performed at the same time while
the ear controller ox is open:
a. Install the optional counter interface type A if required.
b. Tray Heaters: If the Pro C900 or Pro C900s is to be
installed in a high humidity / high temperature (HH)
environment, connect the Tray Heaters. It is recommended
to connect the tray heaters connector to CN606 if mainly
coated paper stocks are to be used.
c. Oil Pump Connector: Measure the workshop 32 amp wall
socket. If the input voltage is 235 volts or above, install the
oil supply connector to CN617. If the input voltage is below
235 volts, install the oil supply connector to CN616. The
default position for the oil supply connector is CN616.
Please repeat this procedure at the customer’s site.
9. Connecting cables: Connect the Fiery controller to the Gigabit
Ethernet slot.
10.Connect the LCT-MF (large capacity tray) (for Pro C900s only)
11.Test the breaker switch
12.Plug the power cord into the power source and turn the machine
on.

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Pro C900 Page 14 of 24
13.Load 200 sheets of 100gsm A4 non-coated into Tray 1
14.Wait till the Pro C900 / Pro C900s comes to idle, then print out the
full SMC report. Keep this initial SMC report with the machine
throughout the run-up and installation process.
Note: Do not use this version of the SMC as the final version.
15.Check the version of system software and update if necessary.
Load any patches that may be required.
Important:
When updating firmware on the Pro C900 and Pro C900s
mainframe please only update one firmware module at a
time.
16.Update all mainframe firmware modules.
Download all the latest machine and peripheral firmware modules
from the Ricoh Technical Website/ Firmware/ Pro C900 - Pro
C900s.
Please use the following links to download the firmware:
Pro C900:
http://partners.ricoh.com.au/web/aubase/technical/software.nsf/w
ebfirmwarebyprod?Openview&RestrictToCategory=AFICIO PRO
C900
Pro C900s:
http://partners.ricoh.com.au/web/aubase/technical/software.nsf/w
ebfirmwarebyprod?Openview&RestrictToCategory=AFICIO PRO
C900S
Important:
The Perfect Binder should be delivered to site still in its
packaging/pallet. Do not run the Perfect Binder up in the
workshop and then ship to the customer’s site. This is
because the run down and run-up procedure is very
complex and time consuming.
17.Remove all peripherals from their packaging and follow each
peripheral’s run-up procedure as instructed in the relevant service
manual.
18.While referring to the Pro C900 / Pro C900s service manual and
the order of installation information found in this document,
configure all options to the mainframe. Make sure that the correct
entrance guides and mounting brackets are installed.
19.Update all peripheral firmware modules.
Important:
Ensure that ALL of the latest mainframe firmware modules
are installed before updating each peripheral’s firmware.
Each peripheral’s firmware must be updated in the correct
order starting from the option closest to the mainframe.
An error could occur when an update is attempted by
selecting multiple peripheral firmware modules at the same
time. Always update each peripheral’s firmware one
peripheral at a time. Failure to do this may lead to the
replacement of the BCU board.

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Pro C900 Page 15 of 24
Note: The Ring Binder and Perfect Binder peripherals have
multiple firmware modules. These peripherals require all their
firmware modules to be selected simultaneously.
Note: When installing the SR5000, booklet finisher, cover interposer and
Z-fold, check RTB RG178020 Option Firmware Update PDF for the correct
Z-Fold EPROM and firmware versions. Please use the following link to
download the RTB, Technical Website/ Documents/ Pro C900 - Pro C900s
/ Installation Documents section;
http://partners.ricoh.com.au/web/aubase/technical/documents.nsf
/allbymodel/94D8EB5828119049CA2575D0008274B9?OpenDocum
ent
20.Fit all hardware modification parts that are required to the
mainframe and peripherals.
21.Fit all decals and badges.
22.Turn the machine on and print the PS Test page. Keep the PS Test
page for the print quality check procedure that will be performed
as part of Step 3, on-site installation.
Stage 2: Transporting the machine
The following information details important notes on the moving of the
machine.
Review the site survey report (performed by a service representative in
the pre-sales process) and inform the transport company of any site
related issues.
•Turn off the mainframe and remove the fusing unit. This will need
to be transported separately to the mainframe. Please inform the
transport company to keep the fusing unit level during
transportation to the customer’s site.
•There have been a couple cases reported where the transport
company have strapped the machine to the side of the truck with
the front of the machine facing out. As the straps have been
tightened the front doors and hinges have been damaged. To
prevent this from occurring instruct the transport companies to
strap the machines to the side of the truck with the rear of the
machine facing out.
•Some installations will require the removal of the rear controller
box or Fiery controller to enable the machine to be moved into the
customer’s site. Please ensure that the procedure in the service
manual is followed step by step. Incorrect positioning of IPU Board
connectors when reinstalling the rear controller box back onto the
mainframe can lead to several issues.
For more details download RTB RG178032, Technical Website/
Documents/ Pro C900 - Pro C900s / Installation. Please use the
following link to download the RTB;
http://partners.ricoh.com.au/web/aubase/technical/documents.nsf
/allbymodel/D6C46395ECECD47ECA2575D00082ABBF?OpenDocu
ment

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Pro C900 Page 16 of 24
Stage 3: On-Site Installation Procedure
Please review the Scope of Works document completed during the pre
sales process.
As part of the pre-sales process a site inspection by the level 4 hardware
colour specialist is required. The site inspection will involve completing a
site survey document called the Scope of Works.
The production sales specialist is responsible for providing this document
to the technician. The site survey will confirm all the necessary
requirements for installing a Pro C900 / Pro C900s model at the
customers’ site.
It is recommended to allow two to three days (depending on the
configuration) for one technician to complete the on-site installation
procedure. This should allow sufficient time to confirm the machine’s
performance prior to handing the machine over to the print solutions
consultant (PSC).
Please follow the on-site installation procedure in the order that is listed
below;
1. Arrive prior to machine delivery and ensure the site is ready for
delivery.
2. If flooring is required, arrange for the floor boards to be delivered
prior to the delivery of the machine. This will allow time for the
floor boards to be correctly levelled and placed in the right
position.
3. Locate the mainframe into position. If flooring is required the
transport company will require a sheet of aluminium (or something
similar) to push the mainframe and options up on to the 19mm
Yellow Tongue floor boards.
4. Install the fusing unit.
5. Levelling the mainframe: This is a critical step. Ensure that the
following guidelines are followed.
a. Front to rear: Must be within ± 2.5mm/1000mm
b. Right to left: Must be within ± 2.5mm/1000mm
6. Fill the oil tank with silicon oil.
7. Oil Pump Connector: Measure the 32 amp wall socket. If the input
voltage is 235 volts or above connect the oil supply connector to
CN617. If the input voltage is below 235 volts, connect the oil
supply connector to CN616. The default position for the oil supply
connector is CN616.
8. Install the LCT-MF (large capacity tray) (Pro C900s only) and all
paper feed options.
9. Install all of the remaining A4 non-coated paper and 100gsm A3
paper into all trays.
10.Install all peripherals as performed in the run-up procedure.
11.Install hardware components for MFP options such as File Format
Converter (FFC), Data Overwrite Security (DOS) and the VM Card.
12.Connect an Ethernet cable to the GW port for @Remote.
Note: After connecting the Ethernet cable and entering the
@Remote IPv4 port details (see p. 16 System Settings:

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Pro C900 Page 17 of 24
Interface Settings) contact the branch L4 connectivity
technician to confirm that @Remote is ready to be installed.
13.Plug the power cord into the power source and turn the machine
on.
14.Complete each MFP options’ (DOS, FFC and VM Card) installation
procedure by referring to the Pro C900 / Pro C900s Service Manual
one at a time.
Configuring the Machine
Fiery Controller Settings
•Input the Fiery controller settings; Fiery IP address and subnet
mask
•Open Internet Explorer and browse to the Pro C900. Input the
following information using the configuration tool;
oSet Fiery date and time
oPS: Set default paper size to metric
oPS: Convert paper sizes from letter/tabloidÎA4/A3
oPCL: Set paper size for system pages to metric
Service Program Mode Settings
•Enter service program mode:
•Perform the Peripheral Height Adjustment using SP5-805-16.
•SP-4303 / APS Special Paper Size Detect / Set to 1
•If the customer is going to replace the TCRUs, enable the
following SP modes so that the PM parts alarm is activated; SP5-
062-001 to 0 and SP7-956-001 to 1.
•SP5-187 PM Counter Print Out in UP / Set to On
•Activate the PM Alarm alert: Set SP5-501-001 to 400K
•Input the following contact numbers;
oService telephone number: SP5-812-001
oService fax number: SP5-812-002
oConsumables Ordering Number: SP5-812-003
•Back up all address book data to the Installation SD Card using
SP5-846-051
•To enable hole-punching in the SR5000 when Z-Folding, enable
SP6-904.
User Tools Settings
System Settings: General Features
•The user may want to turn the panel key sound off
•Check with the customer and set the function priority to suit the
customer needs
•Set the default finisher output trays for copier, document server
(Pro C900s only) and printer
•Set the ADF original table to “Lift when [start] key is pressed” (Pro
C900s only).

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Pro C900 Page 18 of 24
System Settings: Timer Settings
•Set the Energy Saver Timer to 120min
•Set the Panel Off Timer to 60min
•Set System Auto Reset Timer to off
•Set Copier/ Document Server Auto Reset Timer to off (Pro C900s
Only)
•Set date
•Set time
•Check with the customer and set the weekly on / off timer.
Important:
If the weekly timer is not programmed, ask the operator to
leave the machine on for 1 hour after the last print job. This
prevents ozone build up in the cavity that can lead to
blurred image copy quality issues.
System Settings: Interface Settings
•Input @Remote IPv4 IP address, subnet mask and default
gateway details. These settings will be required for @Remote
installation.
System Settings: Administrator Tools
•Enable ‘Settings for Skilled Operators’ – Administrator
Authentication Management ÎMachine Management ÎSet Admin
Authentication to on.
•Enter all address book information.
Copier / Document Server Settings: Edit
•Set one-sided to two-sided margins from 5mm to 0mm
Copier / Document Server Settings: Input / Output
•Set Punch Type to Multi Punch Left on display(GBC StreamPunch)
•Set SR5000 staple Positions on the display
•Specify ring binding and punch positions on the display

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Pro C900 Page 19 of 24
Copy Quality Checks
During the following copy quality checks write the final measurements or
SP mode values on each check sample. Do not throw these check
samples out. All copy quality check samples will remain with the
machine for future reference.
•Scan Image Adjustment (Pro C900s Only):
oScanner sub-scan magnification
oScanner leading edge and side-to- side adjustment
oADF leading edge and side-to-side adjustment.
•Perform the Colour Image Check procedure using the PS Test
Page.
•Colour Registration Check: Check that the grid lines superimpose
on top of one another. The cyan, yellow and magenta main-scan
and sub-scan lines should not deviate from the black main-scan
and sub-scan lines by more than 120µm.
Note: To print the 20mm grid pattern make sure that you print
from a PC using a file that contains black, red, green and blue
print data.
•Ruled line check
•Image shift check between Page 1 and 2
•Image skew check
•Print the print quality (PQ) check file twice: One of the PQ check
samples will be kept with the machine to determine if a copy
quality issue is a machine specification or machine failure. The
other PQ check sample will be returned to the Technical Product
Manager at National Technical Support.
This file can be downloaded from the Technical Website/
Documents/ Pro C900 - Pro C900s / Installation Documents
section. Please use the following link;
http://partners.ricoh.com.au/web/aubase/technical/documents.nsf
/allbymodel/48E0E2592AA4E8F2CA2575D00080B081?OpenDocum
ent
oThis PQ Check file sample will be the machine’s standard
.When there is a print quality issue, please print the PQ
check file. Then compare with the standard PQ check file
oIt is important to use the same media type, media
thickness, print settings and the same Fiery Controller
settings that were used at installation.
•Print and complete the PQ check file information sheet and keep
one copy of this document with the machine and return the
original to the Technical Product Manager at National Technical
Support. This information sheet will detail the media and tray
settings used to print the PQ check file.
This file can be downloaded from the Technical Website/
Documents /Pro C900 - Pro C900s / Installation Documents
section. Please use the following link;
http://partners.ricoh.com.au/web/aubase/technical/documents.nsf
/allbymodel/2B8E36F6D78F31DFCA2575D00080F17E?OpenDocum
ent

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Pro C900 Page 20 of 24
•Perform an Automatic Colour Calibration procedure (Pro C900s
only).
•Copy the C4 Colour Test chart and check for any copy quality
issues (Pro C900s only).
Machine and Peripheral Checks
Please perform the following steps to confirm the correct installation of
the colour high volume production system:
□Pro C900 / Pro C900s mainframe, LCT and bypass ((Printer / Copier).
a. Feed a total of 100 sheets from each Feed Station using
both duplex and simplex modes
□Perfect Binder (PB5000)
a. Print three bound books of 50,100 and 200 (three edge
cut) pages and check the output. Refer to the Perfect
Binder Service manual for all adjustments necessary
□Cover interposer section (CI5010).
a. Check covers are being feed correctly from both trays.
Note: Perform the following check after confirming that the
SR5000 punch unit is punching the holes in the correct
position. See Step 9 (below) SR5000 sheet finisher for details.
b. If fitted with the GBC StreamPunch, feed covers into the
GBC StreamPunch and SR5000 punch and check the
position of the punch holes. If the holes are not in the
correct position adjust the location of the cover interposer
trays. Refer to the CI5010 Service Manual for details.
□Z-folding unit (ZF4000)
a. Print an A3 Z-Fold output and check the first fold position
and second fold position. Adjust if required using SP6-301.
□Booklet finisher (BK5000).
a. Print a 2-sheet booklet. Check that the sides of the booklet
are stacked evenly. If the booklet needs to be stacked
tighter perform the Adjust Output Jog Position adjustment
using SP6-103
b. Check the horizontal fold position of the booklet and adjust
using the Booklet Finisher Adjustment screw. See the
BK5000 service manual for full details.
c. Check the position of the vertical fold and adjust if
necessary using SP6-201.
d. Check the position of the staples in the band adjust SP6-
200 if necessary