Service Training Manual A095/A096/A097: Ricoh Group Companies

SERVICE TRAINING MANUAL
A095/A096/A097
RICOH GROUP COMPANIES

S
E
R
V
I
C
E
T
R
A
I
N
I
N
G
M
A
N
U
A
L
A
0
9
5
/
A
0
9
6
/
A
0
9
7
RICOH GROUP COMPANIES
A095/A096/A097
SERVICE TRAINING
MANUAL
LEGEND
PRODUCT CODE COMPANY
GESTETNER RICOH SAVIN
A095 2545D FT6645 9450
2555D FT6655 9550
2565D FT6665 9650
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 10/93 Original Printing
1 1/94 Revised pages
4 7/94 A097 addition
SECTION 1
OVERALL MACHINE
INFORMATION
1. SPECIFICATION
Configuration: Console
Copy Process: Dry electrostatic transfer system
Toner Supply Control: Fuzzy Control
Photoconductor: OPC drum
Originals: Sheet/Book
Original Size: Maximum A3/11" x 17"
Original Alignment: Left rear corner
Copy Paper Size: Maximum A3/11" x 17"
Minimum A5/51/2" x 81/2" (Tray)
B5/81/2" x 11" (1.5K LCT)
A6/51/2" x 81/2" (By-pass)
Duplex Copying: Maximum A3/11" x 17"
Minimum A5/51/2" x 81/2" (sideways)
Copy Paper Weight: Paper tray: 52 ~ 128 g/m
2
, 14 ~ 34 lb
Bypass feed table: 52 ~ 157 g/m
2
, 14 ~ 42 lb
Duplex copying: 64 ~ 104 g/m
2
, 17 ~ 24 lb
Reproduction Ratios: 4 Enlargement and 6 Reduction
A4/A3 Version LT/LDG Version
Enlargement 200%
141%
122%
115%
200%
155%
129%
121%
Full Size 100% 100%
Reduction 93%
82%
75%
71%
65%
50%
93%
85%
77%
74%
65%
50%
STM 1-1 FT6645/6655/6665
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
Copying 1.20 kVA 1.30 kVA
Maximum 1.45 kVA 1.50 kVA
FT6665 (A097) copier
120 V
machine
230 V
machine
120 V
machine
230 V
machine
Warm-up 1.20 kVA 1.20 kVA 1.25 kVA 1.25 kVA
Stand-by 0.25 kVA 0.22 kVA 0.25 kVA 0.24 kVA
Copying 1.80 kVA 1.70 kVA 1.80 kVA 1.75 kVA
Maximum 1.80 kVA 1.70 kVA 1.80 kVA 1.75 kVA
*Full System:
Mainframe with dual job feeder, compact
sorter stapler and 3,500-sheet large capacity
tray
Mainframe with dual job feeder, floor type
tray
Mainframe with recirculating document
handler, finisher and 3,500-sheet large
capacity tray
Rev. 7/94
FT6645/6655/6665 1-2 STM
Noise Emission:
Copying (FT6645/6655 copiers) 55 dB (A) 62 dB (A)
Copying (FT6665 copier) 60 dB (A) 64 dB (A)
Full System:
Mainframe with dual job feeder, compact
tray
Mainframe with dual job feeder, floor type
tray
Mainframe with recirculating document
handler, finisher and 3,500-sheet large
capacity tray
Dimensions: 690 x 690 x 980 (W x D x H Mainframe only)
1280 x 690 x 1020 (W x D x H Mainframe with
copy tray, platen cover)
Weight: Copier only: (Without the optional platen cover
= Approximately 2 kg)
FT6645 (A095) copier: Approximately (333 lbs)
Zoom: From 50% to 200% in 1% steps
Copying Speed:
A4/LT (sideways) A3/DLT B4/LG
FT6645 copier 45 23 27
FT6655 copier 55 28 35
FT6665 copier 65 33 41
Warm-up Time: Less than 5 minutes (20C)
First Copy Time:
(A4/81/2" x 11" sideways
from the 1st feed station)
3.1 seconds FT6645/6655 (A095/A096 copiers)
2.7 seconds FT6665 (A097 copier)
Copy Number Input: Number keys, 1 to 999 (count up or count down)
Manual Image Density 7 steps
Selection:
Rev. 7/94
Sound Pressure Level:
The measurements are
made according to
ISO7779
STM 1-3 FT6645/6655/6665
Automatic Reset: 1 minute standard setting; can also be set from 1
second to 999 seconds or no auto reset.
Copy Paper Capacity: By-pass feed table: approximately 50 sheets
Paper tray: approximately 550 sheets
Tandem tray: approximately 500 sheets/side,
1000 total
Large capacity tray: approximately 1,500
sheets
Duplex: 50 sheets
Toner Replenishment: Black Only: Cartridge exchange
1,100 g/cartridge, Yield 38,000 copies
(6% originals)
Developer
Replenishment:
Black Only: 1Kg/Bag, 120,000 copies
(6% originals)
Optional Equipment: Type 610, Platen cover
DF60, Dual job feeder
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
Bottle Capacity:
7,500cc, 120,000 copies (6% originals)
Rev. 7/94
FT6645/6655/6665 1-4 STM
2. MACHINE CONFIGURATION
2.1 COPIER OVERVIEW
There are two types of mainframe.
FT6645 (A095) copier
FT6655 (A096) FT6665 (A097) copiers
550
550
550
(3,500)
50
Rev. 7/94
(3,500)
500 x 2 or 500
550
1,500
50
Three 550-sheet paper trays Optional
3,500-sheet large capacity tray
Tandem paper tray
(including two 500-sheet paper tray)
One 550-sheet paper tray
1,500-sheet built-in large capacity tray
Optional 3,500-sheet large capacity tray
STM 1-5 FT6645/6655/6665
2.2 SYSTEM OVERVIEW
System A
The mainframe FT6645 (A095) with dual job feeder and compact sorter
stapler.
System B
Mainframe type FT6645/6655/6665(A095/A096/A097) with dual job feeder
and floor type sorter stapler. The mainframe in the illustration below is the
FT6655 (A096).
Rev. 7/94
Compact
sorter stapler
ST24 (A374)
Dual job feeder DF60 (A376)
3,500-sheets
large capacity
tray
RT31 (A380)
Dual job feeder DF60 (A376)
3,500-sheets
large capacity tray
RT31(A380)
Floor type
sorter stapler
ST25 (A377)
FT6645/6655/6665 1-6 STM
System C
The mainframe FT6665/6665 (A096/A097) with recirculating document
handler and finisher.
NOTE: All references to (A096 copier only) now refers to (A096 and
A097 copiers).
3,500-sheets
large capacity tray
RT31 (A380)
Recirculating document handler DH400 (A378)
Finisher
SR400 (A379)
Rev. 10/94
STM 1-7 FT6645/6655/6665
3. COPY PROCESS AROUND THE DRUM
1. OPC DRUM
The organic photo conductive (OPC) drum (100 mm diameter) has high
resistance in the dark and low resistance under light.
2. DRUM CHARGE
In the dark, the charge corona unit gives a uniform negative charge to the
OPC drum. The charge remains on the surface of the drum. The amount of
negative charge on the drum is proportional to the negative grid bias voltage
applied to the grid plate on the charge corona unit.
3. EXPOSURE
An image of the original is reflected to the OPC drum surface via the optics
section. The charge on the drum surface is dissipated in direct proportion to
the intensity of the reflected light, thus producing an electrical latent image on
the drum surface.
The amount of charge remaining as a latent image on the drum depends on
the exposure lamp intensity controlled by the exposure lamp voltage.
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.
10
9
8
7
6
5
4
3
1 2
11
FT6645/6655/6665 1-8 STM
5. DRUM POTENTIAL SENSOR
The drum potential sensor detects the electrical potential on the drum to
compensate image processing elements.
6. DEVELOPMENT
Positively charged toner is attracted to the negatively charged areas of the
drum, thus developing the latent image. (The positive triboelectric charge of
the toner is caused by friction between the carrier and toner particles.)
The development bias voltage applied to the development roller shafts
controls two things:
1) The "breakaway" level at which toner is attracted to the drum and at
which toner remains on the development rollers.
2) The amount of toner to be attracted to the drum.
The higher the negative development bias voltage is, the less toner is
attracted to the drum surface.
7. PRE-TRANSFER LAMP (PTL)
The PTL illuminates the drum to remove almost all the negative charge from
the exposed areas of the drum. This makes image transfer easier.
8. IMAGE TRANSFER
Paper is fed to the drum surface at the proper timing so as to align the copy
paper and the developed image on the drum surface. Then, a negative
charge is applied to the reverse side of the copy paper by the transfer belt,
producing an electrical force which pulls the toner particles from the drum
surface onto the copy paper. At the same time, the copy paper is electrically
attracted to the transfer belt.
9. PAPER SEPARATION
Paper separates from the OPC drum by the electrical attraction between the
paper and the transfer belt. The pick-off pawls help to separate the paper
from the drum.
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.
STM 1-9 FT6645/6655/6665
4. MECHANICAL COMPONENT LAYOUT
2
3 4 5
11
10
12
7 6
29
26
35
34
25
24
31
30
16
32 33
15
14
13
27
19
18
23
22
21
17
20
28
8 9
1
39
38
37
36
FT6645/6655/6665 1-10 STM

1. 3rd Mirror
2. 2nd Mirror
3. 1st Mirror
4. Exposure Lamp
5. Lens
6. Cleaning Brush
7. Cleaning Blade
8. Quenching Lamp
9. Charge Corona Unit
10. OPC Drum
11. 6th Mirror
12. 4th Mirror
13. 5th Mirror
14. Erase Unit
15. Drum Potential Sensor
16. Toner Hopper
17. Development Unit
18. Pre-Transfer Lamp
19. Pick-up Roller, Bypass
20. Feed Roller, Bypass
21. Separation Roller, Bypass
22. Registration Rollers
23. Transfer Belt
24. Vertical Transport Rollers
25. Tandem Tray (A096 copier)
550-sheet Tray (A095 copier)
26. Universal Tray
27. 1500-sheet LCT (A096 copier)
550-sheet Tray (A095 copier)
28. Toner Collection Bottle
29. Transfer Belt Cleaning Blade
30. Hot Roller
31. Pressure Roller
32. Jogger Fences
33. Duplex Positioning Roller
34. Duplex Pick-up Roller
35. Duplex Feed Roller
36. Separation Belt
37. Junction Gate
38. Exit Rollers
39. Optics Cooling Fan
STM 1-11 FT6645/6655/6665
5. DRIVE LAYOUT

8
O
O
O
O
O
1 10
11
O
9
2
3
4
5
6
O
7
0
O
0 Main Motor
O Scanner Drive Motor
O Fusing/Duplex Drive Motor
O Paper Feed Motor
O Toner Collection Motor
O Registration Clutch
O By-Pass Feed Motor
O BY-Pass Feed Clutch
O Development Drive Motor
1. OPC Drum
2. Scanner Unit
3. Transfer Belt Unit
4. Paper Exit Unit
5. Fusing Unit
6. Duplex Unit
7. Paper Trays
8. Paper Feed Units
9. Toner Hopper
10. Development Unit
11. Cleaning Unit
FT6645/6655/6665 1-12 STM
6. PAPER PATH
6.1 STANDARD COPYING
Paper feed begins from the exterior LCT, by-pass feed table or paper feed
stations in the paper tray unit. The copy paper then follows one of two paths
inside the copier. The path followed depends on which mode the operator
has selected. For copy processing, all sheets follow the same paths from the
paper feed mechanism [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.
[D]
[C]
[B]
[A]
[A]
[F]
[E]
STM 1-13 FT6645/6655/6665
6.2 MULTIPLE 2-SIDED COPYING
In this mode the junction gate [A] directs sheets exiting the fusing unit to the
duplex tray entrance. After that, all sheets follow the path through the duplex
entrance rollers [B].
After all front side copying is completed, the sheets on the duplex tray are fed
in order from the bottom to the top and follow the path through the duplex
feed mechanism and vertical transport rollers [C] to the registration rollers
[D]. After that, these sheets follow the same path as standard copying from
the registration rollers to the sorter.
a. Front Side
[A]
[B]
[D]
[C]
b. Rear Side
FT6645/6655/6665 1-14 STM
7. ELECTRICAL COMPONENT DESCRIPTION
Refer to the electrical component layout on the reverse side of the Point to
Point for symbols and index numbers.
NOTE: For RT31 descriptions, see Section 7, page 3
Symbol Name Function Index
No.
Motors
M 1 Scanner Drive Drives the 1st and 2nd scanners
(dc servo).
42
M 2 Exhaust Fan Removes the heat from around
the fusing unit.
43
M 3 Main Drives the main unit components. 44
M 4 Development Drive Drives the development unit. 45
M 5 By-pass Feed Drives the by-pass feed rollers. 46
M 6 3rd Scanner Drive Drives the 3rd scanner (dc
stepper)
47
M 7 Toner Bottle Drive Rotates the toner bottle to supply
toner to the toner hopper.
48
M 8 Charge Wire Cleaner
Drive
Drives the main charge wire
cleaner to clean the charge wire.
49
M 9 Jogger Drives the jogger fences to
square the paper stack in the
duplex tray (dc stepper).
50
M10 Lens Horizontal Drive Shifts the lens horizontal position. 51
M11 Lens Vertical Drive Shifts the lens vertical position. 52
M12 Optic Cooling Fan Removes heat from the optics
unit.
53
M13 Fusing/Duplex Drive Drives the fusing unit, the duplex
unit, and the paper exit rollers.
54
M14 Paper Feed Drives all feed and transport
rollers in the paper tray unit.
90
M15 1st Lift Raises the bottom plate in the 1st
paper tray.
91
M16 2nd Lift Raises the bottom plate in the
2nd paper tray.
92
M17 Toner Collection Transports the collected toner to
the toner collection bottle.
93
STM 1-15 FT6645/6655/6665
No.
M18 3rd Lift
(A095)
Raises the bottom plate in the 3rd
paper tray.
94
M19 Side Fence Drive
(A096/A097)
Opens and closes the front and
the rear side fences of the
tandem tray.
95
M20 Rear Fence Drive
(A096/A097)
Moves the papers stacked in the
left tandem tray to the right
tandem tray.
96
M21 LCT Motor
(A096/A097)
Lifts and lowers the LCT bottom
plate to bring paper to the feed
position and allow loading of the
paper.
127
Magnetic Clutches
MC1 Toner Supply Turns the toner supply roller to
supply toner to the development
unit.
57
MC2 Registration Drives the registration rollers. 58
MC3 By-pass Feed Starts paper feed from the
by-pass feed table.
60
MC4 Duplex Transport Drives the duplex transport rollers
to transport the paper to the
vertical transport rollers.
64
MC5 Duplex Feed Starts paper feed from the duplex
tray to the duplex transport rollers.
65
MC6 1st Feed Starts paper feed from the 1st
feed tray.
99
MC7 2nd Feed Starts paper feed from the 2nd
feed tray.
101
MC8 3rd Feed Starts paper feed from the 3rd
feed tray.
104
Rev. 7/94
FT6645/6655/6665 1-16 STM
No.
Switches
SW1 By-pass Table Detects if the by-pass feed table
is open or closed.
25
SW2 Front Door Safety Cuts the DC power line and
detects if the front door is open or
not.
29
SW3 1st Tray Set
(A095)
Detects if the 1st tray is set or not. 66
SW4 2nd Paper Size Determines what size paper is in
the 2nd (universal) paper tray.
67
SW5 Toner Overflow Detects when the toner collection
bottle is full.
75
SW6 Toner Collection
Bottle Set
Detects if the toner collection
bottle is set or not.
77
SW7 Lower Front Door
Safety
Detects if the front door is open
or not.
83
SW8 3rd Tray Set
(A095)
Detects if the 3rd tray is set or not. 84
SW9 Main Provides power to the copier 122
SW10 Tray Down
(A096/A097)
Lowers the LCT bottom plate. 126
Solenoids
SOL 1 Junction Gate Moves the junction gate to direct
copies to the duplex tray or to the
paper exit.
55
SOL 2 Duplex Positioning Controls the up-down movement
of the positioning roller.
56
SOL 3 By-pass Pick-up Controls the up-down movement
of the pick-up roller for by-pass
feed.
61
SOL 4 Guide Plate Opens the guide plate when a
paper misfeed occurs around this
area.
59
SOL 5 Transfer Belt
Positioning
Controls the up-down movement
of the transfer belt unit.
62
Rev. 7/94
STM 1-17 FT6645/6655/6665
No.
SOL 6 Pressure Arm Presses the paper on the duplex
tray against the duplex feed
rollers.
63
SOL 7 Tandem Lock Locks the left tandem feed tray
and separates the right and left
tandem trays.
97
SOL 8 1st Pick-up Controls the up-down movement
of the pick-up roller in the 1st
feed station.
98
SOL 9 1st Separation Roller Controls the up-down movement
of the separation roller in the 1st
feed station.
100
SOL10 2nd Pick-up Controls the up-down movement
of the pick-up roller in the 2nd
feed station.
102
SOL11 2nd Separation Roller Controls the up-down movement
of the separation roller in the 2nd
feed station.
103
SOL12 3rd Pick-up Controls the up-down movement
of the pick-up roller in the 3rd
feed station.
105
SOL13 3rd Separation Roller Controls the up-down movement
of the separation roller in the 3rd
feed station.
106
Sensors
S 1 Scanner HP Informs the CPU when the 1st
and 2nd scanners are at the
home position.
1
S 2 Platen Cover
Position1
Informs the CPU that the platen
cover is in the up or down
position (related to APS/ARE
function).
2
S 3 Platen Cover
Position2
Informs the CPU that the platen
cover is in the up or down
position to detect if the original
has been removed or not.
3
FT6645/6655/6665 1-18 STM
No.
S 4 Lens Vertical HP Informs the CPU that the lens is
at the full-size position.
4
S 5 Lens Horizontal HP Informs the CPU that the lens is
at the horizontal home position.
5
S 6 3rd Scanner HP Informs the CPU when the 3rd
scanner is at the home position.
6
S 7 By-Pass Paper End Informs the CPU that there is no
paper in the by-pass feed table.
7
S 8 Guide Plate Position Informs the CPU if the
registration guide plate is closed
or not.
8
S 9 Jogger HP Detects if the duplex jogger
fences are at the home position
or not.
9
S10 Vertical Transport Detects the leading edge of the
paper to determine the paper
feed timing of the next sheet.
10
S11 Duplex Exit Detects the leading edge of the
paper to determine the duplex
transport clutch on timing.
11
S12 Duplex Entrance
Sensor
Detects the leading edge of the
paper to determine the duplex
feed clutch off timing.
14
S13 Duplex Paper End Detects paper in the duplex tray. 13
S14 Duplex Transport Detects the leading edge of the
paper to control the jogger motor
and the positioning solenoid on
timing.
12
S15 Exit Detects misfeeds. 15
S16 Fusing Exit Detects misfeeds. 16
S17 Paper Guide Detects misfeeds. 17
S18 Auto Image Density Senses the background density
of the original.
20
S19 Original Length2 Detects original length. 21
S20 Original Length1 Detects original length. 22
S21 Original Width Detects original width. 23
Rev. 12/93
STM 1-19 FT6645/6655/6665
No.
S22 By-Pass Paper Size Informs the CPU what size paper
is in the by-pass feed table.
26
S23 Toner Density Senses the amount of toner in
the black developer.
27
S24 Registration Detects misfeeds and controls
registration clutch off-on timing.
28
S25 Toner End Detects toner end condition. 30
S26 Auto-Response Returns the display from the
screen saver.
34
S27 Drum Potential Detects the drum surface
potential.
39
S28 Image Density Detects the density of the ID
sensor pattern on the drum.
41
S29 1st Paper End Informs the CPU when the 1st
cassette runs out of paper.
68
S30 1st Paper Near End Informs the CPU when the 1st
cassette is in near end condition.
69
S31 1st Paper Feed Controls the 1st paper feed clutch
off/on timing and the 1st pick-up
solenoid off timing.
70
S32 2nd Paper Near End Informs the CPU when the 2nd
71
S33 1st Lift Detects the correct feed height of
the 1st cassette.
72
S34 2nd Paper End Informs the CPU when the 2nd
73
S35 Toner Collection
Motor
Detects the toner collection motor
operation.
74
S36 2nd Lift Detects the correct feed height of
the 2nd cassette.
76
S37 3rd Lift Detects the correct feed height of
the 3rd cassette.
78
S38 3rd Paper Near End
(A095 copier only)
Informs the CPU when the 3rd
79
S39 3rd Paper End Informs the CPU when the 3rd
80
FT6645/6655/6665 1-20 STM
No.
S40 3rd Paper Feed Controls the 3rd paper feed
clutch off/on timing and the 3rd
pick-up solenoid off timing.
81
S41 2nd Paper Feed Controls the 2nd paper feed
clutch off/on timing and the 2nd
pick-up solenoid off timing.
82
S42 Base Plate Down
(A096/A097)
Detects when the bottom plate is
completely lowered to stop the
1st lift motor.
85
S43 Side Fence
Positioning
(A096/A097)
Informs the CPU when the
tandem tray side fences are open.
86
S44 Rear Fence Return
(A096/A097)
tandem tray rear fence is in the
return position.
87
S45 Rear Fence HP
(A096/A097)
tandem tray rear fence is in the
home position.
88
S46 Left Tandem Paper
End
(A096/A097)
Informs the CPU when the left
tandem tray runs out of paper.
89
S47 LCT Near End
(A096/A097)
Detects the paper near end
condition.
123
S48 Tray Down
(A096/A097)
Detects when the tray is
completely lowered to stop the
LCT motor.
124
S49 Tray Paper Set
(A096/A097)
Informs the CPU when the paper
is set on the LCT bottom tray.
125
PCBs
PCB 1 AC Drive Provides AC power to the
exposure lamp and fusing lamp.
108
PCB 2 Main Controls all machine functions. 109
PCB 3 Optic Control Controls all optics components. 110
PCB 4 High Voltage Control Controls the output of both power
packs and development bias.
111
Rev. 7/94
STM 1-21 FT6645/6655/6665
No.
PCB 5 Paper Feed Control Controls all components in the
paper bank.
112
PCB 6 DC Power Supply
Unit
Provides DC power. 113
PCB 7 Guidance Controls the guidance display. 120
PCB 8 Operation Panel Controls the LED matrix, and
monitors the key matrix.
121
Lamps
L1 Exposure Applies high intensity light to the
original for exposure.
18
L2 Fusing (2 in A097) Provides heat to the hot roller. 32
L3 Quenching Neutralizes any charge remaining
on the drum surface after
cleaning.
37
L4 Erase Discharges the drum outside the
image area.
38
L5 Pre-transfer Reduces the charge on the drum
surface before transfer.
40
Power Packs
PP1 Transfer Provides high voltage for the
transfer belt and controls the
transfer belt positioning solenoid.
117
PP2 Charge Provides high voltage for the
charge corona wires, and the grid
plate. Controls QL, PTL, and
charge wire cleaner motor
functions.
119
Others
TS1 Optics Thermoswitch Opens the exposure lamp circuit
if the optics unit overheats.
19
TF1 Fusing Thermofuse Opens the fusing lamp circuit if
the fusing unit overheats.
33
Rev. 7/94
FT6645/6655/6665 1-22 STM
No.
TH1 Fusing Thermistor Senses the temperature of the
hot roller.
24
TH2 Optics Thermistor Monitors the temperature of the
optics cavity.
36
TH3 Drum Thermistor
(Located on the ID
Sensor Assy)
Monitors the temperature of the
OPC drum.
41
H1 Transfer
Anti-Condensation
Turns on when the main switch is
off to prevent moisture from
forming on the transfer belt.
31
H2 Optics
Anti-Condensation
Turns on when the main switch is
off to prevent moisture from
forming on the optics.
35
RA1 Main Power Relay Controls main power. 107
CO1 Total Counter Keeps track of the total number
of copies made.
114
NF1 Noise Filter Removes electrical noise. 115
CB1 Circuit Breaker Provides back-up high current
protection for the electrical
components.
116
LA1 Lightening Arrestor Removes current surges from the
AC input lines.
118
FT6665 (A097) copier only (unique items)
No.
Motors
M22 AC Drive Cooling
Fan
Removes heat from around the
AC drive unit.
141
M23 Optic Cooling Fan-2 Removes heat from the optic unit. 142
M24 Duplex Cooling Fan Cools the paper on the duplex
tray to reduce the heat around
the drum.
143
Rev. 10/94
STM 1-23 FT6645/6655/6665
8. AC AND DC POWER DISTRIBUTION

The above illustration shows how ac power (120V/220V~240V) from the wall
outlet is supplied to each component.
When the copier is plugged in and the main switch is turned off, ac power is
supplied to the anti-condensation heaters. When the main switch is turned
on, the ac power supply to the anti-condensation heaters is cut off and ac
power is supplied to the ac drive board. The ac drive board supplies power to
the exposure and fusing lamps without voltage step down.
The ac power is also supplied to the dc power supply board via main switch.
The dc power supply board converts the wall outlet ac power into +38, +24,
+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.
Rev. 12/93
FT6645/6655/6665 1-24 STM
This page intentionally left blank
STM 1-25 FT6645/6655/6665
9. FT6665 (A097) COPIER UNIQUE POINTS
The following are the FT6665 (A097) copiers 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.
The paper tray and peripheral configuration of the FT6665 copier is exactly
the same as the FT6655 copier.

Rev. 7/94
FT6645/6655/6665 1-26 STM
Item Unit Description Reason
1
Drive Motor Main Motor Due to higher paper transport and copy
process speed
2
Fusing/Duplex Drive Motor
3
Development Drive Motor
4
Exterior Right Door Printed model name is different
5
Optics Exposure Lamp Exposure lamp wattage is changed. Refer
to STM page 2-31.
6
Optics Fan Filter To keep the optics cool in spite of a longer
exposure lamp on time, a thinner filter is
used.
7
Optics Control Board ROM on the optics control board is
different due to higher scanner motor
speed.
8
Paper Feed Separation Roller torque
limiter
Due to higher paper feed speed, torque
limit is increased.
9
Duplex Brush Roller Due to higher paper transport speed, roller
diameter is decreased (A095/A096 copier:
40mm, A097 copier: 25mm).
10
Positioning Roller Arm Due to higher copy speed, the arm is
moved more frequently. Therefore, lighter
arm is used.
11
Duplex Paper End Sensor Due to higher copy speed, the pressure
arm moves more frequently. To ensure
the paper end detection, the detection
mechanism on the pressure arm is
replaced with reflective photo sensor.
12
Fusing Pressure Springs Due to higher copy speed, the spring
tension is increased to maintain sufficient
fusing ability.
13
Fusing Lamp Due to higher copy speed, lamp wattage
is increased. (120V machine has two
fusing lamps.)
14
Pressure Roller
Cleaning Roller
Due to higher copy speed, higher cleaning
ability is required. So, the contact
pressure between the pressure roller and
the cleaning roller was increased. To
facilitate servicing, the cleaning roller can
be replaced. (Cleaning roller unit is
replaced for A095/A096 copiers.)
Oil Supply Roller Cleaning
Roller (not illustrated)
Due to the higher fusing roller rotation
speed, the oil supply roller tends to collect
foreign material. Thus, a cleaning roller
has been added.
15
Fans AC Drive Cooling Fan Due to higher lamp power, motor speed,
etc. the machine generates more heat.
Therefore, three new fans are added.
16
Optic Cooling Fan-2
17
Duplex Cooling Fan
Rev. 7/94
STM 1-27 FT6645/6655/6665
Item Unit Description Reason
18
Others DC Power Supply Unit
(120V machine only)
Since fans are added and motor speed is
increased, the DC power supply unit is
improved.
19
DC Harness Connectors for new fans are added.
20
Paper Guides To ensure the correct paper transport, the
guides are added.
21
AC Drive Board Since one fusing lamp was added, the AC
Drive Board was modified. (120V machine
only)
Rev. 10/94
FT6645/6655/6665 1-28 STM
SECTION 2
DETAILED SECTION
DESCRIPTIONS
1. PROCESS CONTROL
1.1 OVERVIEW
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).
Temperature Sensor
ID Sensor
Lamp Voltage
Grid Voltage
QL
VD Pattern
VD Pattern
VL Pattern
VL Pattern
Erase Lamp
Drum Potential Sensor
Original Exposure Glass
Original Scale
ADS Pattern
Toner Supply On time
Development. Bias
TD Sensor
Toner Supply Control
Image Density Control
(Fuzzy Control)
Main PCB
Paper
Latent image Control
Exposure Control
Charge Control
Latent Image Control
Image Density Control
(Fuzzy Control)
STM 2-1 FT6645/6655/6665
1.1.1 Latent Image Control
The figure shows the changes of the drum potential during the copy process.
Vo: The drum potential just after charging the drum.
VD (Dark Potential): The drum potential just after exposing the black
pattern (VD pattern)
VL (Light Potential): The drum potential just after exposing the white
pattern (VL pattern)
VR (Residual Voltage): The drum potential just after exposure by the
erase lamp.
After long usage following installation or a PM, drum potential will gradually
increase due to the following factors:
Dirty optics or exposure lamp deterioration
Dirty charge corona wire, grid plate and corona casing.
Change of the drum sensitivity
In this copier, the change in drum potential is detected by the drum potential
sensor and the following items are controlled to maintain good copy quality.
The grid bias voltage
The exposure lamp voltage
The development bias voltage.
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.
QL Charge
Vo
Exposure
Black White
Erase
Potential
Sensor
Drum
VD
VL
VR
FT6645/6655/6665 2-2 STM
1.1.2 Image Density Control
Image density is controlled by the following sensors:
Toner density sensor (TD sensor)
Image density sensor (ID sensor)
Data from the TD sensor is used to keep the toner concentration in the
developer at a constant level. However, the image on the OPC drum varies
due to the variation of toner chargeability (influenced by the environment,
humidity) even if the toner concentration is constant. The ID sensor
compensation causes toner concentration to change to keep the image
density on the OPC drum constant.
The following items are controlled to maintain a constant copy image density:
Toner supply clutch on time
Toner supply level data (VREF) of the TD sensor
Rev. 12/93
STM 2-3 FT6645/6655/6665
1.2 PROCESS CONTROL DATA INITIAL SETTING
The following flow chart shows all the steps that will be performed whenever
the machine is turned on while the hot roller temperature is below 100C.
This initializes all the process control settings.
Main SW or Timer On (Fusing Temp. < 100C)
Charge wire cleaning (if more than 5 K copies are made since
last cleaning
Drum Potential Sensor Calibration
Drum Conditioning Start (Fusing Temp. = 180C)
VSG Adjustment
VR Measurement
VD/VL/VR 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.
'

Rev. 4/15/94
FT6645/6655/6665 2-4 STM
1.3 LATENT IMAGE CONTROL
1.3.1 Drum Potential Sensor Calibration

The drum potential sensor [A] is located just above the development unit. The
sensor has a detector which detects the strength of the electric field from the
electric potential on the drum. The output of the sensor depends on the
strength of the electric field.
Since the output of the sensor is affected by environmental conditions, such
as temperature and humidity, the sensor output is calibrated during process
control data initial setting (hot roller temperature is less than 100C at main
switch/timer turn on).
The High Voltage Control PCB [B] has two relay contacts. Usually RA602
grounds the drum. However, during the initial setting, the main PCB turns
RA601 on and RA602 off and applies the voltage to the drum shaft.
By measuring the output of the drum potential sensor when 100 V and 800
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.
Drum
Case
Sensor
Output
Amp.
Rev. 4/15/94
[A]
Main PCB
[B]
High Voltage
Control Board
STM 2-5 FT6645/6655/6665
1.3.2 Drum Conditioning
When the fusing temperature reaches 180C, the machine starts the drum
conditioning process. In this mode, the main motor, main charge corona,
erase lamp and development bias are activated for about 30 seconds and
drum sensitivity and residual voltage (VR) are stabilized, as in continuous
copy runs.
1.3.3 VSG Adjustment
During drum conditioning, the ID sensor checks the bare drums reflectivity
and calibrates the output of the ID sensor to 4 0.2 V.
1.3.4 VR Measurement

The solid line in the figure above shows the relationship between the drum
potential and the original density. To get constant copy quality throughout the
drums life, this relationship must be maintained.
Since this relationship tends to change to the one represented by the dotted
line, compensations are required. Factors causing this change are changes
in the optics section, in the charge section and in drum sensitivity.
The residual voltage (VR) cannot be compensated even if the exposure lamp
voltage is increased. Therefore, the VR change has to be compensated by
other means.
After the drum conditioning the main control board turns on the erase lamps.
Then the drum potential is checked by the potential sensor. This measured
drum potential is in fact VR. This VR is used as the standard for the VD and
VL corrections.
NOTE: In the figure above, the residual voltage (VR) for the new drum is
0V. Actually, there is some residual voltage even on the new
drum.
Rev. 4/15/94
Vo
VD
VL
VR
Drum
Potential
Light Original Density Dark
New Drum
Used Drum
FT6645/6655/6665 2-6 STM
1.3.5 VD Correction
The drum potential, just after the black pattern (VD Pattern) is exposed (VD:
Dark Potential), tends to lower during drum life due to a decrease in the
drums capacity to carry a charge.
To check the actual VD, the first scanner moves to the home position and the
VD pattern (Black) located on the bottom side of the exposure glass bracket
is exposed on the drum.
The main control board measures VD through the drum potential sensor and
adjusts it to a target value by adjusting the grid bias voltage (VGRID).
On the other hand, there is a change of the drum residual voltage (VR), so
that the target VD voltage is compensated as follows:
Target VD Value: VD = VR + (770)
The adjusted grid bias voltage (VGRID) is kept in memory until the next
process control data initial setting.
[-V] VD
770
VR
VR
Drum
Potential
Dark
Light
Original Density
VD Compensated
After many copies
New Drum
Exposure
Glass
VD Pattern
STM 2-7 FT6645/6655/6665
1.3.6 VL Correction
Dirty optics and/or exposure lamp deterioration decreases the intensity of the
light that reaches the drum. In addition to this, the drum sensitivity also
changes during the drums life. These factors change the drum potential just
after white pattern exposure (VL: Light Potential).
To check the actual VL, the first scanner moves under the VL pattern (White)
located underneath the original scale. The pattern is exposed on the drum.
The main control board measures VL through the drum potential sensor and
adjusts it to a target value by adjusting the exposure lamp voltage (VLAMP).
The residual voltage (VR) change also affects VL, so that VLs target voltage
is compensated as follows:
Target VL Value: VL = VR + (140)
The adjusted exposure lamp voltage (VLAMP) is stored in memory until the
next process control data initial setting.
Exposure
Glass
VL Pattern
[-V]
770
VR
VR
VR
140
VD
Only VD
Compensated
VD and VL
Compensated
New Drum
Dark Light Original Density
Drum
Potential
VL
FT6645/6655/6665 2-8 STM
1.3.7 VR Correction
Potentials (VR, VD, VL) are monitored by the drum potential sensor. (This is
done only when the fusing temperature is less than 100C when the machine
is turned on.)
During the check cycle, the VD and VL patterns are exposed and the drum
potential on the areas of each pattern is checked by the potential sensor.
Compare the curve of the VD and VL compensated drum potential with the
curve of the new drum. They are parallel but the compensated potential is still
higher (VR) than the new drum potential. To prevent dirty backgrounds due to
increased residual potential, development bias (VBB) is applied as follows:
VBB= VR + (220)
The adjusted development bias (VBB) is stored in memory until the next
process control initial setting.
[-V]
VR
VD
VL
VR
New Drum
VD and VL Compensated
Development Bias (VBB)
Dark Light Original Density
Drum
Potential
VR
770
140
STM 2-9 FT6645/6655/6665
1.3.8 Initial Setting Sequence
The following graph shows the sequence of events during process control
data initial setting.

1. Potential sensor calibration (Fusing Temp < 100C)
By measuring the output of the drum potential sensor when 100 V and
800 V are applied to the drum, the sensor output (V100 and V800) is
calibrated automatically (See page 2-5 for details).
2. VR, VD, VL potential detection (Fusing Temp 180C)
After about 30 seconds of drum conditioning, VD and VL patterns are
generated by using the previous grid bias voltage (VGRID) data and
exposure lamp voltage (VLAMP) data to detect the VR, VD, VL data.
The machine calculates the new VGRID and VLAMP data using the
detected VR, VD, VL data.
NOTE: The lens moves as VD & VL are checked. This allows each
pattern to be placed on the drum in alignment with the potential
sensor.
1. Potential
sensor
calibration
2. VR, VD, VL
potential
detection
4. ID sensor
pattern
potential
detection
3. VD, VL
correction
V800
V100
VD New VD
New VL
New VR
VL
VR
Scanner
Motor
Exposure
Lamp
forward
reverse
for the purpose
of ADS sensor
correction
Latent Image Control
Potential
Sensor
Output
Rev. 4/15/94
FT6645/6655/6665 2-10 STM
3. VD and VL corrections
Using the calculated VGRID and VLAMP data, VR, VD, and VL patterns are
developed again and the new VR, VD, and VL data are detected.
If both VD and VL data are within specifications, the new VGRID, VLAMP
and development bias (VBB) are determined based on the new VD, VL,
and VR values.
Specifications:
VD = 770 + VR 20 V
VL = 140 + VR 20 V
If VD is outside specifications, VGRID is shifted one step (20V/step). Then the
VD pattern is measured again and VD is detected again. The same is done
for VL and VLAMP.
The above process continues until both VD and VL fall within specifications.
The graph on the previous page shows the example when only VL was
outside specifications at the first VL detection and came within specifications
after one VL correction (VLAMP is changed 0.5V/step , VGRID is changed
20V/step).
If V100 or V800 at drum potential sensor calibration is outside specifications or
if VD or VL do not fall within specifications after VGRID or VLAMP are shifted to
the maximum or minimum level, the machine stops VD or VL correction and
uses the previous VGRID and VLAMP values during copying.
In this case, nothing is indicated on the machine but the SC counter is
incremented.
Related SC codes (see FSM troubleshooting section page 6-1 and 6-11):
Code Condition
361 Incomplete drum potential sensor calibration
364 Abnormal VD detection
365 Abnormal VL detection
Development bias is also decided by using VR as follows.
VBB = VR + (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).
STM 2-11 FT6645/6655/6665
1.4 IMAGE DENSITY CONTROL
1.4.1 Toner Density Sensor
Developer consists of carrier particles (iron) and toner particles (resin and
carbon). Inside the development unit, developer passes through a magnetic
field created by coils inside the toner density sensor. When the toner
concentration changes, the voltage output by the sensor changes accordingly.
<Toner Density Sensor Initial Setting>
When new developer with the standard toner concentration (2.0% by weight,
20 g of toner in 1000 g of developer) is installed, developer initial setting must
be performed by using SP mode (
SP Adjustment PAGE 1).
During this setting, the output voltage (VOUT) from the auto gain control
circuit (AGC) on the main control board PCB varies to change the sensor
output voltage from the toner density (TD) sensor. This is done by changing
the gain data, see below.
VOUT = VIN x
Gain Data
256
= 12 x
Gain Data
256
If the gain data is high, VOUT becomes high, and the sensor
output voltage becomes high. As a result, the sensor
characteristic becomes as illustrated by curve A. If the data is
low, VOUT becomes low, and the sensor output voltage becomes
low. As a result, the sensor characteristic shifts as illustrated by
curve C.
1
1
2
3
4
5
0
1 2 3 4
New Developer
C
B
A
V
Toner Weight %
Sensor
Output
(V)
REF
A: VOUT (Gain data) is high.
B: VOUT is within the specification.
C: VOUT (Gain data) is low.
Main PCB
VIN VOUT
AGC
TD
Sensor
VD (12 V)
GND
Sensor
Output
VOUT = VIN x
Gain
256
= 12 x
Gain
256
FT6645/6655/6665 2-12 STM
By selecting the proper gain data, the sensor output is set within the targeted
control level (VREF, VREF = 2.5 0.1 V). Now, the sensor characteristic is
illustrated by curve B and the TD sensor initial setting is completed.
The selected gain data is stored in memory, and VOUT from the auto gain
control circuit stays constant during the toner sensor detection cycle.
<Toner Supply Criteria>
Every copy cycle, toner density in the developer is detected. The sensor
output voltage (VTD) during the detection cycle is compared with the toner
supply level voltage (VREF).
VTD VREF: Add more toner
VTD < VREF: Add little toner
Toner Weight %
Sensor
Output
(V)
1
2
3
4
5
0
1 2 3 4 5
V
VREF
TD
STM 2-13 FT6645/6655/6665
<Toner Supply Clutch on Time>
To stabilize toner concentration, toner supply amount (toner supply clutch on
time) is controlled by referring to VREF and VTD.
The toner supply amount is calculated at every copy. The toner supply
amount is determined by using the following factors.
' VREF VTD
VREF VTD (VTD = VTD of the previous copy cycle)
By referring to these factors, the machine recognizes the difference between
the current toner concentration (VTD) and the target toner concentration
(VREF). The machine also understands how much toner concentration has
changed and predicts how much the toner supply amount will probably
change.
By changing the toner supply amount precisely, toner concentration (image
density) is kept at a constant level.
Since the toner supply clutch on time updating is under fuzzy control, the
relation among VTD, VTD, VREF cannot be expressed by a simple algebraic
formula.
<VREF Correction>
The image on the OPC drum changes due to variation of toner chargeability
(influenced by the environment) even if the toner concentration is constant.
The image density sensor (ID sensor) directly checks the image on the OPC
drum and shifts VREF data (under fuzzy control) to keep the image on the
OPC drum constant, as explained in the next section.
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.
Previous Copy Last Copy Next Copy
VREF
VTD
VTD
FT6645/6655/6665 2-14 STM
1.4.2 Image Density Sensor Detection

VSG and VSP are checked by the ID sensor [A]. The ID sensor is located
underneath the drum cleaning section.
There is no ID sensor pattern in the optics. A pattern image is made on the
OPC drum by the charge corona unit [B] and the erase lamp [C].
VSG is the ID sensor output when checking the erased drum surface.
VSP is the ID sensor output when checking the ID sensor pattern image.
To compensate for any variation in light intensity from the sensor LED, the
reflectivity of both the erased drum surface and the pattern on the drum are
checked.
VSG is detected every time the machine starts copying.
During VSG detection, the development sleeve rollers do not rotate and no
development bias is applied.
VSP is detected after copying is completed if 10 or more copies have been
made since VSP was last detected. Since the transfer belt must be released
when checking VSP, a VSP check cannot be done during continuous copying.
LED
ON
LED
ON
VSG
VSP
4 V
Drum
[A]
[B]
[C]
Bias
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 29 30 31
VSP Detection
VSG
Detection
VSP Detection
1st Series of
Copies (8
copies)
3rd Series of
Copies (17
copies)
2nd Series
of Copies (5
copies)
VSG
Detection
VSG
Detection
VSG
Detection
VSP Detection
STM 2-15 FT6645/6655/6665
1.4.2.a ID Sensor Bias

While developing the ID sensor pattern, ID sensor bias is applied. ID sensor
bias is determined during process control data initial setting as follows:
1. Apply charge while grid voltage is 700 V to create the ID sensor pattern.
2. Check the drum potential (VP) of the ID sensor pattern.
3. Adjust the ID sensor bias (VIDB) so that it satisfies the following formula.
VIDB = VP (300) (V)
= VP + 300 (V)
4. Change the bias to the calculated VIDB and detect VSP. VSG (detected
during VSG adjustment sequence in the process control data initial
setting) and VSP are used to determine VREF data at process control data
initial setting. VIDB is not changed until the next process control data
initial setting is done.
<VREF correction timing>
After the series of copies is completed in the case that 10 or more copies
have been made, VREF is updated by referring to the previous VREF (VREF),
VSG, VSP and the current TD sensor output (VTD).
Since this VREF data updating is under fuzzy control, the relationship among
VREF, VREF, VSG, VSP and VTD cannot be expressed by a simple algebraic
formula.
VREF is updated not only in the case above, but also during developer initial
setting and during process control data initial setting.
700 V
Bias
2 1
3
4
FT6645/6655/6665 2-16 STM
1.4.3 Sensor Abnormal Conditions
a. ID sensor (VSG,VSP) abnormal
Whenever VSG falls under 2.5 V or VSP rises over 2.5 V, the CPU fixes the
VREF data and toner concentration is controlled only by using TD sensor
output. This is the detect mode of toner supply.
VSG and VSP are still detected as usual during abnormal conditions and if
output returns to normal levels (VSG 2.5 V, VSP 2.5 V), the CPU returns
the toner concentration control to normal mode.
b. TD sensor (VTD) abnormal
Whenever VTD rises over 4.0 V or VTD falls under 0.5 V, the CPU shifts the
toner supply to the fixed supply mode. In this condition, the CPU never stops
the toner supply. The fixed toner supply amount can be changed in four steps
(4%, 7%, 11%, 14%) by using SP mode. The default fixed toner supply
amount is 4%.
VTD is still detected as usual during the abnormal condition and if its output
returns to a normal level, the CPU returns the toner concentration control to
normal mode.
c. Drum Potential Sensor abnormal
Whenever V100 rises over 0.7 V or V100 falls under 0.1 V or whenever V800
rises over 4.2 V or V800 falls under 2.7 V, the CPU also shifts the toner
supply to the fixed supply mode, as for a TD sensor (VTD) abnormal
condition.
For following SC codes, no code is indicated on the op panel but the SC
counter is incremented.
Related SC codes. (See FSM troubleshooting section pages 6-1 and 6-8 thru
6-11):
Code Condition
351 Abnormal VSG Detection (VSG > 4.2 V)
352 Incomplete TD Sensor Initial Setting
353 Abnormal VSP Detection (VSP > 2.5 V)
354 Abnormal VSG Detection (VSG 2.5 V)
355 Abnormal VTD Detection (VTD > 4 V)
356 Abnormal VTD Detection (VTD < 0.5 V)
357 Abnormal VSP Detection (VSP/VSG 25%)
358 Abnormal VSP/VSG Detection (VSP/VSG < 2.5%)
361 Incomplete Drum Potential Sensor Calibration
Rev. 4/15/94
STM 2-17 FT6645/6655/6665
2. DRUM UNIT
2.1 OVERVIEW
The drum unit consists of the components as shown in the above illustration.
An organic photoconductor drum (diameter: 100 mm) is used for this model.
3
7/8
6
4
5
12
9
2
14
1
13
15
16
10
11
1. OPC Drum
2. OPC Drum Protective Shutter
3. Erase Lamp
4. Drum Potential Sensor
5. Pre-transfer Lamp
6. Pick-off Pawl
7. Image Density Sensor
8. Drum Thermistor
9. Cleaning Brush
10. Toner Collection Coil
11. Cleaning Blade
12. Ozone Filter
13. Cleaning Filter
14. Charge Power Pack
15. Quenching Lamp
16. Main Charge Corona Unit
FT6645/6655/6665 2-18 STM
2.2 OPC DRUM CHARACTERISTICS
An OPC has the characteristics of:
1. Being able to accept a high negative electrical charge in the dark. (The
electrical resistance of a photoconductor is high in the absence of light.)
2. Dissipating the electrical charge when exposed to light. (Exposure to light
greatly increases the conductivity of a photoconductor.)
3. Dissipating an amount of charge in direct proportion to the intensity of the
light. That is, where stronger light is directed to the photoconductor
surface, a smaller voltage remains on the OPC.
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.
STM 2-19 FT6645/6655/6665
2.3 DRUM CHARGE
2.3.1 Overview
This copier uses a double corona wire scorotron system for drum charge.
Two corona wires are required to give sufficient negative charge on the drum
surface because of a rather high drum speed (330 mm/sec.) A095/A096 and
(430mm/sec.) A097. The stainless steel grid plate makes the corona charge
uniform and controls the amount of negative charge on the drum surface by
applying the negative grid bias voltage.
The charge power pack [A] gives a constant corona current to the corona
wires (-1100 A) 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.
Rev. 9/94
[A]
FT6645/6655/6665 2-20 STM
2.3.2 Air Flow Around the Drum
The exhaust fan [A] located above the fusing unit provides an air flow to the
charge corona unit to prevent uneven built-up of negative ions that can cause
an uneven charge of the drum surface as shown.
An ozone filter [B] absorbs the ozone (O3) around the drum.
The exhaust fan rotates slowly during stand-by and rotates quickly during
copying to keep the temperature inside the machine constant.
[A]
[B]
STM 2-21 FT6645/6655/6665
2.3.3 Charge Wire Cleaning Mechanism
The flow of air around the charge corona wire may deposit toner particles on
the corona wires. These particles may interfere with charging and cause low
density bands on copies.
The wire cleaner pads [A] automatically clean the wires to prevent such a
problem.
The wire cleaner is driven by a dc motor [B]. Normally the wire cleaner [C] is
located at the front end position (home position). After 5000 or more copies
are made and fusing temperature is less than 100C after the main switch is
turned on, the wire cleaner motor turns on to bring the wire cleaner to the
rear end and then back to the home position.
When the wire cleaner moves from the rear to the home position (black arrow
in the illustration), the wire cleaner pads clean the wires.
There are no home position and return position sensors. The CPU monitors
the input voltage (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.
[A]
[A]
[B]
[C]
[C]
FT6645/6655/6665 2-22 STM
2.4 ERASE
2.4.1 Overview
LE: Lead edge erase margin 3.5 2.5 mm
SE: Side erase margin total of both sides 3 mm or less
Lo: Original width
Lc: Charged width of drum
EL: Lead edge erase
Es: Side erase
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 LEDs turn on according to the customers designation.
SE
LC
LO ES
LE
EL
STM 2-23 FT6645/6655/6665
2.4.2 Lead Edge and Trail Edge Erase
The entire line of LEDs turns on when the main motor turns on. They stay on
until the erase margin slightly overlaps the lead edge of the original image on
the drum (lead edge erase margin). It prevents the shadow of the original
lead edge from appearing on the copy paper. This lead erase margin is also
necessary for the lead edge of the copy paper to separate from the hot roller.
The width of the lead edge erase margin can be adjusted by SP mode
( SP Adjustment mode: PAGE 3).
When the scanner reaches the return position, the charge corona, the grid
bias, and the exposure lamp turn off. However, the charged area on the drum
surface is a little longer than the actual original length in order to have the
entire latent image of the original.
The entire line of LEDs turn on when the trail edge of the latent image has
passed under the erase lamp unit. This prevents developing unnecessary
parts of the drum surface, reducing toner consumption and drum cleaning
load.
The LEDs stay on to erase the lead edge of the latent image in the next copy
cycle. After the final copy, the erase lamps turn off at the same time as the
main motor.
2.4.3 Side Erase
Based on the combination of copy paper size and the reproduction ratio data,
the LEDs turn on in blocks. This prevents the shadow of the original side
edge and unexposed front and rear sides of the drum surface in reduction
mode from being developed. This reduces toner consumption and drum
cleaning load.
In the DJF mode, the horizontal original standard position on the exposure
glass is 5 mm away from the rear scale.
In the RDH mode, the horizontal center of the original is aligned with the
center of the exposure glass.
In the platen cover mode, the horizontal original standard position on the
exposure glass is the left rear scale edge.
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
LEDs on in DJF and RDH modes.
1
FT6645/6655/6665 2-24 STM
2.5 CLEANING
2.5.1 Overview
This copier uses the counter blade system for drum cleaning.
The blade [A] is angled against drum rotation. This counter blade system has
the following advantages:
Less wearing of the cleaning blade edge.
High cleaning efficiency.
Due to the high efficiency of this cleaning system, a pre-cleaning corona and
cleaning bias system are not used for this copier.
The cleaning brush [B] is used to support the cleaning blade.
The brush collects toner from the drum surface and the cleaning blade
scapes off any remaining toner and drops it into the cleaning brush. Toner on
the cleaning brush is scraped off by the mylar [C] and falls to the toner
collection coil [D]. Toner is transported to the toner collection bottle by the
toner collection coil.
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.
4 mm
[A]
[C]
[B]
[D]
STM 2-25 FT6645/6655/6665
2.5.2 Drive Mechanism
The drive force from the main motor is transmitted to the cleaning unit drive
gear via the timing belt [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].
[A]
[B]
[C]
[D]
[E]
FT6645/6655/6665 2-26 STM
2.5.3 Cleaning Blade Pressure Mechanism and Side-to-Side Movement
The spring [A] always pushes the cleaning blade against the OPC drum. The
cleaning blade pressure can be manually released by pushing up the release
lever [B]. To prevent cleaning blade deformation during the transportation,
the release lever is locked in the pressure release (upper) position.
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.
[A]
[C]
[B]
[D]
STM 2-27 FT6645/6655/6665
2.5.4 Toner Collection Mechanism
Toner collected by the cleaning unit is transported to the toner collection
bottle [A] through the toner collection tubes. Three helical coils are used for
toner transport.
One coil [B] is driven by the main motor via drive belts, the second [H] is
driven by the cleaning brush and the third coil [C] is driven by an independent
toner collection drive motor [D].
The actuator disk [E] on the toner collection drive motor monitors the proper
rotation of the toner collection coil [C] to prevent the coil from being damaged
by toner clogged in the collection tube. The main PCB monitors the sensor
output and increases the motor speed if the sensor monitors that the toner
collection motor rotates at a speed lower than normal. Also, the CPU will
display an SC 342 if no signal changes (ON OFF) are detected for more
than 2.55 seconds while the toner collection motor is turning.
When the toner collection bottle [A] becomes full, the toner pressure in the
bottle increases and presses the gear [F] against the toner overflow switch
[G]. After the toner overflow switch is activated, finishing of the copy job, or
up to 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).
Rev. 12/93
[A]
[E]
[B]
[F]
[C]
[G]
[D]
[H]
FT6645/6655/6665 2-28 STM

2.5.5 Pick-off mechanism
The pick-off pawls are always in contact with the drum surface with weak
spring pressure. They move side to side during the copy cycle. This
movement is made via a shaft [A] and an eccentric cam [B].
2.5.6 Pre-Transfer Lamp (PTL)
After the latent image is developed but before the image is transferred to the
copy paper, the drum surface is illuminated by the pre-transfer lamp [C]. This
illumination reduces the negative potential on the drum surface. This
prevents toner particles from being re-attracted to the negatively charged
drum during the paper separation process. It also makes transfer and paper
separation easier.
The Pre-Transfer lamp consists of a line of LEDs extending across the full
width of the drum.
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.
Rev. 10/94
[D]
[B]
[A]
[C]
STM 2-29 FT6645/6655/6665
2.6 QUENCHING
In preparation for the next copy cycle, light from the quenching lamp (QL) [A]
neutralizes any negative charge remaining on the drum.
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.
[A]
Rev. 10/94
FT6645/6655/6665 2-30 STM
3. OPTICS
3.1 OVERVIEW
The optics unit reflects an image of the original on the exposure glass onto
the OPC drum. This forms a latent electrical image of the original.
To increase the copy speed from 55cpm to 65 cpm, not only the paper
transport speed but also the copy process speed (scanner motor speed
A095/A096: 330mm/sec., A097: 430mm/sec.) is increased. To compensate
for this, stronger exposure light is required. Therefore, the wattage of the
exposure lamp is changed.
On these models a halogen lamp is used for the exposure lamp [A].
(A095/A096: 85V, 200 W; A097: 85V, 225W). The lamp surface is frosted to
ensure even exposure.
Six mirrors are used to make the optics unit smaller and obtain the wide
reproduction ratio range (50 ~ 200%).
The lens [B] is driven by two stepping motors for (1) vertical direction (parallel
to the paper feed direction) and (2) horizontal direction movements.
To correct focal length change in reduction and enlargement modes, the third
scanner unit [C] (4th and 5th mirrors) position is changed by a stepping motor.
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.
Rev. 7/94
[A]
[B]
[C]
[D]
[E]
STM 2-31 FT6645/6655/6665
3.2 SCANNER DRIVE
A dc servo motor is used as the scanner drive motor [A]. Scanner drive
speed is 330 mm/sec. (A095/A096 copiers) and 430mm/sec. (A097 copier)
during forward scanning, and 1950 mm/sec. when the scanner returns to
home.
The scanner drive motor drives the first [B] and second scanners [C] using
two scanner drive wires via the timing belt [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.
[A]
[D]
[B]
[E]
[C]
Rev. 7/94
FT6645/6655/6665 2-32 STM
3.3 VERTICAL LENS DRIVE
The lens vertical drive motor [A] changes the lens vertical position in
accordance with the selected reproduction ratio.
A stepping motor (approx. 0.095 mm/step) and drive belt are used to drive
the lens. The maximum lens vertical shift distance is 290 mm (from the
position at 50% to the position at 200%).
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.
[A]
[B]
Rev. 4/15/94
(Enlarge HP)
(Reduce HP)
(Enlarge Enlarge)
(Reduce Reduce)
(Enlarge Reduce)
(Reduce Enlarge)
Reduce Enlarge
HP (100%)
steps 30 30 30 30
STM 2-33 FT6645/6655/6665
3.4 HORIZONTAL LENS DRIVE
The original horizontal position on the exposure glass varies depending on
the mode (such as platen, DJF and RDH modes) for easy original handling.
However, the center is the standard position for paper feed.
Therefore, the lens horizontal position has to be changed according to paper
size, reproduction ratio, original feed modes and the edit modes (centering,
margin adjust, etc.).
A stepping motor (approx. 0.07 mm/step) is used to drive the lens through the
lens drive belt.
The lens horizontal home position sensor [A] is used to detect the lens
horizontal position for A4/LT sideways, in full size and platen mode.
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). 1
[A]
Enlarge
Reduce
HP
40
40
40
steps
FT6645/6655/6665 2-34 STM
3.5 HORIZONTAL LENS POSITIONING
3.5.1 For Original Position

There are three standard original positions for the platen, DJF and RDH
modes.
In platen mode, the original is aligned with both the rear [A] and the left [B]
original scales (rear left corner [C] is the standard position).
In RDH mode, the original position is the center of the left scale [B].
In DJF mode, the original position is 5 mm to front of the platen mode original
position to maintain the original transport path (5 mm from the rear scale).
The above figure shows the lens horizontal positions for each original mode
when identical size paper is used.
3.5.2 For Paper Size

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.
[A]
[B]
[C]
2.5
143.5
5
100%
Copy Paper
Lens Position
Horizontal
Platen
DJF
RDH
(Center)
100%
Copy Paper
Original Rear Edge
Horizontal
Lens Position
STM 2-35 FT6645/6655/6665
3.5.3 For Reproduction Ratio
Original Rear Edge

When the reproduction ratio is changed, the vertical position of the lens is
changed. At the same time, the total focal length has to be changed to adjust
the image focusing. 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%.
Original Copy Paper
3rd Scanner Position
100%
100% 50%
50%
200%
200%
Rev. 4/15/94
FT6645/6655/6665 2-36 STM
3.6 3RD SCANNER DRIVE
To compensate the focus for reproduction and lens position changes, the 3rd
scanner (4th and 5th mirrors) position is changed.
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.
[A]
[B]
(Reduce/Enlarge HP)
(Reduce/Enlarge Reduce/Enlarge)
(Initialize)
(Reduce/Enlarge Enlarge/Reduce)
(Reduce/Enlarge Reduce/Enlarge)
40 steps 40 steps
STM 2-37 FT6645/6655/6665
3.7 OPTICS CONTROL CIRCUIT

The optic control board communicates with the main board through a data
bus. The optics control board monitors all the sensor signals, encoder output,
thermistor output and controls all motors in the optics.
At the programmed time, the main CPU sends a scanner start signal to the
optics control CPU.
The CPU generates a pulse-width modulation (PWM) signal. The PWM
signal goes to a driver circuit, which sends drive pulses to the scanner drive
motor.
An encoder in the scanner drive motor generates pulse signals.
A speed/direction control circuit monitors the scanner speed and the direction
of the signals, and uses this data to regulate the motor speed.
The home position sensor monitors the position of the scanner. When the
main switch is turned on, the main CPU confirms the position of the scanner
by moving the scanner out of the home position and back again. 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.
M
M
M
M
M
E
Optics Control Board Main
Control
Board
AC Drive
Board
Sensors
Optic Thermistor
Exposure Lamp
Encoder
Scanner Drive
Horizontal Lens
Drive
Vertical Lens
Drive
3rd Scanner
Drive
Optic Cooling
Fan
Data
Bus
Optics Control
CPU Main
CPU
FT6645/6655/6665 2-38 STM
3.8 AUTOMATIC IMAGE DENSITY CONTROL SYSTEM (ADS)

In ADS mode the original background density is sensed by the ADS sensor
[A] and the main CPU determines an appropriate development bias voltage
for the original to prevent dirty backgrounds from appearing on copies.
The ADS sensor board is mounted on the rear side of the optics side plate.
The sensor board is covered by the sensor housing cover which has a small
hole to direct the reflected light from the original to the ADS sensor.
The ADS sensor standard voltage is adjusted to 2.7 V when process control
data initial setting is performed. The exposure lamp turns on with ID level 4 at
the home position and the light reflected by the 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.
[A]
[B]
STM 2-39 FT6645/6655/6665

In the full size mode, the CPU samples the ADS sensor output when the
scanner scans the original from 9.7 mm to 18 mm [B] from the left scale
edge. The CPU takes the maximum ADS sensor output during this sampling
period and compares it with the stored 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.
Rev. 12/93
90 mm
20 mm
A B
Peak hold
[V]
ADS
Sensor
Output
ADS
Original
Voltage
A =
9.7
M
(mm)
M = 1.0 (m = 50 ~ 100)
M =
m
100
(m = 101 ~ 200)
B =
8.25
m
x 100 (mm)
m: reproduction ratio
(50 ~ 200)
FT6645/6655/6665 2-40 STM
3.9 MANUAL IMAGE DENSITY CONTROL
When the image density is set manually, the voltage applied to the exposure
lamp changes as shown in the table below.

VLAMP: Exposure lamp voltage at ID level 4.
This value is determined at process control data initial setting.
VBB: Development bias (negative) voltage at ID level 4.
This value is determined at process control data initial setting.
Lighter Darker
VBB
VBB 60
VBB 90
VLAMP 5.5
VLAMP 3.5
VLAMP 1.5
VLAMP
VLAMP +0.5
VLAMP +3.0
VLAMP +4.5
Dev. Bias
Voltage VBM
(negative)
Exposure
Lamp Voltage
Manual ID
Position
5 3 7 6 4 2 1
Rev. 4/15/94
STM 2-41 FT6645/6655/6665
3.10 UNEVEN LIGHT INTENSITY CORRECTION

The entire exposure lamp surface is frosted to ensure even exposure.
To compensate for reduced light at the edge of the lens, a shading plate is
placed in front of the lens. 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.
[D]
[D]
[D]
[A] [B] [C]
exposure
intensity
illumination
distribution
original
[A] [B] [C]
Shading plate
FT6645/6655/6665 2-42 STM
3.11 ORIGINAL SIZE DETECTION IN PLATEN MODE
There are three reflective sensors (APS sensors) in the optics cavity for the
original size detection. Original width Sensor [A] is used for sensing the
original width and Original Length Sensor-1 [B] and Original Length Sensor-2
[C] sense the original length.
Inside each APS sensor, there is an LED [D] and three photoelectric devices
[E]. The light generated by the LED is broken up in three beams and each
beam scans a different point of the exposure glass. If the original or platen
cover is present over the scanning point, the beam is reflected and each
reflected beam exposes a photoelectric device and activates it.
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.
[E]
[D]
[A]
[C]
[B]
STM 2-43 FT6645/6655/6665

Width Sensor Length Sensor 2 Length Sensor 1
9 8 7 6* 5 4* X2* 3 2 1 X1*
11 x 17 O O O 1 O 1 O O O O O
81/2 x 14 1 O O 1 O 1 O O O 1 O
81/2 x 11 1 O O 1 O 1 O 1 1 1 O
11 x 81/2 O O O 1 O 1 O 1 1 1 O
51/2 x 81/2 1 1 1 1 O 1 O 1 1 1 O
81/2 x 51/2 1 O O 1 1 1 O 1 1 1 O
NOTE: -1: Active -0: Inactive
*Sensors #4 and #6 are not used for LT/DLT version machines.
Their values are always 1.
Sensors #X2 and X1 are not used for LT/DLT version machines.
Their values are always .
The check is done when the platen position sensor [A] turns on. This is when
the platen is positioned about 15 cm above the exposure glass. At this time,
only the sensor(s) located underneath the original receive the reflected light
and are on. Other sensor(s) are off. Through the on/off data of the nine
(seven for LT/DLT version machine) sensors, the main CPU can recognize
the original size.
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 machines productivity.
Rev. 4/15/94
[A]
FT6645/6655/6665 2-44 STM
4. DEVELOPMENT
4.1 OVERVIEW
This copier uses a double roller (diameter 20 mm each) development (DRD)
system. This system differs from single roller development systems in that (1)
it develops the image in a narrower area, (2) it develops the image twice, and
(3) the relative speed of each development roller against the drum is
reduced. Also, finer toner (Approx. 9 m) and developer (Approx. 70 m) are
used. Both the DRD system and new supplies improve the image quality,
especially of thin horizontal lines, the trailing edges of the half-tone areas,
and black cross points.
The paddle roller [A] picks up developer in its paddles and transports it to the
upper development roller [B]. Internal permanent magnets in the
development rollers attract the developer to the development roller sleeve.
The upper development roller carries the developer past the doctor blade [C].
The doctor blade trims the developer to the desired thickness and creates
backspill to the cross mixing mechanism.
The development rollers continues to turn, carrying the developer to the OPC
drum [D]. When the developer brush contacts the drum surface, the
negatively charged areas of the drum surface attract and hold the positively
charged toner. In this way, the latent image is developed.
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].
[A]
[D]
[B]
[C]
STM 2-45 FT6645/6655/6665
4.2 DRIVE MECHANISM
The gears of the development unit are driven by the development drive gear
[A] when the development motor [B] (dc servomotor) turns.
The gears of the toner hopper are driven by the toner supply roller drive gear
[C] when the toner supply clutch [D] activates.
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.
[A]
[D]
[B]
[E]
[C]
FT6645/6655/6665 2-46 STM
4.3 CROSSMIXING
This copier uses a standard cross-mixing mechanism to keep the toner and
developer evenly mixed. It also helps agitate the developer to prevent
developer clumps from forming and helps create the triboelectric charge.
The developer on the turning development rollers [A] is split into two parts by
the doctor blade [B]. The part that stays on the development rollers forms the
magnetic brush and develops the latent image on the drum. The part that is
trimmed off by the doctor blade goes to the backspill plate [C].
As the developer slides down the backspill plate to the agitator [D], the mixing
vanes [E] move it slightly toward the rear of the unit. Part of the developer
falls into the auger inlet and is transported to the front of the unit by the auger
[F].
The agitator moves the developer slightly to the front as it turns, so the
developer stays level in the development unit.
[B]
[A]
[C]
[D]
[E]
[F]
[A]
[B]
[C]
[D]
[E]
[F]
STM 2-47 FT6645/6655/6665
4.4 DEVELOPMENT BIAS
4.4.1 Overview

The high voltage control board [A] applies the negative development bias to
the lower sleeve roller through the receptacle [B] and the lower sleeve roller
shaft [C]. Then the bias is applied to the upper sleeve roller through the rear
sleeve roller holder made of conductive resin.
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.
[A]
[B]
[C]
FT6645/6655/6665 2-48 STM
4.4.2 Bias Control In Copy Cycle
The bias output is determined by five factors.
The total bias is described as;
ADS Mode: VB = VBB + VBU + VBMG + VBA
Manual ID Mode: VB = VBB + VBU + VBMG+ VBM
VB: Total bias
VBB: Base bias
VBA: ADS Compensation
VBU: User Tool mode ID Selection Compensation
VBMG: Magnification Compensation
VBM: Manual ID Selection Compensation
1) Base Bias (VBB)

As explained in the process control section, the base bias for development is
determined by the residual voltage (VR) measured in process control data
initial setting.
VBB = VR + (220)
2) ADS Compensation (VBA)

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: VADS) as follows:
VBA = 234 x (VADS 2.3)
NOTE: VBA has a limited range from 0 V to 300 V.
[V]
VD
VL
Drum
Potential
VR
Original Density
VBB
Light Dark
1 2 2.7
VBA
(negative)
300
0
1.02 V
1 2 2.3
Dark VADS (V) Light
STM 2-49 FT6645/6655/6665
3) Manual ID Selection Position Compensation (VBM)
According to the manual ID selection position, the bias is compensated as
follows:

VLAMP: Exposure lamp voltage at ID level 4. This value is determined at
process control data initial setting.
4) User Tool Mode ID Selection Compensation (VBU)
In the User Tool mode, the image density level can be selected from five
steps. The VBU is determined by the User Tool ID position setting as follows:

5 4 3 2 1
VBU
(negative)
0
+30
+60
60
30
User Tool
ID Position
Lighter Darker
Lighter Darker
VBB
VBB 60
VBB 90
VLAMP 5.5
VLAMP 3.5
VLAMP 1.5
VLAMP
VLAMP +0.5
VLAMP +3.0
VLAMP +4.5
Dev. Bias
Voltage VBM
(negative)
Exposure
Lamp Voltage
Manual ID
Position
5 3 7 6 4 2 1
Rev. 4/15/94
FT6645/6655/6665 2-50 STM
5) Magnification Compensation (VBMG)
VBMG is determined by the selected reproduction ratio as follows:

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.
Dev. Bias
Voltage
(negative)
100
60
40
20
30
50%
123%
141% 160%
142%
122%
116%
161%
115% 80% 61%
81%
62%
STM 2-51 FT6645/6655/6665
4.4.4 ID Sensor Pattern Bias
While developing the ID sensor pattern, ID sensor bias is applied. ID sensor
bias is determined during process control data initial setting as follows:
1. Apply charge while grid voltage is -700V to create the ID sensor pattern.
2. Check the drum potential (VP) of the ID sensor pattern.
3. Adjust the ID sensor bias (VIDB) so that it satisfies the following formula.
VIDB = VP (300)
= VP + 300 (V)
4. Change the bias to the calculated VIDB and detect VSP. VSG (detected
during VSG adjustment sequence in the process control data initial
setting) and VSP are used to determine VREF data at process control data
initial setting. VIDB is not changed until the next process control data
initial setting is done.
700 V
Bias
2
1
3
4
FT6645/6655/6665 2-52 STM
4.5 TONER SUPPLY
4.5.1 Toner Supply Mechanism
When the toner supply clutch [A] turns on, the agitator [B] moves the toner
from front to rear and sends the toner to the toner supply roller.
The toner supply magnetic clutch [A] located in the development motor
assembly [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.
[A]
[D]
[C]
[E]
[F]
[F]
[B]
[B]
STM 2-53 FT6645/6655/6665
4.5.1a Toner Density Detection
Developer consists of carrier particles (iron) and toner particles (resin and
carbon). Toner concentration is measured by the toner density sensor. Inside
the developer unit, developer passes through a magnetic field created by
coils inside the toner density sensor (A). When the toner concentration falls,
the voltage output by the toner density sensor changes accordingly and the
toner supply clutch is activated.
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.
[A]
FT6645/6655/6665 2-54 STM
4.5.2 Toner End Detection
The toner end sensor [A] detects if sufficient toner remains in the toner
hopper. The toner end sensor monitors the toner end condition each time the
toner supply clutch turns on. When there is little toner inside the toner hopper
and toner pressure on the toner end sensor becomes low, the toner end
sensor outputs a pulse signal for each copy cycle (one detection pulse per
copy).
The toner near end indication is displayed on the LCD after receiving the
pulse signal 150 times (If no pulse signal is output twice continually, the pulse
count is canceled).
Fifty copies are allowed after entering toner near end condition. After fifty
copies are made in the toner near end condition, the machine enters the
toner end condition and copying is prohibited.
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.
[A]
STM 2-55 FT6645/6655/6665
4.5.3 Toner Supply Control
By using an SP mode ( Adjustment mode: PAGE 7), the following 3 kinds
of toner supply controls can be selected.
Auto Process Control Mode
Detect Mode
Fixed Mode
1) Auto Process Control Mode
Originals have various image proportions and image densities. For the
best toner supply control, it is necessary to link the amount of toner
supplied on each copy cycle to the amount of toner consumed for each
copy.
Fuzzy control is used in this model to provide this kind of toner supply
control.
Fuzzy Control 1
According to data of the TD sensor, the CPU checks the following at
every copy cycle:
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.
1
Rev. 4/15/94
FT6645/6655/6665 2-56 STM
Fuzzy Control 2
The image on the OPC drum changes due to variations in toner
chargeability (influenced by the environment) even if toner
concentration is constant.
The ID sensor directly checks the image on the OPC drum and shifts
the VREF data under fuzzy control to keep the image on the OPC drum
constant.
NOTE: The toner supply amount is changed at every copy cycle.
The target toner density sensor output is updated under the
following conditions:
1. During toner density sensor initial setting
2. During process control data initial setting
3. After the copy job is completed when 10 or more copies have
been made since the last update. (VSP check)
(Refer to section 2.1.4 "Image Density Control" for details.)
2) Detect Mode
In this mode, only the TD sensor is used to control the toner
concentration (VREF data is fixed). The machine performs only fuzzy
control 1.
In ID sensor abnormal condition, the machine automatically enter this
mode.
3) Fixed Mode
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.
1
Rev. 4/15/94
STM 2-57 FT6645/6655/6665
4.5.4 Bottle Drive Mechanism
For easy access, the toner bottle is just inside the front cover. The bottle is
positioned horizontally.
The bottle drive mechanism transports toner from the bottle to the toner
hopper [A]. A worm gear [B] on the bottle drive motor drives this mechanism.
The toner bottle has a spiral groove [C] that helps move the toner to the toner
hopper.
To prevent toner from scattering when the toner bottle is removed from the
holder, toner shutter [D] which covers the hole [E] is installed on the toner
bottle.
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.
[A]
[C]
[B]
[D]
[E]
FT6645/6655/6665 2-58 STM
5. IMAGE TRANSFER
5.1 PRE-TRANSFER LAMP
The pre-transfer lamp [A] located in the drum unit is used to prevent
incomplete toner transfer.
After the latent image is developed but before the image is transferred to the
copy paper, the drum surface is illuminated by the pre-transfer lamp. This
illumination reduces the negative potential on the drum surface charged by
the main charge corona and partially discharged by the exposure. 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.
[A]
STM 2-59 FT6645/6655/6665
5.2 IMAGE TRANSFER AND PAPER SEPARATION
OVERVIEW
This model uses a unique transfer belt unit instead of the transfer and
separation corona unit. The transfer belt unit consists of the following parts:
[A] Transfer belt
A belt (length: 321 mm) with high electrical resistance which holds a high
negative electrical potential and attracts the toner on the OPC drum onto
the paper. Also the electrical potential attracts the paper itself and helps
paper separation from the OPC drum.
[B] Transfer bias roller
Applies transfer voltage to the transfer belt.
[C] Transfer belt lift lever (driven by a solenoid)
Lifts the transfer belt to contact the transfer belt with the OPC drum.
[D] Transfer power pack
Generates the constant transfer current.
[E] Transfer belt cleaning blade
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.
[F]
[E] [C]
[D]
[A] [B]
FT6645/6655/6665 2-60 STM
5.3 IMAGE TRANSFER AND PAPER SEPARATION
MECHANISM
The registration rollers [A] start
feeding the paper [B] to the gap
between the OPC drum [C] and
the transfer belt [D] in proper
timing.
Immediately when the leading
edge of the paper reaches the gap
between the transfer belt and
the OPC drum, the transfer belt
lift lever [E] raises the transfer
belt to contact the OPC drum.
The lift lever is driven by a
solenoid
Then a negative transfer bias
1.5 K ~ 2.0 KV is
applied to the transfer bias roller
[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.
[A]
[B]
[C]
[D]
[A]
[E]
[F]
[G]
800 V
1.3 K~ 1.8KV
1.5 K ~ 2.0 KV
STM 2-61 FT6645/6655/6665
After the image transfer is
completed, the charge on the
transfer belt holds the paper to
the transfer belt.
After separating the paper from
the transfer belt, the transfer belt
is discharged to ground by the
discharge plate [A].

The transfer power pack [B] inside
the transfer belt unit monitors
the current fed back from the
discharge plate to adjust the
transfer current. This way,
the current stays constant even if
the paper, environmental
conditions, and the transfer belt
surface resistance are changed.
Rev. 4/15/94
[A]
[B]
[A]
[B]
FT6645/6655/6665 2-62 STM
5.4 TRANSFER BELT UNIT LIFT MECHANISM
The transfer belt lift solenoid [A] located inside the transfer belt unit turns on
to raise the transfer belt to contact the OPC drum at the appropriate timing.
The front lever [B] and the rear lever [C] are connected to the solenoid by
links [D] and push up the stays [E] when the solenoid turns on.
The support spring [F] helps the solenoid to raise the transfer belt.
The solenoid turns off after the copy job is finished.
The transfer belt must be released from the OPC drum for the following
reasons:
1. To prevent the ID sensor pattern on the OPC drum from being rubbed by
the transfer belt because the transfer belt is located between the
development unit and the ID sensor.
2. To decrease the load to the transfer belt cleaning blade. It is better to
have toner from non-image areas removed by the drums cleaning
system than by the transfer belts cleaning system (for example Vd, VL,
and ID patterns ).
3. To prevent change of OPC drum characteristics by the influence of
additives inside the rubber belt.
[B]
[A]
[F]
[E]
[E]
[D]
[C]
STM 2-63 FT6645/6655/6665
5.5 PAPER TRANSPORTATION AND BELT DRIVE
MECHANISM
The transfer belt is driven by the main drive motor [A] through belt and gears.
Since the transfer belt electrically attracts the paper [B], the transport fan is
not required.
The charge on the transfer belt is discharged by the discharge plate to
reduce paper attraction and paper is separated by the paper stiffness above
the transfer belt drive roller [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.
[F]
[C]
[A]
[B]
[E]
[D]
[E]
[D]
[F]
FT6645/6655/6665 2-64 STM
5.6 TRANSFER BELT CLEANING MECHANISM
Some toner may adhere to transfer belt when paper jams occur, or when the
by-pass feed table side fences are set in the wrong position causing the
erase lamp to miss some toner. The adhered toner must be removed to
prevent the rear side of the copy paper from being stained.
The cleaning blade [A] scrapes off any toner remaining on the transfer belt.
A counter blade system is used for the transfer belt cleaning. The surface of
the transfer belt is coated to make it smooth and so prevent the cleaning
blade from being flipped by the transfer belt.
The lever [B] on the front end of the cleaning blade releases the cleaning
blade when the transfer belt unit is lowered and the lever is pushed by the
transfer belt unit support prop. (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.
[D]
[A]
[B]
[C]
STM 2-65 FT6645/6655/6665
5.7 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.
Rev. 4/15/94
[A]
[B]
FT6645/6655/6665 2-66 STM
6. PAPER FEED
6.1 OVERVIEW
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
1st 550 sheets tray 500 + 500 sheets tandem feed tray
2nd 550 sheets universal tray 550 sheets universal tray
3rd 550 sheets tray 1500 sheets built-in LCT
Paper can also be fed using the by-pass feed table which has an
independent feed mechanism. The by-pass feed table can hold 50 sheets of
paper.
All feed stations use an FRR feed system. Rotation of the pick-up roller [A]
drives the top sheets of paper from each tray to the feed [B] and the
separation [C] rollers. The feed and separation rollers then take over paper
drive. If more than one sheet is fed by the pick-up roller, the separation rollers
rotates in the opposite direction and prevents all but the top sheet from
passing through to the registration rollers.
Rev. 7/94
[A]
[A]
[B]
[B]
[C]
STM 2-67 FT6645/6655/6665
6.2 FRR FEED SYSTEM

This copier uses an FRR paper feed system using three rollers.
6.2.1 Pick-up Roller
The pick-up roller [A] is not in contact with the paper stack before it starts
feeding paper. Shortly after the Start key is pressed, the pick-up roller drops
down and feeds the top sheet between the feed [B] and the separation rollers
[C]. At almost the same time that the papers leading edge arrives at the feed
roller, the pick-up roller lifts off the paper stack so that it does not interfere
with the operation of the feed and separation rollers. The feed and separation
rollers then take over the paper feed process.
6.2.2 Feed and Separation Rollers
There is a one-way bearing inside the feed roller so it can turn only in one
direction. The separation roller is driven in the opposite direction to the feed
roller. 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.
[B]
[A]
[C]
FT6645/6655/6665 2-68 STM

The direction in which the separation roller [A] turns depends on the frictional
forces acting on it. The slip clutch applies a constant clockwise force (F1).
When there is a single sheet of paper being driven between the rollers, the
force of friction between the feed roller [B] and the paper (F2) is greater than
F1. So, the separation roller turns counterclockwise.
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.
[B]
[A]
[B]
[A]
F2
F2 F1
F1
F2
F3
F3 F1
F1
STM 2-69 FT6645/6655/6665
6.3 SLIP CLUTCH MECHANISM
The slip clutch [A] consists of the input hub [B] and the output hub [C] which
is the case of the clutch as well. The magnetic ring [D] and the steel spacers
[E] are fitted onto the input hub. The ferrite ring [F] is fitted into the output
hub. 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.
[E]
[C]
[G]
[F]
[B]
[D]
[A]
FT6645/6655/6665 2-70 STM
6.4 FRR FEED DRIVE MECHANISM
The rotation of the paper feed motor [A] is transmitted to the gear [B] via the
timing belt [C], and then transmitted to the separation roller via the feed
clutch gear [D], gear [E], gear [F] and gear [G].
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].
[A]
[B]
[C]
[K]
[L]
[J]
[D]
[D]
[F]
[G]
[H]
[B]
[E]
[I]
STM 2-71 FT6645/6655/6665

When the paper feed station is selected and the start key is pressed, the feed
clutch [A], separation roller solenoid [B], and the pick-up solenoid [C] turn on
at once.
When the feed clutch [A] activates to rotate the feed roller [D], the feed roller
and the pick-up roller [E] turn together because they are linked by the idle
gear [F].
When the separation roller solenoid [B] turns on, the separation roller [G]
contacts the feed roller [D] then rotates together with the feed roller in spite of
the separation rollers drive in the opposite direction due to the torque limiter
function in the separation roller [G].
When the pick-up solenoid [C] activates, the pick-up roller [E] lowers to make
contact with the top sheet of the paper stack and send it to the feed and
separation rollers.
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.
[A]
[E]
[B]
[F]
[D]
[G]
[I]
[H]
[C]
FT6645/6655/6665 2-72 STM
6.5 SEPARATION ROLLER RELEASE MECHANISM
In this model, the separation roller [A] is normally away from the feed roller
[B]. When the paper feed station is selected and the start key is pressed, the
separation roller solenoid [C] moves the separation roller into contact with the
feed roller as explained in the previous two pages.
This contact/release mechanism has the following three advantages:
1. When the paper feed motor turns on, all separation rollers in each feed
stations rotate. If the separation roller is away from the feed roller, it
reduces the mechanical load to the paper feed motor and drive
mechanism, and also reduces wear of the rubber surface of the
separation roller due to the friction between the separation roller and the
feed roller.
2. After paper feeding is completed, paper sometimes remains in the gap
between the feed roller and the separation roller.
If the feed tray is drawn out in this condition, it is possible for the
remaining paper to be torn.
When the separation roller is away from the feed roller, remaining paper
is released from the gap between the feed and the separation rollers.
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.
Rev. 10/94
[C]
[A]
[B]
STM 2-73 FT6645/6655/6665
6.6 PAPER RETURN MECHANISM
When the paper feed clutch [A] activates and the feed roller drive shaft [B]
rotates, the lever [C] rotates together with the shaft. However, the lever is
immediately stopped by the stopper [D].
When the appropriate quantity of paper has been fed and the paper feed
clutch turns off, the paper feed motor still rotates to turn the separation roller
[E] in the reverse direction. The separation roller, still contacting the feed
roller, turns the feed roller in the reverse direction until the lever hits the
rubber cushion [F].
By this feed roller reverse mechanism, the paper remaining in the gap
between the feed and the separation rollers returns 3mm to the paper feed
tray.
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.
[A]
[D]
[B]
[E]
[C]
[F]
[C]
3 mm
[C]
FT6645/6655/6665 2-74 STM
6.7 PAPER SKEW PREVENTION MECHANISM
In this model, paper corner holders [A] are not used to facilitate paper loading.
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.
[A]
[B]
[B]
STM 2-75 FT6645/6655/6665
6.8 PAPER LIFT MECHANISM
When the tray is set in the machine, the machine detects this condition by
using several detection methods as shown in the table:
Feed station A095 copier A096/A097 copiers
1st Tray set switch Tray set signal through the connector
2nd Paper size switch Paper size switch
3rd Tray set switch LCT set signal through the connector
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].
[A]
[D]
[B]
[E]
[C]
[F]
Rev. 7/94
FT6645/6655/6665 2-76 STM

When the lift motor turns on, the pick-up solenoid [A] activates to lower the
pick-up roller [B]. When the top sheet of paper reaches the proper paper feed
level, the paper pushes up the pick-up roller and the actuator [C] on the
pick-up roller supporter [D] activates (unblocks) the lift sensor [E] to stop the
lift motor. The pick-up solenoid also turns off.
After several paper feeds, the paper level gradually lowers then the lift sensor
is de-activated (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.
Rev. 4/15/94
[A]
[D]
[B]
[E]
[C]
[F]
[G]
[H]
[I]
STM 2-77 FT6645/6655/6665
6.9 PAPER NEAR END / PAPER END DETECTION
A feeler [A] on the lift arm shaft rotates counterclockwise in accordance with
the change of the top paper level. When almost 50 sheets are left in the tray,
the feeler activates the paper near end sensor [B] and informs the copier
CPU of the paper near end condition.
If paper is loaded in the paper tray, the paper end feeler [C] is raised by the
paper stack and the paper end sensor [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.
[A]
[B]
[C]
[D]
[E]
FT6645/6655/6665 2-78 STM
6.10 TANDEM FEED TRAY (A096/A097 COPIERS)
6.10.1 OVERVIEW
500 sheets of paper can be set in each of the left [A] and right trays [B].
Paper is fed from the right tray. When the paper in the right tray runs out, the
paper in the left tray is automatically transported to the right tray. After the
paper is transported to the right tray, paper feeding resumes.
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.
[A]
[B]
[A]
[B]
Rev. 7/94
STM 2-79 FT6645/6655/6665
6.10.2 Fences Drive Mechanism
The side fences [A] of the right tray are normally closed. They open only
when paper in the left tray is transported to the right tray.
The side fences are driven by the side fence drive motor [B] (stepping motor).
When the paper loaded in the left tray is transported to the right tray, the side
fence drive motor turns counterclockwise to open the side fences until the
side fence positioning sensor [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.
[A]
[D]
[A]
[B]
[C]
FT6645/6655/6665 2-80 STM
6.10.3 Rear Fence Drive Mechanism
When the paper end sensor [A] in the left tray detects paper and the paper
end sensor in the right tray detects the paper end condition, the rear fence
drive motor [B] (dc motor) in the left tray rotates counterclockwise to drive the
rear fence [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].
[A]
[B]
[D]
[C]
[E]
STM 2-81 FT6645/6655/6665
6.10.4 Tandem Tray Lock Mechanism
Normally the left (supply) tray lock lever [A] in the right tray [B] fits in the hole
[C] in the left tray [D]. During copying, if there is no paper in the left tray, the
tray lock solenoid [E] turns on to release the tray lock lever so that the left
tray can be separated from the right (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.
Rev. 12/93
[A]
[C]
[E]
[F]
[G]
[D]
[B]
FT6645/6655/6665 2-82 STM
6.11 PAPER SIZE DETECTION
For the first and the third feed trays, the paper size is stored by using the SP
mode ( SP Special Feature PAGE 5).
For the second feed tray (universal tray), the paper size switch [A] detects the
paper size. The paper size switch has five microswitches inside. The paper
size switch is actuated by an actuator plate [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.
4
[A]
[B]
SW Actuate....0
De-actuate....1
Paper size L: Lengthwise
S: Sideways
A4/A3
Version
LT/DLT
version
01111 A3L 11 x 17L
00111 B4L 81/2 x 14L
10011 A4L 81/2 x 11L
01001 A4S 81/2 x 11S
00100 81/2 x 13 51/2 x81/2S
00010 8 x 10S
00001 A5S 8 x 10L
10000 8 x 13L
11000 10 x 14L
11100 11 x 15L
11110 A5L 51/2 x81/2L
1 2 3 4 5
STM 2-83 FT6645/6655/6665
6.12 VERTICAL TRANSPORT MECHANISM
The vertical transport rollers [A] in each feed unit is driven by the paper feed
motor. The vertical transport rollers and the driven vertical transport rollers
[B], on the upper and the lower vertical guide plates, transport the paper from
each feed unit to the registration roller.
The upper [C] and lower [D] vertical transport guides can be opened to
access jammed paper in the vertical transport area.
The lower vertical transport guide separates from the upper guide to gain
wider jam removal space.
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.).
[A]
[B]
[C]
[D]
Rev. 7/94
FT6645/6655/6665 2-84 STM
6.13 TRAY POSITIONING MECHANISM
- Tray Lock Mechanism -
When the feed tray is set in the paper feed unit, the lock lever [A] drops
behind the lock plate [B] on the Accuride support bracket to lock the tray in
the proper position.
- Side-to-side Positioning Mechanism
(1st and 3rd feed tray for A096/A097 copiers)-
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.
[B]
[A]
Rev. 7/94
[D]
[C]
STM 2-85 FT6645/6655/6665

- Side-to-side Positioning Mechanism -
(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.
[A]
[A]
[B]
Rev. 7/94
FT6645/6655/6665 2-86 STM
6.14 BUILT IN LCT
6.14.1 Paper Tray Lift Mechanism

Drive from the reversible LCT motor [A] is transmitted through a worm gear
[B] to the drive pulley shaft [C]. The tray wires [D] are fixed in the slots [E] at
the ends of the tray support rods [F] and [G].
When the LCT motor rotates forward and the drive pulley shaft [C] turns
counterclockwise, the tray support rods and the tray bottom plate [H] move
upward. The tray goes up until the top paper pushes up the pick-up roller and
the lift sensor in the third feed unit is activated.
The paper near end sensor [I] detects the paper near end condition when it is
activated by the actuator [J] on the rear end of the right support rod [G].
To lower the tray bottom plate [H], the LCT motor rotates in reverse and the
drive pulley shaft [C] turns clockwise, the tray support rods and the tray
bottom plate move downward. The tray goes down until the tray down sensor
[K] is activated by the actuator.
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.
Rev. 10/94
[A]
[G]
[B]
[H]
[C]
[I]
[D]
[J]
[E]
[K]
[F]
[E]
[E]
[E]
[L]
STM 2-87 FT6645/6655/6665
6.14.2 Tray Lock Mechanism
When the tray starts moving up, the tray lock lever [A] drops in the hole on
the base plate to engage the stopper [B], locking the tray in position. This
prevents the tray from being pulled out while in the up position.
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.
[A]
[B]
[C]
FT6645/6655/6665 2-88 STM
6.15 BY-PASS FEED TABLE
6.15.1 Feed Mechanism / Paper End Detection
The by-pass feed table uses the FRR feed system. The by-pass feed motor
[A], pick-up solenoid [B], and by-pass feed clutch [C] control paper feeding
from the by-pass feed table.
The by-pass paper end sensor [D] detects if there is paper on the by-pass
feed table.
When there is no paper on the by-pass feed table, the paper end feeler [E]
drops in the cut out [F] of the lower guide plate and the paper end sensor [D]
deactivates. 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.
[D]
[B]
[E]
[F]
[C]
[A]
STM 2-89 FT6645/6655/6665
6.15.2 Table Open/Close Detection
When the by-pass feed table is opened, the by-pass table switch [A] is
activated by part of the feed table [B]. Then the CPU turns on the by-pass
feed indicator on the operation panel.
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.
[A]
[B]
FT6645/6655/6665 2-90 STM
6.15.3 Paper Size Detection
The paper width detection is necessary to decide the lens horizontal position
because the standard position of the optics (rear left corner) and the paper
(center) is different.
The by-pass paper size sensor [A] (variable resistor) monitors the paper
width. When the paper side fences [B] and [C] are positioned according to the
paper width, the rear side fence is connected to the lever of the by-pass
paper size sensor. The electrical resistance of the sensor changes in
accordance with the side fence position, This informs the CPU of the paper
width.
At the first copy from the by-pass feed table, the scanner makes a full
distance scan. 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.
[B]
[A]
[C]
STM 2-91 FT6645/6655/6665
6.16 PAPER REGISTRATION
The registration rollers [A] have two functions. One is aligning the lead edge
of the paper with the leading edge of the latent image on the OPC drum.
When the CPU receives the signal from the registration sensor, the
registration clutch turns on. It turns off 90ms after the trailing edge of the
paper is detected by the registration sensor.
The other function is to correct skewing of paper fed from the trays. When the
leading edge of the paper reaches the registration rollers, the vertical
transport rollers [B] continuously turn to transport the paper. On the other
hand, the registration roller is not turning. The leading edge of the paper is
pushed against the registration roller. 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.
[B]
[A]
FT6645/6655/6665 2-92 STM
6.17 REGISTRATION DRIVE MECHANISM

Through the timing belt [A], main motor [B] rotation is transmitted to the
registration clutch [C]. When the registration clutch activates, the main motor
drive is transmitted to the lower registration roller [D], then to the upper
registration roller [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.
[G]
[E]
[A]
[B]
[C]
[D]
[E]
[F]
STM 2-93 FT6645/6655/6665
6.18 GUIDE PLATE RELEASE MECHANISM
When a paper misfeed occurs between the vertical transport rollers and the
registration rollers, the lower paper guide plate [A] automatically opens.
When the registration sensor is not activated at a certain jam check timing,
the guide plate solenoid [B] turns on. The lever [C] raises the lock lever [D] on
the guide plate to release the pin [E] on the rear side frame. Then, the guide
plate falls open.
The actuator [F] on the guide plate activates the guide plate position sensor
[G] when the guide plate opens.
To prevent the guide plate from being left open, if the guide plate position
sensor is activated, copying is prohibited and a caution guidance is displayed
on the 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.
Rev. 12/93
[A]
[B]
[C]
[D]
[E]
[F]
[G]
[H]
FT6645/6655/6665 2-94 STM
7. IMAGE FUSING
7.1 OVERVIEW
After the image is transferred, the copy paper enters the fusing unit. Then the
image is fused to the copy paper by a heat and pressure process through the
use of a hot roller [A] and pressure roller [B].
The fusing lamp [C] located inside the hot roller is turned on and off to
maintain the operating temperature of 185C. The CPU monitors the hot roller
surface temperature through a thermistor [D] which is in contact with the hot
rollers surface. A thermofuse [E] protects the fusing unit form overheating.
The hot roller strippers [F] separate the copy paper from the hot roller and
direct it to the fusing exit rollers [G]. The fusing exit sensor [H] monitors the
progress of the copy paper after passing through the fusing unit and acts as
a misfeed detector while the exit rollers drive the copy paper to the inverter
section.
The hook positions of the tension springs [I] on the pressure lever [J] adjust
the roller pressure.
Rev. 12/93
[F]
[A]
[H]
[E]
[B]
[J]
[D]
[C]
[G]
[I]
STM 2-95 FT6645/6655/6665
7.2 OIL SUPPLY AND CLEANING
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.
The cleaning roller [C] collects any foreign substance (toner, paper dust) on
the pressure roller.
Due to the higher fusing roller rotation speed of the FT6665 (A097), the oil
supply roller tends to collect foreign substances. A cleaning roller [D] for the
oil supply roller has been added.
Due to the higher copy speed, overall lamp wattage has been increased. The
120V machine has two 550W fusing lamps.
Rev. 7/94
[A]
[C]
[A]
[B]
FT6645/6655 (A095/A096)
FT6665 (A097)
[D]
FT6645/6655/6665 2-96 STM
7.3 FUSING ENTRANCE GUIDE
The entrance guide [A] for this machine is adjustable for thick or thin paper.
With thin paper, set the entrance guide in the upper position. This slightly
lengthens the paper path which prevents the paper from creasing in the
fusing unit. With thick paper, set the entrance guide in the lower position.
This is because thick paper does not bend as easily, and is therefore less
prone to creasing. Also, the lower setting allows more direct access to the
gap between the hot and pressure rollers. This prevents thick paper from
buckling against the hot roller, which can cause blurring at the leading edge
of the copy.
In this model, the transfer belt improves paper transport and the paper path
to the fusing entrance is stabilized. This reduces the chance of paper
creasing due to paper skews in the fusing unit.
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.
[A]
STM 2-97 FT6645/6655/6665
7.4 FUSING DRIVE MECHANISM
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.
The FT6665 (A097) has a mounting bracket [F] which carries the two 550W
fusing lamps.
FT6665 (A097)
Rev. 7/94
[A]
[C]
[B]
[D]
[E]
FT6645/6655 (A095/A096)
[F]
FT6645/6655/6665 2-98 STM
7.5 FUSING LAMP CONTROL
When the main switch is turned on the CPU starts sending a trigger pulse to
the fusing control circuit to turn on the fusing lamp.
When the CPU detects a fusing temperature of 200C through the thermistor,
the copier starts fusing idling. This idling period can be adjusted by SP mode
( SP Adjustment: PAGE 1). When the fusing idling finishes, the warm-up
period is completed and the Ready indicator turns on. After this, fusing
temperature is controlled at 185C. If the fusing temperature is above 100C
when the main switch is turned on, the copier does not go into the fusing
idling mode.
If the main switch is turned on and for example the temperature is 80C, or
any temperature less than 100C, the machine will start process control
initial setting from that point. When the fusing temperature reaches 180C
the machine starts drum conditioning.
The CPU also changes the fusing lamp on period at every check cycle. The
change is calculated according to the result of the previous check. This
keeps the fusing temperature as close as possible to the target temperature.
If the fusing lamp is turned on or off while the exposure lamp is on, the power
supplied to the exposure lamp may fluctuate, possibly degrading the copy
image. To prevent this, the fusing lamp does not change while the exposure
lamp is on: it stays either on or off.
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
1
Rev. 10/94
200
150
100
50
*1
C
200 C
180 C
185C
' : Main SW on
: Process control data
initial setting start
J: Get ready
: Idling start
'

J
100 C
STM 2-99 FT6645/6655/6665
7.6 INVERTER AND PAPER EXIT
After passing the fusing unit, copies enter the inverter unit where paper is
distributed to the paper exit rollers [A] or the duplex unit. The fusing exit
sensor [C] and exit sensor [D] monitor paper misfeeds.
The junction gate solenoid changes the position of the junction gate [B]. In
duplex mode, the junction gate solenoid turns on to raise the junction gate to
guide the paper into the duplex unit.
The duplex entrance sensor [E] is used not only to monitor paper misfeed
detection, but also to activate the duplex jogger motor.
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.
Rev. 12/93
[A]
[D] [B]
[E]
[F]
[C]
[H]
[F]
[H]
[G]
FT6645/6655/6665 2-100 STM
7.7 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].
[A]
[C]
[B]
[D]
STM 2-101 FT6645/6655/6665
8. DUPLEX
8.1 OVERVIEW
In this mode the junction gate [A] directs sheets exiting the fusing unit to the
duplex tray entrance. After that, all sheets follow the path through the
entrance rollers [B]. After all front side copying is completed, the sheets in the
duplex tray are fed out in order from the bottom to the top, following the path
through the duplex feed mechanism, passing the duplex transport sensor [E],
the duplex exit sensor [C], and vertical transport rollers [D] to the copier
registration rollers.
Rev. 10/94
[A]
[B]
[D]
[C]
[E]
FT6645/6655/6665 2-102 STM
8.2 DRIVE MECHANISM
The duplex drive gear [A] transmits drive from the fusing/duplex drive motor
[B] to the duplex unit. This drive is transmitted to the duplex paper feed
section under the control of the duplex feed clutch [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.
Rev. 4/15/94
[C]
[D]
[B]
[E]
[A]
STM 2-103 FT6645/6655/6665
8.3 DUPLEX ENTRANCE TO DUPLEX TRAY
After paper passes through the junction gate, it pushes the feeler [A] up. The
feeler and the paper guide [B] form one part, so that when the feeler is
pushed up, the paper guide is moved out of the paper path.
The paper then enters the duplex unit. After the papers trailing edge passes
the feeler, the paper guide falls back into place and pushes each sheet
under the brush roller.
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].
Rev. 12/93
[A]
[B]
[C]
[A]
[C]
[B]
[D]
[D]
FT6645/6655/6665 2-104 STM
8.4 DUPLEX STACKING
The jogger motor (stepping motor) [A] drives the side fence drive wire [B] to
move the side fences [C] inward or outward.
When the main switch is turned on, the jogger motor rotates to place the
jogger fences at the home position by monitoring the signal of the jogger
home position sensor [D].
When the start key is pressed, the jogger motor rotates to position the side
fences according to the selected paper size. 30 ms after the duplex entrance
sensor detects the leading edge of the paper (OFF ON), the jogger motor
rotates to position the jogger side fences 10 mm away from the selected
paper size. When the copy paper is delivered in the duplex tray,
approximately 150 ms after the duplex entrance sensor detects the trailing
edge of the paper (ON OFF), the jogger fences move inward to square the
paper. 30 ms after the duplex entrance sensor detects the leading edge of
the next copy paper, the jogger fences move back to the previous positions
(10 mm away from the paper size) again.
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.
Rev. 12/93
[B]
[C]
[A]
[D]
[B]
[C]
10 mm
10 mm
STM 2-105 FT6645/6655/6665
8.5 DUPLEX POSITIONING ROLLER MECHANISM
The positioning roller [A] is normally in the upper position. 150ms after the
duplex entrance sensor [B] detects the trailing edge of the paper (ON
OFF), the positioning solenoid [C] turns on to lower the positioning roller until
it contacts the paper. The positioning roller continuously rotates clockwise
while the fusing/duplex motor [D] rotates. The positioning solenoid stays on
until the leading edge of the paper hits the separation belts [E].
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.
Rev. 10/94
[A]
[C]
[D]
[B]
[A]
[E]
[C]
FT6645/6655/6665 2-106 STM
8.6 DUPLEX PAPER FEED
The paper on the duplex tray is fed in order from the bottom to the top sheet.
After all copies are stacked on the duplex tray, the duplex pressure solenoid
[A] turns on to lower the pressure arm [B] so that the pressure arm presses
the paper against the pick up roller [C].
Then, the duplex feed clutch [D] turns on to rotate the pick-up roller [C],
separation belts [E] and the feed roller [F].
The separation belts [E] and the feed roller [F] rotate in opposite directions.
Only the bottom sheet is fed because the separation belt prevents any other
paper from feeding.
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.
[B]
[A]
[E]
[F]
[C]
[D]
[B]
STM 2-107 FT6645/6655/6665

200ms after the duplex transport sensor [A] detects the leading edge of the
paper, the duplex feed clutch [F] turns off, and the duplex transport clutch [J]
turns on. The paper is then transported by the duplex transport rollers [G].
When the paper activates the duplex exit sensor [H], the duplex transport
clutch [J] turns off momentarily and the paper waits there until the feed timing
is adjusted to match the registration clutch on timing of the previous sheet.
The duplex transport clutch then turns on and feeds the sheet to the vertical
transport section.
When the duplex transport sensor [A] detects the trailing edge of the last
sheet, the duplex transport clutch turns off and the pressure solenoid [B]
turns off to raise the pressure arm [C]. At this moment, the duplex paper end
sensor [D] confirms that no paper remains on the duplex tray.
The duplex paper end actuator [E] is located on the pressure arm and moves
with the pressure arm.
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.
[G]
Rev. 4/15/94
[B]
[J]
[D]
[E]
[A]
[F]
[A]
[G]
[H]
FT6645/6655/6665 2-108 STM
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
the pressure arm to activate
the duplex paper end sensor
[D].
FT6665 (A097 copier)
The A097 duplex paper end
sensor [F] is a reflective type
photo sensor which is located
on the bottom plate (just
beside the duplex pick-up
roller). It is activated as paper
passes.
Rev. 7/94
[D]
[E]
[F]
STM 2-109 FT6645/6655/6665
SECTION 3
DUAL JOB FEEDER
DF60
(Machine Code: A376)
1. SPECIFICATIONS
Original Feed Mode: Automatic document feed mode
Automatic reverse document feed mode
Semi-automatic document feed mode
Mixed sized mode
Pasted original mode
Preset mode
Combine originals mode
Original Size, Weight and
Table Capacity:
Paper Weight
40.7
g/m
2
46.5 52.8 64.0 81.4 104.7 128.0
11 lb 12.5 14 17 22 28 34
Maximum number of
originals to be set
50 50 50 50 50 30 25
A3 lengthwise B B B
A4 lengthwise B B B
A4 sideways B B B
A5 sideways
B4 lengthwise B B B
B5 lengthwise B B B
B5 sideways B B B
F (8" x 13") lengthwise B B B
11" x 17" lengthwise B B B
81/2 x 14" lengthwise B B B
81/2 x 11" lengthwise B B B
81/2 x 11" sideways B B B
51/2" x 81/2" lengthwise
51/2" x 81/2" sideways
8" x 13" (F) lengthwise B B B
81/2 x 13" (F4)
lengthwise
B B B
8" x 101/2" lengthwise B B B
8" x 10" sideways B B B
l: 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
A
4
/
A
3

v
e
r
s
i
o
n
L
T
/
D
L
T

v
e
r
s
i
o
n
STM 3-1 FT6645/6655/6665
Original Standard Position: Rear left
Original Separation: Feed and friction belt
Original Transport: One flat belt
Power Source: DC24V from the copier, 2.0A (average)
Power Consumption: 70W
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 3-2 STM
2. COMPONENT LAYOUT
2.1 MECHANICAL COMPONENT LAYOUT
1. Friction Belt
2. Original Stopper
3. Press Roller
4. Side Fence
5. Original Table
6. Exit Roller
7. Inverter Pawl
8. Inverter Roller
9. Transport Belt
10. Pick-up Rollers
11. Pull-out Roller
12. Feed Roller
1
7 2
8
3
9
4
10
5
11
6
12
STM 3-3 FT6645/6655/6665
Point for symbols and index numbers.
No.
Motors
M1 Feed-in Drives the feed-in system
(pick-up, feed, pull-out rollers,
separation belts)
1
M2 Belt Drive Drives the transport belt. 2
M3 Feed-out Drives the feed-out and the
inverter system.
5
Sensors
S1 DF Position Informs the CPU when the DJF
is being closed so that original
size detection sensors can
check the original size.
7
S2 Feed-out Checks for original misfeeds and
sets original stop timing when in
auto-reverse mode.
8
S3 Registration2 Detects the leading edge of the
original to turn off the feed-in
clutch and to change the feed-in
and belt drive motors speeds.
Also detects the original length.
10
S4 Original Width3 Detects the original width. 11
S7 Registration1 Detects the trailing edge of the
original to change the belt-drive
motor speed. Also, detects the
original length and original jam.
14
S8 Original Feed Detects if the originals reach the
feed roller or not.
15
S9 Original Set Detects if the originals are set
on the feed table.
16
FT6645/6655/6665 3-4 STM
No.
S10 Pulse Count Counts the pulses generated by
the pulse generator disc to
determine the original length.
19
Solenoids
SOL1 Inverter Energizes to invert the original
when copying two sided
originals.
4
SOL2 Stopper Lifts the original stopper and
lowers the press roller to feed
the set of originals to the feed
roller.
9
SOL3 Separation Transmits drive to the
separation belts.
18
PCBs
PCB1 DF Main Board Controls all DJF functions. 3
PCB2 Indicator Panel
Board
Contains operator indicators.
No callouts, no component
(not drawn)
21
Switches
SW1 Lift Informs the CPU when the DJF
is lifted and also serves as the
jam reset switch for the DJF.
6
SW2 Feed Cover Detects if the feed cover is
closed.
17
Clutches
MC1 Feed-in Transmits the feed-in motor
drive to the pick-up and feed
rollers, and to the separation
belts.
20
STM 3-5 FT6645/6655/6665
4. BASIC OPERATION
4.1 ONE-SIDED ORIGINAL FEED
When an original is set on the DJF feed table, the leading edge is stopped by
the stopper [A], and the feeler [B] activates the original set sensor. The Insert
Original indicator light goes out and the DJF informs the copiers CPU that
the originals have been set.
When the Start key is pressed, the copiers CPU sends the feed-in signal to
the 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.
[A] [B]
[C]
[D]
[A]
FT6645/6655/6665 3-6 STM

The feed-in clutch [A] activates when the DJF receive the feed-in signal.
200ms after the feed-in clutch activate, the feed-in motor feeds all originals to
the feed roller [B].
When the originals reach the feed roller, the stopper solenoid [C]
de-activates to lower the original stopper [D] and to lift up the original press
rollers [E].
When the originals pass through (between the separation belts [F] and feed
roller), only the bottom original is separated and fed onto the exposure glass.
Until then, the feed-in motor rotates slowly (372mm/sec) to ensure proper
original feeding. 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).
[A]
[B]
[C]
[D]
[E]
[F]
[B]
[F]
[D]
[G]
[E]
STM 3-7 FT6645/6655/6665

When the leading edge of the original reaches the exposure glass, the
original is transported by the transport belt [A] (belt drive motor turns on 200
ms after the start key is pressed).
When the trailing edge of the original passes through registration sensor - 1
[B], the feed-in motor turns off. When the trailing edge of the original passes
through registration sensor - 2 [C], the belt drive motor gradually decreases
its speed to stop the original at the proper place on the exposure glass.
200ms after the belt drive motor turns off, the feed-in motor turns on until the
next original activates registration sensor - 2 [C], the next original waits until
the first original copy jobs complete. This operation reduces the original feed
in time.
When the scanner reaches the return position, the copiers CPU sends the
feed-out and feed-in signals to the DJF CPU in order to exchange the original
for the next original.
When the DJF receives the feed-out signal, the belt drive and feed-out
motors turn on.
When the scanner reaches the return position after scanning the last original,
the copiers CPU sends only the feed-out signal to feed-out the last original.
If the original A4/81/2" 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.
Rev. 4/15/94
[A] [C] [B]
FT6645/6655/6665 3-8 STM
4.2 TWO-SIDED ORIGINAL FEED

Unlike one-sided original feed, the back side of the original must be copied
first to keep the originals and copies in the correct order.
During original feed-in, the sequence is the same as for one-sided feed;
however, the belt drive motor continues rotating until the original reaches the
inverter section. The DJF CPU also energizes the feed-out motor and the
inverter solenoid [A] for a short time.
After the inverter mechanism inverts the original (10 pulses after the feed-out
sensor [B] activates), the belt drive motor reverses and the original is fed
towards the original scale. It is stopped at the correct position on the
exposure glass, and the DJF CPU sends the copy start signal.
When the scanner reaches the return position, the copiers 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.
[A]
[B]
STM 3-9 FT6645/6655/6665
4.3 PRESET MODE
Two sets of originals for independent copy jobs can be set on the original tray
at the same time.
While the first set of originals [A] remains on the original tray, both the original
set sensor feeler [B] and original feed sensor feeler [C] are actuated. If the
second set of originals [D] has been set (stopped by the original stopper [E])
and the first set of originals [A] are all fed-in, the original set sensor feeler [B]
is still actuated and only the original feed sensor is deactuated. Therefore,
the copiers 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.
[A]
[B]
[C]
[D]
[E]
[F]
FT6645/6655/6665 3-10 STM
4.4 COMBINE 2 ORIGINALS MODE
4.4.1 Overview
Two originals are fed onto the exposure glass at once in the combine 2
originals mode as shown in figure 1. This allows copying 2 originals onto one
sheet of paper automatically either in the full size mode or in the reduction
mode. If it is used together with the duplex mode, 4 originals can be copied
on a single sheet of paper automatically.
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.
[Fig.2]
[Fig.1]
Rev. 4/15/94
STM 3-11 FT6645/6655/6665
4.4.2 Operation

The DF operation in the combine 2 original mode is as follows:
[Figure 1]
The first original is fed in the same manner as the one-sided original
mode. When registration sensor-2 detects the trailing edge of the first
original, the feed-in and the belt drive motors stop and the feed-in clutch
turns on again to prepare for the second original feed.
[Figure 2]
As soon as the feed-in and the belt drive motor turn off, the belt drive
motor starts rotating in reverse to align the first original against the
original scale. Then the belt drive motor turns off.
[Figure 3]
50ms after the feed-in motor turns off, the feed-in motor turns on again at
a lower speed (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.
Rev. 4/15/94
Figure 1
Figure 2
Figure 3
FT6645/6655/6665 3-12 STM

[Figure 4]
Soon after the feed-in motor turns off, both the feed-in and the belt drive
motors turn on again at the lower speed (372mm/sec).
After registration sensor-2 detects the trailing edge of the second original,
the feed-in and the belt drive motors turn off and gradually the belt drive
speed reduces to stop the original at the proper place on the exposure
glass.
[Figure 5]
After the copying of these originals is finished, the belt drive motor and
the feed-out motor turn on to feed out the originals. 50mm before the
trailing edge of the first original de-activates the feed-out sensor, both the
belt drive and the feed-out motor rotate at the lower speed to improve
original stacking.
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.
Figure 4
Figure 5
STM 3-13 FT6645/6655/6665
5. ORIGINAL SEPARATION

The drive from the feed-in motor [A] is transmitted to the pick-up rollers [B]
and the feed roller [C] through the feed-in clutch [D] as shown. The feed roller
and the friction belts [E] are used to feed-in and separate the originals [F].
Only the bottom original is fed because the friction belt prevents any other
originals from feeding.
Original feed starts when the feed roller starts turning and advances the
bottom original of the stack. The feed roller moves the original past the
separation belt because the driving force of the feed roller is greater than the
resistance of the friction belt. The friction belt prevents multiple feeds
because the resistance of the friction belt is greater than the friction between
original sheets.
[A]
[B]
[C]
[D]
[E]
[C]
[E]
[F]
[B]
FT6645/6655/6665 3-14 STM
6. SEPARATION BELT DRIVE MECHANISM

Normally the separation belt is not driven. When the copy job is completed,
the separation solenoid [A] activates for 100ms to transmit the drive from the
feed-in motor [B] to the separation belts [C] as shown.
By this operation, the part of the friction belt that contacts the feed roller [D]
or the original changes to prevent multiple feeding.
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.
[A]
[B]
[C]
[D]
STM 3-15 FT6645/6655/6665
7. THIN / THICK ORIGINAL MODES
This document feeder has two different ways of stopping originals at the
correct position on the exposure glass. They are called the thin original mode
and the thick original mode. The mode used is determined by using the
copiers User Tool No.12.
1. Thin Original Mode
The original is stopped at the correct position on the exposure glass
based on encoder pulse count. The belt drive motor stops shortly after
the original trailing edge passes registration sensor - 2. (Exact timing
depends on registration adjustment.)
In the pasted original mode, the DJF automatically selects this mode.
2. Thick Original Mode
When thick original mode is selected, the belt drive motor remains
energized to carry the original approximately 10 mm pass the left scale.
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 STM
8. ORIGINAL SIZE DETECTION

The DJF detects original width through the on/off combination of the three
original width sensors -1 [A], -2 [B], -3 [C], it also detects the original length
through the use of the registration sensors -1 [D], -2 [E] and the pulse count
sensor [F].
The DJF CPU counts the pulses between registration sensor - 2 [E] on timing
and registration sensor - 1 [D] off timing.
Based on this pulse count, the CPU determines the original length.
The reason for using two registration sensors are:
1) Registration sensor -2 [E] is used to stop the pre-fed original to wait until
the previous original is fed out. For precise control, the original stop
position must be after the pull out rollers [G]. Therefore, registration
sensor -2 is placed after the pull-out roller.
2) Registration sensor -1[D] checks the trailing edge of the original. This
check is used to place the original on the exposure glass.
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.
[A]
[B]
[C]
[F]
[E]
[D]
[E]
[G]
STM 3-17 FT6645/6655/6665
9. LIFT MECHANISM

When the DJF is opened, the lift springs [A] provide enough force to ensure
that the DJF does not fall onto the exposure glass. When the DJF is closed,
points "'", "^", and "" are aligned and no upward force is provided to the
DJF.
The lift switch [B] is actuated when the DJF is closed. The copier then shifts
to the document feeder mode. The lift switch also serves as the reset switch
for DJF misfeeds.
When a book or thick (maximum thickness 60 mm) original is copied, the DJF
acts as a cover for the original as shown in the figure [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.
[A]
[D]
'
'
^
[B]
[C]
FT6645/6655/6665 3-18 STM
10. ORIGINAL MISFEED DETECTION
Registration sensor -1 and the feed-out sensor are used for misfeed checks
to light the original misfeed indicator.
1. One sided original
': If registration sensor -1 does not activate within 150 pulses after the
feed-in motor starts turning, the CPU determines that the original will not
arrive (ON check).
^: If registration sensor -1 does not de-activate within 120 pulses, the CPU
determines that the original is still there (OFF check).
: If the current paper size data is 40mm longer or 80mm shorter than the
previous original size data (this check is disabled in the mixed size
original mode).
: If the feed out sensor does not activate within 125 pulses after the
feed-out motor starts turning, the CPU determines that the original will not
arrive (ON check).
I: 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).
Registration
Sensor 1
Feed-out Sensor
Copying
Feed-in Motor
'
^
I
Feed-out Motor
STM 3-19 FT6645/6655/6665
2. Two sided original
Registration sensor -1 and the feed-out sensor are used for misfeed checks
to light the original misfeed indicator.
Registration ON/OFF check is the same as for one-sided originals.

': If the feed-out sensor does not activate within 130 pulses after the
arrive (ON check).
^: If the feed-out sensor does not de-activate within 200 pulses, the CPU
determines that the original is still there (OFF check).
: If the feed-out sensor does not activate within 130 pulses after the
arrive (ON check).
: If the feed-out sensor does not de-activate within 200 pulses, the CPU
determines that the original is still there(OFF check).
I: If the feed out sensor does not activate within 125 pulses after the
arrive (ON check).
I: 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).
Belt Drive
Motor
Feed-out
Sensor
1st Copying
Feed-out
Motor
'
J
2nd Copying
Forward
Reverse
FT6645/6655/6665 3-20 STM
11. TIMING CHART
11.1 DJF Timing Chart (1 sided original mode)
STM 3-21 FT6645/6655/6665
1
1
.
2
D
J
F

T
I
M
I
N
G

C
H
A
R
T

(
C
O
M
B
I
N
E

2

O
R
I
G
I
N
A
L
S

M
O
D
E
)
F
T
6
6
4
5
/
6
6
5
5
/
6
6
6
5
3
-
2
2
S
T
M
SECTION 4
SORTER STAPLER
ST25
1. SPECIFICATIONS
Configuration: Console
Number of Bins: 20 + Proof Tray
Paper for Proof Tray:
Size Maximum: A3, 11" x 17"
Minimum: A6 lengthwise, 51/2" x 81/2"
Weight: 52~ 157 g/m
2
,14~ 42 lb
Capacity: 250 sheets (80 g/m
2,
20 lb)
Paper for Bins: See the table below.
Sort Stack Staple
Maximum paper size A3, 11" x 17" A3, 11" x 17" A3, 11" x 17"
Minimum paper size A5, 51/2" x 81/2"
lengthwise
Sideways:
A4, 81/2" x 11"
Lengthwise:
A5, 51/2" x 81/2"
B5, 81/2" x 11"
Maximum paper
weight
157 g/m
2
, 42 lb 157 g/m
2
, 42 lb 80 g/m
2
, 20 lb
Minimum paper weight 52 g/m
2
, 14 lb 52 g/m
2
, 14 lb 64 g/m
2
, 17 lb
Maximum capacity all sizes:
50 sheets/bin
2 sided copies:
40 sheets/bin
all sizes:
40 sheets/bin
2 sided copies:
35 sheets/bin
all sizes:
50 sheets
Staple Position: a = 6 3 mm
b = 6 3 mm
c = 6 3 mm
d = 66 3 mm
e = 132 2 mm
= 45 5
c
d
a
b
e
STM 4-1 FT6645/6655/6665
Staple Replenishment: Cartridge exchange (5,000 pieces/cartridge)
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:
(W x D x H)
566 x 583 x 978 mm
Weight: Approximately 47kg
Rev. 4/15/94
FT6645/6655/6665 4-2 STM
2. COMPONENT LAYOUT
1. Proof Tray
2. Proof Exit Rollers
3. Proof Transport Rollers
4. Upper Entrance Guide
5. Turn Gate
6. Lower Entrance Guide
7. Sorter Transport Rollers
8. Sorter Exit Rollers
9. Staple Unit
10. Grip Assembly
11. Helical Wheels
12. Jogger Plate
13. Bins
14. Upper Guide Plate
1
2
3
4
5
6
7
8
9
10
11
12
13
14
STM 4-3 FT6645/6655/6665
2.2 DRIVE LAYOUT
1. Main Motor
2. Main Drive Belt
3. Proof Drive Belt
4. Sorter Drive Belt
5. Helical Wheels
6. Staple Unit Drive Belt
7. Gripper Motor
8. Bin Drive Motor
9. Wheel Drive Belts
10. Grip Drive Belt
11. Jogger Motor
12. Staple Unit Drive Motor
13. Jogger Drive Belts
14. Bin Rear Plate Drive Motor
15. Sorter Exit Drive Belt
16. Sorter Exit Motor
1
2
3
4
5
6
7
8
9
10
12
13
14
15
9
9
5
13
16
5
13
11
FT6645/6655/6665 4-4 STM
Please refer to the electrical component layout on the reverse side of the
Point to Point (Water Proof Paper) for symbol and index number.
Symbol Name Function
Index
No.
Motors
1 Main Drives the paper transport rollers. 1
2 Staple Feeds the staples and drives the
stapler hammer.
10
3 Grip Drives the grip assembly forward
and backward into the bin to grip
the copies and bring them to the
stapling position.
16
4 Bin Drive Drives the bins upward and
downward by rotating the three
helical wheels.
18
5 Jogger Drives the jogger plate to jog the
copies against the front side plate.
20
6 Staple Unit Drive Drives the staple unit according
to the staple position and angle.
23
7 Bin Rear Plate Drive Drives the bin rear plate down
and up.
24
8 Sorter Exit Delivers the paper into the bins. 27
Sensors
1 Bin Jam (LED) Detects if there is paper jams at
the distribution section and
detects if there is paper in the
bins (light emitting element).
3
2 Proof Exit Detects paper jams at the proof
tray exit.
4
3 Entrance Detects paper jams at entrance
guides.
5
4 Staple HP Detects if the staple hammer is in
the home position.
8
5 Staple End Detects staple end. 9
6 Paper Detects whether copies are under
the hammer.
11
STM 4-5 FT6645/6655/6665
Index
No.
7 Staple Unit HP Detects if the staple unit is in the
home position.
13
8 Grip HP Detects if the grip assembly is in
the home position.
15
9 Bin Jam (Photo Tr.) Detects paper jams at the
distribution section and detects if
there is paper in the bins (light
receiving element).
17
10 Wheel Sensor Detects the bin position. 19
11 Bin HP Detects if the bins are in the
home position.
21
12 Jogger HP Detects if the jogger plate is in the
home position.
22
13 Bin Rear Plate Open Detects if the bin rear plate is in
the open position.
25
14 Bin Rear Plate HP. Detects if the bin rear plate is in
the home (closed) position.
26
Solenoids
1 Turn Gate Opens and closes the turn gate
to direct the copies into either the
proof tray or the bins.
2
2 Grip Opens and closes the grip arms
to grip copies on the bins.
12
3 Grip Arm Positioning Moves the grip assy to the rear
and front to catch or release the
paper to carry to the stapler.
14
PCBs
1 DC Supply Provides DC power (Input: 24V
DC, Output:24V/5V DC)
7
2 Main Control Controls all sorter stapler
functions.
28
Switches
1 Door Safety Cuts the DC power when the
front door is opened.
6
FT6645/6655/6665 4-6 STM
4. BASIC OPERATION
4.1 NORMAL (PROOF MODE) AND SORT/STACK MODE
Copies exiting the copier pass through the entrance guide plates [A] to the
turn gate section. The turn gate [B] will send copies either to the proof tray or
to the bins, depending on the mode.
- Normal (proof) mode - (from the turn gate section to the proof tray)-
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.
[A]
[C]
[B]
[D]
[A]
STM 4-7 FT6645/6655/6665
- Sort mode - (from the turn gate section to the bins)
In this mode, the turn gate solenoid stays off to keep the turn gate [A] at the
upper position. The main motor turns clockwise to rotate the sorter transport
rollers [B] and the exit motor rotates the exit rollers [C].
The turn gate directs copies to the sorter bins through the sorter transport
section, then the first copy is delivered between the top bin [D] and the upper
guide plate [E].
The jogger plate [F] then jogs to square each copy.
Before the next copy reaches the sorter exit roller, the bin drive motor [G]
rotates 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.
Bins advances each time copies are delivered.
[G]
[D]
[E]
[F]
[B]
[H]
[I]
[A]
[C]
FT6645/6655/6665 4-8 STM
- Stack mode - (from the turn gate section to the bins)
As with sort mode, the turn gate solenoid stays off and the turn gate [A] also
stays up when the start key is pressed. The main motor turns clockwise to
rotate the sorter transport rollers [B] and the exit motor rotates the exit rollers
[C].
The turn gate directs copies to the sorter bins through the sorter transport
section, then the copies are delivered between the top bin [D] and the upper
guide plate [E].
The jogger plate [F] then jogs to square each copy.
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.
[G]
[D]
[E]
[F]
[B]
[H]
[I]
[A]
[C]
STM 4-9 FT6645/6655/6665
4.2 STAPLE MODE
When the final set of copies is jogged [Fig. 1], the staple unit staples the
stacked copies as follows: The grip arms move inside the front side plate and
catches the paper. The bin rear plate is turned so as to be flat with the sorter
bin. 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].
[Fig. 1] [Fig. 2]
[Fig. 3]
FT6645/6655/6665 4-10 STM

The grip assembly brings the stapled copies back to the bin and the bin rear
plate returns to the original position.
The grip assembly releases the copies and return to outside the front side
plate so as not to disturb the bin movement [Fig. 4].
The bin advances one step [Fig. 5].
When the final set of copies is stapled, the staple unit is returned to the home
position.
There are two staple modes.
1) Automatic stapling:
In ADF mode, when the staple mode is selected before pressing the start
key, copies will be delivered to each bin and stapled automatically.
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.
[Fig. 4]
[Fig. 5]
STM 4-11 FT6645/6655/6665
5. TURN GATE SECTION
The turn gate [A] sends copies to the proof tray or the sorter bins depending
on the mode. In the proof mode, the turn gate solenoid [B] turns on and the
main motor [C] turns clockwise (as viewed from the rear) when the start key
is pressed.
The turn gate [A], directs copies upward through the proof transport section
to the proof tray. In this mode, the main motor drive is transmitted by both
the proof drive belt [D] and sorter drive belt [E]. However the one way clutch
in each sorter transport roller drive gear [F] does not transmit the drive to the
sorter transport rollers.
In the sort, stack and staple modes, the turn gate solenoid stays off to direct
copies downward to the sorter transport section. When the start key is
pressed, the main motor [C] turns counterclockwise (as viewed from the
rear).
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.
REAR VIEW:
Rev. 10/94
[C]
[E]
[F]
[H]
[A]
[B]
[C]
[D]
[G]
[I]
FT6645/6655/6665 4-12 STM
6. BIN DRIVE MECHANISM
The bin drive mechanism moves the bins up and down to receive copies.
The main components in this mechanism are the bin drive motor [A], the
three helical wheels [B], the wheel sensor [C], and the bins [D] themselves.
There are four pins on each bin. Three of them fit in the slot on the helical
wheels. Another pin fits into the slot [E] of the front side frame.
The pins slide up and down in these slots.
Three timing belts transmit the drive from the bin drive motor to the three
helical wheels. When the motor rotates clockwise, the bins lift (black arrow)
and when it rotates counterclockwise, the bins lower (white arrow). There is a
wheel sensor actuator on the front helical wheel, the actuator has a slot
which detects when the helical wheel has rotated 360 degrees.
When the bins are advanced, the helical wheels rotate once (360 degrees )
for each step.
As the pitch of the spiral on the helical wheel is greater when bins are at the
staple and paper exit area than when bins are elsewhere, the amount of bin
shift is greater when bins are at the staple and paper exit area. This leaves
enough space to staple [F] and stack paper [G] and reduces the total
machine height.
[A]
[B]
[C]
[D]
[E]
15
45
30
40
15
40
15
[G]
[F]
STM 4-13 FT6645/6655/6665
7. BIN HOME POSITION
The bin home position sensor [A] and the wheel sensor [B] ensure that the
sorter exit roller is between the upper guide plate [C] and the 1st bin [D]
when all the bins are in the 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.
[B]
[E]
[A]
[C]
[D]
FT6645/6655/6665 4-14 STM
8. JOGGER SECTION
When the Start key is pressed in the sort, staple and stack modes, the copier
sends the paper size information to the sorter stapler. In accordance with this
data, the jogger motor [A] drives the jogger plate [B] from the jogger home
position to where the width is 10 mm wider than the selected paper.
300 ms after the trailing edge of the copy passes underneath the jam sensor,
the jogger motor rotates forward and in reverse. This makes the jogger plate
push all the copies against the front side plate to square the sheets. When
the jogger plate pushes the paper, the plate shifts to a position 5 mm wider
than the paper size when the bins lift. It shifts to a position 1 mm narrower
than the paper size when the bins lower.
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.
[B]
[A]
Copier Main
Motor
Jam Sensor
Jogger Motor
300 msec.
ON
STM 4-15 FT6645/6655/6665

Normally all rollers in the sorter stapler transport the paper at a speed of
360mm/sec.
To have enough paper jogging time, the sorter exit motor [A] rotation speed
changes to transport the paper quickly and to stack the paper smoothly into
the bins as follows:
360mm/sec: When the sorter exit roller [B] catches the leading edge of the
paper
1,000mm/sec: After the jam sensors [C] detects the leading edge of the
paper
600mm/sec: When releasing the trailing edge of the paper
The transport roller [D] is driven at a speed of 360mm/sec constantly,
however, when the sorter exit roller [B] rotates quickly, the transport rollers
also rotate quickly with the pulled paper because of the one way clutch in the
drive gear [E].
- Jogger Off Conditions -
1. Under the following conditions, the jogger plate does not jog after copies
are delivered to the bins.
If paper is loaded in a bin by hand while the sort/stack or staple mode
is selected.
If the selected paper size does not match stapling specifications.
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.
Fig. 1
[A]
[B]
[C]
[E]
[C]
[D]
FT6645/6655/6665 4-16 STM
9. BIN REAR PLATE DRIVE SECTION
The bin rear plates [A] basically stand up as shown in Fig.1. They are
lowered only during stapling as shown (Fig.2).
In the staple mode when all copies have been jogged by the jogger plate, the
bin rear plate drive motor [B] rotates gear [C]. Gear [C] drives the piston rod
[D] to push the lever [E] down.
The holder [F] engaging the pin [G] on the bin rear plate lowers in
accordance with the lever [E] position. Thus, the bin rear plate becomes flat
so as not to interfere with the copies being brought to the staple position by
the grip assembly.
During stapling, the bin rear plate open sensor [H] is interrupted by the
actuator [I] (Fig.2).
When the bin rear plates are in the home position, the bin rear plate HP
sensor [J] is interrupted by the actuator [I](Fig. 1).
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.
Fig. 1
Fig. 2
[A]
[B]
[C]
[D]
[E]
[F]
[I]
[H]
[J]
[F]
[A]
[G]
[G]
[I]
STM 4-17 FT6645/6655/6665
10. GRIP ASSEMBLY
The grip assembly works as follows:
When the staple unit reaches the staple position, the grip arm positioning
solenoid [A] activates and the plunger is pulled in to move the grip arms
[B] to the rear side of the machine. This is to access the paper on the
bin.
Since the grip arm positioning solenoid has a strong magnet inside, the
plunger keeps this condition until the solenoid is energized by an
opposite charge.
The right upper part of the illustration (squared part) shows the
mechanical linkage as seen from the top.
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.
[A]
[B]
[C]
OFF
OFF
OFF
OFF
Grip Arm Positioning
Solenoid
Grip solenoid
Bin Rear Plate
Drive Motor
Staple Unit
Drive Motor
FT6645/6655/6665 4-18 STM

After the bin rear plate drive motor lowers the bin rear plate, the grip motor
[A] turns clockwise (white arrow) until the gripper [B] carries the paper to
the staple position.
After stapling is finished, the grip motor turns counterclockwise to move
the stapled copies caught by the grip arms back to the bin.
When the grip solenoid [C] activates in the opposite way (as when it
activates to catch the paper), the return springs [D] open the grip arms to
release the papers which remains in the bin.
The grip arm positioning solenoid [E] activates to return the grip arms to
the home position to prepare for the next staple cycle.
The grip home position sensor [F] is actuated while the gripper is in the
home (grip) position.
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).
[A]
[B]
[C]
[D]
[E]
[F]
OFF
OFF
OFF
OFF
OFF
Bin Rear Plate
Drive Motor
Grip Motor
Grip Solenoid
Grip Arm Positioning
Solenoid
Staple Motor
STM 4-19 FT6645/6655/6665

11. STAPLE UNIT
11.1 STAPLE UNIT DRIVE MECHANISM
The staple unit moves from the home position (top slant position) to the rear
side of the machine in order to change the staple position. The staple HP
sensor [A] is blocked when the staple unit is in the home position. In Top
Slant mode, the stapler is only at the home position. In "Top" ("Bottom")
single staple mode, the staple unit moves to the front (rear) single staple
position and stays there until all stapling is completed. It then returns to the
home position. In "2 Staples" mode or "Bottom" single staple mode, the
staple positions differ according to the paper size. The staple unit drive motor
[B] is a stepping motor, and the staple position is decided by the number of
steps from the home position.
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).
1
[A]
[B]
FT6645/6655/6665 4-20 STM
11.2 STAPLER
The stapler motor [A] drives the staple sheet drive belt [B].
The staple sheets are fed under the hammer [C].
The stapler motor drives the staple hammer via gears [D], two eccentric
cams [E], and two links [F].
When the aligned copies are brought to the staple position by the grip
assembly the stapler motor starts rotating. When the cams complete one
rotation, the staple home position sensor [G] is de-actuated. The stapler
motor then stops.
When the paper sensor in the grip assembly does not detect that the copies
are under the hammer, the stapler motor does not rotate.
A paper sheet [H] with a notch cut-in is positioned at the bottom of the staple
cartridge. This paper sheet is fed out after the last staple sheet. When the
leading edge of the notch in the sheet is detected by the staple end sensor
[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.
[G]
[A]
[D]
[B]
[F]
[E]
[C]
[H]
[I]
STM 4-21 FT6645/6655/6665
- Staple Prohibit Conditions -
1. Under the following conditions, the staple mode is disabled when the
staple key on the operation panel is pressed.
If paper is in a bin before the main switch is turned on.
If the paper is fed from the by-pass feed table.
2. Under the following conditions, the staple mode is canceled.
If paper is loaded in a bin by hand while the staple mode is selected.
If only one sheet is delivered to the bin.
If the stack, slip sheet or interrupt modes are selected.
3. Under the following conditions, the manual stapling mode in sort mode is
prohibited.
If paper is loaded in a bin by hand while the sort mode is selected.
If the paper size in the bin does not match stapling specifications.
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 STM
12. JAM DETECTION
- Sorter Jams -
The sorter stapler main control board detects jams when the following
conditions are detected. In these cases, a jam signal is sent to the copier, the
copier stops the paper feed and indicates a sorter misfeed.
- Normal (Proof) mode -
J1: The entrance sensor has not turned on for the 1,250 ms after the copier
exit sensor turns on.
J2: The entrance sensor stays on for the appropriate number of pulses (for
example, 280 pulses for A4 sideways) or more.
J3: The proof exit sensor has not turned on for 300 pulses after the entrance
sensor turns on.
J4: The proof exit sensor stays on for the appropriate number of pulses (for
- In Sort/stack or Staple Mode -
J1 and J2: Same as the Normal mode.
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
J7: The jam sensor turns on while the bin drive motor turns on.
436pls*
600pls*
280pls
300pls
J1
J3
J2
J4
J5
J6
J7
280pls
(1,250m sec)
280 pls
ON Check
Copier Exit Sensor
Entrance Sensor
Proof Exit
Sensor
Jam Sensor
*This is the jam checking timing for the 1st bin. Timing
depends on the bins.
1 pulse 3.61 ms
STM 4-23 FT6645/6655/6665
13. TIMING CHART
13.1 A377 SORTER/STAPLER TIMING CHART (PROOF MODE)
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
Timing Chart Signal
FT6645/6655/6665 4-24 STM
13.2 A377 SORTER/STAPLER TIMING CHART
(STAPLE MODE)
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.
Motor ON
Signal Timing Chart
Staple ON
Proof mode
Staple mode
Exit signal
Paper size data
Bin data
Sorter busy
S/S Exit signal
Proof count
Job complete
Entrance sensor
Jam sensor
Sorter exit motor
Sorter main motor
Jogger motor
Staple unit
drive motor
Grip motor
Grip HP sensor
Grip positioning
solenoid
Grip solenoid
Staple motor
Bin rear plate
drive motor
Bin drive motor
NOTE 1
NOTE 1
NOTE 2
NOTE 3
300 ms
STM 4-25 FT6645/6655/6665
SECTION 5
RECIRCULATING DOCUMENT
HANDLER
DH400
1. SPECIFICATIONS
Original Size: Max A3, 11" x 17"
Min A5 lengthwise, 5 1/2" x 8 1/2"
(No A5 Sideways, 8 1/2 x 5 1/2)
Original Weight: 52~104 g/m
2

(14~28 lb) (ARF)
52~128 g/m
2
(14~34 lb) (ADF)
Original Feed Mode: Automatic Feed (ADF)
Automatic Recycle Feed (ARF)
Original Capacity: Max 50 sheets (A4, 8 1/2" x 11")
Original Separation: Feed and Friction Belts system
Original Transport: One flat belt
Original Stop System: DC servo motor control system
Copying Speed: Continuous copy
55 cpm (A4S, 11" x 81/2", 1st feed station)
Single copy
55 cpm (A4S, 11" x 8 1/2", 1st feed station)
Number of Cycles
per Document:
Max 30 times
Power Source: 24V (from copier), 5 A
Dimensions:
(W x D x H)
645 x 516 x 132 millimeters
(25.4 x 20.4 x 5.2 inches)
Weight: Approximately 18 kg (39.7 lb)
STM 5-1 FT6645/6655/6665
1 2
13 12 11
3 4 5 6 7 8 9 10
1. Friction Belts
2. Feed Roller
3. Original Gate
4. Pick-up Rollers
5. Original Stacker
6. Push-plate
7. Feed-out Rollers
8. Exit Relay Belts
9. Inverter Pawls
10. Inverter Roller
11. Transport Belt
12. Pull-out Roller
13. Pulse Generator
FT6645/6655/6665 5-2 STM
3. ELECTRICAL COMPONENT DESCRIPTIONS
Please refer to the electrical component layout on the reverse side of the
Point to Point (Water Proof Paper) for symbol and index number.
Index
No.
Motors
M1 Feed-in Motor Drives the feed-in system
(pick-up rollers, feed roller, and
pull-out roller). (dc servo)
3
M2 Transport Belt Motor Drives the transport belt. (dc
servo)
4
M3 Inverter Motor Drives the inverter roller and the
exit relay belts.
9
M4 Feed-out Motor Drives the feed-out unit. 15
M5 Friction Belt Motor Drives the friction belts 21
Solenoids
SOL1 Original Gate
Solenoid
Energizes to open the original
gate.
22
SOL2 Inverter Solenoid Energizes to invert the original
when copying a two-sided
original.
8
SOL3 Push Plate Solenoid Energizes to push the stack of
originals to the feed-in section.
14
Switches
SW1 Lift Switch Informs the copier CPU when the
RDH is lifted and also serves as
the jam reset switch for the RDH.
7
SW2 Feed-in Unit Safety
Switch
Detects if the feed-in unit is set
correctly.
23
SW3 Feed-out Unit Safety
Switch
Detects if the feed-out unit is set
correctly. 10
STM 5-3 FT6645/6655/6665
Index
No.
Sensors
S1 Original Set Sensor Informs the copier CPU that
originals have been placed and
causes the Insert Original
indicator to go out.
17
S2 Recycle Sensor Informs the CPU when the top
original is fed from the original
stacker.
19
S3 Registration Sensor Sets original stop timing and
measures the originals length.
18
S4 Original Width
Sensor
Determines the width of the
original.
20
S5 Pulse Generator
Sensor
Generates the pulses used to
measure the originals length.
1
S6 Inverter Sensor Sets original stop timing when in
auto reverse mode.
11
S7 Feed-out Sensor Checks for original misfeeds. 13
S8 One Turn Sensor Informs the CPU when the
pick-up roller turns one rotation.
6
S9 RDH Position Sensor Informs the CPU when the RDH
is being closed so that APS
sensor can begin checking the
original size.
16
Magnetic Clutch +
CL1 Feed-in clutch Energizes to rotate the feed roller. 2
Printed Circuit Boards
PCB1 RDH Main PCB Controls all RDH functions. 12
PCB2 Indicator Panel PCB Contains indicators for the
operator.
5
FT6645/6655/6665 5-4 STM
4. BASIC OPERATION
4.1 ONE-SIDED ORIGINAL FEED
When an original is placed in the RDH, the Set Original indicator goes out
and the RDH informs the copier that originals have been set.
When the Start key is pressed, the copier CPU sends the feed-in signal to the
RDH. On receipt of this signal, the original gate solenoid turns on, opening
the original gate. At the same time the push-plate solenoid and the feed-in
motor turn on. The push-plate and pick-up rollers move the entire stack of
originals to the feed position.
After that, the feed-in motor starts turning again. The bottom original is fed in
by the feed roller and the friction belts and delivered to the exposure glass by
the transport belt.
After a very short period, the second original is also fed in until its leading
edge reaches the registration sensor. This is in preparation for the next copy
cycle.
When the scanner reaches the return position, the copier CPU sends the
feed-out and the feed-in signals to the RDH in order to feed in the second
original. If the first original is A4/Letter size (sideways feed) or smaller, it is
not fed out as the next original is transported to the exposure glass. It is just
moved to the right side of the exposure glass. After completing the second
scan, the third original is fed in and the first original is fed out from the unit.
This continues until all originals have been copied.
The originals are stacked on the original table where they wait for the next
copy cycle.
4.2 TWO-SIDED ORIGINAL FEED
Unlike one-sided original feed, the back-side of the original must be copied
first to keep the originals and copies in correct order.
During original feed-in, the sequence is the same as for one-sided feed;
however, the RDH CPU also energizes the feed-out motor and the inverter
solenoid a short time after the originals leading edge has passed the RDH
registration sensor. The transport belt motor continues to feed the original
until the inverter mechanism inverts the original for the back-side copying.
Then, the transport belt motor reverses to feed the original towards the scale,
and stops the original at the correct position on the exposure glass.
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.
STM 5-5 FT6645/6655/6665
5. FEED-IN DRIVE MECHANISM

The pick-up rollers [A], feed roller [B], and the pull-out rollers [C] are driven by
the feed-in motor [D] through the timing belt, the gears and the feed-in clutch
[E].
-Basic Operation-
The feed-in motor is a reversible dc motor. When the feed-in motor rotates
forward (counterclockwise), all the rollers turn in the original feed direction.
(The feed roller can rotate only when the feed-in clutch is on.)
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 *
Pull-out
On
On/Off
On
Off
On/Off
On
(* Only when the feed-in clutch turns on, the feed roller rotates.)
[A]
[B]
[C]
[D]
[E]
FT6645/6655/6665 5-6 STM

When the Start Key is pressed, the feed-in motor starts turning
counterclockwise. Drive is transferred to the pick-up rollers through gears [E]
and [G] and to the feed-in clutch through gears [H] and [J]. The timing of the
feed roller rotation is controlled by the feed-in clutch [K].
Next, the feed-in motor reverses (clockwise). The pick-up rollers stop turning
due to the one-way bearing inside the gears [F] and [H]. However, the feed
roller continues turning in the same direction through gears [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.
[H]
[I]
[J]
[G]
[F]
[K]
[L]
[E]
Rev. 4/15/94
STM 5-7 FT6645/6655/6665
6. ONE-TURN SENSOR
The one-turn sensor [A] is located at the rear end of the pick-up roller shaft. It
counts the rotations of the pick-up rollers.
Every 360
o
, 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.
[A]
[B]
FT6645/6655/6665 5-8 STM
7. ORIGINAL SETTING FOR RECYCLE
When the Start Key is pressed, the original gate solenoid [A] is energized to
open the original gate. At the same time, the push plate solenoid [B] is
energized and the pick-up rollers start turning. The pick-up rollers and the
push plate move the entire stack of originals to the feed-in section.
At this time, the originals turn the recycle sensor on. After that, the originals
are fed one by one from the bottom of the stack. The recycle sensor stays on
until the last original is fed.
The copied originals are fed out from the feed-out unit onto the original
stacker where they wait for the next cycle.
When the last original is fed in from the feed-in section, the recycle sensor
turns off. This informs the RDH CPU that all the originals have been fed in for
the first set of copies.
Soon after the last original passes the recycle sensor, the original gate is
opened again and the push plate and the pick-up rollers move the stack of
originals to the feed-in section for the second cycle. This is the pre-stacking
cycle. However, the last few originals of the first cycle have not fed out yet, at
this moment. 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
8 1/2"x11" originals (sideways feed and 100% reproduction ratio).
[B]
[A]
STM 5-9 FT6645/6655/6665
8. ORIGINAL FEED-IN
Soon after the entire stack of the originals are moved to the feed-in position
(1), the feed-in clutch and the friction belt motor turn on. The friction belt
motor rotates for 50 milliseconds counter to the direction of the feed roller
rotation to ensure the separation of the bottom original (2).
When the leading edge of the original reaches the registration sensor, the
feed-in clutch turns off and the feed-in motor reverses (3). From this time
onward, the pull-out rollers take over and feed the original to the transport
section.
The registration sensor also serves to measure the original length. The RDH
CPU determines the original size by counting how many pulses it receives
while the original passes the sensor.
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.
(1)
(3)
(2)
50m sec
(1) (2)
(3)
(1)
(2)
(2)
(2)
(3)
100ms
Registration Sensor
Feed-in MC
Feed-in Motor
Transport Belt
One-turn Sensor
Friction Belt
Motor
Motor
FT6645/6655/6665 5-10 STM
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.
[D]
[B]
[C]
[E]
[A]
STM 5-11 FT6645/6655/6665
When the Start key is pressed, the two sided original is fed into the transport
section. The inverter solenoid is energized at the same time as the transport
belt motor and the friction belt motor turns on. (1)
When the trailing edge of the original passes the registration sensor, the
inverter motor [D] starts turning. (2)
The original passes over the exposure glass and goes into the inverter
section. Since the inverter pawls are already open at that time, the original is
inverted and directed back to the transport belt section. The transport belt
motor reverses 239 pulses after the leading edge of the original passes the
inverter sensor [E]. (3)
The transport belt then moves the original to the original scale.
The back side of the original is copied first.
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.
Registration Sensor
Inverter Sensor
Inverter Sol.
Transport Belt Motor
Inverter Motor
239 pls
(1)
(2)
(3)
(1)
(3)
(2)
(1)
Motor
Friction Belt
FT6645/6655/6665 5-12 STM
10. ORIGINAL FEED-OUT MECHANISM
When the RDH receives the feed-out signal from the copier, the transport belt
motor, the inverter motor, and the feed-out motor [A] start turning. Since the
inverter solenoid is off at this time, the inverter pawls are positioned to direct
the original to the exit relay belts [B]. The original is fed to the feed-out unit by
the exit relay belts and then fed out of the RDH unit.
The feed-out motor drops to half of its normal speed 100 milliseconds after
the originals leading edge passes the feed-out sensor [C]. It stays at half
speed until 180 milliseconds after the originals trailing edge passes the
feed-out sensor. This lower speed prevents uneven stacking of originals.
For B4/81/2" x 14" and larger originals, the feed-out motor changes its speed
280 milliseconds after the originals leading edge passes the feed-out sensor.
[B]
[C]
[A]
STM 5-13 FT6645/6655/6665
11. 1 SIDED ORIGINAL TO 2 SIDED COPY MODE
When making two-sided copies, only the even pages of the original stack are
scanned and copied to paper fed from the selected paper tray. They are
stored in the duplex tray. Then the originals are recirculated and the odd
pages of the originals are copied onto the sheets stored in the duplex tray.
When making two or more sets of copies, the following copy sets are made in
the same way as the first set copy.
Therefore, the original recirculates twice for each copy set.
11.1 -Operation-
(For example)
Two sets of two-sided copies are made from four one-sided originals.
1) When the start key is pressed, the 4th and 2nd originals are
scanned then these copies are stacked in the duplex tray. The
3rd and 1st originals have only passed over the exposure glass
[Fig. 1].
2) Soon after the 1st recirculation is completed, the second
recirculation starts. The 4th original passes over the exposure
glass without being scanned then the 3rd original is scanned.
This image is copied onto the copy which has been fed from the
duplex tray and is then fed out to the finisher [Fig. 2].
3) The 2nd original passes over the exposure glass without being
scanned and then the 1st original is scanned. The copy from the
duplex tray is fed for copying the 1st original and then fed out to
the finisher. At this moment, the duplex tray becomes empty [Fig.
3].
4) The following steps repeat steps 1) to 3). [Fig. 4] to [Fig. 6].
FT6645/6655/6665 5-14 STM
1 2 3 4: 1st recirculated
1 2 3 4: 2nd recirculated
' J: 3rd recirculated
0 O O O: 4th recirculated
: Without exposing
(for RDH)
Rev. 4/15/94
<Duplex>
<RDH>
<Paper tray>
2
4
1
3
2
4
1st
SET
1
2
2
4
3
4
3
1
2
2
4
3
4
3
1
2
0
O
O
O
O
J
2
4
1
3
J
2
4
0
O
O
O
0
O
1
3
'
J 1
2
3
4
J
2nd
SET
STM 5-15 FT6645/6655/6665
12. ALTERNATE PAPER FEED (FT6665 A097
ONLY)
An alternate paper feed system can be used when the RDH and Finisher are
installed.
This alternate paper feed system is a relatively efficient way to make two or
more two-sided copies from two or more one-sided originals when the copier
is equipped with an RDH.
When making two-sided copies, first the even pages of the original stack are
copied to the paper from the selected paper tray. These are then stored in
the duplex tray. After the originals are recirculated, the odd pages of the
originals are copied to the sheets stored in the duplex tray.
When making two or more sets of copies, the even pages of the recirculated
originals are copied and they are stored in the duplex tray. The odd pages of
the recirculated originals are copied to the sheets stored in the duplex tray.
There are many benefits for this system.
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.
Rev. 10/94
FT6645/6655/6665 5-16 STM
Operation
(For example)
Two sets of two-sided copies are made from four one-sided originals.
1) When the start key is pressed the 4th and 2nd originals are scanned,
then these copies are stacked in the duplex tray. The 3rd and 1st
originals have only passed over the exposure glass [Fig 1].
2) The 4th original is scanned a second time and the copy is stacked in the
duplex tray. Soon after this, the bottom copy in the duplex tray is fed until
its leading edge reaches the duplex exit sensor (stand-by position). This
is in preparation for reverse side copying [Fig 2].
3) The 3rd original is now scanned. The copy which has been in the
stand-by position is fed for copying the 3rd original and then fed out to the
exit tray [Fig 3].
4) The 2nd original is scanned and then it is stacked in the duplex tray.
Soon after this, the bottom copy in the duplex tray is fed in preparation for the
reverse side copying [Fig 4].
5) 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 5].
6) The 4th original is fed across the exposure glass and out from the RDH
without exposing. After this, the bottom copy in the duplex tray is fed in
preparation for the reverse side copying [Fig 6].
7) The 3rd original is scanned. The copy which has been in the stand-by
position is fed for copying the 3rd original and then fed out to the exit tray
[Fig 6].
8) The 2nd original passes over the exposure glass. After this, the bottom
copy in the duplex tray is fed in preparation for the reverse side copying
[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].
Rev. 10/94
STM 5-17 FT6645/6655/6665
Fig 1 Fig 2 Fig 3
Fig 4 Fig 5 Fig 6
Rev. 10/94
3
4
1
2
2
4
<Duplex tray>
<Paper tray>
<RDH>
'

2
4
J
4
J
2
4
'

4
O
'

2
J
2

4
O
O
J
'

O
O
O
'
2
2
4
O
O
O
0
O
'

J
J
2
4
3
4
O
0
'

J
O
0
2
4
: Recirculated
B: 3rd recirculated
: Without exposing
(for RDH)
FT6645/6655/6665 5-18 STM
13. ORIGINAL MISFEED SENSING
The copier CPU lights the original misfeed indicator if the previous original
remains on the exposure glass after manual copying and RDH feed is
attempted. When the RDH is lifted and the previous original is removed, RDH
copying is permitted.
13.1 One-sided original
If the registration sensor is not actuated within 750 milliseconds after the
feed-in motor starts turning, the Original Misfeed indicator lights (ON check).
If the registration sensor does not turn off within 640 milliseconds, the CPU
determines that there has been an original misfeed (OFF check).
If the inverter sensor is not actuated within 700 milliseconds after the inverter
motor starts turning (ON check) or if the inverter sensor does not turn off
within 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).
Rev. 10/94
Registration
Sensor
Inverter
Sensor
Feed-out
Sensor
Feed-in
Motor
Inverter
Motor
ON Check
(750 ms)
OFF Check
(640 ms)
ON Check
(700 ms)
OFF Check
(850 ms)
ON Check
(700 ms)
OFF Check
(1250 ms)
STM 5-19 FT6645/6655/6665
13.2 Two-sided original
The ON/OFF check timing of the registration sensor is the same as in the
one-sided original mode.
For original inversion, if the inverter sensor is not actuated within 750
milliseconds after the inverter motor turns on (ON check) or if the inverter
sensor does not turn off within 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.
Rev. 10/94
Registration
Sensor
Inverter
Sensor
Feed-out
Sensor
Transport
Belt Motor
Inverter
Motor
ON Check
(750 ms)
OFF Check
(640 ms)
ON Check
(700 ms)
OFF Check
(1250 ms)
ON
(750 ms)
Check
OFF
(700 ms)
Check
ON
(750 ms)
Check
OFF
(700 ms)
Check
ON
(750 ms)
Check
OFF
(700 ms)
Check
FT6645/6655/6665 5-20 STM
SECTION 6
FINISHER
SR400
(Machine Code:A379)
1. OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
Paper Size: Maximum: 11" x 17"/A3
Minimum: 51/2" x 81/2"/A6
Paper Weight: Standard copying/Stack mode
14 ~ 42 lb/52 ~ 157 g/m
2
Staple mode
17 ~ 20 lb/64 ~ 80 g/m
2
Paper Capacity: 1,500 sheets:
81/2" x 11"/A4 or smaller size (20 lb/80 g/m
2
)
1,000 sheets:
81/2" x 14"/B4 or larger size (20 lb/80 g/m
2
)
Stapler Capacity: 81/2" x 11"/A4 (20 lb/80 g/m
2
):
from 2 to 50 sheets
81/2" x 14"/B4 or large size (20 lb/80 g/m
2
):
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)
Rev. 4/15/94
STM 6-1 FT6645/6655/6665
Stapling Position:

Dimensions: 26.4" x 20.2" x 37.4"
(671 mm x 514 mm x 950 mm)
Rev. 4/15/94
a
b
a a
b
b
a = 0.24" 0.12" (6 3 mm)
b = 0.24" 0.12" (6 3 mm)
a = 0.24" 0.12" (6 3 mm)
b = 0.24" 0.12" (6 3 mm)
a = 0.24" 0.12" (6 3 mm)
b = 5.20" 0.12" (13.2 3 mm)
(1 staple) (2 staples)
FT6645/6655/6665 6-2 STM

Rev. 4/15/94
8
7
5
6
12
11
9
10
1
13
4
2
3
1. Stack Height Sensor Feeler
2. Shift Tray
3. Shift Tray Positioning Roller
4. Jogger Unit
5. Positioning Roller
6. Stack Feed-out Belt
7. Stapler Unit
8. Alignment Brush Roller
9. Lower Transport Rollers
10. Entrance Rollers
11. Junction Gate
12. Upper Transport Rollers
13. Exit Rollers
STM 6-3 FT6645/6655/6665
1.3 ELECTRICAL COMPONENT DESCRIPTION
Point (water proof paper) index numbers.
Index
No.
Motors
M1 Transport Drive Drives transport rollers. 23
M2 Shift Tray Lift Moves the shift tray up or down. 24
M3 Exit Drive Drives the exit and shift tray
positioning rollers.
22
M4 Stack Feed-out Drives the stack feed-out belt. 5
M5 Jogger Moves the jogger fences. 17
M6 Stapler Drive Moves the stapler unit. 14
M7 Shift Moves the shift tray side to side. 8
M8 Staple Drives the staple hammer. 12
Sensors
S1 Entrance Detects copy paper entering into
the finisher.
25
S2 Jogger Unit Entrance Detects copy paper entering into
the jogger unit.
18
S3 Jogger Unit Paper Detects copy paper in the jogger
unit.
6
S4 Stack Feed-out Belt
HP
Detects the home position of the
stack feed-out belt.
15
S5 Jogger HP Detects the jogger home position. 16
S6 Exit Detects misfeeds in exit area. 3
S7 Stack Height 1 Detects copy paper stack height
in staple mode.
2
S8 Stack Height 2 Detects copy paper stack height
in sort/stack mode.
1
S9 Shift Tray Lower Limit Detects the lower limit of the shift
tray position.
13
S10 Stapler Hammer HP Detects the staple hammer home
position.
11
FT6645/6655/6665 6-4 STM
Index
No.
S11 Shift Tray Half-Turn Detects shift tray side-to-side
position.
7
S12 Stapler Unit HP Detects the stapler unit home
position.
9
S13 Staple End Detects staples in the cartridge 10
Switches
SW1 Front Door Safety
(Switch)
Cuts dc power when the front
door is opened.
26
SW2 Shift Tray Upper
Limit (Switch)
Detects the upper limit of the shift
tray position.
4
Solenoids
SOL1 Positioning Roller Lowers the positioning roller in
the jogger unit.
19
SOL2 Junction Gate Drives the junction gate. 21
PCBs
PCB1 Main Control Controls overall finisher operation. 20
STM 6-5 FT6645/6655/6665
1.4 DRIVE LAYOUT

1. Exit Drive Motor
2. Upper Transport Drive Belt
3. Shift Tray Lift Motor
4. Transport Drive Motor
5. Transport Drive Belt
6. Lower Transport Drive Belt
7. Shift Tray Lift Belt
8. Shift Motor
9. Shift Cam
10. Exit Roller
11. Stack Feed-out Motor
12. Jogger Motor
13. Stapler Drive Motor
14. Stapler Drive Belt
15. Jogger Drive Belt
16. Stack Feed-out Belt
8
7
5
6
9
10
1 4 2 3
11
13
12
14
15
16
FT6645/6655/6665 6-6 STM
1.5 BASIC OPERATION

After the copy is completed, the paper is directed to the finisher. If the
sort/stack mode is selected, the junction gate [A] directs the paper upwards
to transport it to the shift tray [B]. In these modes, the shift tray is shifted from
side to side to stagger and separate sets of copies. The amount of shift is
approximately 30 mm.
When the staple mode is selected, the junction gate directs the paper below
to transport the paper to the jogger unit [C]. Each time a copy is delivered to
the jogger unit, the positioning roller [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.
[A]
[B]
[C]
[D]
[E]
[F]
Rev. 4/15/94
STM 6-7 FT6645/6655/6665
2. SECTIONAL DESCRIPTIONS
2.1 PAPER DELIVERY SWITCHING

Depending on the selected finishing mode, the copies are directed up or
down by the junction gate [A], is controlled by a solenoid.
(1) When the exit sensor of the copier is activated while in the sort/stack
mode, the solenoid [B] stays off. The junction gate directs the copies up
to deliver them to the shift tray.
(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.
Sort/Stack Mode Staple Mode
[B]
[A]
FT6645/6655/6665 6-8 STM
2.2 SHIFT TRAY UP/DOWN MECHANISM

The vertical position of the shift tray [A] is controlled by the shift tray lift motor
(dc motor) [B] through gears and timing belts [C]. When the main switch is
turned on, the tray position is initialized to the upper position. The trays
uppermost position is detected when the shift tray pushes up the actuator [D]
to deactuate (unblock) the stack height sensor 1 [E].
While copying, the actuator [D] is gradually raised as the copy stack grows. In
the sort/stack mode, when stack height sensor 2 [F] remains actuated for 4
seconds, the shift tray lift motor [B] rotates, lowering the tray unit for 50 ms.
When staple mode is selected the shift tray lowers automatically to allow
space under the positioning roller [J] for the stapled copy job. In staple mode
as the copy job builds up and stack height sensor 1 [E] remains unblocked
for 4 seconds, the motor rotates, lowering the tray until stack height sensor 1
is blocked.
When the tray reaches its lower limit position, the lower limit sensor [G] is
actuated by the actuator [H], and copy operation stops.
After the copy process is finished and the machine stops, the tray is raised to
its upper most position 4 seconds after the copies are removed.
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.
Rev. 10/94
[A]
[E]
[D]
[F]
[B]
[H]
[J]
[C]
[I]
[G]
STM 6-9 FT6645/6655/6665
2.3 SHIFT TRAY SIDE-TO-SIDE SHIFT MECHANISM

In the sort/stack mode, the shift tray [A] moves from side to side to stagger
and separate sets of copies.
The horizontal position of the shift tray is controlled by the shift motor (dc
motor) [B] and the shift cam (helical cam) [C]. After one set of originals is
copied and delivered to the shift tray, the shift motor [B] starts rotating, driving
the shift cam through the timing belt. The pin [D] fixed to the shift tray base
plate [E] is positioned in the groove on the shift cam, creating the side-to-side
movement required to stagger copies.
When the shift cam rotates 180 degrees (when the tray is fully shifted.), the
plate [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.
[A]
[B] [C]
[D]
[E]
[F]
[G]
[H]
FT6645/6655/6665 6-10 STM
2.4 STAPLE UNIT PAPER POSITIONING
In the staple mode, copies are vertically and horizontally aligned in the jogger
unit before being stapled.
For horizontal paper alignment, the jogger motor [A] moves both the front and
the rear jogger fences [B] to align the copies.
For vertical paper alignment, the positioning roller [C] and the alignment
brush roller [D] push the copy against the stack stopper [E].
After the trailing edge of the copy passes the jogger unit entrance sensor [F],
the positioning roller solenoid [G] is energized for 280 ms pushing the
positioning roller into contact with the paper. 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].
[F]
[E]
[C]
[D]
[A]
[B]
[G]
[H]
[F]
[C]
STM 6-11 FT6645/6655/6665
2.5 JOGGER MOVEMENT

When the Start key is pressed, the copier sends the paper size information to
the finisher. In accordance with that data, the jogger motor (stepper motor)
starts rotating to position the front and rear jogger fences [A] 7 mm away from
the selected papers edges. (1)
After the trailing edge of the copy passes the jogger unit entrance sensor,
each jogger fence moves inward 5 mm. They stop 2 mm away from the paper
edges. (2)
Just after the positioning roller pushes the copy back, each jogger fence
moves inward 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.
7 mm 2 mm
(2) (1) (3)
[A] [B]
FT6645/6655/6665 6-12 STM
2.6 STAPLER

The staple hammer [A] is driven by the staple motor [B] via gears [C], two
eccentric cams [D], and two links [E].
When the aligned copies are brought to the staple position by the positioning
roller, alignment brush roller, and jogger fences, the stapler motor starts
rotating. 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.
[E]
[C]
[B]
[A]
[F]
[D]
[G]
STM 6-13 FT6645/6655/6665
2.7 STAPLER UNIT SIDE-TO-SIDE MOVEMENT

Customers can select one of the following three different staple modes:
Staple 1: Top left
Staple 2: Bottom left
Staple 3: Top/Bottom left
The stapler drive motor [A] (stepper motor) moves the stapler unit [B] from
side to side. When the Start key is pressed, the stapler moves from its home
position to the staple position.
If staple mode 3 is selected, the stapler unit moves to the front staple position
first, then moves to the rear staple position. However, for the next copy set, it
staples in the reverse order; that is, at the rear side first and then at the front.
After the job is completed, the stapler unit moves back to its home position.
(The stapler unit home position sensor [C] is actuated.)
[A]
[B]
[C]
FT6645/6655/6665 6-14 STM
2.8 FEED-OUT TO SHIFT TRAY

After being stapled, the stack feed-out motor [A] starts rotating. The pawl [B]
on the lift belt [C] transports the set of stapled copies up, and feeds it to the
shift tray. Approximately 0.6 second after the stack feed-out motor starts, the
motor stops for 400 ms. At this moment, the exit rollers [E] catch the stapled
copies to feed them out to the shift tray. Then the motor rotates again until
the pawl unblocks its home position sensor [D].
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.

[A]
[D]
[B]
[B]
[C]
[E]
STM 6-15 FT6645/6655/6665
SECTION 7
LARGE CAPACITY TRAY
RT31
1. SPECIFICATIONS
Copy Paper Size: A4 sideways
B5 Sideways
8 1/2" x 11" sideways
Copy Paper Weight: 64 ~ 105g/m
2
; 16~24lb
Power Source: DC24V, 5V (from the copier)
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)
STM 7-1 FT6645/6655/6665

1. Bottom Plate
2. Tray Drive Belt
3. Separation Roller
4. Transport Rollers
5. Feed Roller
6. Pick-up Roller
1
2
3
4
6
5
FT6645/6655/6665 7-2 STM
Refer to the electrical component layout on the reverse side of the Point to Point (Water proof
Paper) for symbols and index numbers.
Symbol Name Function Index No.
Sensors
S50 Paper End Informs the CPU that there is no
paper on the LCT bottom plate.
129
S51 Paper Near End Informs the CPU that about 60
sheets of paper remain on the LCT
bottom plate.
130
S52 Paper Position Detects the paper position. 131
S53 Tray Down Informs the CPU that the LCT
bottom plate is in the lowest
position.
133
S54 Feed Controls the paper feed clutch
off-on timing and the pick-up
solenoid off timing.
136
S55 Lift Detects the correct paper feed
height.
137
Switches
SW11 Feed Unit Cover Detects if the feed unit cover is
open or not.
Note:* There are two separate
switches.
128
SW12 LCT Cover Detects if the LCT cover is open or
not.
Note:* There are three separate
switches.
134
SW13 Tray Down Lowers the LCT bottom plate. 135
Motors
M22 LCT Lifts and lowers the LCT bottom
plate to bring paper to the feed
position and allow loading of the
paper.
132
M23 Feed Drives all feed and transport rollers. 140
Others
SOL14 Pick-up Controls the up-down movement of
the pick-up roller.
138
MC9 Feed Starts paper feed from the LCT. 139
* See copier Point to Point
diagram coordinates K9 &
K10
STM 7-3 FT6645/6655/6665
4. MECHANICAL OPERATION
The LCT uses an FRR feed system which uses three rollers.
The pick-up [A], separation [B] and feed [C] rollers are common with those of
the by-pass feed unit of the mainframe but different from those of the paper
feed stations in the paper tray unit.
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.
[A]
[B]
[C]
[D]
[E]
[F] [G]
FT6645/6655/6665 7-4 STM
5. PAPER LIFT MECHANISM
The bottom plate [A] of the LCT is raised and lowered by the LCT motor [B]
and the drive belts [C]. When the main switch is on and the LCT cover is
closed, the pick-up solenoid [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].
[A]
[B]
[C]
[C]
[F]
[D]
[E]
STM 7-5 FT6645/6655/6665

If the tray down switch [A] is pressed, or paper runs out, or a paper jam
occurs in the LCT, the LCT motor [B] rotates counterclockwise to lower the
bottom plate. However, it is not lowered all the way down at this time. When
the paper position sensor [C] turns off, the LCT motor stops once. At this
point, the bottom plate (or the top sheet of paper) is positioned about 5cm
below the top. This gives enough space for the customer to replenish about
500 sheets of paper.
If the tray down switch is then pressed again, the bottom plate moves down
and stops once again when the top sheet of paper just passes the paper
position sensor. In this way, the bottom plate is lowered 5cm at each press of
the tray down switch. This allows the customer to replenish paper in
convenient amounts and at the same position.
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.
Rev. 4/15/94
[A]
[B]
[C]
[D]
FT6645/6655/6665 7-6 STM
6. PAPER END DETECTION

The paper end sensor [A] detects paper on the bottom plate. If there is paper
on the table, reflected light from the paper activates the paper end sensor.
When the paper runs out, the paper end sensor de-activates and informs the
copier CPU of the paper end condition.
The paper near end sensor [B] also detects the paper and the tray bottom
plate. If there is enough paper on the table, reflected light from the paper
activates the paper near end sensor.
If less than about 60 sheets of paper remain, the paper near end sensor
de-activates because the black colored bottom plate does not reflect the light
from the sensor LED. When the paper near end sensor is deactivated, the
display for the LCT will change as shown below:
sensor activated sensor de-activated
[A]
[B]
[A]
81/2 x 11
81/2 x 11
Rev. 4/15/94
STM 7-7 FT6645/6655/6665
SECTION 8
SORTER STAPLER ST24
1. SPECIFICATIONS
Paper Size for Bins: Sort or stack mode:
Maximum: 11" x 17"
Minimum: 81/2" x 11"
Staple mode:
Maximum: 11" x 17"
Minimum: 81/2" x 11"
Paper Weight for Bins: Sort or stack mode:
14 - 25 lb
Staple mode:
14 - 21 lb
Number of Bins: 20 bins + proof tray
Bin Capacity: Sort mode: 30 sheets 81/2" x 11"
15 sheets 11" x 17"
Stack mode: 15 sheets
Proof tray - 100 sheets
14 22 lb
- 50 sheets
23 34 lb
- 30 sheets
35 42 lb
Stapler Capacity: From 2 to 20 sheets (20 lb) (2 to 10 sheets
when using 11"x17" or 81/2"x14")
Stapling Position:
Rev. 6/93
a
b
a = b
= 6 2 mm
= 0.24" 0.08"
(Horizontal)
a
b
a = 10 2 mm
= 0.39" 0.08"
b = 16 2 mm
= 0.63" 0.08"
(Diagonal)
STM 8-1 FT6645/6655/6665
Staple Replenishment: Cartridge exchange
(3,000 pieces/cartridge)
Power Source: DC 24V, 5V (from the copier)
Power Consumption: 50 W
Dimensions:
(W x D x H)
16.2" x 23.6" x 27.1"
Weight: About 55.1 lb
(Main Frame : 48.5 lb
Mounting Frame: 6.6)
FT6645/6655/6665 8-2 STM
2. COMPONENT LAYOUT
1. Proof Tray
2. Proof Tray Exit Rollers
3. Vertical Transport Rollers
4. Turn Gate
5. Bin Transport Belt
6. Bin Transport roller
7. Bin Exit Roller
8. Stapler
9. Grip Assembly
10. Bin Support Block
11. Bins
12. Support Bin
13. Jogger Bar
1
2
3
4
5
6
7
8
9
10
11
12
13
STM 8-3 FT6645/6655/6665
2.2 DRIVE LAY OUT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
19
17
20
21
22
23
4. Roller Drive Motor Pulley
3. Rear Roller Drive Belt
2. Proof Tray Exit Roller
Pulley (Rear)
(Proof Tray Exit Roller)
19. Proof Tray Exit Roller
Pulley (Front)
18. Front Roller Drive Belt
15. Bin Transport Drive Gear
14. Bin Transport Belts
17. Vertical Transport
Drive Pulley
11. Bin Lift Motor Pulley
8. Bin Lift Drive Belt
7. Bin Lift Gears
6. Bin Lift Gear/Pulley
12. Rear Bin Lift Wire
13. Rear Bin Support
Block
21. Bin Drive Shaft
20. Front Bin Lift
Pully
16. Front Bin Lift
Wire
22. Front Bin
Support Block
10. Jogger Motor Pulley
13. Lower Jogger Drive Belt
23. Jogger Bar
5. Jogger Drive Shaft
1. Upper Jogger
Drive Belt
FT6645/6655/6665 8-4 STM
2.3 ELECTRICAL COMPONENT DESCRIPTION
Point (Water proof paper) for symbols and index numbers.
Index
No.
Motors
M1 Bin Lift
Lifts and lowers the bins via a belt, gears, and
wires.
23
M2 Jogger
Drives the jogger bar to jog the copies against
the front side plate.
20
M3 Grip
Drives the grip assembly forward and backward
into the bin to grip the copies and bring them to
the stapling position.
13
M4 Stapler Feeds the staples and drives the stapler hammer. 12
M5 Roller Drive
Drives the proof tray exit and vertical transport
rollers, and bin transport belts.
1
Circuit Board
PCB1 Main Control Controls all sorter stapler functions. 18
Solenoid
SOL 1 Turn Gate
Opens and closes the turn gate to direct the
copies into either the proof tray or the bins.
6
Sensors
S1 Bin Lift Timing -1
Monitors the rotation of the bin lift motor by
detecting the timing disk.
24 or 25
S2 Bin Lift Timing -2
Controls the stop timing of the bin lift motor so
that the bin lift timing sensor -1 can detect the
timing disk properly.
24 or 25
S3 Jogger H.P. Detects if the jogger bar is in the home position. 19
S4 Paper Detects if copies are under the hammer. 8
S5 Bin (LED)
Detects if there is paper in the bins (light emitting
element).
3
S6 Bin (Photo transistor)
Detects if there is paper in the bins (light
receiving element).
17
S7 Grip H.P.
Detects if the grip assembly is in the home
position.
16
S8 Bin H.P.
Detects if all the bins are in the down (home)
position.
15
S9 Bin Exit Detects paper jams at the bin exit area. 5
S10 Proof Tray Exit Detects paper jams at the proof tray exit area. 4
S11 Roller Drive Timing
Monitors the roller drive motor speed by
detecting the timing disk.
2
Switches
SW1 Upper Lift Limit
Stops the bin lift motor when this switch detects
the upper limit position of the bins.
22
SW2 Wire Tension
Stops the bin lift motor when this switch detects
the lower limit position of the bins through the bin
lift wire tension.
21
STM 8-5 FT6645/6655/6665
Index
No.
SW3 Front Door Cuts the dc 24 V line when the front door is open. 14
SW4 Sorter Stapler Set
Cuts the dc 24 V line when the sorter stapler unit
is open.
7
SW5 Staple End Detects the staple end condition. 10
SW6 Staple Guide Detects if the staple guide plate is closed. 9
SW7 Staple H.P.
Detects if the staple hammer is in the home
position.
11
FT6645/6655/6665 8-6 STM
3. BASIC OPERATION
3.1 NORMAL MODE AND SORT/STACK MODE
Copies [A] exiting the copier pass through the entrance guide plates to the
turn gate section. The turn gate [B] will send copies either to the proof tray or
to the bins, depending on the mode.
- Normal mode - (from the turn gate section to the proof tray)
When the S/S CPU receives the motor ON signal from the copier, the roller
drive motor [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].
[E] [C]
[G]
[F]
[B]
[A]
[D]
STM 8-7 FT6645/6655/6665
- Sort/Stack mode - (from the turn gate section to the bins)

The turn gate solenoid [A] stays off and the turn gate [B] stays up when the
S/S roller drive motor [C] starts rotating. The turn gate directs copies
downward and the bin transport belt [D] exits copies to the bin through the
bin transport and bin exit rollers [E, F].
The jogger bar [G] then moves the copy towards the front and jogs it against
the front side plate to square the copies.
The bin lift motor [H] turns on when this jogging operation is almost finished
and advances each bin one step up along the bin cam track [I]. The bin lift
motor stops at the proper timing to position the next bin at the bin exit
section. 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.
[G]
[C]
[I]
[B]
[D]
[E]
[F]
[H]
[A]
FT6645/6655/6665 8-8 STM
3.2 STAPLE MODE

When the final set of copies is jogged in the sort mode, the staple unit staples
the stacked copies as follows:
(Figure 1)
If the final copy is exited to a bin other than the first one, all the bins lower to
the home position (the first bin is positioned at the bin exit section). The
jogger bar [A] moves towards the front to jog the copies stacked in the first
bin. Then it stops 15mm away from the paper side edge.
(Figure 2)
The bins move one step up to place the first bin at the stapling section.
(Figure 3)
The grippers [B] move forward, and grip the copies.
(Figure 4)
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.
[A]
(Fig. 1) (Fig. 2)
[B]
(Fig. 3)
(Fig. 4)
STM 8-9 FT6645/6655/6665

(Figure 5)
The stapler staples the copies.
(Figure 6)
The copies are pushed back into the bin. Then the grippers open and return
to the home position.
The bins move one step up for the next stapling.
When the final set of copies is stapled, the bins lower and stop when the final
bin used just before the stapling operation is positioned at the bin exit section.
There are two staple modes.
1) Automatic stapling:
In ADF/ARDF mode, when the staple mode is selected before pressing
the start key, copies will be delivered to each bin and stapled
automatically.
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.
(Fig. 5)
(Fig. 6)
FT6645/6655/6665 8-10 STM
4. TURN GATE SECTION
The turn gate directs copies to the proof tray or to the bins depending on the
mode.
In the normal mode, the turn gate solenoid [A] turns on together with the
roller drive motor when the S/S CPU receives the motor ON signal from the
copier. The turn gate [B] rotates clockwise to direct copies upward [C]
through the vertical transport section to the proof tray. The turn gate solenoid
stays on during the copy cycle, and turns off when the proof tray exit sensor
detects the trailing edge of the last copy and the S/S CPU receives the motor
OFF signal from the copier.
In the sort, stack, or staple mode, the turn gate solenoid stays off to keep the
turn gate up so that copies are directed downward [D] to the bin transport
section.
However, a certain number of pulses (depending on the paper size) after the
bin exit sensor detects the leading edge of the copy, the turn gate solenoid
turns on. When the trailing edge of the copy passes the turn gate (50 msec.
after the S/S CPU receives the paper exit signal from the copier), the turn
gate solenoid turns off to direct the next copy downward. 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.
[B]
[A]
[B]
[A]
[C]
[D]
STM 8-11 FT6645/6655/6665
5. ROLLER DRIVE AND CONTROL
The roller drive motor (stepper motor) [A] drives the proof tray exit rollers
[B], vertical transport rollers [C], bin transport belts [D], bin transport rollers
[E], and bin exit rollers [F] via the front and rear roller drive belts [G,H],
pulleys, and gears, as shown above.
The roller drive motor turns on when the S/S CPU receives the motor ON
signal from the copier. When the proof tray exit sensor [I] (in the normal
mode) or the bin exit sensor [J] (in the sort/stack/staple mode) detects the
trailing edge of the final copy, the S/S CPU informs the copier through the
fiber optic cable and the interface 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].
[G]
[E]
[J]
[D]
[F]
[I]
[B]
[K] [A]
[H]
[L]
[C]
FT6645/6655/6665 8-12 STM
The S/S CPU controls the motor rotation at 2 speeds (normal and high
speeds) to exit copies as fast as possible.
The normal speed depends on the copiers paper transport speed. The S/Ss
paper transport speed is almost the same but is slightly faster than the
copiers.
In the normal mode, the roller drive motor changes the paper transport
speed from normal to high (500 mm/sec., fixed) when the S/S CPU receives
the paper exit signal from the copier. The roller drive motor changes the
paper transport speed from high to normal 100 milliseconds after the proof
tray exit sensor detects the trailing edge of the copy.
In the sort/stack/staple mode, the roller drive motor also changes the paper
transport speed from normal to high and then from high to normal. The
timing is the same as in the normal mode, but the bin exit sensor is used to
detect the trailing edge instead of the proof tray exit sensor. The high speed
is almost double the normal speed, and it changes depending on the paper
size (900, 960 , or 1,000 mm/second).
STM 8-13 FT6645/6655/6665
6. BIN DRIVE AND CONTROL

All 20 bins [A] and the support bin [B] rest on the bin support blocks [C].
The front and rear bin support blocks are connected by the bin lift shafts [D]
the ends of which are fixed on the bin lift wires [E] as shown. The bin lift
motor [F] (dc motor) drives the bin lift wires through the bin lift drive belt [G],
bin lift gears [H], and the bin lift gear/pulley [I]. Then the bins are driven up
and down along the front and rear bin cam tracks [J].
The S/S CPU controls the amount of bin lift motor rotation by monitoring the
pulses of the timing disc [K] through the bin lift timing sensors 1 and 2 [L,M].
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.
[J]
[G]
[F]
[I]
[C]
[M]
[E]
[H]
[L]
[E]
[K]
[B]
[A]
[C]
[D]
[C]
FT6645/6655/6665 8-14 STM

If the bin lift motor [A] fails to stop the bins at the highest position, the rear
end of the left bin lift shaft [B] contacts the upper lift limit switch [C] (Normal
Closed type) to open the dc 24V line of the bin lift motor.
The front right bin support block [D] has an actuator on its underside. When
all the bins are lowered and the first bin is positioned at the bin exit section,
the actuator blocks the bin home position sensor [E] and the bin lift motor
turns off.
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.
[C]
[B]
[E]
[D]
[A]
[G]
[F]
STM 8-15 FT6645/6655/6665

An end fence mylar [A] is positioned on each bin entrance and an end fence
block [B] is positioned on the mylar. These are positioned with two-sided
tape, as shown in figure 1. There is a twisted spring at the rear end of the bin
entrance to raise the end fence block and mylar. When the bins are
positioned at the bin home position, the support bin [C] and the first bin [D]
are positioned at the bend of the bin cam track [E] as shown. The support
and first bins have a space between them so that the end fence mylar can
fully rise until the end fence block stops it.
The space between the support and first bins is at the bin entrance section
as shown in figure 2. Since the end fence mylar is thin, a copy exits to the
first bin over the mylar. The steep angle of the bin helps the exited copy slide
by its own weight under the mylar against the bin entrance.
While the bins move up along the bend of the bin cam track, the end fence
mylar and block of the first bin are lowered by the support bin. Those of the
second bin [F] rise as shown in figure 3.
When the bin lift motor stops, the first and second bins are positioned as
shown in figure 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.
[A]
[B]
[E]
[C]
[D]
(Fig. 1) (Fig. 2)
[F]
(Fig. 3) (Fig. 4)
FT6645/6655/6665 8-16 STM
7. JOGGER SECTION

When the start key is pressed in the sort, stack, or staple mode, the copier
sends the paper size information to the sorter stapler. When paper enters the
sorter stapler, the jogger bar [A] stays at the home position which is detected
by the jogger home position sensor [B].
After the trailing edge of the copy is detected by the bin exit sensor, the
jogger motor [C] (stepper motor) rotates and reverses to move the jogger
bar via the upper and lower jogger drive belts [D,E]. As the copy exits into
the bin at the center, the jogger bar moves the copy all the way to the front
and continues to push the papers side edge an additional 5 mm (0.2")
against the front side plate [F]. Then the jogger bar moves back to the
position which matches the paper width. Shortly afterward, the jogger bar
returns to its home position. 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.
[D]
[F]
[A]
[E]
[B]
[C]
STM 8-17 FT6645/6655/6665
- Jogger off conditions -
1. Under the following conditions, the jogger bar does not jog after a copy is
delivered to the bin.
If paper is loaded in a bin by hand while the sort/stack, or staple
mode is selected.
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 STM
8. GRIP ASSEMBLY
(Figure 1)
The grip assembly consists of the gripper guide bracket [A], the gripper
assembly [B], and the bin side plate [C]. The major components of the
gripper assembly are the gripper motor [D] (stepper motor), dual cam plate
[E], grip home position sensor [F], grippers [G], and grip cam follower [H].
When the copier main switch is turned on, the grip motor rotates and/or
reverses to position the whole gripper assembly at the home position. The
home position is detected by the grip home position sensor and the sensor
actuator on the dual cam plate.
(Figure 2)
When the bin lift motor stops during the automatic or manual stapling cycle,
the grip motor starts rotating. As the dual cam plate turns counterclockwise,
the cam groove [I] and the pin [J] on the gripper guide bracket move the
whole gripper assembly along the gripper guide rod [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.
[A]
[E]
[B]
[D]
[F]
[H]
[G]
[C]
(Fig. 1)
[L]
(Fig. 3)
[J]
[I]
[K]
(Fig. 2)
STM 8-19 FT6645/6655/6665

(Figure 4)
As the dual cam plate rotates further, the cam groove and the pin move the
whole gripper assembly back with the gripped copies to the stapling position.
Then the grip motor stops as programmed.
(Figure 5 and 6)
The upper gripper has a projection [A] to hook the bin side plate [B]. When
the gripper moves into the bin, the projection moves over the bin side plate.
When the grippers close, the projection hooks the bin side plate. Therefore,
the grippers bring the stacked copies together with the bin side plate.
When the grippers move to the stapling position, the S/S CPU checks if there
is paper or not through the paper sensor [C]. If the paper sensor is activated,
the stapler motor starts rotating.
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.
(Fig. 4)
[C]
[A]
[B]
[C]
(Fig. 5) (Fig. 6)
FT6645/6655/6665 8-20 STM
9. STAPLER

In the automatic or manual stapling mode, the stapler motor [A] rotates when
the grip motor stops rotating after the grippers bring the stacked copies to
the staple position.
The staple gear [B] rotates counterclockwise, and the pin on the gear rotates
the staple arm [C] counterclockwise, then clockwise. The ratchet [D] lowers
and rises to rotate the ratchet wheel [E] counterclockwise. Then the staple
feed rollers [F] turn via gears to feed a staple sheet to the hammer.
While both the front and rear staple arms rotate counterclockwise, the
hammer [G] lowers. At the same time, the staple cam plate [H] lifts the
clincher [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.
[C]
[D]
[A]
[E]
[F]
[B]
[B]
[G]
[I] [H]
[H]
[J]
STM 8-21 FT6645/6655/6665
When all the stapled sheets are fed out of the staple cartridge, a notch cut-in
the staple pressure plate [A] deactivates the staple end switch (Normal
Closed type) [B]. The S/S CPU sends the staple end signal to the copier.
After the stapling job for all the bins is completed, the Add Staple indicator
lights on the copier operation panel and the Ready indicator turns off
whenever the staple mode is selected.
Staple jams are easily cleared by opening the staple guide plate [C]. The
staple guide switch (Normal Closed type) [D] detects if the staple guide plate
is closed or open. When the S/S front door and S/S unit itself are closed with
the staple guide plate open, the 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.

[B]
[A]
[E]
[C]
[D]
FT6645/6655/6665 8-22 STM
- Staple inoperative conditions -
1. Under the following conditions, the staple mode is inoperative when the
staple key on the operation panel is pressed.
If paper is in a bin before the main switch is turned on.
2. Under the following conditions, the staple mode is canceled.
If the paper is loaded in a bin by hand while the staple mode is
selected.
If the number of sheets delivered to the bin exceeds the stapler
capacity.
Stapler capacity: 2 to 20 sheets for 81/2"x11"
2 to 10 sheets for 81/2"x14" and 11"x17"
The stapler capacity can be extended up to 25 or 15 by changing
the SP mode setting (Staple Limit). (The staple function is not
guaranteed.)
If jogger operation has not been performed.
If copies in all the bins are stapled.
3. Under the following conditions, the manual stapling mode in sort mode is
inoperative.
If paper is loaded in a bin by hand while the sort mode is selected.
If the paper size in the bin does not match stapling specifications.
If copies of different widths are delivered to the bin.
If copies already stapled are left in the bin.
STM 8-23 FT6645/6655/6665
10. JAM DETECTION AND STAPLE ERROR
10.1 SORTER JAMS
The sorter stapler main control board detects paper jams in the sorter
stapler, or between the sorter stapler and the copier. The S/S CPU uses the
paper exit ON/OFF signal from the copier, and the proof tray exit sensor [A]
(in normal mode) or the bin exit sensor [B](in sort/stack/staple mode) to
detect the jams.
The timing charts for jam checking in the normal and sort/stack/staple modes
are shown above. There are two time scales: one in seconds and
milliseconds, and the other in pulses. The pulses are the timing pulses from
the roller drive timing sensor. Since the paper transport speed (normal
speed) of the sorter stapler depends on that of the copier, the sorter stapler
cannot operate on a fixed time scale. Therefore, to match the sorter stapler
speed to the copiers, 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.
(200)
(0)
OFF
J3
Reset
8 seconds
122 pulses
(0)
(122)
OFF
J4
200 pulses
Reset
Reset
230 msec
OFF
J2
ON
J1
(0)
OFF
J6
Reset
8 seconds
88 pulses
(0)
(88)
OFF
J8
Reset Reset
(200)
OFF
J7
Reset
ON
J5
200 pulses
(0)
600 msec
(0)
Reset
[Normal Mode]
[Sort/Stack/Staple
Mode]
Proof Tray
Exit Sensor
Copier Paper
Exit Sensor
Bin Exit
Sensor
Copier Paper
Exit Sensor
[A]
[B]
FT6645/6655/6665 8-24 STM
If the proof tray exit sensor or the bin exit sensor is unblocked when the
sorter stapler unit or the front door is opened and closed, or when the main
switch is turned on, a sorter jam signal is sent to the copier.
Sorter jam conditions are reset by opening and closing the sorter stapler unit
or the front door after clearing jammed paper.
When an abnormal condition of the main motor, bin lift motor, or jogger
motor is detected for the first time, the copiers operation panel will indicate a
sorter jam. When the abnormal condition is detected for the second time, the
S/S CPU sends an error signal to the copier. The copiers operation panel will
indicate a service call code.
10.2 STAPLE ERROR
The sorter stapler main control board detects a staple error when the
following conditions are detected. The copiers operation panel will indicate a
sorter jam and stapling operation will stop in these cases.
If the paper sensor detects paper when the sorter stapler front door
is opened and closed or when the main switch is turned on.
If the paper sensor continues to detect paper when the grip
assembly returns to the home position after the stapling operation.
The first time an abnormal condition of the stapler motor or grip
motor is detected.
The second time an abnormal condition is detected, the copiers
operation panel will indicate a service call code.
STM 8-25 FT6645/6655/6665
11. TIMING CHART
Timing Chart 1: Normal Mode (A4 sideways, 5 copies)
Timing Chart 2: Sort Mode (A4 sideways, 2 copies for 5 bins)
Paper Size
Turn Gate Sol. ON
Timing (Pulses)
Bin Lift Motor
ON Timing
Jogger Motor
ON Timing
High Speed
(mm/s)
A3 61 220 ms 40 ms 900
B4 43 225 ms 0 ms 900
A4 sideways 1 230 ms 60 ms 960
A4 lengthwise 21 350 ms 0 ms 900
B5 sideways 1 250 ms 74 ms 1000
B5 lengthwise 8 330 ms 0 ms 900
11" x 17" 65 220 ms 0 ms 900
81/2" x 14" 41 525 ms 0 ms 900
81/2" x 11" sideways 1 230 ms 265 ms 960
81/2" x 11" lengthwise 18 725 ms 0 ms 900
(sec)
0 1 10 5 2 3 4 6 7 8 9 11 12 13 14 16
100ms
100ms
RXD
TXD
ON
OFF
OFF
Turn Gate
Solenoid
Roller Drive
Motor
Proof Tray
Exit Sensor
Interface
Normal
mode
signal
Motor ON
signal
SS paper
exit signal
Motor
OFF signal
High speed
Normal speed
Paper exit signal
from copier
0 1 10 21 5 2 3 4 6 7 8 9 11 12 13 14 15 16 17 18 19 20
(sec)
100ms
50ms
1pls
OFF
ON
100ms

OFF
exit
High
Speed
Normal
Speed
OFF
Up
230ms
Down
60ms
OFF
Forward
Reverse
1 2 3 4 5 5 4 3 2 1
signal
SS paper
RXD
TXD
Turn Gate
Solenoid
Roller
Drive
Motor
Interface
Bin Lift
Motor
Jogger
Motor
Bin Exit
Sensor
Paper exit signal from copier
Motor ON
signal
Motor OFF
signal
Bin Number
FT6645/6655/6665 8-26 STM
Timing Chart 3: Staple Operation (A4 sideways, 2 copies for 5 bins)
(sec)
0 1 10 5 2 3 4 6 7 8 9 11 12 13 14 15
OFF
OFF
OFF
ON
500ms
RXD
TXD
Up
Reverse
Reverse
Forward
Forward
Down
IInterface
Bin Lift Motor
Jogger Motor
Grip Motor
Stapler Motor
Staple ON
signal
Staple count
signal
Job completion
signal
Returns to
H.P.
1 staple cycle
STM 8-27 FT6645/6655/6665

Service Training Manual A095/A096/A097: Ricoh Group Companies

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Training Manual A095/A096/A097: Ricoh Group Companies

Uploaded by

Copyright:

Available Formats

SERVICE TRAINING MANUAL

RICOH GROUP COMPANIES

FT6645/6655/6665 4-18 STM

STM 4-19 FT6645/6655/6665

You might also like