Ricoh FT6645 Installation guide

FT6645/6655/6665
SERVICE TRAINING
MANUAL

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/m2, 14 ~ 34 lb
Bypass feed table: 52 ~ 157 g/m2, 14 ~ 42 lb
Duplex copying: 64 ~ 104 g/m2, 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
Copier only Full system*
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
sorter stapler and 3,500-sheet large capacity
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:
Copier only Full system*
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
sorter stapler and 3,500-sheet large capacity
tray
•Mainframe with dual job feeder, floor type
sorter stapler and 3,500-sheet large capacity
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)
FT6655 (A096) copier: Approximately (360 lbs)
FT6665 (A097) copier: Approximately (360 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 (20°C)
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
12
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
345
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
89
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
❺
❻
❼
❽
❾1
10 11 ❷
9
2
3
4
5
6
❹
7
❶
❸
❶Main Motor
❷Scanner Drive Motor
❸Fusing/Duplex Drive Motor
❹Paper Feed Motor
❺Toner Collection Motor
❻Registration Clutch
❼By-Pass Feed Motor
❽BY-Pass Feed Clutch
❾Development 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

Symbol Name Function Index
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

Symbol Name Function Index
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

Symbol Name Function Index
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
Position–1 Informs the CPU that the platen cover is in the up or down
position (related to APS/ARE
function).
2
S 3 Platen Cover
Position–2 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