Ricoh FT6645 Service Training Manual
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Ricoh FT6645 Service Training Manual

Ricoh FT6645 Service Training Manual

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FT6645/6655/6665
SERVICE TRAINING
MANUAL

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Summary of Contents for Ricoh FT6645

  • Page 1 FT6645/6655/6665 SERVICE TRAINING MANUAL...
  • Page 2 SECTION 1 OVERALL MACHINE INFORMATION...

  • Page 3: Specification

    , 14 ~ 42 lb Duplex copying: 64 ~ 104 g/m , 17 ~ 24 lb Reproduction Ratios: 4 Enlargement and 6 Reduction A4/A3 Version LT/LDG Version Enlargement 200% 200% 141% 155% 122% 129% 115% 121% Full Size 100% 100% Reduction FT6645/6655/6665...
  • Page 4 Rev. 7/94 Power Source: 115V, 60Hz, more than 20A (for N.A) 220 ∼ 240V, 50Hz/60Hz, more than 10A (for EU and AA) Power Consumption: FT6645(A095) and FT6655(A096) copiers Copier only Full system* Warm-up 0.90 kVA 0.90 kVA Stand-by 0.25 kVA 0.25 kVA...
  • Page 5 FT6645 copier FT6655 copier FT6665 copier Warm-up Time: Less than 5 minutes (20°C) First Copy Time: 3.1 seconds FT6645/6655 (A095/A096 copiers) (A4/8 " x 11" sideways 2.7 seconds FT6665 (A097 copier) from the 1st feed station) Copy Number Input: Number keys, 1 to 999 (count up or count down)
  • Page 6 DH400, Recirculating document handler • ST25, 20 bin sorter stapler (Floor type) • ST24, 20 bin compact sorter stapler • SR400, Finisher • RT31, 3,500-sheet Large capacity tray • Type B, Receiving Tray Toner Collection 7,500cc, 120,000 copies (6% originals) Bottle Capacity: FT6645/6655/6665...

  • Page 7: Machine Configuration

    Rev. 7/94 2. MACHINE CONFIGURATION 2.1 COPIER OVERVIEW There are two types of mainframe. FT6645 (A095) copier Three 550-sheet paper trays Optional 3,500-sheet large capacity tray (3,500) FT6655 (A096) FT6665 (A097) copiers 500 x 2 or 500 Tandem paper tray...

  • Page 8: System Overview

    Rev. 7/94 2.2 SYSTEM OVERVIEW System A The mainframe FT6645 (A095) with dual job feeder and compact sorter stapler. Dual job feeder DF60 (A376) Compact sorter stapler ST24 (A374) 3,500-sheets large capacity tray RT31 (A380) System B Mainframe type FT6645/6655/6665(A095/A096/A097) with dual job feeder and floor type sorter stapler.
  • Page 9 System C The mainframe FT6665/6665 (A096/A097) with recirculating document handler and finisher. Recirculating document handler DH400 (A378) Finisher SR400 (A379) 3,500-sheets large capacity tray RT31 (A380) NOTE: All references to (A096 copier only) now refers to (A096 and A097 copiers). FT6645/6655/6665...

  • Page 10: Copy Process Around The Drum

    4. ERASE The erase lamp illuminates the areas of the charged drum surface that will not be used for the copy image. The resistance of drum in the illuminated areas drops and the charge on those areas dissipates. FT6645/6655/6665...
  • Page 11 10. CLEANING The cleaning brush removes toner remaining on the drum after image transfer and the cleaning blade scrapes off all the remaining toner. 11. QUENCHING Light from the quenching lamp electrically neutralizes the charge potential of the drum surface. FT6645/6655/6665...

  • Page 12: Mechanical Component Layout

    4. MECHANICAL COMPONENT LAYOUT FT6645/6655/6665 1-10...
  • Page 13 34. Duplex Pick-up Roller 16. Toner Hopper 35. Duplex Feed Roller 17. Development Unit 36. Separation Belt 18. Pre-Transfer Lamp 37. Junction Gate 19. Pick-up Roller, Bypass 38. Exit Rollers 20. Feed Roller, Bypass 39. Optics Cooling Fan 1-11 FT6645/6655/6665...

  • Page 14: Drive Layout

    Paper Feed Motor 5. Fusing Unit Toner Collection Motor 6. Duplex Unit Registration Clutch 7. Paper Trays By-Pass Feed Motor 8. Paper Feed Units BY-Pass Feed Clutch 9. Toner Hopper Development Drive Motor 10. Development Unit 11. Cleaning Unit FT6645/6655/6665 1-12...

  • Page 15: Paper Path

    [A] through the registration rollers [B], transfer belt [C], and fusing unit [D]. After that, copies are delivered to the sorter bins [E] or proof tray [F], however, 2 sided copies are diverted for further processing. 1-13 FT6645/6655/6665...
  • Page 16 [C] to the registration rollers [D]. After that, these sheets follow the same path as standard copying from the registration rollers to the sorter. FT6645/6655/6665 1-14...

  • Page 17: Electrical Component Description

    1st Lift Raises the bottom plate in the 1st paper tray. 2nd Lift Raises the bottom plate in the 2nd paper tray. Toner Collection Transports the collected toner to the toner collection bottle. 1-15 FT6645/6655/6665...
  • Page 18 Starts paper feed from the duplex tray to the duplex transport rollers. 1st Feed Starts paper feed from the 1st feed tray. 2nd Feed Starts paper feed from the 2nd feed tray. 3rd Feed Starts paper feed from the 3rd feed tray. FT6645/6655/6665 1-16...
  • Page 19 Controls the up-down movement of the pick-up roller for by-pass feed. SOL 4 Guide Plate Opens the guide plate when a paper misfeed occurs around this area. SOL 5 Transfer Belt Controls the up-down movement Positioning of the transfer belt unit. 1-17 FT6645/6655/6665...
  • Page 20 (related to APS/ARE function). Platen Cover Informs the CPU that the platen Position–2 cover is in the up or down position to detect if the original has been removed or not. FT6645/6655/6665 1-18...
  • Page 21 Exit Detects misfeeds. Fusing Exit Detects misfeeds. Paper Guide Detects misfeeds. Auto Image Density Senses the background density of the original. Original Length–2 Detects original length. Original Length–1 Detects original length. Original Width Detects original width. 1-19 FT6645/6655/6665...
  • Page 22 Detects the correct feed height of the 3rd cassette. 3rd Paper Near End Informs the CPU when the 3rd (A095 copier only) cassette is in near end condition. 3rd Paper End Informs the CPU when the 3rd cassette runs out of paper. FT6645/6655/6665 1-20...
  • Page 23 Provides AC power to the exposure lamp and fusing lamp. PCB 2 Main Controls all machine functions. PCB 3 Optic Control Controls all optics components. PCB 4 High Voltage Control Controls the output of both power packs and development bias. 1-21 FT6645/6655/6665...
  • Page 24 Controls QL, PTL, and charge wire cleaner motor functions. Others Optics Thermoswitch Opens the exposure lamp circuit if the optics unit overheats. Fusing Thermofuse Opens the fusing lamp circuit if the fusing unit overheats. FT6645/6655/6665 1-22...
  • Page 25 Motors AC Drive Cooling Removes heat from around the AC drive unit. Optic Cooling Fan-2 Removes heat from the optic unit. Duplex Cooling Fan Cools the paper on the duplex tray to reduce the heat around the drum. 1-23 FT6645/6655/6665...

  • Page 26: Ac And Dc Power Distribution

    +12, +5, -12 volt dc. These dc voltage are supplied to each component via the main control board, paper feed control board, and high voltage control board. The dc voltages for all the peripherals are supplied through the main control board. FT6645/6655/6665 1-24...
  • Page 27 This page intentionally left blank 1-25 FT6645/6655/6665...
  • Page 28 9. FT6665 (A097) COPIER UNIQUE POINTS The following are the FT6665 (A097) copier’s main unique points compared with the other machines in the same series FT6645/6655 (A095, A096) copiers. The copy speed of FT6665 copier is 65 CPM. To achieve this high copy speed, the paper transport and copy process speed were increased from 330 mm/sec FT6645/6655 copier to 430 mm/sec.
  • Page 29 Thus, a cleaning roller has been added. Fans AC Drive Cooling Fan Due to higher lamp power, motor speed, etc. the machine generates more heat. Optic Cooling Fan-2 Therefore, three new fans are added. Duplex Cooling Fan 1-27 FT6645/6655/6665...
  • Page 30 DC Harness Connectors for new fans are added. Paper Guides To ensure the correct paper transport, the guides are added. AC Drive Board Since one fusing lamp was added, the AC Drive Board was modified. (120V machine only) FT6645/6655/6665 1-28...

  • Page 31: Detailed Section Descriptions

    SECTION 2 DETAILED SECTION DESCRIPTIONS...

  • Page 32: Process Control

    (Fuzzy Control) Toner Supply Control Main PCB This model uses two process control methods. One compensates for variation in the drum potential (latent image control) and the other controls the toner concentration and toner supply amount (image density control). FT6645/6655/6665...
  • Page 33 A drum thermistor detects the drum temperature and this data is also used to control the voltages above. It is impossible to explain simply because it is controlled by methods developed in our laboratories using an artificial neural network. FT6645/6655/6665...
  • Page 34 OPC drum constant. The following items are controlled to maintain a constant copy image density: Toner supply clutch on time Toner supply level data (V ) of the TD sensor FT6645/6655/6665...
  • Page 35 Adjustment Measurement Correction TD Sensor Detection ID Sensor Detection/Correction ADS Adjustment : See Latent Image Control section (Page 2-5) for details. : See Image Density Control section (Page 2-12) for details. : See Optics section (Page 2-39) for details. FT6645/6655/6665...

  • Page 36: Latent Image Control

    V are applied to the drum, the sensor output is calibrated automatically. (The machine recognizes the relationship between actual drum potential and the potential sensor output.) To prevent toner attraction during potential sensor calibration an equivelent bias voltage (-100V and -800V) is applied to the development rollers. FT6645/6655/6665...
  • Page 37 . This V is used as the standard for the V corrections. NOTE: In the figure above, the residual voltage (V ) for the new drum is 0V. Actually, there is some residual voltage even on the new drum. FT6645/6655/6665...
  • Page 38 On the other hand, there is a change of the drum residual voltage (V ), so that the target V voltage is compensated as follows: Target V Value: V + (–770) The adjusted grid bias voltage (V ) is kept in memory until the next GRID process control data initial setting. FT6645/6655/6665...
  • Page 39 ) change also affects V , so that V ’s target voltage is compensated as follows: Target V Value: V + (–140) The adjusted exposure lamp voltage (V ) is stored in memory until the LAMP next process control data initial setting. FT6645/6655/6665...
  • Page 40 ) than the new drum potential. To prevent dirty backgrounds due to increased residual potential, development bias (V ) is applied as follows: + (–220) The adjusted development bias (V ) is stored in memory until the next process control initial setting. FT6645/6655/6665...
  • Page 41 The machine calculates the new V and V data using the GRID LAMP detected V data. NOTE: The lens moves as V & V are checked. This allows each pattern to be placed on the drum in alignment with the potential sensor. FT6645/6655/6665 2-10...
  • Page 42 Development bias is also decided by using V as follows. + (–220) 4. ID sensor pattern potential detection This is performed to determine ID Sensor Bias Voltage. The details are explained in the development control section (see page 2-16). 2-11 FT6645/6655/6665...

  • Page 43: Image Density Control

    As a result, the sensor characteristic becomes as illustrated by curve A. If the data is low, V becomes low, and the sensor output voltage becomes low. As a result, the sensor characteristic shifts as illustrated by curve C. FT6645/6655/6665 2-12...
  • Page 44 Every copy cycle, toner density in the developer is detected. The sensor output voltage (V ) during the detection cycle is compared with the toner supply level voltage (V ≥ V : Add more toner < V : Add little toner Sensor Output Toner Weight % 2-13 FT6645/6655/6665...
  • Page 45 NOTE: 1. Toner end condition is detected by the toner end sensor (see the development section for details). 2. The toner supply clutch turns on at the intervals between each copy process while image development is not being performed. FT6645/6655/6665 2-14...
  • Page 46 10 or more copies have been made since V was last detected. Since the transfer belt must be released when checking V , a V check cannot be done during continuous copying. 2-15 FT6645/6655/6665...
  • Page 47 ’, V and V cannot be expressed by a simple algebraic formula. is updated not only in the case above, but also during developer initial setting and during process control data initial setting. FT6645/6655/6665 2-16...
  • Page 48 ≤ 2.5 V) Abnormal V Detection (V Abnormal V Detection (V > 4 V) Abnormal V Detection (V < 0.5 V) Detection (VSP/VSG ≥ 25%) Abnormal V Abnormal V Detection (V < 2.5%) Incomplete Drum Potential Sensor Calibration 2-17 FT6645/6655/6665...
  • Page 49 11. Cleaning Blade 4. Drum Potential Sensor 12. Ozone Filter 5. Pre-transfer Lamp 13. Cleaning Filter 6. Pick-off Pawl 14. Charge Power Pack 7. Image Density Sensor 15. Quenching Lamp 8. Drum Thermistor 16. Main Charge Corona Unit FT6645/6655/6665 2-18...

  • Page 50: Opc Drum Characteristics

    4. Being less sensitive to changes in temperature (when compared to selenium F type drums). 5. Being less sensitive to changes in rest time (light fatigue). This makes it unnecessary to compensate development bias voltage for variations in rest time. 2-19 FT6645/6655/6665...

  • Page 51: Drum Charge

    (-1100 µA) and also supplies the bias voltage to the grid plate. The grid bias is automatically controlled to maintain proper image density according to changes of the OPC drum potential due to dirt build up on the grid plate and charge corona casing. FT6645/6655/6665 2-20...
  • Page 52 An ozone filter [B] absorbs the ozone (O ) around the drum. The exhaust fan rotates slowly during stand-by and rotates quickly during copying to keep the temperature inside the machine constant. 2-21 FT6645/6655/6665...
  • Page 53 (5 V) to the wire cleaner DC motor. When the wire cleaner reaches the end, it is stopped and the motor is locked. At this time, input voltage decreases slightly (to about 4 V) and the CPU causes the motor to rotate in reverse. FT6645/6655/6665 2-22...
  • Page 54 The erase lamp unit consists of a line of 123 LEDs extending across the full width of the drum, the width of each being about 2.5 mm. In editing mode, the appropriate LED’s turn on according to the customer’s designation. 2-23 FT6645/6655/6665...
  • Page 55 To erase the shadow made by the edge of the rear scale in platen cover mode, one more LED at the front side turns on. This is in addition to the LED’s on in DJF and RDH modes. FT6645/6655/6665 2-24...
  • Page 56 To remove the accumulated toner at the edge of the cleaning blade, the drum turns in reverse for about 4 mm at the end of every copy job. The accumulated toner is then removed by the cleaning brush. 2-25 FT6645/6655/6665...
  • Page 57 [A] and the cleaning unit coupling [B]. The cleaning unit drive gear [C] then transmits the force to the front side through the cleaning brush [D]. The force at the front side is used for the toner collection coil gear [E]. FT6645/6655/6665 2-26...
  • Page 58 The pin [C] at the rear end of the cleaning blade holder touches the cam gear [D] which gives a side-to-side movement to the blade. This movement helps to disperse accumulated toner to prevent early blade edge deterioration. 2-27 FT6645/6655/6665...
  • Page 59 100 continuous copies, is allowed, then copying is prohibited and the service call "full toner collection bottle" indication is displayed on the LCD. This condition can be cleared by de-actuating the toner overflow switch while de-actuating then actuating the toner collection bottle switch (item [D] on next page). FT6645/6655/6665 2-28...
  • Page 60 Red illuminating LEDs are used to reduce ultra violet light which would cause light fatique on the OPC drum. 2.5.7 Toner Collection Bottle Set Detection The toner collection bottle set switch [D] prohibits machine operation by indicating SC343 while the toner collection bottle is not set. 2-29 FT6645/6655/6665...
  • Page 61 The quenching lamp consists of a line of 16 LEDs extending across the full width of the drum. Red illuminating LEDs are used for QL to reduce ultra violet light which would cause light fatigue on the OPC drum. FT6645/6655/6665 2-30...
  • Page 62 The toner shielding filter [D] is green (a green filter partly absorbs red light) to improve red original duplication. The optic anti-condensation heater [E] (located on the optic base plate) turns on when the main switch is turned off to prevent the moisture from forming on the optics. 2-31 FT6645/6655/6665...

  • Page 63: Scanner Drive

    [D] and the scanner drive shaft [E]. The second scanner moves at one half the speed of the first scanner. The scanner drive wire is not directly wound around the pulley on the scanner drive motor. FT6645/6655/6665 2-32...
  • Page 64 The lens vertical home position sensor [B] detects the lens vertical position for full size mode. The optic control PCB keeps track of the lens position based on the number of pulses sent to the lens vertical drive motor. 2-33 FT6645/6655/6665...
  • Page 65 The other positions are determined by counting the number of motor drive pulses. Since this model has a horizontal lens drive mechanism, side-to-side registration adjustment for each feed station can be done easily by using SP mode ( SP Adjustment mode: PAGE 4). FT6645/6655/6665 2-34...

  • Page 66: Horizontal Lens Positioning

    To keep high paper feed performance, the center is assigned as the paper feed standard position. Therefore, the lens horizontal position is changed according to the paper size. The figure shows the lens horizontal position for each paper size in full size mode. 2-35 FT6645/6655/6665...
  • Page 67 For this focal length change, the vertical position of the 3rd scanner is also adjusted. The maximum 3rd mirror shift distance is 50 mm (from the position at 100% to the position at 50, 200%). The figure shows the lens horizontal position for 50, 100 and 200%. FT6645/6655/6665 2-36...

  • Page 68: 3Rd Scanner Drive

    A stepping motor [A] (approx. 0.095 mm/step) is used for the 3rd scanner drive. The 3rd scanner home position sensor [B] is used to detect the unit position for full size mode. The optic control PCB keeps track of the unit position based on the number of motor drive pulses. 2-37 FT6645/6655/6665...
  • Page 69 This data is sent to the optics control CPU. The optics thermistor senses the temperature of the optics cavity and controls the on/off operation of the optics fan. FT6645/6655/6665 2-38...

  • Page 70: Automatic Image Density Control System (Ads)

    ADS pattern [B] (white painted) reaches the ADS sensor. The main CPU adjusts the ADS gain data automatically to make the output 2.7 V. This gain data is stored in the RAM board. 2-39 FT6645/6655/6665...
  • Page 71 ADS reference voltage to determine the proper development bias voltage. (See development bias control section for additional details.) The sampling length of ADS sensor output for the original differs depending on the reproduction ratio because the scanner speed is different. FT6645/6655/6665 2-40...

  • Page 72: Manual Image Density Control

    Position : Exposure lamp voltage at ID level 4. LAMP This value is determined at process control data initial setting. Development bias (negative) voltage at ID level 4. This value is determined at process control data initial setting. 2-41 FT6645/6655/6665...

  • Page 73: Uneven Light Intensity Correction

    The shading plate is fixed to the lens unit. The shading plate compensates the light intensity when the lens horizontal position is shifted ([A] to [C]). Also three shading mylars [D] intercept any diffused reflected light from outside the light path. FT6645/6655/6665 2-42...

  • Page 74: Original Size Detection In Platen Mode

    While the main switch is on, these sensors are active and the original size data is always sent to the main CPU. However, the main CPU checks the data only when the platen cover is opened. 2-43 FT6645/6655/6665...
  • Page 75 In case the copy is made with the platen open, the main CPU decides the original size only through the data when the Print key is pressed. This original size detection method eliminates the necessity for a pre-scan and increases the machine’s productivity. FT6645/6655/6665 2-44...
  • Page 76 The development roller is given a negative bias to prevent the toner form being attracted to the non-image areas on the drum surface that may have a slight residual negative charge. After turning another 100 degrees, the developer is returned to the paddle roller [A]. 2-45 FT6645/6655/6665...

  • Page 77: Drive Mechanism

    The above gears are helical gears. Helical gears are more quiet than normal gears. The teeth of the development drive gear are chamfered so that they smoothly engage with the development roller gear [E] when the unit is installed. FT6645/6655/6665 2-46...
  • Page 78 [F]. The agitator moves the developer slightly to the front as it turns, so the developer stays level in the development unit. 2-47 FT6645/6655/6665...

  • Page 79: Development Bias

    The development bias prevents toner from being attracted to the background area of the non-image area on the OPC drum where there is residual voltage. Also, the development bias is used to adjust image density according to the conditions the customer selected. FT6645/6655/6665 2-48...
  • Page 80 According to the original background density, the bias is compensated. The compensation value is determined with the voltage measured by the ADS sensor (ADS sensor output: V ) as follows: = 234 x (V –2.3) NOTE: V has a limited range from 0 V to –300 V. 2-49 FT6645/6655/6665...
  • Page 81 4) User Tool Mode ID Selection Compensation (V In the User Tool mode, the image density level can be selected from five steps. The V is determined by the User Tool ID position setting as follows: Lighter Darker –60 –30 (negative) User Tool ID Position FT6645/6655/6665 2-50...
  • Page 82 161% 116% 115% 122% 141% 160% 4.4.3 Bias Control Out of Copy Cycle To hold the toner on the sleeve rollers while the development sleeve rollers are rotating without image development, a constant –300 V bias is applied. 2-51 FT6645/6655/6665...
  • Page 83 V adjustment sequence in the process control data initial setting) and V are used to determine V data at process control data initial setting. V is not changed until the next process control data initial setting is done. FT6645/6655/6665 2-52...

  • Page 84: Toner Supply

    [C] applies the rotation from the development motor to the toner supply roller gear [D], which drives the agitator gear [E]. Toner is caught in the grooves on the toner supply roller [F]. Then, as the grooves turn past the opening, the toner falls into the development unit. 2-53 FT6645/6655/6665...
  • Page 85 New developer has a standard toner concentration of 2% by weight, 20g of toner within the 1000g of developer. When new developer is installed, developer initial setting must be performed. FT6645/6655/6665 2-54...
  • Page 86 When the main switch is turned off and on, or the front door is opened and closed, the machine drives the toner supply mechanism and monitors the toner end sensor output. If the toner end sensor does not output the pulse signal twice continually, the toner end condition is canceled. 2-55 FT6645/6655/6665...
  • Page 87 1. The results of toner supply control (TD sensor output) in the previous copy cycle. 2. How quickly the toner density is changing. Then the CPU decides the most suitable toner supply amount (toner supply clutch on time) for the next copy cycle by using fuzzy logic. FT6645/6655/6665 2-56...
  • Page 88 In this mode, a fixed amount of toner is supplied every copy cycle as determined (4%, 7%, 11%, 14%) by SP mode ( Adjustment mode: PAGE 7). There is no overtoning detection mechanism. In TD sensor abnormal condition or Drum Potential sensor abnormal condition the machine automatically enters this mode. 2-57 FT6645/6655/6665...
  • Page 89 When the toner is set on the holder and the lever is lowered, the toner shutter [D] opens to supply toner to the toner hopper. The bottle drive motor turns on for 0.7 seconds when the toner end sensor turns on twice continually. FT6645/6655/6665 2-58...

  • Page 90: Image Transfer

    This makes image transfer easier. The pre-transfer lamp is turned on and off by the charge power pack at the same time as when the main motor turns on and off. 2-59 FT6645/6655/6665...
  • Page 91 Removes toner attached on the transfer belt to prevent the rear side of the paper from being stained. [F] Discharge plate Helps paper separation from the transfer belt by discharging the remaining negative charge on the transfer belt. FT6645/6655/6665 2-60...

  • Page 92: Image Transfer And Paper Separation Mechanism

    [F] and attracts the positively charged toner [G] from the OPC drum. It also attracts the paper and separates the paper from the OPC drum. –1.3 K~ –1.8KV –1.5 K ~ 2.0 KV 2-61 FT6645/6655/6665...
  • Page 93 This way, the current stays constant even if the paper, environmental conditions, and the transfer belt surface resistance are changed. FT6645/6655/6665 2-62...

  • Page 94: Transfer Belt Unit Lift Mechanism

    (for example V and ID patterns ). 3. To prevent change of OPC drum characteristics by the influence of additives inside the rubber belt. 2-63 FT6645/6655/6665...

  • Page 95: Paper Transportation And Belt Drive Mechanism

    [C] where the transfer belt is turning. The tapered parts [D] at both sides of the roller [E] help keep the transfer belt [F] at the center position. FT6645/6655/6665 2-64...

  • Page 96: Transfer Belt Cleaning Mechanism

    (The transfer belt unit is lowered when the lever [C] is turned anti-clockwise) When the cleaning blade is released, the edge of the cleaning blade rubs the seal so that the seal [D] removes the toner or paper dust on the cleaning blade edge. 2-65 FT6645/6655/6665...

  • Page 97: Toner Collection Mechanism

    Rev. 4/15/94 TONER COLLECTION MECHANISM Through idle gears [A], transfer belt drive is transmitted to the toner collection coil [B]. The toner collection coil transports the collected toner to the toner collection bottle. See page 2-28 for details. FT6645/6655/6665 2-66...

  • Page 98: Paper Feed

    This model has three drawer tray paper feed stations. The following table shows the configuration of each feed station of the A095, A096 and A097 copiers. Feed station FT6645 (A095 copier) FT6655/6665 (A096/A097) copiers 550 sheets tray 500 + 500 sheets tandem feed tray...

  • Page 99: Frr Feed System

    The separation roller, however, is driven through a slip clutch (torque limiter clutch) which allows it to turn in either direction depending on the friction between the rollers. The separation roller solenoid keeps the separation roller in contact with the feed roller. FT6645/6655/6665 2-68...
  • Page 100 If two or more sheets are fed between the rollers, the forward force on the second sheet (F3), becomes less than F1 because the friction between the two sheets is small. So, the separation roller starts turning clockwise and drives the second sheet back to the tray. 2-69 FT6645/6655/6665...

  • Page 101: Slip Clutch Mechanism

    Ferrite powder [G] packed between the magnetic ring and the ferrite ring [F] generates a constant torque due to magnetic force. The input hub and the output hub slip when the rotational force exceeds the constant torque. This type of slip clutch does not require lubrication. FT6645/6655/6665 2-70...
  • Page 102 If the paper feed station is not selected, the separation roller solenoid [H] de-activates and the separation roller [I] rotates freely in the reverse direction of paper feeding. Gear [B] also transmits the drive to the vertical transport roller [J] via gear [D], idle gear [K] and gear [L]. 2-71 FT6645/6655/6665...
  • Page 103 When the paper feed sensor [H] detects the leading edge of the paper [I], the pick-up solenoid de-energizes to lift the pick-up roller and the paper feed clutch de-energizes at a certain time to wait until it is ready to feed to the registration roller. FT6645/6655/6665 2-72...

  • Page 104: Separation Roller Release Mechanism

    3. When paper misfeeds occur around this area, the customer can easily pull out the jammed paper between the feed and the separation rollers because the separation roller is away from the feed roller. 2-73 FT6645/6655/6665...
  • Page 105 After that, the separation roller solenoid turns off to move the separation roller away from the feed roller. This releases the leading edge of the paper and drops the paper to the paper feed tray. This prevents remaining paper from being torn when the feed tray is drawn out. FT6645/6655/6665 2-74...
  • Page 106 Instead of the corner holders, both paper press arms [B] press down both paper side edges, especially in the case of paper with a face curl. This helps to keep paper from being guided by the tray side fences to prevent paper skew or jam. 2-75 FT6645/6655/6665...

  • Page 107: Paper Lift Mechanism

    When the machine detects that the paper tray is set in the machine, the lift motor [A] rotates and the coupling gear [B] on the tray lift motor engages the pin [C] of the lift arm shaft [D], then turns the tray lift arm [E] to lift the tray bottom plate [F]. FT6645/6655/6665 2-76...
  • Page 108 (blocked) and the lift motor turns on again until the lift sensor is activated (unblocked) again. When the tray is drawn out of the feed unit, the lift motor coupling gear [F] disengages the pin [G] of the lift arm shaft [H], then the tray bottom plate [I] drops. 2-77 FT6645/6655/6665...
  • Page 109 [D] is deactivated. When the paper tray runs out of paper, the paper end feeler drops in the cut out [E] of the tray bottom plate and the paper end sensor is activated. FT6645/6655/6665 2-78...
  • Page 110 Normally both the right and the left trays are joined together. During copying, if there is no paper in the left tray, only the left tray can be pulled out to load paper, as shown. During that time, paper feed continues. 2-79 FT6645/6655/6665...
  • Page 111 [C] is activated. When the rear fence [D] in the left tray pushes paper into the right tray, the side fence drive motor turns clockwise to close the side fences. FT6645/6655/6665 2-80...
  • Page 112 [C] to push the paper into the right tray. When the actuator on the rear fence activates the return position sensor [D], the rear fence drive motor rotates clockwise until the actuator activates the rear fence home position sensor [E]. 2-81 FT6645/6655/6665...
  • Page 113 (feed) tray. The lock lever solenoid also lowers the right tray lock lever [F] to hook itself in the hole [G] on the right tray. Therefore, only the left tray is pulled out to load paper. FT6645/6655/6665 2-82...

  • Page 114: Paper Size Detection

    [B] located on the rear of the tray. Each paper size has its own unique combination as shown in the table and the CPU judges the paper size by this combination of activated switches. 2-83 FT6645/6655/6665...

  • Page 115: Vertical Transport Mechanism

    To reduce the first copy time, the paper feed motor rotates at a quicker speed (430mm/sec.) than normal (330mm/sec). This quick rotation is performed with the FT6645 (A095) and FT6655 (A096) only for the first copy from the first feed station. When using the FT6665 (A097) the feed motor always rotates at the higher speed (430mm/sec.).
  • Page 116 When the feed tray is set in the paper feed unit, the side-to-side positioning plate [C] presses the feed tray against the rubber stopper [D]. By moving the positioning plate, the tray position can be changed to adjust the side-to-side registration. 2-85 FT6645/6655/6665...
  • Page 117 (All feed trays for the A095 copier and 2nd feed tray for the A096/A097 copiers) Side plates [A] are fixed on the positioning plate [B]. By moving the positioning plate (fixed by four screws), the paper position can be changed to adjust the side-to-side registration. FT6645/6655/6665 2-86...
  • Page 118 When paper is present and the tray is up the tray paper set sensor [L] is blocked. When paper runs out and the tray lowers it can not raise again until the tray paper set sensor is unblocked by the addition of paper. 2-87 FT6645/6655/6665...
  • Page 119 When the bottom plate is lowered to the bottom position, the bottom plate presses down the pin [C] on the lock lever. The opposite end of the lever then moves up, allowing the tray to be pulled out. FT6645/6655/6665 2-88...

  • Page 120: By-Pass Feed Table

    When paper is present on the by-pass feed table, the paper pushes up the end feeler [E] to activate the paper end sensor [D]. The CPU turns off the paper end indicator on the LCD panel and turns the start key from red to green. 2-89 FT6645/6655/6665...
  • Page 121 On this model, opening the by-pass feed table does not shift the copier into interrupt mode. The selected modes and input data before opening the by-pass feed table remain. Also other paper trays can be selected while the by-pass feed table is open. FT6645/6655/6665 2-90...
  • Page 122 The registration sensor monitors the length of this paper (between the ON timing by the leading edge and the OFF timing by the trailing edge). From the following copies, the copier is controlled according to this paper length data. 2-91 FT6645/6655/6665...

  • Page 123: Paper Registration

    This makes a little buckle on the paper between the vertical transport rollers and the registration rollers to correct paper skew. Shortly after the leading edge of the paper reaches the registration roller, the registration clutch activates to feed the paper. FT6645/6655/6665 2-92...

  • Page 124: Registration Drive Mechanism

    [E] via two gears [F] at the front side. A paper dust catcher [G] is located at the center of the upper registration roller [E]. This is in line with the feed rollers where most paper dust is generated. 2-93 FT6645/6655/6665...
  • Page 125 LCD panel. An additional sensor is located in the vertical transport unit. The vertical transport sensor [H] detects the lead edge of the paper to determine paper feed timing for the next sheet. FT6645/6655/6665 2-94...

  • Page 126: Image Fusing

    The hook positions of the tension springs [I] on the pressure lever [J] adjust the roller pressure. 2-95 FT6645/6655/6665...

  • Page 127: Oil Supply And Cleaning

    Rev. 7/94 OIL SUPPLY AND CLEANING FT6645/6655 (A095/A096) The oil supply roller [A] is soaked with silicon oil [B]. The roller contacts the hot roller by a spring. It turns with the hot roller and applies a light coat of silicon oil to the hot roller.

  • Page 128: Fusing Entrance Guide

    Therefore, the guide plate standard position is the lower position. (Standard position on previous models was the upper position). Since there are very few reasons to change the guide plate position, there is no guide plate position adjustment lever for customer use. 2-97 FT6645/6655/6665...

  • Page 129: Fusing Drive Mechanism

    Rev. 7/94 FUSING DRIVE MECHANISM FT6645/6655 (A095/A096) The fusing drive gear [A] transmits the drive from the fusing/duplex drive motor to the gear [B] which drives the hot roller gear [C]. Rotation passes from the gear [B] through the idle gear [D] to the exit roller drive gear [E]. The pressure roller is driven by the friction between the two fusing rollers.

  • Page 130: Fusing Lamp Control

    The standard fusing temperature control mode is: On-off control..European version Phase control..Other versions By cutting the JP501 on the optics control board, the standard control mode is switched to the other mode. COPIER A095/A096 A097 WATTAGE 950W 550W + 550W 2-99 FT6645/6655/6665...
  • Page 131 When the paper passes the duplex entrance rollers [F], the paper pushes the paper guide [G] up, and the actuator on the rear end of the paper guide shaft de-activates the paper guide sensor [H]. The paper guide sensor [H] also monitors paper misfeeds. FT6645/6655/6665 2-100...
  • Page 132 INVERTER AND EXIT DRIVE MECHANISM The gear [A] transmits the drive from the fusing/duplex drive motor [B] to the next gear [C]. This gear [C] transmits the drive to the paper exit and the inverter section through the timing belt [D]. 2-101 FT6645/6655/6665...
  • Page 133 [E], the duplex exit sensor [C], and vertical transport rollers [D] to the copier registration rollers. FT6645/6655/6665 2-102...
  • Page 134 [C] and transmitted to the duplex transport section under the control of the duplex transport clutch [D]. The duplex positioning roller is driven by the gear [E], so this roller continuously rotates while the fusing/duplex drive motor is on. 2-103 FT6645/6655/6665...

  • Page 135: Duplex Entrance To Duplex Tray

    The paper guide sensor [D] is responsible for misfeed detection during duplex copying. Movement of the paper guide assembly is detected by the paper guide sensor [D]. FT6645/6655/6665 2-104...

  • Page 136: Duplex Stacking

    The jogger fences move inward to square the paper stack for every copy in the paper stack at the same timing as before. After the last copy of the first side copying enters the duplex tray, the jogger fences remain against the paper stack. 2-105 FT6645/6655/6665...
  • Page 137 30ms after the duplex entrance sensor [B] detects the leading edge (OFF → ON) of the next paper, the positioning roller solenoid turns off to raise the positioning roller so that the positioning roller does not disturb the next sheet as it enters. FT6645/6655/6665 2-106...
  • Page 138 The feed roller advances the bottom sheet past the separation belts because the force of the feed roller is greater than the resistance of the separation belts. The separation belts prevent multiple feeds because the resistance of the separation belt is greater than the friction between multiple pages. 2-107 FT6645/6655/6665...
  • Page 139 The duplex paper end sensor is de-activated (the actuator interrupts the photosensor) only when the pressure arm is in the lower position (solenoid [B] is on) and no paper is present on the duplex tray. FT6645/6655/6665 2-108...
  • Page 140 Due to higher copy speed, the pressure arm moves more frequently. To ensure paper end detection, the detection mechanism on the pressure arm is replaced with a reflective photo sensor. • FT6645/6655 (A095/A096 copiers) The A095/A096 paper end actuator [E] is located on the pressure arm and moves with...
  • Page 141 SECTION 3 DUAL JOB FEEDER DF60 (Machine Code: A376)

  • Page 142: Specifications

    8" x 10" sideways 10" x 14" lengthwise 11" x 15" lengthwise Mixed Original mode Preset mode ADF mode (1 sided originals mode) ARDF mode (2 sided original(s) mode) SADF mode ADF mode, ARDF mode, SADF mode ADF mode, SADF mode FT6645/6655/6665...
  • Page 143 Original Separation: Feed and friction belt Original Transport: One flat belt Power Source: DC24V from the copier, 2.0A (average) Power Consumption: Dimensions (W x D x H): 680 x 508 x 116mm (26.8" x 20.0" x 4.6") Weight: 13kg (28.7lb) FT6645/6655/6665...
  • Page 144 MECHANICAL COMPONENT LAYOUT 1. Friction Belt 7. Inverter Pawl 2. Original Stopper 8. Inverter Roller 3. Press Roller 9. Transport Belt 4. Side Fence 10. Pick-up Rollers 5. Original Table 11. Pull-out Roller 6. Exit Roller 12. Feed Roller FT6645/6655/6665...

  • Page 145: Electrical Component Description

    Also, detects the original length and original jam. Original Feed Detects if the originals reach the feed roller or not. Original Set Detects if the originals are set on the feed table. FT6645/6655/6665...
  • Page 146 DJF. Feed Cover Detects if the feed cover is closed. Clutches Feed-in Transmits the feed-in motor drive to the pick-up and feed rollers, and to the separation belts. FT6645/6655/6665...

  • Page 147: Basic Operation

    DJF. On receipt of this signal, the stopper solenoid [C] activates to raise the stopper to allow the originals to be fed in, and to lower the press rollers [D] to press the originals against the pick-up rollers as shown. FT6645/6655/6665...
  • Page 148 When the leading edge of the original activates registration sensor - 2 [G], the feed-in clutch [A] turns off to reduce the mechanical load and prevent the next original from feeding. Also, the feed motor rotates more quickly (1250mm/sec). FT6645/6655/6665...
  • Page 149 " x 11" sideways or smaller, the original just copied is transported to the right side of the exposure glass then waits until the next original copying is completed. Then the previous original is fed out. This operation also reduces the original feed-in time. FT6645/6655/6665...
  • Page 150 When the scanner reaches the return position, the copier’s CPU sends the invert original signal to the DJF CPU in order to make a copy of the front side. The original is inverted in the same way as for back side copying. FT6645/6655/6665...

  • Page 151: Preset Mode

    CPU recognizes that the first job is completed. If the second job is already preset, the second set of originals is automatically fed to the feed roller [F] in the same manner as the first set of originals was. FT6645/6655/6665 3-10...

  • Page 152: Combine 2 Originals Mode

    If odd numbered originals are placed on the original table, the first original is placed on the exposure glass as shown in figure 2. Only 1-sided originals can be used, and Auto Paper Select (APS) and Auto Reduce/Enlarge modes cannot be used with this mode. 3-11 FT6645/6655/6665...
  • Page 153 (372mm/sec) to feed the second original. A few pulses (0 ~ 14 pulses: depends on the DIP switch adjustment) after registration sensor-2 is activated by the leading edge of the second original, the feed-in motor and the feed-in clutch turn off. FT6645/6655/6665 3-12...
  • Page 154 48 pulses after, the belt drive motor turns off and 60 pulses after the feed-out sensor detect the trailing edge of the second original, the feed-out motor turns off. 3-13 FT6645/6655/6665...

  • Page 155: Original Separation

    The friction belt prevents multiple feeds because the resistance of the friction belt is greater than the friction between original sheets. FT6645/6655/6665 3-14...
  • Page 156 When the pasted original mode is selected, the separation solenoid turns on to drive the separation belt in the same direction as the feed rollers. This disables the separation function to reduce the friction between the original surface and the separation belt. 3-15 FT6645/6655/6665...

  • Page 157: Thin / Thick Original Modes

    Then, the belt drive motor pauses and reverses to feed the original back against the original scale. This forces the original against the left scale and thus aligns the trailing edge of the original with the scale. Thick original mode is selected at the factory. FT6645/6655/6665 3-16...

  • Page 158: Original Size Detection

    A certain distance is required between the sensor and the original scale. Therefore, registration sensor -1 is placed 34.9 mm before sensor -2. The original size is determined by the combination of the detected original width and the length. 3-17 FT6645/6655/6665...

  • Page 159: Lift Mechanism

    [C]. The lift switch is turned off during this condition, so the DJF does not function. The tension of spring [D] returns the DJF to the normal condition after copying a thick original. FT6645/6655/6665 3-18...

  • Page 160: Original Misfeed Detection

    CPU determines that the original will not arrive (ON check). : If the feed-out sensor does not de-activate within 60 pulses after the feed out motor slows down, the CPU determines that the original is still there (OFF check). 3-19 FT6645/6655/6665...
  • Page 161 CPU determines that the original will not arrive (ON check). : If the feed-out sensor does not de-activate within 60 pulses after the feed out motor slows down, the CPU determines that the original is still there (OFF check). FT6645/6655/6665 3-20...

  • Page 162: Timing Chart

    11. TIMING CHART 11.1 DJF Timing Chart (1 sided original mode) 3-21 FT6645/6655/6665...
  • Page 164 SECTION 4 SORTER STAPLER ST25 (Machine Code: A377)

  • Page 165: Specifications

    2 sided copies: 2 sided copies: 40 sheets/bin 35 sheets/bin 6 ± 3 mm Staple Position: 6 ± 3 mm 6 ± 3 mm 66 ± 3 mm e = 132 ± 2 mm θ = 45 ± 5° θ FT6645/6655/6665...
  • Page 166 Power Source: DC24V (from copier) Power Consumption: Average: less than 55W Maximum: in sort/stack mode: less than 55W in staple mode: less than 42W Dimensions: 566 x 583 x 978 mm (W x D x H) Weight: Approximately 47kg FT6645/6655/6665...
  • Page 167 2. Proof Exit Rollers 9. Staple Unit 3. Proof Transport Rollers 10. Grip Assembly 4. Upper Entrance Guide 11. Helical Wheels 5. Turn Gate 12. Jogger Plate 6. Lower Entrance Guide 13. Bins 7. Sorter Transport Rollers 14. Upper Guide Plate FT6645/6655/6665...

  • Page 168: Drive Layout

    12. Staple Unit Drive Motor 5. Helical Wheels 13. Jogger Drive Belts 6. Staple Unit Drive Belt 14. Bin Rear Plate Drive Motor 7. Gripper Motor 15. Sorter Exit Drive Belt 8. Bin Drive Motor 16. Sorter Exit Motor FT6645/6655/6665...

  • Page 169: Electrical Component Description

    Detects paper jams at the proof tray exit. Entrance Detects paper jams at entrance guides. Staple HP Detects if the staple hammer is in the home position. Staple End Detects staple end. Paper Detects whether copies are under the hammer. FT6645/6655/6665...
  • Page 170 PCBs DC Supply Provides DC power (Input: 24V DC, Output:24V/5V DC) Main Control Controls all sorter stapler functions. Switches Door Safety Cuts the DC power when the front door is opened. FT6645/6655/6665...

  • Page 171: Basic Operation

    The turn gate solenoid energizes to turn the turn gate clockwise when the Start key is pressed. The main motor turns counterclockwise to rotate the vertical transport rollers [C] and proof exit roller [D]. The turn gate directs copies through the proof transport section to the proof tray. FT6645/6655/6665...
  • Page 172 (the helical wheels [H] rotate once). When the cut out of the actuator reaches below the wheel sensor [I], the bin drive motor turns off. Bins advances each time copies are delivered. FT6645/6655/6665...
  • Page 173 All copies of the copy run are then fed to the first bin. When the final copy is delivered, the wheel drive motor [G] turns and advances the bin one step (the helical wheels [H] rotate once). When the cut out of the actuator reaches below the wheel sensor [I], the bin drive motor turns off. FT6645/6655/6665...

  • Page 174: Staple Mode

    The grip assembly brings the copies down underneath the stapler [Fig. 2]. The staple unit changes the position (the position varies depending on the copy size and staple mode) and the stapler staples the copies [Fig. 3]. FT6645/6655/6665 4-10...
  • Page 175 2) Manual stapling: In sort mode, after copies are sorted in the bins, the copies will be stapled when the manual staple key is pressed then staple position is selected. In stack mode, manual stapling is impossible. 4-11 FT6645/6655/6665...

  • Page 176: Turn Gate Section

    In this mode, the main motor drive is not transmitted to the proof drive belt [D] because of the one way clutch in the pulley [G]. The entrance [H] and the proof exit [I] sensors monitor the paper jam. FT6645/6655/6665 4-12...

  • Page 177: Bin Drive Mechanism

    This leaves enough space to staple [F] and stack paper [G] and reduces the total machine height. 4-13 FT6645/6655/6665...

  • Page 178: Bin Home Position

    When the main switch is turned on, the bin lift motor [E] lowers the bins (turns counterclockwise) until the bottom bin actuates the bin home position sensor. Then, the bin lift motor raises the bins (turns clockwise) until the wheel sensor activates. Thus, the bins are in the home position. FT6645/6655/6665 4-14...

  • Page 179: Jogger Section

    The jogger plate returns to 10 mm away from the selected paper size for the next copy. When the bin sensor detects that all copies are removed from the bins after jogging is finished, the jogger plate returns to its home position. 4-15 FT6645/6655/6665...
  • Page 180 If copy of smaller width is delivered in the bins later in the "Mixed sizes" mode. 2. If paper is in a bin before the main switch is turned on, the sort/stack mode is disabled when the sort key is touched. FT6645/6655/6665 4-16...
  • Page 181 Under this condition, a pin [G] enters the holder [F] or passes through it. After stapling is completed and stapled paper is returned to the bin, gear [C] rotates 180 degrees and the bin rear plate returns to its home position. 4-17 FT6645/6655/6665...

  • Page 182: Grip Assembly

    ù The grip solenoid [C] activates to close the grip arms and the grip arms catch the papers. Similar to the grip arm positioning solenoid, the plunger keeps the grip arms closed until the solenoid is energized by an opposite charge. FT6645/6655/6665 4-18...
  • Page 183 The sorter stapler main control board sends the appropriate pulses to the grip motor (stepping motor) [A] to determine the grip position and staple position. Vertical staple positions are adjustable by changing the number of the stepping motor pulses from the home position (1 SP Adjustment - PAGE 12). 4-19 FT6645/6655/6665...

  • Page 184: Staple Unit

    During stapling in the "2 Staples" mode, the staple unit goes back and forth to staple the two positions. Horizontal staple positions are adjustable by changing the number of stepping motor pulses from the home position ( SP Adjustment - PAGE 12). FT6645/6655/6665 4-20...
  • Page 185 [I], the sorter stapler unit recognizes the staple near end condition. After the job is completed, the Add Staple indicator lights on the copier operation panel and the Start key turns to red whenever the staple mode is selected. 4-21 FT6645/6655/6665...
  • Page 186 If the paper size in the bin does not match stapling specifications. If only one sheet is delivered to the bin. If smaller width paper is delivered to the bin later in "Mixed Sizes" mode. If copies already stapled are left in the bin. FT6645/6655/6665 4-22...

  • Page 187: Jam Detection

    J5: The jam sensor has not turned on for 600 pulses after the entrance sensor turns on. J6: The jam sensor stays on for the appropriate number of pulses (for example, 280 pulses for A4 sideways) or more. J7: The jam sensor turns on while the bin drive motor turns on. 4-23 FT6645/6655/6665...

  • Page 188: Timing Chart

    13. TIMING CHART 13.1 A377 SORTER/STAPLER TIMING CHART (PROOF MODE) Signal Timing Chart Motor ON Proof mode Paper size dada Exit signal Sorter busy S/S exit signal S/S main motor ON Entrance Sensor Proof exit Sensor FT6645/6655/6665 4-24...
  • Page 189 NOTE: 1. Jogger motor on time differs depending on the paper size. 2. Staple unit drive motor on time differs depending on the paper size. 3. Bin drive motor on time differs depending on the number of copy sets. 4-25 FT6645/6655/6665...

  • Page 190: Recirculating Document Handler Dh400

    SECTION 5 RECIRCULATING DOCUMENT HANDLER DH400 (Machine Code: A378)

  • Page 191: Specifications

    Number of Cycles Max 30 times per Document: Power Source: 24V (from copier), 5 A Power Consumption: Dimensions: 645 x 516 x 132 millimeters (W x D x H) (25.4 x 20.4 x 5.2 inches) Weight: Approximately 18 kg (39.7 lb) FT6645/6655/6665...

  • Page 192: Mechanical Component Layout

    1. Friction Belts 8. Exit Relay Belts 2. Feed Roller 9. Inverter Pawls 3. Original Gate 10. Inverter Roller 4. Pick-up Rollers 11. Transport Belt 5. Original Stacker 12. Pull-out Roller 6. Push-plate 13. Pulse Generator 7. Feed-out Rollers FT6645/6655/6665...

  • Page 193: Electrical Component Descriptions

    Informs the copier CPU when the RDH is lifted and also serves as the jam reset switch for the RDH. Feed-in Unit Safety Detects if the feed-in unit is set Switch correctly. Feed-out Unit Safety Detects if the feed-out unit is set Switch correctly. FT6645/6655/6665...
  • Page 194 APS sensor can begin checking the original size. Magnetic Clutch Feed-in clutch Energizes to rotate the feed roller. Printed Circuit Boards PCB1 RDH Main PCB Controls all RDH functions. PCB2 Indicator Panel PCB Contains indicators for the operator. FT6645/6655/6665...

  • Page 195: Basic Operation

    When the scanner reaches the return position, the copier CPU sends the feed-out signal to the RDH CPU. The RDH then inverts the original in the same way as for back-side copying. FT6645/6655/6665...
  • Page 196 When the feed-in motor reverses, the pick-up rollers stop. However, the feed roller and the pull-out rollers continue turning in the same direction. Roller(s) Feed-in Motor Forward Reverse Pick-up Feed * On/Off On/Off Pull-out (* Only when the feed-in clutch turns on, the feed roller rotates.) FT6645/6655/6665...
  • Page 197 [H], [I], [J], [L], and the feed-in clutch. Since the pull-out roller is installed on the shaft of gear [H], the pull-out roller always turns in the original feed direction whenever the feed-in motor is turned on. FT6645/6655/6665...
  • Page 198 , the notch [B] in the one-turn disk returns to the one-turn sensor and the sensor turns on. When feeding an original, the RDH CPU monitors the rotation of the pick-up rollers through this sensor. It always stops the rollers with their flat surfaces facing up. FT6645/6655/6665...
  • Page 199 In order to set them on the pre-stacked originals, the original gate, and the push plate are energized again after the last original is fed out. This recycle system increases the total copy productivity to 55 cpm for A4, or "x11" originals (sideways feed and 100% reproduction ratio). FT6645/6655/6665...
  • Page 200 The original width is checked by the original width sensor, which is located next to the registration sensor. The original stop position is determined by pulse count from the time the original trailing edge passes the registration sensor. FT6645/6655/6665 5-10...

  • Page 201: Original Inversion Mechanism

    9. ORIGINAL INVERSION MECHANISM Two sided originals are inverted by the inverter rollers [A] and the inverter pawls [B]. When the inverter solenoid [C] is energized, the inverter pawls are opened and the original is inverted. 5-11 FT6645/6655/6665...
  • Page 202 After the back side is exposed, the transport belt motor and the inverter solenoid turn on again. The original is moved to the inverter rollers and inverted, and then moved back to the scale. After the front side is exposed, the original is fed out of the RDH unit. FT6645/6655/6665 5-12...

  • Page 203: Original Feed-Out Mechanism

    180 milliseconds after the original’s trailing edge passes the feed-out sensor. This lower speed prevents uneven stacking of originals. For B4/8 " x 14" and larger originals, the feed-out motor changes its speed 280 milliseconds after the original’s leading edge passes the feed-out sensor. 5-13 FT6645/6655/6665...
  • Page 204 1st original and then fed out to the finisher. At this moment, the duplex tray becomes empty [Fig. The following steps repeat steps 1) to 3). [Fig. 4] to [Fig. 6]. FT6645/6655/6665 5-14...
  • Page 205 4’ 1’ 1’ 2’ 2’ 2’ 1’ 3’ 3’ <Duplex> <Paper tray> 1’ 3’ 1’ 1’ 3’ 3’ 1 2 3 4: 1st recirculated 1’ 2’ 3’ 4’: 2nd recirculated 3rd recirculated 4th recirculated Without exposing (for RDH) 5-15 FT6645/6655/6665...
  • Page 206 Reduced transport time: Before performing the two-sided copy process, the one-sided copy which has been stored in the duplex tray is fed out to a point near the registration rollers simultaneously with other copy processes, thereby saving transport time. FT6645/6655/6665 5-16...
  • Page 207 [Fig 7]. 9) The 1st original is scanned, the copy which has been in the stand-by position is fed for copying the 1st original and then fed out to the exit tray [Fig 7]. 5-17 FT6645/6655/6665...
  • Page 208 Rev. 10/94 <RDH> <Duplex tray> <Paper tray> Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 Fig 6 Recirculated 3rd recirculated : Without exposing (for RDH) FT6645/6655/6665 5-18...

  • Page 209: Original Misfeed Sensing

    850 milliseconds, the Original Misfeed indicator turns on. If the feed-out sensor is not actuated within 700 milliseconds after the inverter sensor turns off (ON check), or if the feed-out sensor does not turn off within 1250 milliseconds, the Original Misfeed indicator lights (OFF check). 5-19 FT6645/6655/6665...
  • Page 210 700 milliseconds (OFF check), the Original Misfeed indicator lights. During original feed-out, ON/OFF checks are performed at both the inverter sensor and the feed-out sensor at the same time as in the one-sided original mode. FT6645/6655/6665 5-20...
  • Page 211 SECTION 6 FINISHER SR400 (Machine Code:A379)

  • Page 212: Overall Machine Information

    2 to 50 sheets " x 14"/B4 or large size (20 lb/80 g/m from 2 to 30 sheets Staple Replenishment: Cartridge exchange (5,000 pieces/cartridge) Power Source: DC 24 V (from copier) Power Consumption: 44.4 W (average) Weight: 35 kg (77.2 lb) FT6645/6655/6665...
  • Page 213 = 5.20" ± 0.12" (13.2 ± 3 mm) b = 0.24" ± 0.12" (6 ± 3 mm) b = 0.24" ± 0.12" (6 ± 3 mm) Dimensions: 26.4" x 20.2" x 37.4" (671 mm x 514 mm x 950 mm) FT6645/6655/6665...
  • Page 214 8. Alignment Brush Roller 2. Shift Tray 9. Lower Transport Rollers 3. Shift Tray Positioning Roller 10. Entrance Rollers 4. Jogger Unit 11. Junction Gate 5. Positioning Roller 12. Upper Transport Rollers 6. Stack Feed-out Belt 13. Exit Rollers 7. Stapler Unit FT6645/6655/6665...
  • Page 215 Detects copy paper stack height in staple mode. Stack Height 2 Detects copy paper stack height in sort/stack mode. Shift Tray Lower Limit Detects the lower limit of the shift tray position. Stapler Hammer HP Detects the staple hammer home position. FT6645/6655/6665...
  • Page 216 Shift Tray Upper Detects the upper limit of the shift Limit (Switch) tray position. Solenoids SOL1 Positioning Roller Lowers the positioning roller in the jogger unit. SOL2 Junction Gate Drives the junction gate. PCBs PCB1 Main Control Controls overall finisher operation. FT6645/6655/6665...
  • Page 217 4. Transport Drive Motor 12. Jogger Motor 5. Transport Drive Belt 13. Stapler Drive Motor 6. Lower Transport Drive Belt 14. Stapler Drive Belt 7. Shift Tray Lift Belt 15. Jogger Drive Belt 8. Shift Motor 16. Stack Feed-out Belt FT6645/6655/6665...

  • Page 218: Basic Operation

    [D], the alignment brush roller [E], and the jogger fences [F] square the stack of copies. After the final copy of the set is squared, the set is stapled, and then delivered to the shift tray. FT6645/6655/6665...

  • Page 219: Sectional Descriptions

    (2) When the exit sensor of the copier is activated while in staple mode, the solenoid is energized. Then, the junction gate directs the copies downward to transport them to the jogger unit. FT6645/6655/6665...

  • Page 220: Shift Tray Up/Down Mechanism

    The shift tray upper limit switch [I] is installed to prevent the drive gears from being damaged if stack height sensor 2 does not work. When the shift tray pushes up the shift tray positioning roller [J], the shift tray lift motor stops. FT6645/6655/6665...

  • Page 221: Shift Tray Side-To-Side Shift Mechanism

    [F] on the shift cam pushes the actuator [G] of the shift tray half-turn sensor [H] and the shift motor stops. The next set of copies is then delivered. The motor rotates repeating the same process and moving the tray back to the previous position. FT6645/6655/6665 6-10...

  • Page 222: Staple Unit Paper Positioning

    The positioning roller rotates to push the paper back and align the trailing edge of the paper against the stack stopper. Both the positioning roller and the alignment brush roller are driven by the transport drive motor through the timing belt [H]. 6-11 FT6645/6655/6665...

  • Page 223: Jogger Movement

    2 mm more so that the leaf spring [B] on the rear jogger fence pushes the copy side edge slightly. After a copy is stacked in the jogger tray, the jogger fences move back 7 mm from the copy edge for the next copy. FT6645/6655/6665 6-12...
  • Page 224 When the cams complete one rotation, the stapler home position sensor [F] turns on detecting the end of the staple operation. The stapler motor then stops. There is a reflecting photosensor [G] in the staple unit to detect the staple end condition. 6-13 FT6645/6655/6665...
  • Page 225 After the job is completed, the stapler unit moves back to its home position. (The stapler unit home position sensor [C] is actuated.) FT6645/6655/6665 6-14...

  • Page 226: Feed-Out To Shift Tray

    The exit drive motor starts rotating to drive the exit rollers when the first copy activates the entrance sensor. The exit drive motor speed is reduced just before each copy paper is completely fed out. This is to ensure an even copy stack. 6-15 FT6645/6655/6665...

  • Page 227: Large Capacity Tray Rt31

    SECTION 7 LARGE CAPACITY TRAY RT31 (Machine Code: A380)

  • Page 228: Specifications

    Power Source: DC24V, 5V (from the copier) Power Consumption: Dimensions (W x D x H ): 403 x 529 x 608mm (15.9" x 20.8" x 23.9") Weight: 19.8kg (43.7lb) Tray Capacity: 3,500 sheets (may vary slightly depending on paper weight) FT6645/6655/6665...

  • Page 229: Mechanical Component Layout

    2. MECHANICAL COMPONENT LAYOUT 1. Bottom Plate 2. Tray Drive Belt 3. Separation Roller 4. Transport Rollers 5. Feed Roller 6. Pick-up Roller FT6645/6655/6665...

  • Page 230: Electrical Component Description

    Feed Drives all feed and transport rollers. Others SOL14 Pick-up Controls the up-down movement of the pick-up roller. Feed Starts paper feed from the LCT. See copier Point to Point diagram coordinates K9 & FT6645/6655/6665...

  • Page 231: Mechanical Operation

    The LCT feed motor [D] drives the pick-up, separation, feed, and transport [E] rollers. The pick-up and feed rollers rotate only when the LCT feed clutch [F] activates. Paper feeding starts when the LCT pick up solenoid [G] activates. FT6645/6655/6665...
  • Page 232 [D] activates and the LCT motor [B] rotates clockwise to raise the bottom plate until the top sheet pushes up the pick-up roller [E]. When the lift sensor [F] is de-actuated, the copier CPU de-activates the LCT motor [B] and the pick-up solenoid [D]. FT6645/6655/6665...
  • Page 233 By adding paper and pressing the tray down switch repeatedly, it is possible to lower the bottom plate to its limit. When the bottom plate lowers sufficiently the tray down sensor [D] will be blocked. This informs the CPU that the LCT bottom plate is at the lowest position. FT6645/6655/6665...

  • Page 234: Paper End Detection

    LED. When the paper near end sensor is deactivated, the display for the LCT will change as shown below: x 11 x 11 sensor de-activated sensor activated FT6645/6655/6665...

  • Page 235: Sorter Stapler St24

    SECTION 8 SORTER STAPLER ST24...
  • Page 236 11"x17" or 8 "x14") Stapling Position: (Diagonal) (Horizontal) a = 10 ± 2 mm a = b = 6 ± 2 mm = 0.39" ± 0.08" = 0.24" ± 0.08" b = 16 ± 2 mm = 0.63" ± 0.08" FT6645/6655/6665...
  • Page 237 Cartridge exchange (3,000 pieces/cartridge) Power Source: DC 24V, 5V (from the copier) Power Consumption: 50 W Dimensions: 16.2" x 23.6" x 27.1" (W x D x H) Weight: About 55.1 lb (Main Frame : 48.5 lb Mounting Frame: 6.6) FT6645/6655/6665...
  • Page 238 2. Proof Tray Exit Rollers 9. Grip Assembly 3. Vertical Transport Rollers 10. Bin Support Block 4. Turn Gate 11. Bins 5. Bin Transport Belt 12. Support Bin 6. Bin Transport roller 13. Jogger Bar 7. Bin Exit Roller FT6645/6655/6665...
  • Page 239 22. Front Bin Block Support Block 17. Vertical Transport 10. Jogger Motor Pulley Drive Pulley 13. Lower Jogger Drive Belt 15. Bin Transport Drive Gear 5. Jogger Drive Shaft 14. Bin Transport Belts 1. Upper Jogger Drive Belt 23. Jogger Bar FT6645/6655/6665...
  • Page 240 Stops the bin lift motor when this switch detects Upper Lift Limit the upper limit position of the bins. Stops the bin lift motor when this switch detects Wire Tension the lower limit position of the bins through the bin lift wire tension. FT6645/6655/6665...
  • Page 241 Cuts the dc 24 V line when the sorter stapler unit Sorter Stapler Set is open. Staple End Detects the staple end condition. Staple Guide Detects if the staple guide plate is closed. Detects if the staple hammer is in the home Staple H.P. position. FT6645/6655/6665...

  • Page 242: Normal Mode And Sort/Stack Mode

    [C] rotates all the rollers in the S/S paper path. At the same time, the turn gate solenoid [D] is energized and the turn gate turns clockwise. The turn gate directs copies to the proof tray [E] through the vertical transport and proof tray exit rollers [F,G]. FT6645/6655/6665...
  • Page 243 This bin movement is done for each copy in the sort mode and for the final copy of each original in the stack mode. The up and down movement of the bins in both the sort and stack modes is the same as that for other moving bin type sorters. FT6645/6655/6665...
  • Page 244 The grippers bring the copies up underneath the stapler. At the same time, the jogger bar jogs the copies stacked in the second bin as a preparation for the next stapling. Then the jogger bar returns to the position 15mm away from the paper side edge. FT6645/6655/6665...
  • Page 245 2) Manual stapling: In sort mode, after copies are sorted in the bins, the copies will be stapled when the staple key is pressed. In stack mode, manual stapling is impossible. FT6645/6655/6665 8-10...
  • Page 246 This turn gate movement is to correct the facecurl of the trailing part of the copy. This will flatten the copy, or give it a slight backcurl, and will help stack and jog copies in the bins smoothly. 8-11 FT6645/6655/6665...

  • Page 247: Roller Drive And Control

    PCB. Then the copier sends the motor OFF signal to the S/S to stop the roller drive motor. The S/S CPU monitors the roller drive motor speed by counting pulses from the timing disc [K] through the roller drive timing sensor [L]. FT6645/6655/6665 8-12...
  • Page 248 The high speed is almost double the normal speed, and it changes depending on the paper size (900, 960 , or 1,000 mm/second). 8-13 FT6645/6655/6665...

  • Page 249: Bin Drive And Control

    Bin lift timing sensor 1 is used for counting the timing pulses. Bin lift timing sensor 2 is used to determine the motor stop timing so that the edge of the timing disc slots is not positioned at timing sensor 1. FT6645/6655/6665 8-14...
  • Page 250 If the bin lift motor fails to stop lowering the bins at the bin home position, the rear bin lift wire [F] loosens its tension. Then the wire tension switch [G] (Normal Open type) is deactuated to open the dc 24V line of the bin lift motor. 8-15 FT6645/6655/6665...
  • Page 251 4. The copy in the first bin is prevented from moving out of the jogged position by the lowered end fence mylar. The end fence mylar and block of the second bin are ready to receive the next copy. FT6645/6655/6665 8-16...
  • Page 252 This jogger bar movement is performed for each copy to square the copy stack in the exited bin. In the automatic or manual staple modes, the jogger bar also moves to ensure squaring the stacked copies before stapling. 8-17 FT6645/6655/6665...
  • Page 253 If the selected paper size does not match stapling specifications. • If copies of different widths are delivered to the bins. 2. If paper is in a bin before the main switch is turned on, the sort/stack mode is disabled when the sorter key is pressed. FT6645/6655/6665 8-18...
  • Page 254 [K] into the bin. (Figure 3) When the high portion of the grip cam [L] (small cam of the dual cam plate) pushes up the grip cam follower, the grippers close to grip the stacked copies in the bin. 8-19 FT6645/6655/6665...
  • Page 255 When the stapler motor stops, the grip motor starts rotating in reverse. Then the gripper assembly returns the stapled copies into the bin, the grippers open, and the gripper assembly returns to the home position. FT6645/6655/6665 8-20...
  • Page 256 [I]. The hammer and the clincher staple the copies. Then, while the staple arms rotate clockwise, the hammer rises and the clincher lowers. When the staple home position switch (Normal Closed type) [J] is deactivated, the stapler motor stops. 8-21 FT6645/6655/6665...
  • Page 257 Add Staple indicator lights on the copier operation panel. The stapler can be swung on the stapler support bracket [E] which has two lock positions . One is for horizontal stapling and the other is for diagonal (25 degrees) stapling. FT6645/6655/6665 8-22...
  • Page 258 If the paper size in the bin does not match stapling specifications. • If only one sheet is delivered to the bin. • If copies of different widths are delivered to the bin. • If copies already stapled are left in the bin. 8-23 FT6645/6655/6665...
  • Page 259 Therefore, to match the sorter stapler speed to the copier’s, the copier sends a signal to S/S CPU; this controls the normal speed of the roller drive motor (high speed never changes) and this generates the pulse rate. FT6645/6655/6665 8-24...

  • Page 260: Staple Error

    • The first time an abnormal condition of the stapler motor or grip motor is detected. The second time an abnormal condition is detected, the copier’s operation panel will indicate a service call code. 8-25 FT6645/6655/6665...
  • Page 261 74 ms 1000 B5 lengthwise 330 ms 0 ms 11" x 17" 220 ms 0 ms " x 14" 525 ms 0 ms " x 11" sideways 230 ms 265 ms " x 11" lengthwise 725 ms 0 ms FT6645/6655/6665 8-26...
  • Page 262 Timing Chart 3: Staple Operation (A4 sideways, 2 copies for 5 bins) (sec) Staple ON Staple count Job completion signal signal signal IInterface Bin Lift Motor Down Forward Jogger Motor Reverse Returns to H.P. 500ms Forward Grip Motor Reverse Stapler Motor 1 staple cycle 8-27 FT6645/6655/6665...

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