A084/A083 Service Training Manual

A084/A083
SERVICE TRAINING
MANUAL
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2000 RICOH Corporation. All rights reserved.
LEGEND
PRODUCT CODE COMPANY
GESTETNER RICOH SAVIN
A084 2580ZDF FT8780 9080
A083 2580RDZ FT8880 9080RF
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 5/92 Original Printing
1 8/92 A084 Addition and A353
accessory
2 11/92 Replacement Pages
3 12/93 Replacement Pages
SECTION 1
OVERALL MACHINE
INFORMATION
1. SPECIFICATIONS
Copier
Configuration: Console
Copy Process: Dry Electrostatic Transfer System
Originals: Sheet/Book
Original Size: Maximum: 11" x 17"
Copy Paper Size: Maximum: 1st and 2nd tray 81/2" x 14"
3rd tray 11" x 17",
Minimum: 1st and 3rd tray 51/2" x 81/2"
2nd tray 81/2" x 11"
Copy Paper Weight: Standard Copying: 14 ~ 42 lb,
Duplex Copying: 17 ~ 28 lb,
Warm Up Time: Within 8.0 minutes (room temp. 68F, 20C)
First Copy Time: 3.9 seconds (81/2" x 11", feed from 3rd tray)
Copying Speed: 80 copies/minute (81/2" x 11")
Optional Equipment: 20 Bin Sorter Stapler B
Menu Reader
Key Counter
BTU Ratings:
Mode FT8780
Stand by 6464 BTU
Copy Cycle 5818 BTU
Rev. 2/94
STM 1-1 FT8780/8880
Reproduction Ratios: See the following table:
LT/DLT version
Enlargement
200%
155%
129%
121%
Full Size 100%
Reduction
93%
77%
74%
65%
50%
Zoom: 50 ~ 200%
Copy Exit Tray Capacity: 250 Sheets
Toner Replenishment: Cartridge exchange (1500 g)
Toner Yield: 55K/Cartridge (6% original)
Developer Type: FT8800
Toner Type: FT8800
Paper Feed: 1st tray (550 sheets)
2nd tray (3,000 sheets)
3rd tray (1,500 Sheets)
Power Source: 120 V, more than 20 A (LT/DLT version)
Power Consumption:
Maximum during LT/DLT version
Stand-by 1.90 kw
Copying Cycle 1.71 kw
Dimensions: Copier Only: 49.3" x 29.9" x 56.9"
Copier w/LCT: 67.7" x 29.9" x 56.9"
Full System (Copier, LCT and Sorter Stapler)
With 1 Sorter: 81.5" x 34.4" x 56.9"
With 2 Sorters: 103" x 34.4" x 56.9"
Weight:
Copier Only: 63 dB
With Sorter: 64 dB
Noise Emission:
Rev. 7/92
FT8780/8880 1-2 STM
Copier Only: 892 lb
With 2 Sorter Staplers: 1308 lb
Document Feeder
Original Size:
Stack feed mode Single feed mode Duplex mode
Maximum 11" x 17" 11" x 17" 11" x 17"
Minimum 51/2" x 81/2" 51/2" x 81/2" 81/2" x 5 1/2"
Original Weight:
Stack feed mode Single feed mode Duplex mode
Maximum 34 lb 43 lb 25 lb
Minimum 14 lb 11 lb 14 lb
Feed-in Unit Capacity: 50 Sheets (20 lb)
CFF Original Stack Height: Maximum: 50 mm
Original Set: Stack face down
Rev. 11/92
STM 1-3 FT8780/8880
2. COPY PROCESSES AROUND THE DRUM

1
2
3
4
5
6
7
8
10
9
FT8780/8880 1-4 STM
1. DRUM CHARGE
In the dark, the charge corona unit gives a uniform positive charge to the selenium drum.
The charge remains on the surface of the drum because the photoconductive selenium
has electrical resistance in the dark.
2. EXPOSURE
An image of the original is reflected to the selenium drum surface via the optics
assembly. 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.
3. ERASE
The erase lamp illuminates the areas of the charged drum surface that will not be used
for the copy image. The resistance of the drum in the illuminated areas drops and the
charge on those areas dissipates.
4. DRUM POTENTIAL SENSOR
The drum potential sensor detects the electric lines of force from the electric potential on
the drum to compensate image processing elements.
5. DEVELOPMENT
Negatively charged toner is attracted to the positively charged areas of the drum, thus
developing the latent image. (The negative triboelectric charge is caused by friction
between the carrier and toner particles.)
6. PRE-TRANSFER
The pre-transfer corona (PTC) applies a negative dc charge and an ac charge to the
drum. The dc charge increases the negative potential of the toner to improve toner
transfer to paper. The ac charge decreases positive charge on the drum and makes
paper separation easier. The pre-transfer lamp (PTL) also makes paper separation
easier by illuminating the drum and decreasing the positive charge on the drum.
7. IMAGE TRANSFER
Paper is fed to the drum surface at the proper time so as to align the copy paper and the
developed image on the drum surface. Then, a strong positive charge is applied to the
back side of the copy paper, providing an electrical force which causes the copy paper to
be attracted to the drums surface. At the same time, the toner particles are pulled to the
copy paper from the drums surface.
8. PAPER SEPARATION
A strong ac corona discharge is applied to the back side of the copy paper, reducing the
positive charge on the copy paper and breaking the electrical attraction between the
paper and the drum. Then, the stiffness of the copy paper causes it to separate from the
drum surface. The pick-off pawls help to separate paper which has low stiffness.
9. CLEANING
The cleaning brush first removes remaining toner on the drum surface. Then, the
cleaning blade which is angled against drum rotation (counter blade system) removes
the rest of the toner. The flick roller mechanically removes the toner on the cleaning
brush.
10. QUENCHING
Light from the quenching lamp electrically neutralizes the drum surface.
STM 1-5 FT8780/8880
3. MECHANICAL COMPONENT LAYOUT
3.1 COPIER

18 19
20
21
22 23 24 25 26 27 28 29 30 31 1 2
3
4
5
6
7 8 9 10 11 12 13 14 15 16 17
1. First Mirror
2. Second Mirror
3. Third Mirror
4. Inverter Guide Plates
5. Duplex Tray
6. Third Tray
7. Pick-up Roller
8. Separation Roller
9. Paper Feed Roller
10. Vertical Transport Unit
11. Relay Rollers
12. Pick-off Pawls
13. Transfer and Separation
Corona Unit
14. Horizontal Transport Unit
15. Registration Rollers
16. Pre-transfer Corona Unit
17. Second Tray
18. First Tray
19. Toner Hopper
20. Development Unit
21. Drum Thermistor and Drum
Potential Sensor
22. Erase Lamp
23. Fifth Mirror
24. Fourth Mirror
25. Sixth Mirror
26. Charge Corona Unit
27. Quenching Lamp
28. Cleaning Unit
29. Transport Unit
30. Pressure Roller
31. Hot Roller
FT8780/8880 1-6 STM
3.2 ARDF

1 2 3 4 5 6 7 8 9
10
11
12 13 14 15 16 17 18
1. Original Tray Extension
2. Upper Exit Rollers
3. Upper Inverter Gate
4. Lower Inverter Rollers
5. Upper Inverter Rollers
6. Switch Back Gate
7. Switch Back Tray
8. Upper Relay Roller
9. Friction Tab
10. 1st Pick-up Rollers
11. 2nd Pick-up Rollers
12. Separation Rollers
13. Lower Relay Roller
14. Pressure Rollers
15. Transport Belt
16. Lower Inverter Gate
17. Lower Exit Rollers
18. CFF Guide
STM 1-7 FT8780/8880
4. ELECTRICAL COMPONENT DESCRIPTIONS
Refer to the electrical component layout on the reverse side of the Point to
Point (Waterproof paper) index numbers.
4.1 COPIER
Name Function Index. No.
Motors
1st Tray Drive Drives the bottom plate in the 1st tray. 132
2nd Tray Drive Drives the bottom plate in the 2nd tray. 139
3rd Tray Drive Drives the bottom plate in the 3rd tray. 65
Charge Wire Cleaner Drives the charge corona wire cleaner. 74
Development Drives the development unit. 51
Fusing Cooling Fan Cools fins of the de-curling roller. 58
Fusing Exhaust Fan Removes the heat in the de-curling unit. 56
Lens Horizontal Drive Shifts the lens horizontal position. 54
Lens Vertical Drive Shifts the lens vertical position. 57
Main Drives the main unit components. 73
Mirror Unit Drive Positions the mirror unit. 78
Optics Cooling Removes the heat from the optics unit. 77
Scanner Drive Drive the 1st and 2nd scanners. 55
T & S Wire Cleaner Drives the transfer and separation wire cleaner. 72
Toner Supply Rotates the toner supply roller. 75
Vacuum Fan Removes the heat and dust in the machine. 52
Clutches
LCT Drive Transmits the main copier drive to the 1st and 2nd
feed sections.
76
Paper Feed - 1st Tray Drives the paper feed roller of the 1st tray. 134
Paper Feed - 2nd Tray Drives the paper feed roller of the 2nd tray. 159
Paper Feed - 3rd Tray Drives the paper feed roller of the 3rd tray. 66
Paper Feed - Duplex Drives the paper feed roller of the duplex unit. 67
Vertical Transport Unit
Drive
Transmits the main copier drive to the vertical
transport unit and the 3rd tray.
68
Registration Drives the registration roller. 79
PCBs
DC Drive Drives dc components. 116
Drum Current Detection Measures the corona current. 106
Main Controls overall machine operation. 122
Motor Control Controls the dc motors. 123
DC Motor Drive Drives the dc motors. 101
Operation Unit Controls the monitor display. 124
Interface Interface between the main PCB and other PCBs. 115
FT8780/8880 1-8 STM
Vacuum Motor Controls the vacuum fan motor operation. 108
Power Packs
Charge Provides power for the charge corona wire. 103
Development Bias Provides power for the development bias. 104
PTC Provides power for the pre-transfer corona wire. 107
Separation Provides power for the separation corona wire. 105
Transfer Provides power for the transfer corona wire. 102
Relays
Anticondensation Heater Provides power to the anticondensation heater. 113
Drum Heater 1 Provides power to the drum heater. 114
Drum Heater 2 Provides power to the drum heater. 110
Fusing SSR (16 A) Provides power to the 720 W fusing lamp. 111
Fusing SSR (20 A) Provides power to the 900/950 W fusing lamp. 112
Relay Unit Provides ac power to ac components. 118
Sensor
Auto Response Turns on the display from the screen saver
condition.
93
Drum Potential Detects the drum surface voltage. 95
Duplex Entrance Detects misfeeds. 12
Exit Detects misfeeds. 10
Fusing Detects misfeeds. 9
Image Density Measures the density of the image on the drum. 87
Jogger Home Position Detects when the duplex side plate is at the home
position.
15
Lens Horizontal Encoder Detects the lens horizontal drive motor operation. 5
Lens Horizontal Home
Position
Detects when the lens is at the horizontal home
position.
4
Lens Vertical Encoder Detects the lens vertical drive motor operation. 7
Lens Vertical Home
Position
Detects when the lens is at the vertical home
position.
6
Lower Limit - 1st Tray Turns off the 1st tray motor when the tray reaches
the down position.
138
Lower Limit - 2nd Tray Turns off the 2nd tray motor when the tray reaches
the down position.
140
Lower Limit - 3rd Tray Turns off the 3rd tray motor when the tray reaches
the down position.
41
Mirror Unit Encoder Detects the mirror drive motor operation. 29
Mirror Unit Home
Position
Detects when the mirror unit is at the home position.
3
Paper End - 1st Tray Detects the presence of paper in the 1st tray. 159
Paper End - 2nd Tray Detects the presence of paper in the 2nd tray. 146
Rev. 7/92
STM 1-9 FT8780/8880
Paper End - 3rd Tray Detects the presence of paper in the 3rd tray. 42
Paper End - Duplex Detects the presence of paper in the duplex tray. 13
Paper Feed - 1st Tray Turn off the 1st tray paper feed clutch. 154
Paper Feed - 2nd Tray Turn off the 2nd tray paper feed clutch. 147
Paper Feed - 3rd Tray Turns off the 3rd tray paper feed clutch. 16
Paper Feed - Duplex Turns off the duplex paper feed clutch. 18
Paper Size 1 - 1st Tray Determines what paper size is in the 1st tray. 133
Paper Size 1 - 2nd Tray Determines what paper size is in the 2nd tray. 142
Paper Size 1 - 3rd Tray Determines what paper size is in the 3rd tray. 35
Paper Volume - 1st Tray Detects the amount of paper in the 1st tray. 131
Paper Volume - 2nd
Tray
Detects the amount of paper in the 2nd tray.
149
Paper Volume - 3rd Tray Detects the amount of paper in the 3rd tray. 31
Pick-up Position -
Duplex
Detects the duplex pick-up roller position.
17
Registration Sensor Detects the lead edge of paper to detect misfeeds. 22
Return Position Detects when the 1st scanner is at the return
position.
27
Scanner Home Position Detects when the 1st scanner is at the home
position.
8
Toner Cartridge Detects when a toner cartridge is in the
machine.
2
Toner Coil Overload Detects the toner collection coil drive gear
operation.
1
Toner Near End Detects toner near end condition. 28
Transport Detects misfeeds. 20
Tray Paper Position Detects the top sheet position in the 2nd tray. 141
Upper Limit - 1st Tray Sends signal to stop lifting up the 1st tray bottom
plate.
161
Upper Limit - 2nd Tray Sends signal to stop lifting up the 2nd tray bottom
plate.
158
Upper Limit - 3rd Tray Sends signal to stop lifting up the 3rd tray bottom
plate.
14
Rev. 7/92
FT8780/8880 1-10 STM
Solenoids
2nd Tray Lock Locks the 2nd tray. 136
Cleaning Brings the cleaning blade into contact with the
drum.
53
Fork Gate 1 Varies the paper path in the duplex unit depending
on paper size.
62
Fork Gate 2 Varies the paper path in the duplex unit depending
on paper size.
63
Inverter Gate Drives the inverter gate up and down. 61
Junction Gate Drives the junction gate up and down. 60
Pick-up - 1st Tray Lifts the pick-up roller of the 1st tray. 155
Pick-up - 2nd Tray Lifts the pick-up roller of the 2nd tray. 148
Pick-up - 3rd Tray Lifts the pick-up roller of the 3rd tray. 70
Pinch Roller Brings the return pinch rollers into contact with a
paper.
59
Pressure Plate Brings the pressure plate on papers in the duplex
unit.
69
Positioning Lowers the positioning roller in the duplex unit. 64
Duplex Paper Stopper Lowers the paper stopper in the duplex unit. 71
Switches
1st Tray Down Lowers the 1st tray bottom plate. 151
1st Tray Set De-energizes power when the 1st tray is slided to
the left.
160
2nd Tray Down Lowers the 2nd tray bottom plate. 150
3rd Tray Down Lowers the 3rd tray bottom plate. 40
Anticondensation Turns on the tray heaters. 23
Error Reset Resets error condition. 11
Left Door 1 Turns off the main motor when the left door is open. 25
Left Door 2 Turns off dc 24 volts lines when the left door is open. 24
Main Supplies power to the copier. 26
Right Door 1 Turns off dc 24 volts lines when the right door is
open.
21
Right Door 2 Turns off the main motor when the right door is
open.
19
Tray Cover Turns off components when the tray left top cover is
open.
153
Heaters
1st Tray Removes humidity from the paper in the 1st tray. 156
2nd Tray Removes humidity from the paper in the 2nd tray. 145
3rd Tray Removes humidity from the paper in the 3rd tray. 92
Drum Warms the drum when it gets too cool. 96
Anticondensation Prevents moisture from forming on lens and mirror. 83
Exposure Lamp Warms the exposure lamp when it gets too cool. 86
STM 1-11 FT8780/8880
Lamps
Exposure Exposes the original with high intensity light. 85
Fusing 1 Provides heat to the hot roller and keeps the roller at
the operating temperature.
89
Fusing 2 Provides heat to the hot roller during warm-up. 90
Pre-Transfer Removes excessive positive charge from the drum
surface to the transfer and separation process.
81
Quenching Electrically neutralizes the drum surface prior to
charging.
82
Thermistors
Drum Monitors the drum temperature. 94
Fusing Monitors the hot roller temperature. 88
Other Components
Total Counter Keeps a count of the number of copies made. 117
FL Stabilizer Stabilizes power to the exposure lamp. 109
PTL Controls the pre-transfer lamp operation. 121
Quenching Lamp Controls the quenching lamp operation. 120
Thermofuse Provides back-up overheat protection in the fusing
unit.
91
Anticondensation
Thermoswitch
Turns off the anticondensation and drum heaters.
84
Power Supply Unit Provides dc power to dc components 119
FT8780/8880 1-12 STM
4.2 ARDF
Symbol Name Function Index. No.
Motors
M1
Feed-in Drives the pick-up rollers, separation rollers
and relay rollers.
2
M2 Belt Drives the transport belt. 16
M3 Inverter Drives the inverter rollers and the exit rollers. 17
M4 Job Separation Drives the job separator. 5
Circuit Boards
PCB1 DF Main Controls overall ARDF functions. 3
PCB2
Indicator Indicates the Insert Original indicator and the
Auto Feed indicator.
6
Solenoids
SOL1
Switch Back Switches the switch back gate position to
directs the original to the switch back tray or
onto the exposure glass.
15
SOL2 Inverter Gate Opens the inverter gate. 23
Sensors
S1 Entrance Cover Detects if the entrance cover is open. 4
S2 Lift Detects if the transport unit is open. 14
S3 Inverter Cover Detects if the inverter cover is open. 22
S4
Pick-up Roller H.P. Detects if the pick-up roller is in the home
position.
1
S5
Job Separation
H.P.
Detects if the job separator is in the home
position.
7
S6
Job Completion Detects that last original of the first job is fed
from the original table.
8
S7
Original Detects if the original is set on the original
table.
9
S8
Registration Sets the feed-in motor, belt motor and inverter
motor off timing. Detects original misfeed.
12
S9 Inverter Jam Detects paper jams in switch back operation. 18
S10
Inverter
Registration
Sets the inverter motor and the belt motor off,
reversing timing. Detects original jams.
19
S11
Inverter Entrance Sets the inverter motor and the belt motor off,
reversing timing, inverter solenoid and switch
back solenoid off timing.
20
S12 Exit Detects paper jams. 21
S13
CFF Detects if the computer form is set in the CFF
guide. Counts the holes lined up on the
computer form.
11
S14 Original Width Detects the original width. 13
S15 Timing Supplies timing pulses to the DF main board. 10
STM 1-13 FT8780/8880
5. DRIVE LAYOUT

1. Main Motor
2. Development Drive Motor
A
C
D
E
F
B
2 1
A
B
C
E
F
D
A : Development Unit
B : Cleaning Unit
C : Relay Transport Unit (to 1st & 2nd Tray)
D : Fusing Unit
E : Vertical Transport Unit
F : Duplex Unit
FT8780/8880 1-14 STM
6. PAPER PATH
6.1 SINGLE SIDED COPY -- COPY FACE DOWN

6.2 DUPLEX MODE (1ST SIDE)

STM 1-15 FT8780/8880
6.3 DUPLEX MODE (2ND SIDE)

6.4 IMAGE OVERLAY MODE (1ST SIDE)

FT8780/8880 1-16 STM
6.5 IMAGE OVERLAY MODE (2ND SIDE)

STM 1-17 FT8780/8880
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FT8780/8880 1-18 STM
FT8880
OVERALL MACHINE
INFORMATION
NOTE: The following documentation will address those areas which are
unique to the FT8880 copier. For additional data please refer to
the "Overall Machine Information" section preceding these pages.
STM 1-19 FT8780/8880
FT8780/8880 1-20 STM
7. SPECIFICATIONS
FT8880 Copier
Copy Process: Dry Electrostatic Transfer System
Originals: Sheet/Book
Original Size: Maximum: 11" x 17"
Copy Paper Size:
Maximum: 1st and 2nd tray 81/2" x 14"
3rd tray 11" x 17"
Minimum: 1st and 3rd tray 51/2" x 81/2"
2nd tray 81/2" x 11"
Copy Paper Weight: Standard Copying: 14 ~ 42
Duplex Copying: 17 ~ 28 lb
Warm Up Time: Within 8.0 minutes (room temp. 68F, 20C)
First Copy Time: 4.8 seconds (81/2" x 11", when fed from 2nd tray)
Copying Speed: 80 copies/minute (81/2" x 11")
60 copies/minute (11" x 17")
Optional Equipment: Menu Reader
Key Counter
Guidance ROM Kit
Reproduction Ratios: See the following table:
LT/DLT version
Enlargement
200%
155%
129%
121%
Full Size 100%
Reduction
93%
77%
74%
65%
50%
STM 1-21 FT8780/8880
Zoom: 50 ~ 200%
Toner Replenishment: Cartridge exchange (1,500 g)
Paper Feed: 1st tray (550 sheets)
2nd tray (3,000 sheets)
3rd tray (1,500 Sheets)
Power Source: 120 V, more than 20 A (LT/DLT version)
Power Consumption: (with RDH and finisher)
Maximum during LT/DLT version
Stand-by 2.01 kW
Copying Cycle 2.01 kW
Dimensions: Copier & RDH: 65.4" x 30.0" x 56.9"
With Finisher: 83.1" x 30.0" x 56.9"
Weight: Copier & RDH: 917 lb
With Finisher: 1027.4 lb
Noise Emission: With Finisher/RDH:
Maximum: less than 70 db
Copy-cycle: less than 69 db (average)
Warm-up: less than 42 db
BTU Ratings:
Mode FT8880
Stand by 6804 BTU
Copy Cycle 6294 BTU
Rev. 2/94
FT8780/8880 1-22 STM
Recycling Document Handler
Original Size:
Stack feed mode Single feed mode CFF mode
Maximum 11" x 17" 11" x 17" 11" x 91/2"
81/2" x 12"
11" x 147/8" Minimum 8" x 101/2" 51/2" x 81/2"
Original Weight:
Stack feed mode Single feed mode CFF mode
Maximum 28 lb 43 lb 20 lb
Minimum 17 lb 14 lb 17 lb
Number of originals to be set:
Weight
Size
17~21 lb 22~28 lb
A3/11" x 17" 30 sheets 20 sheets
Others 50 sheets 30 sheets
Number of Recycles:
Maximum: 60 times
CFF Original Stack
Height:
Maximum: 50 mm (or approx. 2.3")
Original Set:
First sheet on top, stack face down
STM 1-23 FT8780/8880
8. MECHANICAL COMPONENT LAYOUT
8.1. RDH

1
2 3 4 5 6 7
15
8
14 13 12 10 9 11
1. Inverter Roller
2. Inverter Exit Roller
3. Air Knife Nozzle
4. Exit Roller
5. Original Guide
6. Feed-in Belt
7. Original Stopper
8. Right Turn Roller
9. Belt Drive Roller
10. Transport Belt
11. Transport Rollers
12. Original Feed Roller
13. Inverter Entrance Roller
14. Single Feed Exit Gate
15. Inverter Middle Roller
FT8780/8880 1-24 STM
9. ELECTRICAL COMPONENT DESCRIPTIONS
Point (Waterproof paper) when using this table.
9.1. RDH
Name Function Index No.
Motors
Feed Drives the feed and transport rollers. 3
Belt Drive Drives the transport belt. 7
Inverter Drives the inverter and exit rollers. 34
Blower Supplies air to the air knife and draws air from the
vacuum section.
5
Separator Drives the original separator. 21
Sensors
Original Set Detects if the original is set on the document handler. 31
Entrance Detects the original leading edge and de-energizes
the feed belt drive clutch.
33
1st Transport Detects jams in the transport section. 16
2nd Transport Detects the original leading edge and lowers the
original feed motor speed.
15
Registration Detects the original trailing edge for the original stop
position calculation.
12
Inverter Entrance Detects jams in the transport belt section. 24
1st Inverter Detects the original trailing edge and reverses the
inverter drive motor rotation.
29
2nd Inverter Detects the original leading edge and energizes exit
roller release solenoid.
30
Exit Detects the original leading edge and lowers the
inverter drive motor speed.
32
Single Feed Set Detects the leading edge of the original in the single
feed table and turns the original feed motor.
13
Single Feed Exit Detects jams in single feed mode. 25
Lift Detects if the RDH is open. 2
CFF Detects if the computer form is set in the CFF guide.
Counts the holes lined up to the computer form.
9
Original Length Detects if the original stopper is set for 81/2" position. 19
Original Height Detects the original height on the RDH. 20
Separator H.P. Detects if the original separator is in the home
position.
22
Separator Detects if the last original of the original stack is fed. 23
Inverter Unit Cover
(Switch)
Detect if the inverter unit cover is opened.
27
Original Width
(Potentiometer)
Detects the original width in the stack feed mode.
17
STM 1-25 FT8780/8880
Single Feed Original
Width (Potentiometer)
Detects the original width in the single feed mode.
14
Solenoids
Vacuum Shutter Closes the vacuum shutter. 4
Single Feed Gate Lowers the single feed gate. 8
Single Feed Exit Lifts the single feed exit gate. 26
Exit Roller Releases the exit driven rollers from the exit drive
rollers.
28
Clutches
Feed Belt Drive Transmits the original feed motor drive to the feed
belt rollers.
10
Feed Belt Brake Stops the feed belt rotation. 11
PCBs
Main Control Controls overall RDH operation. 6
Blower Motor Control Controls the vacuum motor operation. 1
Indicator Indicates the single feed mode indicators. 18
FT8780/8880 1-26 STM
SECTION 2
DETAILED SECTION
DESCRIPTIONS
1. PROCESS CONTROL
1.1 OVERVIEW
The characteristics of certain copy processes which are related to the copy
image reproduction are affected by various factors. To get stable images over
long periods and in continuous copy runs, these characteristic changes have
to be compensated for.
The following figure and table show how these factors are compensated for
on this copier.

Rev. 7/92
Drum Current
Detection PCB
Development
Bias
ID Sensor
Potential Sensor Exposure Lamp
Charge Corona
Toner
Supply
PTC
Transfer
Corona
Separation
Corona
Main PCB
: Sensing Item
: Controlled Item
FT8780/8880 2-1 STM
Section Characteristics Causes of Change Compensation Method
Drum Charge
Potential
Repeat Stress
Temperature
Humidity
Measure the drum potential of a part
that was exposed (Black Pattern) with
the potential sensor and adjust the
charge corona output.
Sensitivity Repeat Stress
Temperature
Humidity
that was exposed (Light Potential) and
adjust the exposure lamp voltage.
Residual
Voltage
Repeat Stress
Temperature
Humidity
that was erased by the erase lamp
(residual voltage) and adjust the
development bias, light potential, and
dark potential
Charge
Corona
Charge
Potential
Dirtiness
Temperature
Humidity
that was exposed (Black Pattern) and
adjust the charge corona output.
Exposure Lamp Intensity Repeat Stress Measure the drum potential of a part
that was exposed (light potential) and
adjust the exposure lamp voltage.
Mirror
Reflectivity
Lens Clearness
Dirtiness
Development Amount of
Toner Charge
Repeat Stress
Temperature
Humidity
Measure the reflected light intensity of
the ID sensor pattern and adjust the
toner density in the development unit.
Rev. 7/92
STM 2-2 FT8780/8880
1.2 IMAGE CONTROL
1.2.1 Latent Image Control

The figure shows the changes of the drum potential during the copy process.
V0: The drum potential after charging the drum.
Vd (Dark Potential): The drum potential 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 remaining after the exposure
of the erase lamp.
QL Charge
V0
Exposure
Black White
Erase
Potential
Sensor
Drum
Vd
VL
Vr
FT8780/8880 2-3 STM

The solid line in the above figure shows the relationship between the original
density and the resulting drum potential after exposure. To get consistant
copy quality, this relationship must be maintained.
Since this relationship tends to change to the one represented by the dotted
line by various factors, compensations are required as follows:
A decrease in dark voltage (Vd) is compensated for by increasing the charge
corona output. A increase in light voltage (VL) is compensated for by
increasing the exposure lamp voltage. Since the residual voltage (Vr)
increase cannot be compensated for by increasing the lamp voltage, it is
compensated by increasing the development bias voltage and changing the
Vd and VL target values.
1.2.2 Image Density Control
To maintain consistant copy image density, the ID sensor detects the toner
amount of the ID sensor pattern. From this, it is understood that drum
potential is stabilized with the above compensations. According to the
detection results, the toner density in the development unit is controlled so
that the toner amount on the sensor pattern is consistant.
The following sections explain the details of these compensations.
[V]
V0
Vd
VL
Vr
Drum
Potential
Light Original Density Dark
STM 2-4 FT8780/8880
1.3 PROCESS CONTROL DATA INITIALIZATION
The following flow chart shows all the steps that will be performed whenever
the main switch is turned on while the hot roller temperature is below 100C.
This initializes all the process control settings.
Main SW On (Fusing Temp. < 100C)
Drum Potential Sensor Calibration
Drum Conditioning Start (Fusing Temp. = 160C)
Exposure lamp ON
Vsg Adjustment
Lamp Intensity Sensor Calibration
Vr Measurement
Lens position shift
Exposure lamp OFF
Vd Correction
Exposure lamp OFF
Scanner returns to home position (VL Pattern)
Exposure lamp ON
VL Correction
Exposure lamp OFF
V01 Detection
Scanner moves to return position (ADS Pattern)
Exposure lamp ON
Scanner moves to return position (Vd Pattern)
Exposure lamp ON
ADS Adjustment
Charge Corona Current Adjustment
FT8780/8880 2-5 STM
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 electric lines of force from the
electric potential on the drum. The output of the sensor depends on the
number of electric lines of force.
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 initialization.
The drum current detection board has two relay contacts. Usually RA2
grounds the drum. However, during the initialization, the main PCB turns on
RA1 and turns off RA2. The contacts of RA1 then close while the contacts of
RA2 open. This allows the output of the Bias P.P to be applied to the drum
shaft.
By measuring the outputs of the drum potential sensor when +100 V and
+800V are applied to the drum, the sensor output is calibrated automatically.
Rev. 11/92
[A]
Drum
Case
Sensor
Output
Amp.
Potential Sensor
RA2
Relay
Drum Current
Detection PCB
RA1
Bias
P.P.
TRIG 1 (800V)
TRIG 2 (100V)
PWM
Sensor
Main PCB
STM 2-6 FT8780/8880
1.3.2 Drum Conditioning
When the fusing temperature reaches 160C, the machine starts the drum
conditioning process. In this mode, all the coronas and lamps around the
drum are activated and drum sensitivity is 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 V.
1.3.4 Lamp Intensity Sensor Calibration

The exposure lamp intensity is monitored by the main PCB through the fiber
optics cable. A photodiode on the main PCB converts the light intensity to a
dc voltage. The main PCB sends a PWM signal with a 100% duty cycle to the
FL stabilizer and checks the monitored voltage, adjusting it to +3 V. This +3 V
is used as the light intensity standard.
PWM
Main PCB
FL
Stabilizer
FT8780/8880 2-7 STM
1.3.5 Charge Corona Current Adjustment

The charge corona current is measured and adjusted automatically by the
drum current detect and main PCBs.
The charge corona current flows to the drum current detect PCB through the
drum and the drum shaft. The drum shaft is grounded by the drum current
detect PCB usually. However, during the process control data initialization,
the main PCB activates the corona current circuit in the drum current
detection PCB which converts the drum current to a voltage and separates it
into ac and dc component outputs. Then, the main PCB reads them through
A/D converters as digital data. The main PCB adjusts the corona current by
controlling the PWM signal to the charge corona power pack.
When the auto drum current adjustment mode is selected by the SP mode,
the drum current detect PCB is used to measure and adjust other corona
outputs in the same way.
Rev. 7/92
Drum Current Detect PCB MainPCB
Potential S.
Id Set
STM 2-8 FT8780/8880
1.3.6 Vr Measurement

The drum residual voltage (Vr) tends to increase during the drums life due to
electrical fatigue. The residual voltage cannot be reduced even if the
exposure lamp voltage is increased. Therefore, the Vr change has to be
compensated by other means.
The main PCB checks the drum potential just after the erase lamp exposure,
by the drum potential sensor during drum conditioning. The drum potential is
in fact Vr. This measured Vr is used as the standard for the following other
compensations.
1. Vd Correction
2. VL Correction
Drum
Potential
Original Density
Dark Light
V0
Vd
VL
Vr
FT8780/8880 2-9 STM
1.3.7 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. (See A in illustration above)
To check the actual Vd, the first scanner moves to the return position and the
Vd pattern (Black) located on the bottom side of the exposure glass bracket
is exposed on the drum.
The main PCB measures Vd through the drum potential sensor and adjust it
to a target value by adjusting the charge power pack output. (See B in
illustration above)
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 V
The adjusted charge power pack output control value (PWM value) is kept in
memory until the next initialization.
If the target value cannot be achieved within the charge power pack output
control range, the copier indicates the system error on the CRT screen. The
copier tries the Vd check again after the error reset. Even if the second Vd
adjustment fails, no SC condition is displayed. The previous power pack
output control data will be used in this case.
Exposure
Glass
Vd Pattern
[V]
Drum
Potential
Original Density Dark Light
Vd
Vr
B
A
STM 2-10 FT8780/8880
1.3.8 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 to the home position and the
VL pattern (White) located on the bottom side of the exposure glass bracket
is exposed on the drum. (See A in above illustration)
The main PCB measures the VL through the drum potential sensor and
adjusts it to a target value by adjusting the exposure lamp output. (See B in
above illustration)
The residual voltage change also affects VL, so that VLs target voltage is
compensated as follows:
Target Value of VL: VL1 = Vr + 50
_
5N (volt)
NOTE: N is the setting for the exposure lamp adjustment in the SP mode.
Maximum of 5N = 50
The adjusted exposure lamp output control value (PWM value) is kept in
memory until the next initialization.
If the target value cannot be achieved within the exposure lamp output
control range, the copier indicates the system error on the CRT screen. The
copier tries the VL check again after the SC reset. If the second VL
adjustment fails, no SC condition is displayed. The previous exposure lamp
output control data will be used in this case.
B
Rev. 7/92
VL Pattern
[V]
Drum
Potential
VL
Vr
A
FT8780/8880 2-11 STM
1.3.9 V01 Measuring

Since the ID sensor pattern on the drum is made by the erase lamp and
charge corona (except for 81/2" x 14" copy mode due to the lens horizontal
movement. See toner density detection and supply section for details), the
sensor pattern density varies with drum potential just after the charge corona
(V0) is applied.
To measure the toner density properly, the development bias for the ID
sensor pattern is corrected by measuring the actual drum potential after the
charge corona.
During the process control data initialization, the drum potential after the
charge corona is applied when the drum sensitivity is stabilized (V01) will be
measured and used to determine the bias voltage for the ID sensor pattern
development in continuous copy run. The details will be explained in the
toner density detection section.
Rev. 7/92
[V]
Drum
Potential
V0
Vd
STM 2-12 FT8780/8880
1.3.10 ADS Adjustment

The ADS pattern is located underneath the exposure glass bracket. During
the process control data initialization, the ADS reference voltage is adjusted.
The first scanner is moved to the return position. The main PCB checks the
ADS voltage through the ADS fiber optics cable. The measured voltage is
calibrated to the standard voltage (3 V) as the reference for the auto image
density control.
Rev. 7/92
ADS Pattern
ADS Pattern
Exposure Glass
FT8780/8880 2-13 STM
1.4 COMPENSATIONS DURING COPY CYCLE
During continuous copying, the drum sensitivity changes due to the electrical
fatigue. The drum sensitivity also changes during rest time.
The following compensations are used for the drum sensitivity changes in the
copy cycle:

1.4.1 VL Compensation
The drum light potential (VL) varies during copy runs. Since the value will
change due to the drum characteristics the development base bias is
compensated during the copy cycle.
At the beginning of each original scanning, the VL sensor pattern is
developed on the drum. The main PCB monitors the drum potential (VL2) of
the latent image of the VL sensor pattern through the drum potential sensor,
and adjusts the development base bias.
See development bias section for details.
Development Base Bias: VBB = VL2 + 170 + 5N
NOTE: N is the setting for the exposure lamp adjustment in the SP mode.
Drum
Potential
Original Density
Dark Light
VBB
V0
Vd
VL
Vr
VL Pattern
STM 2-14 FT8780/8880
1.4.2 V02 Measuring

During the process control data initialization, V01 is measured to determine
the development bias for the ID sensor pattern in continuous copy runs. This
bias cannot be used for the initial part of the copy run (less than 10 copies)
due to the different drum potential after the charge corona is applied.
Whenever the Start key is pressed, the drum potential after the charge
corona is measured at the beginning of the copy run (V02).
V02 is used to determine the development bias voltage for the ID sensor
pattern which is made at the first copy.
The details will be explained in the Image Density Control section.
Rev. 7/92
9 10 11 2 3 4 5 1
Start key
Charge
Corona
Exposure
Lamp
Scanner
F
R
Drum
Potential
Sensor V02 VL2 VL2 VL2 VL2 VL2 VL2 VL2 VL2
FT8780/8880 2-15 STM
2. DRUM
2.1 OVERVIEW

This model uses an FO-type drum made by applying a urethane resin coating
[A] on an F-type drum [B]. This coating provides a long life and minimize the
white line problems on the half-tone areas.
For the F-type drum, the trapping layer [C] is made by the drum conditioning
process. Since the FO-type drums are coated after the charge carrying layer
has been made, it is not necessary to perform the drum conditioning at the
new drum installation.
When drum temperature drops below the permissible level, extreme
sensitivity changes occur. Additionally, temperature changes can cause
condensation. To maintain a constant drum temperature, a drum heater [D]
(100 V 140 W) which is controlled by a thermistor [E] and two thermoswitches
[F] is used.
Rev. 7/92
[E]
[D]
[F]
[A] [C]
[B]
Aluminum
STM 2-16 FT8780/8880
2.2 DRUM HEATER CONTROL

The drum thermistor monitors the drum surface temperature. When the
measured temperature reaches 41C, the main PCB determines that the
copier is ready to make copies.
When the main switch is off, the drum heater relays (RA353 and RA354) are
off, so that the drum heater is controlled by the 65C thermoswitch. The
thermoswitch is on at 50C and off at 65C.
When the main switch is on, RA354 is on and bypasses the 65C
thermoswitch from the drum heater control circuit. RA353 turns on or off
according to the temperature detected by the drum thermistor.
The drum surface temperature is controlled between 41C and 50C.
To minimize the power consumption, RA353 is turned on to bypass the drum
heater during the copy cycle.
CN-3
CN-2
CN-1
RA353
RA354
5V
CN104-A4
CN251-B26
CN251-B25
CN251-A30
CN251-B30
CN255-B9
CN255-A28
24V
24V
CN102-A2
CN103-B26
24V ON
RA
RA353 RA354
AC100V
RA
160C 65C
Drum Heater 1
Drum Heater 2
Drum
Heater 1
Drum
Heater 2
Drum Thermistor
Drum Heater
A/D
Converter
Drum Thermistor
Interface PCB Main PCB
FT8780/8880 2-17 STM
3. DRUM CHARGE
3.1 CHARGE CORONA UNIT

This copier uses a dual carbon coated tungsten wire for the drum charge.
The corona wire generates a corona of positive ions when the charge power
pack [A] applies a high voltage.
The output of the charge power pack is determined by the CPU based on the
process control data.
The charge power pack has a leakage sensor. If a leak (short circuit) is
sensed, the output is interrupted.
[A]
STM 2-18 FT8780/8880
3.2 CORONA UNIT VENTILATION

If ozone produced by the corona charge stays in the charge corona area, it
may cause uneven corona charging to the drum. To prevent this, ozone is
vacuumed out by the vacuum fan through the duct and toner filter in the
transport unit, then changed to oxygen by the ozone filter before being
removed from the copier.
FT8780/8880 2-19 STM
3.3 CORONA WIRE CLEANER

Paper dust, or toner particles on the charge corona wires may interfere with
charging and cause an uneven charge on the drum. The wire cleaner
prevents this problem by automatically wiping the charge corona wires clean.
Once every 5000 copies, the wire cleaner is activated when the main switch
is turned on. The hot roller temperature must be less than 100C for the wire
cleaner to be activated.
When the dc motor in the front end block turns on, it drives the cleaner
bracket from the home position to the rear end of the corona unit and then
back again.
STM 2-20 FT8780/8880
3.4 CHARGE CORONA POWER PACK

The main PCB sends a PWM (Pulse Width Modulation) signal to the charge
corona power pack. According to the PWM ratio, the dc power pack outputs a
high dc voltage to the charge corona wires. The main PCB determines the
PWM ratio based on the process control data.
There is a safety relay (RA303) on the dc drive board which is activated by a
signal from the main PCB. In case of the SC conditions related to the high
voltage devices and the abnormal exposure lamp on, the main PCB turns off
RA303 to cut the 24 Vdc to the power pack through its contact.
Rev. 11/92
DC Power Supply
Main PCB
DC Drive PCB
Drum Current
Detect PCB
Charge
Corona P.P.
PWM
TRIG
GND
24 V
FT8780/8880 2-21 STM
4. ERASE
4.1 OVERVIEW

The electrical charge of the area that does not require any image will be
removed by the erase lamp unit [A].
This reduces toner consumption, and the load on the cleaning unit.
The erase lamp unit consists of 90 yellow-green LEDs. This reduces drum
light fatigue and allows precise control of the light width.
The erase lamp unit is controlled by the main PCB based on factors such as
the reproduction ratio, paper size, SP mode settings, and the image editing
settings.
The maximum erase margin error in the image editing mode is 6 mm.
[A]
STM 2-22 FT8780/8880
4.2 ERASE LAMP CIRCUIT

The main PCB sends the serial bit data to the erase lamp unit with the clock
signal. The latch signal holds the ON/OFF condition of the LEDs.
The following charts show the erase lamp control timing.
1. When the ID sensor pattern is not made.
(LT, Full Size, and 3rd Feed Mode)
2. When the ID sensor pattern is made.
(LT, Full Size, and 3rd Feed Mode)

NOTE: 1. Depends on the paper feed station.
2. Depends on the paper size.
3. Will be changed in Margin Adjustment and Image Editing Mode.
Rev. 7/92
Main PCB Erase Lamp Unit DC Power
Supply
300 204
816 *1 82
53 *3
47 *3
1102*1 420* 1633
50
300 204
816 *1
108 59 54
1466 *1
82
53*3
47*3
50
1602 *1 420 *2 1633
VL Pattern
Start Main Motor ON Regist Trail Edge Main Motor OFF
Start Main Motor ON Regist Trail Edge Main Motor OFF
All ON
All ON
All ON
All ON
VL Pattern
ID Pattern V02
FT8780/8880 2-23 STM
5. OPTICS
5.1 OVERVIEW

The optics unit reflects an image of the original on the exposure glass onto
the selenium drum. This forms a latent electrical image of the original.
On this model, to minimize power consumption, a fluorescent lamp is used
for the exposure lamp [A].
Six high reflection mirrors are used to make the optics unit smaller and obtain
a wide reproduction ratio range (50
_
200%).
The lens [B] is driven by two stepper motors for (1) vertical direction (parallel
to the paper feed direction) and (2) horizontal direction movements.
To correct for focal length changes in reduction and enlargement modes, the
mirror unit [C] (4th and 5th mirrors) position is adjusted by a stepper motor.
The exposure glass has a special coating on one side to minimize the static
electricity which may be produced by the original using the document feeder.
The coated side is marked and should face up.
Rev. 7/92
[A]
[B]
[C]
STM 2-24 FT8780/8880
5.2 SCANNER DRIVE

A dc servo motor is used as the scanner drive motor [A].
The scanner drive motor drives the first [B] and second scanners [C] using
four scanner drive wires. The second scanner speed is half of the first
scanner speed.
The first and second scanners are supported by the front and rear guide rails
[D]. To minimize the friction between the scanners and guide rails, the
scanner movement free play is minimized by high wire tension.
Rev. 7/92
[A]
[C]
[D]
[B]
FT8780/8880 2-25 STM
5.3 SCANNER POSITION SENSORS

There are two scanner position sensors located at the front side of the optics
unit.
The scanner home position sensor [A] is used to detect the home position at
the machine initialization and during the scan cycle.
The scanner return position sensor [B] is used to detect the scanner position
for the process control data initialization (Vd and ADS data). The return
position sensor is not used during normal copying.
[A]
[B]
STM 2-26 FT8780/8880
5.4 VERTICAL LENS DRIVE

The lens vertical drive motor [A] changes the lens vertical position in
accordance with the selected reproduction ratio.
A stepper motor (Approx. 1.8 (0.05 mm)/step) is used to drive the lens
through the lens drive belt.
The lens vertical home position sensor [B] detects the lens vertical position
for full size mode. The motor control PCB keeps track of the lens position
based on the number of pulses sent to the lens vertical drive motor.
The lens vertical drive encoder [C] installed on the drive pulley is used to
detect if the vertical lens base locks.
Rev. 7/92
[A]
[B]
[C]
FT8780/8880 2-27 STM
5.5 HORIZONTAL LENS DRIVE

The original horizontal position on the exposure glass varies in modes (such
as platen, ADF, and CFF modes) for easy original handling. On the other
hand, the center is the standard position of the paper feed.
Therefore, the lens horizontal position has to be changed according to paper
size, reproduction ratio, and the original modes.
A stepper motor (approx. 7.5 (0.35 mm)/step) is used to drive the lens
through the lens drive wire.
The lens horizontal home position sensor [A] is used to detect the lens
horizontal position for LT sideways, full size, and ADF mode.
The other positions are determined by counting the number of motor drive
pulses.
The lens horizontal drive encoder [B] installed on the drive pulley is used to
detect if the horizontal lens base locks.
[A]
[B]
STM 2-28 FT8780/8880
5.6 HORIZONTAL LENS POSITIONING
5.6.1 For Original Position

There are three standard original positions for the platen, ADF, and CFF
modes.
ADF mode original position is 5 mm to rear of the platen mode original
position to maintain the original transport path (5 mm from the front scale).
CFF mode original position is 17.7 mm (5 + 12.7 mm) to rear of the platen
mode original position. This is to maintain the traction hole part transport path
(12.7 mm) in ADF.
The above figure shows the lens horizontal positions for each original mode
when the identical size paper is used.
5.6.2 For Paper Size

To keep the 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.
6.35
2.5
12.7
5
CFF
ADF
100%
Horizontal
Lens Position
Platen
Original Front
Edge
Copy Paper
100%
Horizontal
Lens
Position
Original Front
Edge
Copy Paper
FT8780/8880 2-29 STM
5.6.3 For Reproduction Ratio

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 horizontal position of the
lens is also adjusted.
The figure shows the lens horizontal position for 50, 100 and 200%.
50% 100% 200%
Copy Paper
Vertical
Horizontal
Lens Position
Original
Front Edge
STM 2-30 FT8780/8880
5.7 MIRROR UNIT DRIVE

To maintain the proper focus at the various reproduction ratios, the mirror unit
(4th and 5th mirrors) position is changed.
A stepper motor (Approx. 7.5 (0.1 mm)/step) is used for the mirror unit drive.
A mirror unit home position sensor [A] is used to detect the unit position for
full size mode. The motor control PCB keeps track of the unit position based
on the number of motor drive pulses.
[A]
FT8780/8880 2-31 STM
5.8 MOTOR DRIVE CIRCUIT

The motor control PCB communicates with the main PCB through the serial
interface lines. The motor control PCB monitors all the sensor signals and
controls the motors through the dc motor drive PCB.
The development motor and the main motor are also controlled by the dc
motor control PCB.
M
M
M
M
E
Main
PCB
Sensors Encoders
Motor
Control PCB
DC Motor
Drive PCB
Horizontal
Drive
Vertical Drive
Mirror Unit
Drive
Encoder
Serial
Interface
Scanner
Drive
STM 2-32 FT8780/8880
5.9 EXPOSURE LAMP UNIT

This copier uses a fluorescent lamp [A] (100 V 84 W). Using this type of lamp
has the following advantages:
Low power consumption
There is no bright point and it is easy to get even luminescence
A narrow light wave band allows more accurate focusing for various
kinds of originals
High-speed scanner operation vibration resistance
Omni-directional luminescence reduces original shadow
Since low fluorescent tube temperature will result in delayed lighting and
intensity variation, a tube-type heater (38 V 60 W) [B] is used to maintain the
fluorescent tube temperature at approximately 40C.
The lamp unit has a thermister [C] to monitor the lamp temperature and a
thermofuse [D] (139C) for safety.
[C]
[A]
[B]
[D]
FT8780/8880 2-33 STM
5.10 EXPOSURE LAMP CONTROL

Exposure lamp intensity must be stabilized during the copy cycle to get a
constant latent image on the drum. The main PCB [A] monitors and maintains
the light intensity through a fiber optics cable [B]. According to the measured
value, a lamp power signal (PWM signal) is sent to the fluorescent lamp
stabilizer [C].
The PWM signal output is determined based on the standard value (+3 V at
PWM 100% duty cycle) which is set at the process control data initialization
(see the Process Control Section for details).
Rev. 7/92
[C]
[B]
[A]
PWM
STM 2-34 FT8780/8880
5.11 AUTO IMAGE DENSITY CONTROL

The original background density is read through a fiber optics cable on the
exposure lamp unit. The sampled strip is at the leading edge of the original
and the size depends on the scanner speed (reproduction ratio).
The fiber optics cable conducts the light to a photodiode on the main PCB.
The photodiode then converts the density to the ADS voltage. The CPU
compares it with the standard ADS value (+3 V), which is set at the process
control data initialization by checking density of the white pattern underneath
the left exposure glass holder and adjust the development bias accordingly.
Detailed bias control is described in the development bias section.
50 mm 26 mm
50 mm
26 mm
166 mm
FT8780/8880 2-35 STM
5.12 UNEVEN LIGHT INTENSITY CORRECTION

The slit plate [A] corrects the uneven light intensity at the ends and center of
the fluorescent lamp [B] and evenly distributes light reflected from the original.
To compensate for reduced light at the lens edges, the shading plate [C] is
located in front of the lens. Additionally, the shading plate compensates the
light intensity when the lens horizontal position is shifted.
[B]
[A]
[C]
STM 2-36 FT8780/8880
5.13 ANTI-CONDENSATION HEATER

To prevent condensation in the optics unit, a 40 W anti-condensation heater
[A] is installed at the bottom of the lens unit.
The anti-condensation heater is controlled by a thermoswitch [B] (On at 17C,
Off at 25C) under the following conditions:
1. The main switch is off.
2. The main switch is on, fusing lamp off in stand-by mode.
3. Machine off condition in weekly timer mode.
The anti-condensation heater has a thermofuse (169C).
5.14 OPTICS COOLING FAN

The light intensity will be decreased if the fluorescent lamp temperature
becomes too high. The optics cooling fan [A] blows in cool air from outside
through an air filter [B]. Air from the fan also passes through the 6th mirror slit
[C] to the drum area. This prevents the optics area from being contaminated
by scattered toner in the drum unit.
[B]
[A]
[B]
[A]
[C]
FT8780/8880 2-37 STM
6. DEVELOPMENT
6.1 OVERVIEW

This copier uses a double roller (diameter 20 mm each) development system.
This system differs from single roller development system in that (1) it
develops the image in a narrow area and (2) it develops the image twice.
Also, fine toner and developer (smaller particle size) are used. As a result,
the image quality, especially of thin lines, the trailing edge of half-tone areas,
and black solid areas are improved.
A dc motor is used to drive the development unit.
The developer is supplied to the developer guide [A] upper side by the
paddle roller [B]. The magnet of the upper development roller [C] attracts the
developer to the roller surface.
The doctor blade [D] trims the developer to the desired thickness and creates
a back spill to the cross mixing mechanism [E]. The developer is transferred
to the lower development roller [F] and then returned to the agitator roller [G]
area via a paddle roller.
The development motor has two speeds. When the motor turns at high
speed, the developer is supplied to the development rollers. After image
development, the motor turns at slower speed to return the developer to the
development unit from the development roller sleeves. This prevents
developer spillage during the unit replacement.
The development rollers are given a positive bias to prevent the toner from
being attracted to the non-image areas, on the drum surface, that may have a
slight residual positive charge. The bias voltage is determined based on the
factors checked by the process control system.
[G]
[E]
[B]
[D]
[C]
[F]
[A]
FT8780/8880 2-38 STM
6.2 DRIVE MECHANISM

All the development unit parts, except the toner supply brush, are driven by
the development drive motor (dc motor).
The toner supply brush is driven by the toner supply motor.
The development motor drives the development drive gear through two
timing belts. The rotation is transferred as follows:
Since reversed toner mixing vane rotation could damage something, a
one-way clutch is installed to the mixing vane drive gear.
Development
Drive Gear [A]
Auger
Drive
Gear [B]
Idle Gear
Idle Gear [C]
Paddle Roller [G]
Timing Belt [E]
Upper/Lower
Dev. Roller [D]
Toner Mixing Vane
Drive Gear [F]
[D]
[C]
[B]
[A]
[F]
[E] [G]
STM 2-39 FT8780/8880
6.3 CROSS MIXING

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 upper development roller is split into two parts
by the doctor blade. The part trimmed by the doctor blade goes to the
backspill plate [A].
As the developer slides down the backspill plate to the agitator [B], the mixing
vanes [C] move it slightly toward the rear of the unit.
Part of the developer falls into the auger inlet [D] and is transported to the
front of the unit by the auger [E].
The agitator moves the developer slightly to the front as it turns, so the
developer stays level in the development unit.
[C]
[E]
[A]
[D]
[B]
FT8780/8880 2-40 STM
6.4 DEVELOPMENT BIAS
6.4.1 Bias Power Pack

PWM Duty Cycle = t2/t1 x 100 (%)
Output = 10 x PWM Duty Cycle (V)
TRIG1 TRIG2 OUTPUT (V)
L H +800
H L +100
L L depends on the PWM signal
H H 0
The bias power pack has three input terminals. Two of them are used as the
output selector as shown in the table. When both terminals are low, the
output can be controlled by the other input terminal which receives the PWM
signal from the main PCB.
+800V and +100V are used to calibrate the drum potential sensor in the
process control data initialization.
Rev. 7/92
Potential Sensor
RA2
Control
Drum Current
Detection PCB
RA1
Bias
P.P.
TRIG 1 (800V)
TRIG 2 (100V)
PWM
Sensor Input
Main PCB
STM 2-41 FT8780/8880
6.4.2 Bias Control In Copy Cycle
The bias output is determined by four factors.
The total bias is described as;
(ADS Mode) V B = VBB + VBA + VBS
(Manual ID Mode) V B = VBB + VBM
1) Base Bias (V BB)

As explained in the process control section, the base bias for development is
determined by the drum light potential (VL) measured in each original scan.
The base bias is also affected by the exposure lamp adjustment setting in the
SP mode.
VBB = VL2 + 170 + 5N
NOTE: N = Number of the lamp adjustment setting in SP mode.
2) ADS Compensation (V BA)

According to the original background density, the bias is compensated. The
compensation value is determined with the voltage measured by the ADS
sensor (ADS Voltage) as follows:
VBA = --146 x (VADS -- 2.75)
NOTE: VBA has a limited range from 0 V to +260 V.
Drum
Potential
Dark Light Original Density
VBB
V0
Vd
VL
Vr
(V)
260
200
100
0
1 2 3
0.97 V
2.75 V
Dark ADS voltage (V) Light
FT8780/8880 2-42 STM
3) Manual ID Selection Position Compensation (V BM)

According to the manual ID selection position, the bias is compensated as
follows:
VBM = 60 x M -- 240 (When M = 1 to 6)
60 x M -- 360 (When M = 7)
NOTE: M = Manual ID selection position. M ranges from 1 (darkest) to 7
(lightest).
When manual ID is set to 7 (lightest), the charge corona output is
lowered by 10% PWM duty cycle.
4) SP Mode ID Selection Compensation (V BS)
In the SP mode, the image density level in the ADS mode can be selected
from four steps. The VBS is determined by the SP setting as follows:
Selected level VBS (V)
L +60
N 0 (Default)
H
_
60
VH
_
120
(V)
7 4
1
_
60
_
180
_
120
120
0
60
ID Selection
STM 2-43 FT8780/8880
6.4.3 Bias for the ID Sensor Pattern

The lens horizontal position is different depending on the paper size selected.
On the other hand, the ID sensor position is fixed at one position. Therefore,
the ID sensor pattern on the back side of the exposure glass bracket will be
positioned on the drum only when 81/2" x 14" size paper is selected.
The sensor pattern on the drum is made for each paper size as follows
(100%):
Paper Size Pattern (Black)
81/2" x 11"/51/2" x 81/2" Outside image of exposure glass (no light)
81/2" x 14" ID sensor pattern on the exposure glass
bracket
11" x 17" Exposure lamp off (no light)
The potential of the drum in these cases, the no light and the ID sensor
pattern exposure, is not the same. So the ID sensor bias (VBP) is determined
using two base voltages, V0 for the no-light condition and VD for the pattern.
VBP (no light) =
_
360 + V0
VBP (ID Pattern) =
_
360 + Vd
The Vd value which is determined during the process control data
initialization will be used.
V01 and V02, which are explained in the process control section, are used for
the VBP calculation as the V0 (drum potential after the charge corona) value.
The VBP can be changed by the SP mode (Toner Density Correction).
The following compensation will be applied to the above VBP.
Setting L N H VH
(V)
_
60 0 +60 +120
Rev. 11/92
VL Pattern
ID Sensor
Pattern
Outside
Lens Position
11" x 17"
81/2" x 14"
81/2" x 11"
Exposure Glass
Default: H (+60 V)
FT8780/8880 2-44 STM
7. TONER DENSITY DETECTION AND SUPPLY
7.1 TONER SUPPLY MECHANISM

The main PCB monitors the ID sensor pattern density on the drum through
the ID sensor once every ten copies and turns on the toner supply motor
when the pattern density is low (if Vsp/Vsg 1/13).
The toner supply motor [A] turns the toner supply roller [B] for a certain period
based on the paper size, supply amount set by SP mode and pattern density.
A brush roller with a low rotation torque that can supply large amounts of
toner even with low operation speed, is used for the toner supply roller.
Toner mixing vanes [C] turn slowly while contacting the inner wall surface of
the toner tank whenever the development motor is turning. This prevents
toner blockages, and supplies toner to the toner agitator [D].
[A]
[B]
[B]
[D]
[C]
STM 2-45 FT8780/8880
7.2 TONER DENSITY DETECTION
7.2.1 ID Sensor Pattern Production

Drum sensitivity varies from copy to copy. Especially, drum rest time effects
drum sensitivity.
To compensate the sensitivity changes in the copy run, the ID sensor
development timing and development bias is controlled using two copy
counters.
Counter A:
Counts the copy number. Resets when the Start key is pressed.
Counter B:
Counts the copy number. Resets if the accumulated number is 10 or
above when the Start key is pressed, or when the ID sensor pattern is
made.
NOTE: Both counters are reset when the main switch is turned on or the
doors are opened.
The ID sensor pattern is made in the following conditions:
1) At the leading edge of the first copy cycle after the main switch is
turned on or when the doors are opened.
2) If A 10
At the trailing edge of the copy cycle when;
A = 10n (n: any numeric number)
3) If A < 10
When the last copy is finished and B 10, then the pattern is
developed at the leading edge of the next copy cycle.
1 2 3 1 2 10 11 1 2
1 2 3 1 2 10 11 1 2
1 2 3 4 5 13 1 2 3
Counter A
Counter B
Main SW
ON
Start Key Start Key Start Key
ID Sensor Pattern
FT8780/8880 2-46 STM
7.2.2 Toner Density Detection

The ID sensor measures the density of the ID sensor pattern developed on
the drum. The main PCB receives two values of the sensor output, the value
for the sensor pattern (Vsp) and the value for the bare drum (Vsg).
Toner will be supplied under the following condition:
Vsp/Vsg 1/13
(V)
Vsg = 4.0
1/13 Vsg = 0.31
0
1/13 Vsg
0
(T)
Vsg
Vsp
Low image
density
High image density
Bare
drum
Sensor
pattern
LED
ON
LED
ON
Vsg Vsp
STM 2-47 FT8780/8880
7.2.3 ID Sensor Abnormal Conditions
a. Vsp Abnormal
If the measured Vsp is 1.4 V (when Vsg = 4 V) or more and this condition is
detected five times in a row, a system error condition will be indicated on the
CRT. When this occurs the 7% fixed toner supply control will be used for the
rest of the copy run.
b. Vsg Abnormal
If the measured Vsg during ID sensor pattern detection is 2.5 V or less and
this condition is detected five times in a row, a system error condition will be
indicated on the CRT. When this occurs the 7% fixed toner supply control will
be used for the rest of the copy run.
If both abnormal values return to normal during the copy run, the toner supply
control will also be returned to normal.
7.3 TONER SUPPLY AMOUNT
Vsp (V)
(at Vsg = 4.0 V)
Toner Supply Amount Data in SP Mode
15% 30% 45% 60%
0.3 Vsp < 0.4 7 15 15 30
0.4 Vsp < 0.5 15 30 45 45
0.5 Vsp 30 45 60 60
The toner supply ratio is determined based on the supply amount data in SP
mode and Vsp values as shown in the above table.
The toner supply roller turns for a period of time based on the selected supply
ratio and selected paper size.
Rev. 7/92
FT8780/8880 2-48 STM
7.4 TONER CARTRIDGE

When the toner cartridge is set, the toner cartridge sensor [A] is de-actuated.
The main PCB monitors the toner cartridge sensor signal and detects if the
cartridge is replaced at the toner end condition. The main PCB inhibits
copying if there is no toner cartridge.
The toner cartridge is also used as the used toner collection tank. The copy
image becomes poor if the collected toner is re- used. To prevent accidental
re-use of the collected toner, a spring plate lock mechanism [B] is installed.
The lock allows the toner cartridge shutter to be pulled and returned only
once.
[A]
[B]
STM 2-49 FT8780/8880
7.5 TONER END DETECTION
7.5.1 Toner Near End Detection

Toner near end is detected by measuring the physical amount of toner
remaining in the toner tank by the following mechanism.
The toner near end feeler [A] has a magnet [B] and is installed on the toner
mixing vane drive shaft [C]. The toner near end sensor [D] is located
underneath the toner tank (outside) and the sensor actuator [E] (inside)
contains a magnet. When the toner tank has enough toner, the toner near
end feeler does not lower due to the resistance of toner.
When the remaining toner amount in the toner tank becomes below
approximately 250 grams, the near end feeler lowers and repulses the
sensor actuator by the magnets repulsive force. This actuates the toner near
end sensor. When the main PCB senses the toner near end sensor actuation
three times in a row, the toner near end condition is displayed on the CRT
screen to let the operator know to replace the toner cartridge. In the toner
near end condition, copies can be made until the toner end is detected by the
ID sensor.
Rev. 11/92
[C]
[B]
[A]
[D]
[E]
FT8780/8880 2-50 STM
7.5.2 Toner End Detection
When little toner remains in the toner tank, the amount of toner supplied to
the development unit decreases, and the image of the ID sensor pattern gets
lighter.
When the Main PCB detects the low ID sensor pattern density condition
(Vsp/Vsg > 1/8) more than three times in a row during the toner near end
condition (physical check), the toner end condition is displayed on the CRT
screen and copying is inhibited until the toner cartridge is replaced.
Note: The copier must be in a toner near end condition before toner
end can be determined.
STM 2-51 FT8780/8880
8. IMAGE TRANSFER AND PAPER
SEPARATION
8.1 PRE-TRANSFER DISCHARGE

The pre-transfer corona (PTC) [A] and pre-transfer lamp (PTL) [B] are used
to prevent incomplete toner transfer and pick-off pawl marks on the copy.
To prevent incomplete toner transfer, the PTC reduces drum potential by
applying an ac corona. The PTC also applies a dc negative charge at the
same time to keep the toner potential negative.
The PTL further reduces the drum potential. Since the PTC gave a negative
charge not only to the toner but also to the non image (no toner) area on the
drum, the PTL reduces the negative charge on the drum which may attract
copy paper and cause pick-off pawl marks.
[A]
[B]
FT8780/8880 2-52 STM
8.2 IMAGE TRANSFER

The copy paper is fed from the registration section to the transfer and
separation section through the guide mylar [A] which holds the copy paper so
that the paper sticks to the drum surface.
The transfer corona [B] applies a positive charge on the back side of the copy
paper to attract the negatively charged toner image from the drum to the copy
paper.
[A]
[B]
STM 2-53 FT8780/8880
8.3 PAPER SEPARATION

To break the attraction between the paper and the drum, the separation
corona applies an ac corona to the back side of the paper. The stiffness of
the paper then causes it to separate from the drum. The pick-off pawls [A],
which are located below the cleaning unit, assist paper separation.
Two corona wires are used to improve separation by widening the discharge
area. Also, a larger corona current is applied at the leading edge of the paper
for the same purpose.
[A]
FT8780/8880 2-54 STM
8.4 TC/SC WIRE CLEANER

The transfer and separation corona unit contains wire cleaners to remove
paper dust and/or toner particles which may get on the corona wires.
Once every 5000 copies, the wire cleaners are activated when the main
switch is turned on. The hot roller temperature must be less than 100C for
the wire cleaner to be activated.
STM 2-55 FT8780/8880
8.5 PICK-OFF PAWLS

The pick-off pawls assist the paper separation process.
The pick-off pawls are normally kept in contact with the drum.
When the transport unit is lowered, the pick off pawls are released from the
drum.
The pick-off pawl shaft is in contact with the cam gear [A] which is located at
the front side and driven by the drum flange gear. The cam gear gives
side-to-side movement to the pick-off pawl shaft to prevent toner from
accumulating on the pick-off pawls.
Rev. 11/92
[A]
FT8780/8880 2-56 STM
8.6 TRANSPORT UNIT

Four transport belts are used to transport the copied paper to the fusing
section. A vacuum fan draws air through the holes on the transport unit to
hold the paper on the transport belts.
The transport unit is pushed up and locked into position by the front and rear
guide rollers. Turning the transport unit release lever to the left releases the
lock and lowers the unit to clear paper jams.
If ozone produced by the coronas stays in the drum area, it will cause uneven
corona charging or affect drum sensitivity causing poor image problems.
The vacuum fan draws the ozone through the air duct and transports it to the
ozone filter. Ozone is changed to oxygen by the filter and removed from the
copier.
STM 2-57 FT8780/8880
9. CLEANING
9.1 OVERVIEW

This copier uses the counter blade system for drum cleaning.
The blade is angled against drum rotation. This counter blade system has the
following advantages:
Less wearing of the cleaning blade edge.
High cleaning efficiency.
The cleaning brush is used to support the cleaning blade. A looped-type
brush is used for better efficiency.
The brush collects toner from the drum surface that is scraped off by the
cleaning blade. The flick bar [A] and the flick roller [B] mechanically remove
toner on the cleaning brush. The flick blade [D] removes toner from the flick
roller. Toner is transported to the toner cartridge by the toner collection coil
[C].
To remove the accumulated toner at the edge of the cleaning blade, the drum
turns in reverse for about 20 mm at the end of every copy job. The
accumulated toner is removed by the cleaning brush by this action.
All the driven gears except the drum drive gear have one-way clutches to
prevent reverse rotation during this operation.
Rev. 11/92
[B]
[C]
[A]
[D]
FT8780/8880 2-58 STM
9.2 DRIVE MECHANISM

Drive 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 then transmits the force to the front side through the cleaning brush [C]
and flick roller [D]. The force at the front side is used for the blade cam gear
[E] and toner collection coil gear [F].
There is a one-way clutch in the transport unit drive gear [G] to prevent the
drive parts in the cleaning unit from turning backwards, when the main motor
reverses.
Rev. 7/92
[B]
[A]
[G]
[D]
[C]
[E]
[F]
STM 2-59 FT8780/8880
9.3 CLEANING BLADE PRESSURE MECHANISM
When the cleaning solenoid [A] is energized, the solenoid arm lowers the
pressure arm [B]. This frees the pressure release lever [C] and the blade
spring [D] applies pressure to the cleaning blade.
To ensure cleaning blade operation, +38 Vdc is applied initially to the
cleaning solenoid to bring the blade against the drum, then +24 Vdc is
applied to the solenoid to hold the blade there.
[B]
[A]
[D]
[C]
FT8780/8880 2-60 STM
9.4 CLEANING BLADE SIDE-TO-SIDE MOVEMENT

The cleaning blade is held on the cleaning blade holder with a shoulder
screw [A] at its center so that the cleaning pressure is evenly applied to the
drum surface.
The cleaning blade holder touches the cam gear [B] which gives a
side-to-side movement to the blade. This movement prevents the cleaning
blade from being damaged.
[B]
[A]
STM 2-61 FT8780/8880
9.5 TONER COLLECTION MECHANISM

Toner collected by the cleaning unit is transported to the toner cartridge
through the toner collection tubes. Three helical coils are used to transport
the collected toner.
A magnetic disk torque limiter [A] is used on the toner collection coil drive
mechanism to prevent the coil from being damaged by toner clogged in the
collection tube. The toner collection coil drive gear [B] has two actuators for
the coil overload sensor. The main PCB monitors the sensor output and will
display an SC code if no signal changes are detected for more than 3
seconds while the development motor is turning.
[B]
[A]
FT8780/8880 2-62 STM
9.6 TONER SCATTERING PREVENTION

The cleaning unit has two air outlets covered by the cleaning filters on its
back side. The vacuum fan draws air from the cleaning unit through the
cleaning filters [A] and the toner filter [B] located above the transport section.
This prevents the toner in the cleaning unit from being scattered to the drum
area.
[A]
[B]
STM 2-63 FT8780/8880
9.7 CLEANING SOLENOID CIRCUIT

The main PCB energizes RA301 for 0.3 seconds to supply +38 V for the
cleaning blade solenoid at the initial solenoid activation. RA301 is then turned
off and +24 Vdc is supplied to the cleaning solenoid.
The main PCB sends a pulse signal to the coil overload sensor through the
interface PCB. When the overload sensor is actuated, the pulse signal is
returned to the main PCB. The main PCB is monitoring this signal change for
toner collection coil blocking.
Main PCB DC Drive PCB
Interface PCB
Overload
Sensor
Cleaning
Sol
Scan 2
Scan 2
FT8780/8880 2-64 STM
9.8 CLEANING BLADE SOLENOID CONTROL

The main motor turns in reverse for 40 pulses at the end of every copy job. At
this time, the cleaning solenoid is kept on to clean off the toner on the
cleaning blade edge. When the drum temperature is more than 49C, the
toner on the cleaning blade edge may soften and clog due to heat. To
prevent this, the cleaning blade is released from the drum at the start of the
drum reverse rotation. The blade touches the drum again while the drum is
still turning in reverse (due to inertia) to clean the edge of the blade.
The cleaning solenoid off timing is determined based on the accumulated
number of copies as follows:
Accumulated copy number Off Timing
100 copies 15 seconds after the main motor off
< 100 copies 5 minutes after the main motor off
This is to minimize toner scattering in the machine.
The cleaning solenoid is turned off when the main switch is off or the front
doors are opened.
Rev. 2/94
STM 2-65 FT8780/8880
10. QUENCHING

To neutralize any charges remaining on the drum, a cold cathode fluorescent
lamp [A] (CFL) is used as the quenching device.
When the main PCB sends a trigger signal to the the CFL stabilizer [B], ac
power (480Vac/5mA) is supplied to the CFL.
[B]
[A]
FT8780/8880 2-66 STM
11. PAPER FEED
11.1 OVERVIEW

This machine feeds paper from three trays. (Capacity: 1st tray [A]: 550, 2nd
tray [B]: 3000, 3rd tray [C]: 1500).
Paper is positioned at the center of the trays.
This copier uses an FRR (Feed + Reverse Roller) paper feed system which
uses three rollers: pick-up roller, feed roller, and separation roller. A
permanent magnet is used as a torque limiting device for the separation roller.
One anticondensation switch for all tray heaters is installed on this copier. A
tray heater is installed on each tray and turns on when the anticondensation
switch is on while the main switch is off.
[C]
[A]
[B]
STM 2-67 FT8780/8880
11.2 PAPER FEED AND SEPARATION

Whenever the main motor is on and the paper feed clutch is off, main drive is
applied to the separation roller shaft [B] through two gears [A & D]. This
causes the separation roller shaft to turn in the direction indicated by the
arrow in the illustration. The separation roller shaft attempts to drive the
separation roller [E] backwards. However, the separation roller is prevented
from turning backwards by the one way bearing in the swing arm (See page
2-71) and instead the torque limiter [C] slips. Thus, the separation roller
remains stationary. The separation roller shaft speed is reduced by the low
rotational drive ratio of the drive gear [D] against the feed clutch gear [A].
This reduces the main motor load as it tries to turn the separation roller
through the torque limiter.
[A]
[D]
[B]
[C]
[E]
FT8780/8880 2-68 STM

Using the paper feed trigger signal from the main control board, the paper
feed clutch [A] turns on and paper feed roller shaft [B] begins to turn. A
one-way clutch drives the paper feed roller [C]. The pick-up roller [D] rotates
via an idler gear. Then, paper feed begins. A one-way clutch allows the
separation roller shaft to drive at high speed in the direction indicated by the
white arrows in the illustration. This is because the high rotational drive ratio
of the drive gear [E] against the feed clutch gear. However, as the separation
roller [F] rotates in contact with the paper feed roller, the separation roller
rotates in the direction of the black arrow.
Paper is fed by the operation described above. The paper feed sensor [G]
senses the paper and the pick-up solenoid activates. The pick-up roller is
then lifted up to its upper position which is out of the paper path.
Simultaneously, the paper feed clutch temporarily turns off.
This process of turning off the paper feed clutch as paper reaches the paper
feed sensor is called pre-registration and is necessary due to the high copy
speed. The paper waits at that point until the proper time, and then the clutch
turns on again to feed the paper to the following transport relay rollers.
[A]
[C]
[E]
[B]
[D]
[F]
[G]
STM 2-69 FT8780/8880
11.3 FRR OPERATION

The direction in which the separation roller turns depends on the frictional
forces acting on it. The magnetic torque limiter applies a constant clockwise
force [F1]. When there is a single sheet of paper being driven between the
rollers, the force of the friction between the feed roller and paper [F2] is
greater than F1. So, the separation roller turns counter clockwise.
If 2 or more sheets are fed between the rollers, the forward force on the lower
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
sheet back to the tray.
11.4 MAGNETIC TORQUE LIMITER
Depending on the inner and outer magnetic force, the torque is transmitted to
the separation roller shaft as shown below.
Separation roller drive [A] Rotor [B] Inner magnet [C] Outer
magnet [D] Casing [E] Separation roller rotation
F2
F1
F2
F1
F3
F1
F1
F2
F2
[C]
[E]
[D]
[B]
[A]
FT8780/8880 2-70 STM
11.5 PAPER RETURN MECHANISM

The paper feed clutch [A] turns on and the paper feed roller shaft turns in the
direction indicated by the arrow in the illustration. The swing lever [B] is
raised by spring tension until it contacts the stopper [C]. In this condition,
paper feed begins.
When the clutch turns off, the swing arm remains in the raised position. The
separation roller [D] and feed roller [E] can rotate in the direction of paper
return until the swing lever meets the inside stay [F]. Then, the separation
roller and feed roller stop rotating. This operation returns paper between the
reverse and feed rollers to the tray to prevent paper damage when the tray
unit is pulled out.
[C]
[A]
[B]
[C]
[D]
[F]
3 mm
[E]
STM 2-71 FT8780/8880
11.6 PAPER END DETECTION

The paper end sensor [A] is installed under of the tray bottom plate. The
paper end condition is detected by the photo-interrupter and feeler [B]. When
there is no paper remaining in the tray, the feeler rises from the tray bottom
hole to deactuate the photo-interrupters for the 1st and 3rd tray, and to
actuate the photo-interrupter for the 2nd tray.
1st and 3rd Trays
[A]
[B]
2nd Tray
[A]
[B]
FT8780/8880 2-72 STM
11.7 PAPER VOLUME DETECTION

Each tray uses a pulse generator [A] to determine the quantity of paper in the
tray. The amount of paper present is based on the number of pulses
generated between the time the tray starts moving up and the time the upper
limit sensor turns off.
Rev. 7/92
[A]
STM 2-73 FT8780/8880
11.8 PAPER TRAY DRIVE MECHANISM
11.8.1 1st & 3rd Trays

Drive from a reversible motor [A] is transmitted though a worm gear [B] to the
drive pulley [C] shaft. The tray wires have metal beads on them. These beads
are inserted in the slots at the ends of the tray support bracket [D] of the
bottom plate, so, when the wire pulley turns (counterclockwise, rear view),
the beads on the wires drive the tray support bracket and the tray moves
upward. The tray goes up until the upper limit sensor [E] is actuated by the
top sheet pushing up the pick-up roller [F].
To lower the tray, the pulley turns clockwise until the lower limit sensor [G] is
actuated by the actuator of the bottom plate [H].
3rd Tray
[B]
[C]
[A]
[D]
[F]
[E]
[G]
[H]
1st Tray
[A]
[D]
[B]
[C]
FT8780/8880 2-74 STM
11.8.2 2nd Tray

Drive from a reversible motor [A] is transmitted trough a timing belt and a
worm gear [B] to the drive gear [C] shaft. The tray chains connect the ends of
the tray support bracket [D] of the bottom plate, so, when the drive gear turns
(clockwise, rear view), the chains drive the tray support bracket and the tray
moves upward. The tray bottom plate goes up until the upper limit sensor [E]
is actuated by the top sheet pushing up the pick-up roller [F].
If the tray down switch is pressed or paper runs out, the drive gear rotates
counterclockwise to lower the bottom plate. However, it is not lowered all the
way down at this time. When the tray paper position sensor [G] turns off
(de-activated), the drive motor stops. At this point, the bottom plate (or the
top sheet of paper) is positioned about 70 mm below the feed position. This
gives enough space for the customer to replenish about 500 sheets of paper.
If the tray down switch is pressed again, the bottom plate again moves down,
and once the top sheet of paper passes the paper position sensor the drive
motor again stops. In this way, the bottom plate is lowered 70 mm at each
press of the tray down switch. This allows the customers to replenish paper in
convenient amounts and at the same position.
The bottom plate stops going down when the lower limit sensor [H] is
actuated by the actuator of the bottom plate even if the paper tray position
sensor is on.
[H]
[A]
[C]
[B]
[D]
[E]
[F]
[G]
[G]
STM 2-75 FT8780/8880
11.9 TRAY LOCK MECHANISM
11.9.1 1st & 3rd Trays

When the tray is set, it is positioned by the lock arm [A]. The roller of the lock
arm presses against the lock plate [B]. The lock lever [C] engages the 1st
tray top cover stopper [D] (in case of the 3rd tray: tray stopper [E]) to prevent
the top cover of the 1st tray from being opened or the 3rd tray from being
pulled out while the tray is in the up position.
When the tray moves to the down position, the tray bottom pushes the
release lever and 1st tray top cover stopper or 3rd tray stopper is
disengaged, allowing the top cover or 3rd tray to be opened or pulled out.
[B]
[A]
[B]
[A]
[C]
[E]
3rd Tray
[D]
[D]
[C]
1st Tray
FT8780/8880 2-76 STM
11.9.2 2nd Tray

When the tray is set, it is positioned by the lock arm [A]. The roller of the lock
arm presses against the lock plate [B]. And the lock lever [C] engages the
right side plate stopper [D] to prevent the tray from being pulled out while the
tray is in the up position.
When the tray moves to the down position, the lock solenoid [E] turns on.
The lock lever then releases the right side stopper, allowing the tray to be
pulled out. The solenoid will remain on for one minute. After one minute, the
lock solenoid turns off. The tray cannot be pulled out. The lock solenoid will
turn off while the tray is pulled out.
[C]
[B]
[A]
[D]
[C]
[E]
[E]
STM 2-77 FT8780/8880
11.10 SIDE-TO-SIDE REGISTRATION
11.10.1 1st Tray

The plate [A] under the tray bottom plate can be moved from rear to front by
loosening 5 screws. This plate position determines the side-to-side
registration.
11.10.2 2nd & 3rd Trays

The tray stopper [B] is fixed to the tray side. The tray stopper bumper [C] is
fixed to the main body or tray body. The tray stopper and bumper determine
the side-to-side registration.
Note: Do not adjust 3rd tray stopper, side-to-side registration is set
through the SP mode. Refer to Section 5 of the FSM.
[A]
[C]
[B]
3rd Tray
Rev. 7/92
[B]
[C]
2nd Tray
FT8780/8880 2-78 STM
11.11 PAPER SIZE DETECTION
11.11.1 1st Tray

The rear side fence [A], front side fence [B], and rear plate [C] can be moved
to change the paper size. This is accomplished by loosening the knob screws
and moving these fences and plate to another position.
The paper size detection sensors are mounted under the paper tray bottom
plate. When the rear side fence is inserted into one of the paper size position
slots, it enters one of the four photo-interrupters. The signal from this sensor
informs the CPU which size paper (LT, LG, HLT) is in the tray.
[B]
[C]
[A]
STM 2-79 FT8780/8880
11.11.2 2nd Tray

The rear side fence [A] and front side fence [B] can be moved to change the
paper size. This is accomplished by loosening the knob screw and moving
the rear and front side fences to another slot.
The paper size detection sensors are mounted under the paper tray bottom
plate. When the rear side fence is inserted into one of the paper size position,
it enters one of the three photointerrupters. The signal from this sensor
informs the CPU which size paper (LT, LG), is in the tray.
[B]
[A]
FT8780/8880 2-80 STM
11.11.3 3rd Tray

The operator can easily adjust the paper side guide posts [A] and end plate
[B] for any paper size by pressing the stopper lever and sliding the side guide
posts and end plate to the desired position.
The guide post brackets have the actuator plates mounted on their bottom.
These plates activate 6 sensors (photo-interrupters) mounted under the
bottom plate.
The CPU determines the following paper size by reading the combination of
sensors activated. (HLT, LT, LG, DLT sideways, LT lengthwise)
[A]
[B]
STM 2-81 FT8780/8880
11.12 2ND TRAY END FENCE

When the tray is pulled out, the rear fence [A] is held in place by the front
stay [B]. This makes paper setting easier.
When the tray is pushed in, the rear side plate [C] guides the rear fence to its
home position.
[A]
[B]
[C]
FT8780/8880 2-82 STM
11.13 FEED UNIT DRIVE MECHANISM

Feed roller drive of the 1st & 2nd tray is provided by the copier main motor.
When the LCT drive clutch [A] turns on, drive from the transport section [B] of
the copier main motor is transmitted via gears and a timing belt to the 1st and
2nd paper feed mechanism. [C & D]
The feed roller drive of the 3rd tray is provided by the vertical transport
section.
[B]
[C]
[A]
[D]
STM 2-83 FT8780/8880
12. TRANSPORT UNIT AND REGISTRATION
12.1 OVERVIEW

The copy paper travels one of the 3 paper paths to the registration rollers [A],
which correct paper skew and then feed the paper to the drum at the proper
time for image transfer. The copy paper exiting the 1st [B] or 2nd [C] paper
feed station passes through the relay guide section [D] to the registration
rollers. The copy paper exiting the 3rd paper feed station [E] passes through
the vertical transport section [F] and transport unit (the horizontal relay guide
section [G] and horizontal transport section [H]) to the registration rollers.
[H]
[G]
[E]
[F]
[A]
[D]
[B]
[C]
FT8780/8880 2-84 STM
12.2 VERTICAL TRANSPORT

The vertical transport unit contains relay rollers [A] and their guide plates for
the duplex and 3rd tray. The vertical transport unit with the 3rd tray can be
slid out by the 2 accuride rails [B] (upper and lower).
The duplex paper feed sensor [C] is installed on the vertical transport unit to
detect misfeeds.
The paper feed for the 3rd tray is driven from the vertical transport unit.
12.3 RELAY KNOB MECHANISM
To make it easier to clear paper jams between the duplex unit and the
horizontal transport unit, the upper relay rollers can be turned by the relay
knob [D]. This delivers the jammed paper to the horizontal transport unit [E].
The relay knob shaft gear [F] has a one-way clutch. It can be turned in the
direction of the arrow shown in the illustration.
Rev. 7/92
[A]
[C]
[B]
[B]
[F]
[D]
[E]
STM 2-85 FT8780/8880
12.4 DRIVEN GUIDE PLATE RELEASE MECHANISM

The driven guide plate [A] is supported by the support bracket [B]. Torsion
springs [C] hold it in the closed position. There are magnets [D] at the front
and rear. The magnets grip the drive guide plate.
Plate springs [E] are installed to the front and rear ends of the back side of
the driven guide plate. When the unit is pushed in, the roller [F] of the main
body side presses against the back plate to ensure magnetic attachment and
to prevent the driven guide plate from releasing due to a paper jam in the
machine.
12.5 UNIT LOCK LEVER
When the vertical transport unit is set to the main body, it is locked by the
lock lever [G] applying pressure to the stopper bracket [H] of the main copier.
[G]
[H]
[C]
[B]
[D]
[F]
[E]
[A]
[D]
FT8780/8880 2-86 STM
12.6 PAPER DUST CLEANING ROLLER

Paper passes the paper dust cleaning roller [A] before it reaches the
registration roller [B]. The paper dust cleaning roller is a teflon-coated roller,
which is charged by contact friction with the scraper [C]. This mechanism
attracts paper dust, and removes it from the copy paper. The paper dust pan
[D] collects the paper dust from the paper dust cleaning roller and the scraper.
Rev. 7/92
[A]
[B]
[D]
[C]
STM 2-87 FT8780/8880
12.7 DRIVE MECHANISM

All horizontal transport section rollers (with the exception of the registration
roller) begin to rotate together with the main motor [A]. The registration clutch
[B] engages according to the appropriate registration timing. When the clutch
engages, the registration roller will begin to rotate.
Main motor drive [C] also is transmitted through a joint [D] to the vertical
transport unit drive clutch [E]. The upper relay roller begins to turn at the
same time.
When the 3rd paper tray is selectected and the start key is pressed, the
vertical transport unit drive clutch turns on. The lower relay roller [G] together
with the 3rd paper tray unit drive gear [H] begin to rotate.
A one-way clutch is built-in to the upper relay drive gear [I]. Due to the
one-way clutch, when clearing a paper jam, there will be no load from the
main motor and the upper relay rollers will rotate freely.
Rev. 10/94
[A]
[B]
[I]
[D]
[C]
[G]
[H]
[E]
[F]
FT8780/8880 2-88 STM
13. FUSING
13.1 OVERVIEW

The image fusing on the copy paper is made by the hot roller [A] and
pressure roller [B]. The hot roller has three heat pipes [C]. These pipes
deliver extra heat from both ends of the hot roller to the center of the roller to
distribute heat evenly along the roller. This is especially effective for small
paper that passes only through the center of the roller. The hot roller has two
internal fusing lamps (720/900 W). Both lamps turn on during initial warm-up,
and as necessary to keep the hot roller at operating temperature (198C).
However, to limit maximum power consumption, the 720 watt lamp does not
operate during the copy cycle. The CPU monitors the hot roller temperature
through a thermistor. A thermofuse (192C) protects the unit against
overheating.
The oil supply roller [D] applies silicon oil to the hot roller directly. Silicone oil
is used for several reasons: it keeps rollers clean by reducing the amount of
toner transferred to them, it reduces adhesion between paper and the hot
roller, and it reduces paper curl. As the toner designed for this machine
includes a substitute for the silicone oil, only a small amount oil is used for
fusing.
The hot roller and pressure roller have stripper pawls [E] to prevent
wrap-around jams.
The pressure roller is cleaned by a steel cleaning roller [F]. Toner adheres to
steel more readily than to silicon rubber.
Rev. 7/92
[A]
[D]
[C]
[E]
[B]
[F]
[C]
STM 2-89 FT8780/8880
13.2 HEAT PIPE CONFIGURATION AND OPERATION
PRINCIPLES

The heat pipes are hollow metal tubes. Water capillary tubes [A] run along
the inside of the heat pipe. These capillary tubes are used as heat transfer
elements. When one end of the heat pipe is superheated [B], it causes
vaporization. The vaporization creates a high-speed flow of steam [C] to the
low temperature area. When the steam reaches that area, the steam cools
[D] (The low temperature area is heated by the steam). Thus, it causes
condensation. The condensed water is returned to the heating section by
capillary action.
This cycle (vaporization steam transfer condensation) repeats again
and again. The heat is transferred along the heat pipe continuously and
efficiently.
Rev. 11/92
[A]
[C]
[D]
[B]
FT8780/8880 2-90 STM
13.3 PRESSURE MECHANISM

The fusing pressure is constantly applied between the hot roller [A] and
pressure roller [B] by the upper pressure lever [C] and lower pressure lever
[D] which are lifted up by the fusing unit release lever [E] via the pressure
cam [F]. The pressure can be adjusted by using the pressure adjustment
screw [G].
The fusing pressure is released by turning the fusing unit release lever
counterclockwise. This is helpful for clearing paper jams.
[A]
[C]
[B]
[E]
[D]
[G]
[F]
STM 2-91 FT8780/8880
13.4 OIL SUPPLY

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
silicone oil to the hot roller.
[A]
[A]
[B]
FT8780/8880 2-92 STM
13.5 DE-CURLING AND COOLING MECHANISM

The de-curling roller [A] cools the copy paper exiting through the fusing unit.
This prevents sheets in the duplex tray from sticking together because the
toner, being too hot, is still "tacky".
The copy paper may be back-curled after it passes the fusing unit. The
de-curling roller and the de-curling belt [B] make the copy paper face-curl to
improve paper stacking in the sort mode. It is better for copy paper to be
face-curled than to be back-curled in this copier because the copy paper is
stacked facing down in sort mode.
The de-curling roller has, inside it, a heat pipe similar to the hot roller heat
pipe. It releases the heat from the paper to the fins [C]. The fusing cooling fan
[D] in the duct [E] at the machine rear side cools the fins. There is a duct [F],
above the de-curling roller, and a fusing exhaust fan [G] that discharge the
heat in the de-curling unit through the inverter unit, out of the machine.
[A]
[B]
[C]
[C]
[E]
[G]
[F]
[D]
[B]
[A]
STM 2-93 FT8780/8880
13.6 FUSING DRIVE MECHANISM

Main motor drive is provided to the fusing unit through the transport timing
belt [A], fusing drive belt [B], and fusing drive gear [C]. The fusing unit and
fusing drive section are precisely positioned by the position guide [D]. This
minimizes the fusing drive load and prevents drive gear abrasion.
The pressure roller [E] is held against the hot roller [F] and is friction driven
by the hot roller. The inverter unit is driven by the hot roller gear [G] through
relay gears [H] and the de-curling belts drive roller shaft [I].
[G]
[C]
[D]
[E]
[H]
[F]
[I]
[B]
[A]
[I]
FT8780/8880 2-94 STM
13.7 FUSING LAMPS OPERATION

Warm up:
After the main switch is turned on, the 900 W lamp turns on first and after
one second, the 720 W lamp turns on...(*1). This is because if both lamps
turned on simultaneously, it would result in an extremely high current load.
These lamps stay on until the temperature reaches 198C. The ready
temperature is 178C, when the drum heater is ready.
NOTE: While the fluorescent lamp in the optics turns on at the process
control initial setting, after the main switch is turned on, the 720 W
lamp turns off...(*2).
Stand-by (*3):
Both lamps turn on at 195C and turn off at 198C. For the same reason as
with the warm-up period, the 900 W lamp turns on first and after one second,
the 720 W lamp also turns on...(*4).
Copying cycle:
900 W lamp turns on when the temperature drops below 195C. The 720 W
lamp does not turn on...(*5).
A .....720 W lamp
B .....900 W lamp
C .....Ready temperature (178C)
D .....Heater on temperature (195C)
E .....Heater off temperature (198C)
F......Main switch on
G.....Start key on
Rev. 7/92
E (198C)
D (195C)
C (178C)
F G
B
A 1S
Ready
*5
*4
*1 *2
1S
*3
STM 2-95 FT8780/8880
SP mode
RESET SET
USER
TOOL
No
159C
(169C)
169C
(169C)
Yes
179C
(189C)
189C
(189C)
( ): Cover sheet or slip sheet mode (Thick paper)
Lower limit temperature:
If the hot roller surface temperature drops below the lower limit temperature
while copying, the copier stops and both fusing lamps turn on. (This may
happen during a long continuous copy run using DLT paper.) When the hot
roller returns to 195C, the copier automatically resumes the copy run. The
lower temperature limit can be changed by the SP mode and user tools as
shown above. (Default = RESET & No)
Rev. 7/92
FT8780/8880 2-96 STM
14. INVERTER AND PAPER EXIT
14.1 OVERVIEW

After passing the fusing unit, copies come to the inverter unit which chiefly
consists of the inverter roller [A], inverter gate [B], inverter gate solenoid [C],
return drive rollers [D], return pinch rollers [E], pinch solenoid [F], junction
gate [G], and junction gate solenoid [H]. The inverter unit can be opened to
the right after pulling out the fusing and inverter units. This helps to clear
paper jams.
The inverter unit does the following jobs.
(1) Ordinary copying: Copies pass through the unit straight to the exit
rollers [I].
(2) Duplex copying: Copies are turned over and then sent to the
duplex tray [J].
(3) Overlay image copying: Copies are sent directly to the duplex tray.
(4) Face-down feed-out: Copies are turned over and then sent to the exit
rollers.
The following section discusses the inverter operation in detail.
[C]
[F]
[H]
[E]
[D]
[A]
[B]
[G]
[E]
[B]
[I]
[G]
[D]
[A]
[J]
STM 2-97 FT8780/8880
14.2 ORDINARY COPYING
The inverter gate [A] stays at the
upper position (the inverter gate
solenoid stays off) and the junction
gate [B] stays at the lower position
(the junction gate solenoid stays off),
and copies go straight through the
inverter units to the exit rollers.

14.3 DUPLEX COPYING
The inverter gate solenoid and
junction gate solenoid turn on. The
inverter gate turns counterclockwise,
to direct copies up between the
inverter guide plates [C]. The trailing
edge of the copy passes the fusing
sensor.Then 40 ms later, the pinch
roller solenoid turns on for 300 ms.
Copies are inverted and fed out by
the return drive rollers [D] and the
return pinch rollers [E]. The junction
gate directs copies to the duplex unit
[F].
[A]
[B]
[C]
[F]
[E]
[D]
FT8780/8880 2-98 STM
14.4 OVERLAY IMAGE COPYING
The inverter gate solenoid stays off
and the junction gate solenoid turns
on. Copies go straight to the junction
gate [A] and are directed by the
junction gate to the duplex unit [B].

14.5 FACE-DOWN FEED-OUT
The inverter gate solenoid turns on
and the junction gate solenoid stays
off. Copies are sent up between the
inverter guide plates and then fed out
by the return drive rollers and return
pinch rollers. The junction gate
directs copies to the exit rollers.
[A]
[B]
STM 2-99 FT8780/8880
15. DUPLEX
15.1 OVERVIEW

Copies are fed to the duplex tray when in duplex copying or overlay copying
mode. The copies wait in the tray until the copying of the second original
starts. The duplex tray has a maximum capacity of 50 sheets. When a copy
number greater than 50 is entered, 50 (copies) is displayed in the copy
entered counter and only 50 copies are printed.
The duplex tray uses a feed system similar to the one used by the paper
trays for paper feed. It uses three rollers: pick-up [A], feed [B], and separation
[C] rollers. The main difference between duplex and paper tray paper feed, is
that for duplex paper feed, the bottom sheet is fed first, but for paper tray
paper feed, the top sheet is fed first.
[C]
[B]
[A]
FT8780/8880 2-100 STM
15.2 DUPLEX ENTRANCE

Copies transported from the inverter section pass through the relay guide
plates [A] to the duplex tray section.
To clear paper jams between the inverter section and duplex tray, the relay
guide plate can be opened and closed by the spring [B]. Since the spring
pressure [D] is applied to the upper fork gate feed roller [E], paper jammed in
the middle can best be removed by turning the knob [C] manually. (see upper
illustration).
This will move the jammed paper to the duplex tray for easy removal.
A photo-interrupter is installed in the duplex tray entrance [F] for detecting
paper jams and for jogger motor drive timing.
[A]
[B]
[D]
[A]
[E]
[C]
[F]
[F]
STM 2-101 FT8780/8880
15.3 FORK GATE

1 2 3
HLT LT, LG DLT
B ON ON OFF
C ON OFF OFF
After paper passes through the duplex entrance sensor, the two fork gates
[A] provide three possible paper routes to the duplex tray. The paper route
depends on the paper size.
The fork gate solenoids [B, C] turn on and off depending on paper size as
shown.
[A]
[B]
[C]
FT8780/8880 2-102 STM
15.4 STACKING MECHANISM

The paper stopper solenoid [A] energizes and the paper stopper [B] turns
counterclockwise.
When the positioning solenoid [C] energizes, the positioning roller [D] is
lowered via the lowered release link so that it contacts the bottom plate. The
positioning roller is rotating via the main motor drive, the paper sheet entering
the duplex tray is transported by the positioning roller until it comes to rest
against the paper stopper. The solenoid turns off and the positioning roller is
lifted up when stacking is completed.
[A]
[D]
[B]
[C]
STM 2-103 FT8780/8880
15.5 JOGGER

When the start key is pressed, to start a duplex or overlay copy cycle, the
jogger motor [A] drives the jogger fences [B] inward from the home position to
the waiting position which is 10 mm away from both edges of the stacked
paper. The position is determined by the CPU according to information from
the paper size detection sensors of the paper tray.
After the leading edge of the copy paper passes the duplex entrance sensor,
and after the appropriate timing for the selected paper, the jogger motor
rotates and reverses. This causes the jogger fences to square the paper
stack. Also, this makes the jogger fence return to the waiting positions for the
next copy. This movement is repeated for each sheet placed in the duplex
tray.
The jogger fences have side-weights [C]. These side-weights apply pressure
to the paper edges. The paper flatteners [D] apply pressure to the middle of
the paper. This prevents "paper float".
[A] [D]
[B]
[B]
[C]
[C]
FT8780/8880 2-104 STM
15.6 PAPER END DETECTION

The feeler [A] located on the pressure plate shaft drops into the groove after
the last paper sheet [B] has passed. The photo- interrupter [C] is de-actuated
and paper end is detected.
[A]
[C]
[B]
STM 2-105 FT8780/8880
15.7 PAPER FEED AND SEPARATION

Paper feeding is from the bottom sheet. When the final sheet of paper has
been stacked inside the duplex tray, the paper stopper solenoid [A] and the
pressure plate solenoid [B], which turned on simultaneously with the paper
stopper solenoid, are turned off. The pressure plate [C] presses against the
stacked paper [D] and the paper stopper [E] is lifted up.
When the duplex paper feed clutch [F] turns on, the feed roller [G] and the
pick-up roller [H] are driven, the bottom sheet of paper is fed. During this time
the separation roller [I] is turning in the direction opposite to paper feed to
prevent the feeding of more than one sheet of paper at a time.
Rev. 7/92
[A]
[E]
[G]
[H]
[I]
[C]
[F]
[B]
[C]
[D]
FT8780/8880 2-106 STM

The duplex paper feed sensor [A] is identical to that of the paper feed tray. It
has two functions. Its first function is to check pre-registration. When the
paper reaches the sensor, the duplex paper feed clutch turns off. The paper
waits at that point until the proper time, then the clutch turns on again to feed
the paper to the vertical transport upper relay rollers. Its second function is to
detect paper jams.
The separation roller [B] normally turns in the direction opposite paper feed
when the main motor is rotating. This prevents two or more sheets from being
fed simultaneously. It also reduces wear of the reverse roller surface.
Rev. 7/92
[B]
[A]
STM 2-107 FT8780/8880
15.8 PICK-UP ROLLER STOP MECHANISM

The pick-up roller [A] makes one turn for each paper sheet. The pick-up roller
is flat on one side and, during machine stand-by, the flat side faces up.
Paper feed begins. The feeler [B] installed to the pick-up roller shaft turns.
After the pick-up roller position sensor [C] shifts from being actuated to being
de-actuated, the duplex paper feed clutch is de-engaged (after approximately
3/4 of a turn). The pick-up roller reaches its stop position. A heart-shaped
cam [D] is installed to the roller shaft end. A lock arm [E] rides on the cam.
The roller ordinarily stops when the lock arm is in the depressed portion of
the cam. This ensures that the flat surface of the pick-up roller faces up.
[A]
[E]
[D]
[D]
[C]
[B]
FT8780/8880 2-108 STM
15.9 DUPLEX UNIT LOCK MECHANISM

Like the paper tray, the duplex tray is positioned by the lock arm [A]. The
roller of the lock arm presses against the lock plate [B].
The duplex tray stopper [C] is fixed to the top of the lock arm. The tray
stopper bumper [D] is fixed to the main copier. The tray stopper and bumper
determine the side registration.
[A]
[B]
[C] [D]
STM 2-109 FT8780/8880
15.10 DUPLEX DRIVE MECHANISM

The duplex tray is driven by the main motor drive. The drive from the main
motor is transmitted through the timing belt [A], transport drive pulley [B] to
the duplex tray drive gear [C]. The duplex tray drive gear distributes the drive
to each roller.
[A]
[B]
[C]
FT8780/8880 2-110 STM
16. ARDF
16.1 OVERVIEW

1. One-sided Original Feed
When the start key is pressed after an original is set face down on the
original table [A], the bottom sheet of the original stack is fed onto the
exposure glass [B] by the rollers [C] and the transport belt [D].
After the scanner scans the original on the exposure glass, the transport belt
and the exit rollers [E] feed out the original to the original tray [F].
2. Two-sided Original Feed
In two-sided original feed mode, the inverter gates [G] are open. After the
scanner scans the front side of the original, the original is inverted around the
inverter roller [H] and transported to the scanning position again by the
reversing transport belt.
After both sides of the original are scanned, it is transported to the switch
back tray [I] while the switch back gate [J] is at the lower position. This is to
return the inverted originals to their original page order. Then the original is
fed out to the original tray.
[J]
[B]
[A]
[C]
[H]
[I] [G]
[F]
[D]
[E]
STM 2-111 FT8780/8880
16.2 ORIGINAL DETECTION

When an original is set on the original table [A] , the original sensor feeler [B]
is pushed up by the original and the original sensor [C] is activated.
The paper feed tray has an insert original indicator [D] and an auto feed
indicator [E]. The insert original indicator turns off when the original is set on
the original table. If the machine is set for SADF operation the auto feed
indicator lights for thirty seconds. If another original is set on the original table
during this time, machine operation starts automatically.
[C]
[B]
[A]
[E] [D]
FT8780/8880 2-112 STM
16.3 ORIGINAL SIZE DETECTION

Sensor
Size
SN2 SN4 SN5 SN6
HLT sideways,101/2" x 8", LT lengthwise
LT sideways O
F4 sideways O O
LG sideways, 15" x 11", 14" x 10" O O O
DLT sideways O O O O
The original width sensors detect paper width and the timing sensor [A]
detects the original length.
The original width sensors consist of four reflection-type photo sensors (SN2
[B], 4 [D], 5 [E], 6 [F] for U.S.A. and SN2, 3 [C], 4, 5 for Europe). The above
table shows the determined paper size depending on the sensor status.
While the registration sensor [G] is on, pulse generator pulses are counted to
measure original copy length in the direction of travel. In this way, the original
width sensor data is combined with the original length data and the paper
size is determined.
[F]
[E]
[D]
[C]
[B]
[G]
[A]
STM 2-113 FT8780/8880
16.4 PICK-UP ROLLER

The entrance guide mylar [A] holds the originals against the pick-up roller [B]
to facilitate paper feed.
The pressure release cam [C] lobe pushes the lever [D] upward to release
the pressure mylar [E]. This makes it easier to set the originals.
During paper feed, the cam rotates and the pressure mylar pushes down the
entrance guide mylar due to the force of the return spring.
The pressure mylar lever stops at the stopper [F] to prevent too much
pressure from being applied.
A heart-shaped cam [G] is installed on the pick-up roller shaft. When the cam
follower [H] drops into the depressed portion of the heart- shaped cam, the
pick-up roller stops. At this time, the flat surface of the pick-up rollers is level
with the original table.
Rev. 7/92
[E]
[A]
[D]
[C]
[B]
[F]
[H]
[G]
[C]
[G]
FT8780/8880 2-114 STM
16.5 ORIGINAL SEPARATION

Paper is fed by friction between the separation rollers [A] and the friction tab
[B].
The friction tab permits only the bottom sheet of the set of originals to be fed
by the separation rollers and the pick-up rollers [C] to the relay rollers [D].
The separation rollers have a built-in one-way gear. After the drive motor
stops, it continues to turn in the feed direction.
The friction tab is pressed against the separation rollers by springs [E]. To
prevent multi-feed, spring tension can be adjusted by two adjustment screws
[F] at the front and rear side of the tab holder.
The stopper [G] controls the gap between the friction tab and the separation
rollers to prevent a sheet of paper from being inserted to far.
Rev. 7/92
[D] [A]
[C]
[B]
[F]
[E]
[G]
STM 2-115 FT8780/8880
16.6 ORIGINAL FEED DRIVE MECHANISM

The reversible feed-in motor [A] drives the pick-up rollers [B], the separation
rollers [C], and the relay rollers [D]. Three one-way clutches located in the
two gears [E, F] and a pulley [G], control the rollers rotation.
Upon receiving the paper-feed signal from the copier, the paper feed motor
turns in the direction shown by the black arrow in the illustration. The relay
rollers are driven by the one-way pulley [G]. The pick-up roller and separation
roller are driven by the one-way gear [E]. The other one-way gear [F] idles.
The pick-up roller has a home position sensor [H]. When the sensor detects
feed-in that the roller has completed a full turn, the feed-in motor reverses.
When the motor reverses, the one-way pulley [G] and gear [E] driving the
pick-up and separation rollers become idle and the rollers stop. The relay
rollers continue to turn in the paper feed direction through the one-way gear
[F].
When the registration sensor [I] detects the trailing edge of the original and
the feed-in motor turns off.
[I]
[A]
[F]
[E]
[D]
[C]
[B]
[H]
[G]
FT8780/8880 2-116 STM
16.7 RELAY ROLLER PRESSURE RELEASE MECHANISM

When the entrance cover [A] is opened, the bushing [B] of the lower relay
roller is pressed down by the raised portion of the friction tab frame [C]. This
releases the relay roller pressure to make misfed original removal easier. The
feeler [D] moves away from the entrance cover sensor [E] which detects that
the cover is open.
The exit cover [F] can also be opened for easier misfed original removal.
[A]
[D]
[C]
[E]
[B]
[F]
STM 2-117 FT8780/8880
16.8 JOB SEPARATION

There is a mechanism to separate two different stacks of originals when the
preset mode is used.
When the job separation motor [A] rotates, the job separator [B] is set on top
of the first original stack. The separation motor stops when the job separation
home position sensor [C] is actuated.
When the last original of the first stack is fed from the original table, the feeler
[B] drops into the original table groove and the job completion sensor [D] is
actuated. When this occurs the CPU determines that the first job is finished.
[D]
[B]
[A]
[C]
FT8780/8880 2-118 STM
16.9 ORIGINAL TRANSPORT MECHANISM

Three pressure rollers [A] are built into the transport unit to maintain friction
between the transport belt [B] and the original. Transport belt tension is
provided by two springs [C].
The transport belt is driven by a dc motor [D].
A special coated exposure glass [E] (the coated side is marked and should
face up) is used to prevent the original from sticking due to static electricity.
The exposure glass is grounded to the main body frame through the
conductive front scale [F].
[A]
[B]
[D]
[C]
[E]
[F]
STM 2-119 FT8780/8880

Customers can choose the paper transport mode by "User Tool" depending
on the thickness of the original used. The factory setting is "Thin Paper
Mode".
-- In thin paper mode --
The belt motor stops exactly when the trailing edge of the original passes the
right scale [A] edge. (The timing is measured by the timing sensor after
registration sensor is activated.)
-- In thick paper mode --
To correct skewing on the exposure glass, the original runs 10mm after the
trailing edge passes the right scale. The belt motor then reverses and the
original travels until it meets the right scale.
If extremely thin paper is used in the thick paper mode, the paper may buckle
against the scale. This will result in poor image quality or original copy
wrinkling.
Thin Paper Mode
Thick Paper Mode
FT8780/8880 2-120 STM
16.10 TRANSPORT UNIT LIFT MECHANISM

To make opening the transport unit easier, there are six balance springs [A].
Three springs are on the right and three on the left.
There is a lift sensor [B] to detect if the transport unit opens. When the
transport unit is opened, the feeler [C] actuates the lift sensor.
To keep the transport belt unit parallel to the exposure glass, lift springs [D]
and lift-up springs [E] are installed to the transport unit base and the transport
drive unit at the point where the two units join.
The lift-up springs help prevent damage when the transport unit is open.
[C]
[B]
[A]
[E] [D]
STM 2-121 FT8780/8880
16.11 TRANSPORT BELT UNIT / INVERTER COVER

The inverter cover [A] and the transport belt unit [B] can be opened to allow
easy removal of original jams. The transport unit can be opened by sliding
the release lever [C] to the right.
A brake [D] is installed on each pivot to ensure that the downward movement
of the transport belt unit is gentle when the unit is opened.
An open inverter cover is detected when the feeler [E] moves away
(de-actuated) from the inverter sensor [F].
[C]
[B]
[D]
[E]
[A]
[F]
FT8780/8880 2-122 STM
16.12 ORIGINAL INVERTER MECHANISM

When the signal to invert is received from the copier, the belt motor (drives
transport belt [A]) and the inverter motor (drives inverter rollers [B] and exit
rollers [C]) start rotating.
Simultaneously, the inverter gate solenoid turns on to open the upper inverter
gate [D] and lower inverter gate [E].
The travel distance inside the inverter loop is approximately 200 mm. When
an original exceeding LT sideways is used, the original leading and trailing
edges will overlap.
When 10 pulses from the inverter motor encoder are counted after the
inverter entrance sensor [F] detects the leading edge of the original, the belt
motor starts reversing.
After the inverter registration sensor [G] detects the original leading edge, the
belt motor pulses are counted to determine the timing for the belt motor to
stop.
[C] [A] [B]
[D]
[E]
[G] [F]
STM 2-123 FT8780/8880

For original inversion, the inverter gate solenoid [A] turns on and the upper
[B] and lower [C] inverter gates open to create an inverter loop path.
An inverter entrance sensor [D] and an inverter registration sensor [E]
(reflective-type photosensors) are located in the inverter loop path.
[E]
[C]
[B]
[A]
[D]
FT8780/8880 2-124 STM
16.13 SWITCH BACK MECHANISM

To return the inverted originals to their original page order, the originals are
inverted again and traveled to the switch back tray [A] before being fed-out
from the document feeder.
When the inversion signal is received from the copier, the inverter solenoid
turns on to open the upper and lower inverter gates [B]. At the same time, the
switch back gate solenoid [C] turns on to lower the switch back gate [D]. (If
the next original has been set on the original table, the feed-in motor also
turns on.) After 175 ms, the belt motor and the inverter motor turn on to
transport the original to the switch back tray.
When the inverter entrance sensor [E] senses the trailing edge of the original,
the inverter gate solenoid turns off to close the inverter gates. When 54
pulses from the inverter motor encoder are counted after the inverter
entrance sensor senses the trailing edge, the inverter motor starts reversing
to feed-out the original from the machine.
An inverter jam sensor [F] (a reflection-type photosensor) is installed inside of
the switch back path to detect any remaining paper.
[A]
[F]
[B]
[E]
[D]
[C]
STM 2-125 FT8780/8880
16.14 INVERTER DRIVE MECHANISM

The inverter unit is driven by a dc motor [A].
The drive of the inverter motor [A] is transmitted to the exit rollers [B] through
the two one-way clutches [C]. The exit rollers rotate in the same direction due
to the function of these one-way clutches.
[C]
[A]
[B]
FT8780/8880 2-126 STM
16.15 CFF MECHANISM

There are four guides to maintain computer paper transport and stacking
capabilities.
The CFF stopper [A] of the paper feed unit prevents the original from entering
the ADF paper feed entrance. The rear CFF guide [B] prevents side to side
movement of the original to ensure that the CFF sensor [C] counts the holes
lined up on the computer form.
The CFF sensor [C] is installed in front of the original guide. The CFF sensor
consists of one CFF set sensor [D] and two CFF feed hole sensors [E].
The CFF guide [F] prevents original feed-out failure caused by the perforated
lines. The CFF extension [G] ensures stacking of the computer paper.
When a computer paper is set in the CFF guide, the holes are used to
calculate paper length in order to print one sheet at a time.
[A]
[B]
[F]
[G]
[E]
[D]
[C]
STM 2-127 FT8780/8880
17. OPERATION UNIT

A CRT (9 inches) [A] and a touch panel are used to achieve easy machine
operation.
The touch panel consists of a transparent film [B] and a glass sheet [C] on
which transparent matrix conductors (32 x 25 lines) are printed. The main
PCB scans these matrix lines and detects the touched location on the panel.
Messages are displayed on the CRT by a CPU (16 bit) using two control
ROMs and one character generator ROM on the operation unit PCB [D].
The auto response sensor [E], which is an infrared reflective sensor, detects
if there is an operator in front of the copier. If the auto response sensor has
not detected any objects for a certain time, the main PCB turns off the CRT
display to reduce power consumption and to extend the CRT life. The time
setting can be changed by the user tools.
The operation unit PCB also controls the key panel [F] and communicates
with the main PCB through the serial interface lines.
CGROM
ROM2
ROM1
IC131
IC137
IC138
Serial Interface
[D]
[A]
[C]
[B]
[F]
[E]
Main PCB
CPU
25
32
FT8780/8880 2-128 STM
FT8880
DETAILED SECTION
DESCRIPTIONS
NOTE: The following documentation will address those areas which are
unique to the FT8880 copier. For additional data please refer to the
"Detailed Section Descriptions" section preceding these pages.
FT8780/8880 2-129 STM
FT8780/8880 2-130 STM
18. FT8880 DEVELOPMENT
18.1. Bias for the ID Sensor Pattern
The ID sensor pattern cannot always be used for image density detection.
This is due to the location of the ID sensor and the position and size of the ID
sensor pattern.
Since for certain reduction ratios the outside portion of the exposure glass
and not the ID sensor pattern would be generated. The exposure lamp is
turned off ( no light) in order to produce and ID pattern.
The potential of the drum in these two cases, the no light and the ID sensor
pattern exposure, is not the same. So the ID sensor bias (VBP) is determined
using two base voltages, V0 for the no-light condition and Vd for the pattern.
VBP (no light) = --360 + V0 (Reproduction ratio < 77%)
VBP (ID Pattern) = --360 + Vd (Reproduction ratio 77%)
The Vd value which is determined during the process control data
initialization will be used.
V01 and V02, which are explained in the process control section, are used for
the VBP calculation as the V0 (drum potential after the charge corona) value.
The VBP can be changed by the SP mode (Toner Density Correction).
The following compensation will be applied to the above VBP.
Setting L N H VH
(V) --60 0 +60 +120
Default: H (+60 V)
NOTE: 1) Factory setting is N (OV). If a CRAM is performed reset to factory setting.
2) Unlike the FT8780 it is not necessary to move the lens of the FT8880 horizontally.
This is because the original placement is always in the proper position
to expose it to the central area of the drums surface.
3) This page replaces page 2-44 in section 2 of the STM when referring to the FT8880.
VL Pattern
ID Sensor Pattern
Outside
ID Sensor
Exposure Glass
Enlargement
Ratio <77%
Full Size
STM 2-131 FT8780/8880
19. RDH
19.1. OVERVIEW
19.1.1. No Inversion Original Cycle
When the start key is pressed, the blower motor begins to rotate. It supplies
air to the air knife and draws air from the vacuum section. Sheets are
separated at the leading edge [A] of the paper stack. The air is forced from
the nozzle [B] and the bottom sheet of the paper stack is held against the
feed-in belts [C] by air suction [D]. The feed-in motor drives the feed-in belts,
original feed roller [E], transport rollers [F] and right turn rollers[G]. The feed
motor drives the feed-in belts, original feed roller [E], transport rollers [F] and
right turn rollers [G]. The bottom sheet of the paper is delivered through the
original feed, transport, right turn rollers to the registration section [H] and is
stopped. To stop the original sheet at the proper position in the registration
section, the feed motor rotation speed is reduced by half when the 2nd
transport sensor [I] detects the leading edge of the original. The belt drive
motor then starts to rotate the transport belt [J] to direct the sheet of paper
onto exposure glass. At the same time, the next original is fed.
[D]
[F]
[E] [B] [A] [C]
[J] [I]
[H]
[G]
FT8780/8880 2-132 STM

At the appropriate time, the transport belt delivers the 1st original on the
exposure glass to the inverter section [A], at the same moment the 2nd
original is moved onto the exposure glass, while the 3rd sheet of the original
stack is fed. The 1st original is passed into the inverter section through the
inverter entrance roller [B], inverter middle roller [C], and inverter rollers [D]
until the trailing edge of the original is detected by the 1st inverter sensor [E].
The inverter middle roller and inverter rollers then rotate in the opposite
direction. The inverter exit rollers [F] rotate only in the paper exit direction.
However, the contact between the inverter exit roller and inverter exit drive
roller [G] is released when the 2nd inverter sensor [H] is activated by the
original. This way, the inverter exit roller does not interfere with the original
switch back cycle while the inverter middle and inverter rollers begin reverse
rotation. The original is delivered through the inverter entrance rollers and
inverter exit rollers to the original table. This continues until all originals have
been returned to the original table. The originals are stacked on the original
table where they wait for the next copy cycle.
[B]
[G] [F]
[E]
[C]
[D]
[H]
[A]
STM 2-133 FT8780/8880
19.1.2. Inversion Original Cycle
To the point where the original reaches the inverter section [A], the sequence
is the same as for the no inversion original cycle. The difference begins in
that the inverter rollers [B], rotate in the original exit direction. The original is
now inverted and exited to the original table [C]. This continues until all
originals have been inverted. The inverted originals are then fed from the
original table for copying of the reverse side. The sequence is the same as
for the front side copying. The originals return and are stacked on the original
table where they wait for the next copy cycle.
[B]
[B] [C]
[A]
FT8780/8880 2-134 STM
19.1.3. 1 Sided Original 2 Sided Copy Mode

The "no inversion original cycle" is used for this mode.
All the originals [A] are fed starting from the bottom of the original stack. First,
the odd numbered originals (in the case of the illustration: 1st and 3rd
originals) are copied and the even numbered originals are skipped. The
copied paper [B] is stacked in the duplex tray. The originals are returned to
the original table and the original feed is then repeated. This time the odd
numbered originals are skipped and the even numbered originals are copied
on the reverse side of the copy paper [C], which is fed from the duplex tray.
[A]
[B]
[C]
STM 2-135 FT8780/8880

The "inversion original cycle" is used for this mode. All the originals [A] are
fed starting from the bottom of the original stack. First, the front side of the
originals are copied. The copied paper [B] is stacked in the duplex tray. The
originals [C] are inverted and returned to the original table. The original feed
is then repeated. This time the reverse side of the originals are copied on the
reverse side of the copy paper [D], which is fed from the duplex tray.
[A]
[B]
[D]
[C]
FT8780/8880 2-136 STM

The "Inversion original cycle" is used for this mode. All the originals [A] are
fed starting rom the bottom of the original stack. First, the front side of all the
originals are copied and the copied paper [B] is stacked in the duplex tray.
The originals are inverted and returned to the original table. The original feed
is then repeated. This time, the bottom copy sheet is fed from the duplex tray
and exited from the copier without copying [C]. The reverse side of the 1st
bottom original sheet [D] is then copied to paper [E], which is fed from the
paper tray, and the copy is exited from the copier. This copy sequence
exiting from the duplex tray followed by the paper tray is alternately repeated.
[A]
[B]
[D]
[C]
[E]
STM 2-137 FT8780/8880
19.2. ORIGINAL SET
19.2.1. Stack Feed Mode

1. Original set detection
The originals are detected by the original set sensor [A] when they are
stacked on the original table.
2. Size detection
The original width is detected by the original width sensor [B] under the front
original guide [C]. Moving the guide changes the value of the sensor. (The
sensor is a potentiometer.) The front original guide and rear original guide [D]
are moved by the racks [E] and pinion [F] at the same time. The actuator [G]
of the original stopper activates the original length sensor [H] (photo-
interrupter) to detect if the original stopper is set for the 81/2 inch position. LG
(81/2" x 14" = 216 x 356 mm) or B4 (257 x 364 mm) size is distinguished by
the combination of the original length sensor (activated or not) and the value
of the original width sensor. This is necessary because the LG and B4 widths
are very close.
[E]
[A]
[D]
[C]
[F]
[G]
[H]
[B]
FT8780/8880 2-138 STM

3. Original separator
The original stack which has been fed and returned to the original table, and
the original stack which has not yet been processed, are separated by the
original separator [A] mechanism.
When the start key is pressed, the separator motor [B] rotates until the
original separator actuator [C] activates the separator home position sensor
[D]. The original separator is set on the top sheet of the original stack. The
originals which are fed and returned to the original table are stacked on the
original separator. When the last original (top sheet under the original
separator) is fed from the original table, the original separator drops and
activates the separator sensor [E].
If the next copy cycle continues, the separator motor rotates and the original
separator is set on the top sheet of the original stack again after the trailing
edge of the last original sheet passes through the exit sensor [F].
[E]
[B]
[E]
[A]
[D]
[C]
[E]
[F]
STM 2-139 FT8780/8880
19.2.2. Single Feed Mode

1. Original set detection
The original is detected by the single feed set sensor [A] when the original is
set on the single feed table.
2. Size detection
The original width is detected by the single feed original width sensor [B]
under the rear original guide [C]. Moving the guide changes the value of the
sensor. (The sensor is a potentiometer.) The front original guide [D] and rear
original guide are moved by the racks [E] and pinion [F] at the same time. As
the original length sensor is not used for the single feed mode, the original
length is not detected. Since the widths of a B4 or LG original are very close
the original size is determined by the machine version.
(U.S.A. version machine ... LG, Europe version machine ... B4).
[A]
[D]
[C]
[E]
[B]
[F]
FT8780/8880 2-140 STM
19.3. ORIGINAL FEED
19.3.1. Original Separation/Feed (Original Stack Mode)

1. Air knife and shutter
The air from the blower motor [A] is blown through the air knife nozzles [B] to
the leading edge [C] of the original stack. The blower motor keeps blowing air
from the beginning to the end of the original stack mode to prevent
multi-feeding, (except for a short period if the number of originals are three or
less).
After the originals are separated by the air knife, the vacuum shutter solenoid
[D] is energized by a paper feed signal from the main control PCB. The
vacuum shutter [E] closes the air hole on the vacuum duct [F]. The blower
draws air from the vacuum duct and the bottom sheet of the original stack [G]
is held against the feed-in belts by the suction. At about the same time that
the vacuum shutter solenoid was energized the feed-in belt drive clutch is
energized and the bottom sheet of the original stack [H] is then fed.
[F]
[D]
[E]
[A]
[B]
[B]
[C]
[H]
[F]
[G]
STM 2-141 FT8780/8880

Original Height Sensor
OFF ON
Small
Size
3000 rpm
6000 rpm
8 x 101/2
81/2 x 11
81/2 x 13
Large
Size
3500 rpm
81/2 x 14
10 x 14
11 x 17
Number of Originals
5 or less from 6 to 12 13 or more
Small
Size
3000 rpm
6000 rpm
8 x 101/2
81/2 x 11
81/2 x 13
Large
Size
3500 rpm
81/2 x 14
10 x 14
11 x 17
2. Blower motor speed
To ensure good original separation and original re-stacking on the original
table, the blower motor speed is changed according to the original stack
height, or the number of originals stacked. The blower motor speed is
determined for the 1st copy cycle by the original stack height as detected by
the original height sensor [A] (Table 1). From the 2nd copy cycle, the blower
motor speed is determined by the number of originals counted by the main
control PCB (Table 2).
When the number of originals is 3 or less, the original set sensor is
de-activated when the last original is fed and before the 1st original returns to
the original table. During this period the blower motor stops rotating to ensure
correct stacking of the originals.
Table 1
Table 2
[A]
FT8780/8880 2-142 STM
19.4. SINGLE FEED MODE
19.4.1. Registration

When the single feed set sensor [A] detects the leading edge of the original
the feed motor rotates and the right turn roller [B] transports the original sheet
forward. At the same time the single feed gate solenoid [C] is energized and
the single feed gate [D] is lowered. The feed motor and single feed gate
solenoid are energized until the registration sensor [E] detects the leading
edge of the original. The original is transported until it hits the single feed
gate, which corrects the original feed skew. At the same time the right turn
roller stops rotating.
[D]
[C]
[A]
[D]
[E]
[B]
STM 2-143 FT8780/8880
19.4.2. Feed

When the start key is pressed, the right turn roller [A] and transport belt [B]
rotate. The original is delivered onto the exposure glass. After the scanner
scans the original, the transport belt begins to rotate. At the same time the
inverter entrance roller [C] and inverter middle roller [D] begin to rotate while
the single feed exit solenoid [E] is energized. The single feed exit gate [F] lifts
up, exiting the original to the left top cover [G].
NOTE: If thin paper is used with an upward curl a jam may occur .
19.4.3. Exit Gate
In single feed mode and CFF mode, the single feed exit solenoid is energized
while the belt drive motor is driving the transport belt, and is de-energized
when the transport belt stops rotating. This solenoid on off operation is
performed to increase this solenoids reliability.
[G]
[C]
[A]
[D]
[E]
[B]
[F]
FT8780/8880 2-144 STM
19.5. DRIVE MECHANISM
19.5.1. Feed Motor Drive

All the feed rollers and transport rollers (with the exception of the feed belt
drive rollers [A]) begin to rotate together with the feed motor [B]. The feed belt
drive clutch [C] is energized according to the appropriate original feed timing.
When the clutch is energized, the feed motor drive will be transmitted through
the gears [D], timing belt [E] and the feed belt brake clutch shaft [F] to the
feed belt drive rollers. The feed belt brake clutch [G] stops the feed belt
rotation when the feed belt drive clutch is de-energized to prevent
multi-feeding of originals. When the feed belt brake clutch is energized,the
rotating clutch disk [H] is stopped by the clutch which is fixed to the frame.
[B]
[A]
[C]
[G]
[E]
[C]
[H]
[A]
[F]
[H]
[D]
STM 2-145 FT8780/8880
19.5.2. Belt Drive Motor Drive

The transport belt [A] is driven by the belt drive motor [B] via timing belts and
pulleys.
[A]
[B]
FT8780/8880 2-146 STM
19.5.3. Inverter Motor Drive

The inverter motor [A] rotates forwards or backwards according to the
appropriate timing. The inverter middle [B] and inverter [C] rollers will rotate
both forwards and backwards according to the inverter motor drive. However,
the inverter entrance [D], inverter exit [E] and the exit rollers [F] rotate in only
one direction.
The relay pulley [G] and inverter roller pulley [H] have a built-in one way
clutch inside. When the inverter motor rotates forwards (black arrow
direction), the inverter roller pulley [H] rotates the inverter entrance roller [D].
In this case the relay pulley [G] freely rotates due to the one way clutch
inside. All rollers rotate in the original feed direction.
While the inverter motor rotates backwards (white arrow direction), the relay
pulley [G] rotates the inverter entrance roller [D]. In this case the inverter
roller pulley [H] freely rotates due to the one way clutch inside. The inverter
entrance, inverter exit and exit rollers rotate in the original exit direction.
However, the inverter middle and inverter rollers rotate in the original switch
back direction.
[A]
[B]
[C]
[D] [E] [F]
[A]
[G]
[H]
[D]
STM 2-147 FT8780/8880
19.6. ORIGINAL POSITIONING

Customers can choose the paper transport mode through "User Tools" The
selected setting will depend on the thickness of the original used.
The factory setting is "Thin Paper Mode."
-- In thin paper mode --
The belt motor stops exactly when the trailing edge of the original passes the
right scale [A] edge. (The timing is measured by the timing sensor after
registration sensor is activated.)
-- In thick paper mode --
To correct skewing on the exposure glass, the original runs 10 mm after the
trailing edge passes the right scale. The belt motor then reverses and the
original reverses travel until it meets the right scale.
If extremely thin paper is used in the thick paper mode, the paper may float
near the scale or be "buckled" against the scale. This will result in poor image
quality or original copy wrinkling.
[A]
Thin Paper Mode
Thick Paper Mode
FT8780/8880 2-148 STM
19.7. CFF Mode

When the CFF guide lever [A] is slid to the left, the CFF sensor [B] comes out
of the single feed rear guide [C]. This sensor consists of one CFF set sensor
[D] and two CFF feed hole sensors [E]. The CFF set sensor detects if the
computer form is set in the CFF guide.
The CFF feed hole sensor detects the holes along the computer forms edge.
[E]
[D]
[B]
[C]
[A]
Rev. 11/92
STM 2-149 FT8780/8880
SECTION 3
SORTER STAPLER
(ST23 A/B)
1. OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
Number of Bins: 20 + proof tray
Paper for Proof Tray: Size: Maximum: 11" x 17"
Minimum: 51/2" x 81/2" (sideways)
Weight: 14 ~ 43 lb
Paper for Bins: Sort/Stack Mode:
Size Maximum: 11" x 17"
Minimum: 51/2" x 81/2" (sideways)
Weight 14 lb ~ 43 lb
Staple Mode:
Size Maximum: 11" x 17"
Minimum: 81/2" x 11"
Weight 17 lb ~ 21 lb
Stapler Capacity: From 2 to 50 sheets (20 lb)
Bin Capacity:
1 sided copies 2 sided copies
Sort mode 70 sheets 50 sheets
Stack mode 50 sheets 35 sheets
(20 lb)
Proof Tray Capacity: 250 sheets (20 lb)
20 sheets (translucent paper)
Staple Position: a = b = 5 2 mm
Staple Time: Within 1.5 seconds/staple
Staple Replenishment: Cartridge exchange (5,000 pieces/cartridge)
Power Source: 1st sorter: 100 V (from copier)
2nd sorter: 120 V
a
b
STM 3-1 FT8780/8880
Power Consumption: Maximum: 0.2 kW
Dimensions: (1st sorter only) (22.8" x 32.6" x 41.8")
(1st and 2nd sorter) (44.1" x 32.6" x 41.8")
Weight: 1st sorter: 216lb
2nd sorter: 198 lb
Staple Cartridge: Staple Cartridge Type C,
EDP # 208171
Rev. 2/94
FT8780/8880 3-2 STM
1.2 MECHANICAL COMPONENT LAYOUT

12
1
11
10
9
8
7
6
5
4
3 2
1. Staple Unit
2. Proof Tray
3. Bins
4. Jogger
5. Bin Solenoids
6. Side Bar
7. Relay Gate
8. Diagonal Transport Rollers
9. Distribution Rollers
10. By-pass Tray Gate
11. By-pass Tray
12. Bin Gate
STM 3-3 FT8780/8880
1.3 DRIVE LAYOUT

1. Diagonal Transport Drive Belt
2. Bin Drive Belt (1st to 10th)
3. Main Motor
4. Jogger Unit Drive Belt
5. Staple Unit
6. Side Bar Drive Belt
7. Proof Tray Exit Roller Drive Belt
8. Bin Drive Belt (11th to 20th)
1
6
5
4
7
8
2
3
FT8780/8880 3-4 STM
1.4 ELECTRICAL COMPONENT DESCRIPTION
Symbol Name Function Index No.
Motors
M1
Main Drives the diagonal transport unit, horizontal
transport unit, and distribution unit through
timing belts.
22
M2
Staple Unit
Positioning
Drives the staple unit up or down to the
appropriate bin. (dc stepper)
5
M3
Jogger Unit
Positioning
Drives the jogger unit up or down to the
appropriate bin. (dc stepper)
9
M4
Side bar Drives the side bar side to side according to
the paper size. (dc stepper)
1
M5
Grip Drives the gripper forward into the bin to grip
the copies and bring them to the stapling
position. (dc brush)
12
M6
Staple Feeds the staples and drives the stapler
hammer. (dc brush)
15
M7
Jogger Drives the jogger arm to align the copy. (dc
stepper)
18
M8
By-pass Tray Gate Drives the by-pass tray gate up or down to
switch the paper delivery tray.
36
Switches
SW1
Front Door De-energize the main motor and cuts 24 V
line when the front door is open.
8
SW2
Vertical Transport
Door
De-energize the main motor when the vertical
transport door is open.
6
SW3
Horizontal
Transport Door
Informs the main board if the cover is open.
20
Circuit Boards
PCB1 Main Controls overall sorter stapler functions. 31
PCB2
DC Power Supply Convert ac voltage to 5 V dc and 24 V dc to
supply power to all dc components.
26
PCB3
Bin Solenoid
Control 1
Interfaces between the bin solenoids 1 ~ 10
and the main board.
28
PCB4
Bin Solenoid
Control 2
Interfaces between the bin solenoids 11 ~ 20
and the main board.
30
Solenoids
SOL1~20
Bin Opens and closes the bin gate to direct the
copies into the appropriate bin.
27
SOL21
Grip Opens and closes the bin gate to drive the
grippers to grip copies on the bins.
14
SOL22
Pressure Release Releases pressure of the brake roller when
the paper is fed lengthwise.
38
STM 3-5 FT8780/8880
SOL23
Relay Solenoid Turn the relay gate to transport the copy to
the 2nd sorter.
43
Sensors
S1
Entrance Detects paper jams at the entrance of the
diagonal transport unit.
37
S2
Registration Detects paper jams at the horizontal transport
unit.
21
S3 Proof Tray Exit Detects paper jams at the proof tray exit. 2
S4
Bin/Jam (LED) Detects if paper is in the bin.
Detects paper jams at the bin.
3
S5
Bin/Jam (Photo Tr) Detects if paper is in the bin.
Detects paper jams at the bin.
19
S6
Staple Unit H.P. Detects if the staple unit is in the home
position.
4
S7
Jogger Unit H.P. Detects if the jogger unit is in the home
position.
10
S8 Grip H.P. Detects if the gripper is in the home position. 11
S9
Hammer H.P. Detects if the staple hammer is in the home
position.
13
S10
Jogger H.P. Detects if the jogger arm is in the home
position.
17
S11 Side Bar H.P. Detects if the side bar is in the home position. 33
S12
Tray Gate H.P. Detects if the by-pass tray gate is in the home
position.
34
S13
Tray Gate Upper
Position
Detects if the by-pass tray gate is in the upper
position.
35
S14
Staple Unit
Position
Detects the position of the staple unit.
32
S15 Paper Detect if copies are under the hammer. 7
S16 Staple End Detects if the staple is present. 16
S17
Diagonal
Transport Door
Open
Detects if the diagonal transport door is open.
39
S18 Timing Supplies timing pulses to the main board. 29
S19
Relay Unit Cover
Open
Detects if the relay unit cover is open.
41
S20 Relay Sensor Detects paper jam at the relay unit. 42
Capacitor
C1 Main Motor Protects the PCBs from induced current. 23
Noise Filter
NF1
Noise Filter Removes electrical noise generated by the
copier and the sorter stapler.
25
FT8780/8880 3-6 STM
Relay
RA1 Main Controls main power. 24
Transformer
TF1 Transformer Supplies 100VAC 40
STM 3-7 FT8780/8880
1.5 BASIC OPERATION

Copies exiting the copier enter the sorter or the by-pass tray [A] depending
on the by-pass tray gate [B] position. In normal operation, copies are sent to
the sorter, if paper jams occur in the sorter, the remaining papers in the
copier are fed to the by-pass tray.
If sort/stack mode is not selected, copies are delivered to the proof tray [C]
through the diagonal transport unit [D], the horizontal transport unit [E], and
the distribution unit [F].
When sort/stack mode is selected, copies are delivered to the bins [G] in
order.
The copies in the bins are arranged by the jogger arm [H].
If staple mode is selected, when the last page of the original is delivered to
the 1st bin, the staple unit [I] starts stapling the copies in each bin.
The 1st sorter has capacity to hold 20 sorted copies.
If the 2nd sorter is installed next to the 1st sorter, an additional 20 sorted
copies can be sorted.
After the 20th copy is fed to the distribution unit of the 1st sorter, the relay
gate [J] moves to the upper position and the 21st copy is transported to the
2nd sorter. After the final copy of the designated number has passed under
the relay gate, the relay gate moves down to transport copies to the bins of
the 1st sorter again.
[F]
[H]
[G]
[C]
[I]
[A]
[B]
[D]
[E]
[J]
FT8780/8880 3-8 STM
2. SECTIONAL DESCRIPTION
2.1 PAPER DELIVERY SWITCHING

Depending on the by-pass tray gate [A] position, paper fed from the copier
enters either the sorter or the by-pass tray [B].
The by-pass tray gate is driven by the by-pass tray gate motor [C]. Under
normal operating conditions, the by-pass tray gate is in the home position
(H.P. sensor [D] is actuated) to deliver copies to the sorter. If a sorter paper
jam occurs, the gate rotates on its shaft [E] until the upper tray gate position
sensor [F] is actuated and stops.
[A]
[D]
[F]
[C]
[E]
[B]
[F]
STM 3-9 FT8780/8880
2.2 DIAGONAL TRANSPORT

Paper entering the diagonal transport unit is transported down to the
horizontal transport unit. The front side of the paper advances more than the
back side due to the front transport roller [A] being larger than the back
rollers. This causes the paper to skew as it enters the diagonal transport unit.
This skew prevents the diagonal transport guide [B] from catching the edge of
the copies.
The paper is then moved to the front by the diagonal transport rollers [C].
Where it is aligned as it is guided by the diagonal transport guide [B].
The brake roller [D] prevents the rear side of the paper from falling forward.
If the paper is traveling lengthwise, the pressure release solenoid [E] turns on
to prevent over skewing.
[D]
[E]
[C]
[B]
[A]
[E]
FT8780/8880 3-10 STM
2.3 SORTING

The distribution section has the distribution rollers [A], 20 bin gates, and 20
bin solenoids.
When a bin gate solenoid [B] is off, the return spring [C] holds the bin gate [D]
out of the paper path, allowing the copies to pass to the upper bin.
The appropriate bin gate solenoid turns on and opens the bin gate. The other
solenoids are off. The copies go to the bin [E] through the gate.
[B]
[E]
[C] [A]
[D]
STM 3-11 FT8780/8880
2.4 JOGGER UNIT POSITIONING

The jogger unit [A] vertical position is controlled by the stepper motor [B].
Depending on the rotation of the stepper motor [C], the jogger unit moves to
the appropriate bin.
When the main switch is turned on, the jogger unit will stop in its home
position. During sorter operation, the motor starts rotating when jogger
operation at any bin is complete. This lowers the jogger unit until it reaches to
the next bin and then the motor stops.
When jogger operation for a designated number of copies is complete, the
motor rotates to raise the jogger unit back to its home position.
[C]
[B]
[A]
FT8780/8880 3-12 STM
2.5 PAPER JOGGING
Ordinarily, the side bar [A] is in the home position. It moves to within 10 mm
of the rear of the selected paper size. The side bar is driven by the side bar
motor [B] through the gears and a timing belt.
The jogger arm [C] home position is 10 mm in front of the paper.
After the paper passes the jam sensor, the jogger arm moves twice due to
the forward and reverse rotation of the jogger motor [D]. Jogger arm
movement is controlled through the link [E] and jogger bar [F].
The reverse rotation of the jogger motor prevents motor lock caused by an
overly stiff paper stack. Even if the overly stiff paper interferes with the jogger
arm movement, the arm returns to its home position via the reverse rotation
of the jogger motor.
[B]
[A]
[F]
[E]
[ D]
[C]
[C]
STM 3-13 FT8780/8880
2.6 STAPLE UNIT POSITIONING
The staple unit [A] is hanging on the timing belt [B]. Due to the weight of this
staple unit, accurate positioning is ensured by using worm gear [C] which
transmits the staple positioning motor [D] rotation to the timing belt.
The bracket [E] guiding the staple unit has notches [F] which the staple unit
position sensor [G] senses.
Initially, the staple unit is beside the top bin. When stapling at the first bin is
completed, the staple unit positioning motor [D] energizes to move the staple
unit to the next bin where stapling is repeated.
When stapling at the last bin is completed, the motor [D] rotates to raise the
staple unit back to its home position. The staple positioning motor stops when
the staple unit home position sensor [H] is actuated.
Raising the staple unit requires more torque than lowering it. Thus the motor
speed when raising the staple unit will be approximately half of the lowering
speed.
[G]
[F]
[A]
[B]
[E]
[H]
[D]
[C]
FT8780/8880 3-14 STM
2.7 STAPLING
2.7.1 Gripper
The grip unit [A] grips and moves the jogged paper to the staple position and
returns the stapled paper to the bin.
The grip solenoid [B] and grip motor [C] are built into the grip unit. The motor
moves the grippers [D] back and forth, and the solenoid [B] controls paper
clamping.
When the grippers reach the paper in the bin, the grip solenoid turns on and
the grippers grasp the paper.
The lower gripper arm has a shorter stroke to prevent it from disturbing the
jogged paper in the bin.
Paper gripped by the grippers is moved by the grip motor into stapling
position.
Resetting the main PCB DIP SW101-1 to 101-4 adjusts the stapling position
(0.5 mm increments).
The stapled paper (held by the gripper arms throughout stapling) is returned
to its original position. The grip solenoid turns off to release the stapled
paper, and the gripper arms return to their original position.
The grip H.P. sensor [E] confirms that the grip unit has returned to its home
position.
[C]
[B]
[A]
[D]
[E]
STM 3-15 FT8780/8880
2.7.2 Stapler
The paper sensor [A] prevents stapler operation when there is no paper in
position. Also, it detects staple error if the paper sensor remains actuated
when the stapler finishes its operation.
The staple motor [B] drives the stapling mechanism and transporting of the
staples from the cartridge [C].
The hammer H.P. sensor [D] checks if the staple hammer [E] is in the home
position.
The staple end sensor [F] checks if staples are present.
[A]
[E]
[D]
[B]
[C]
[F]
FT8780/8880 3-16 STM
2.8 1ST AND 2ND SORTER CONNECTION

When the 2nd sorter is connected, paper must be relayed from the 1st sorter
to the 2nd sorter. A relay solenoid [A] has been added to the 1st sorter for
this purpose.
A relay unit is also added to the 1st sorter to transport paper to the 2nd sorter.
The relay unit is driven by the 2nd sorter main motor [B].
The relay sensor [C] detects paper jams at the relay unit.
The relay unit cover [D] is provided to enable removal of misfed papers.
The photosensor [E] detects if the cover [D] is open.
[A]
[B]
[D]
[C]
[E]
STM 3-17 FT8780/8880
2.9 DOOR SWITCHES

Doors and guide plates are provided to enable removal of misfed papers.
Each door has a safety switch to detect opening and closing. These switches
also perform the jam reset function.
FT8780/8880 3-18 STM
2.10 JAM DETECTION
2.10.1 Jam Detection Condition
The jam detection timing is determined by pulses from the timing sensor. The
diagram below illustrates the timing interval in which each sensor detects
paper jams in operation.

*1. Jam detection timing depends on the bin position
Bin No. Pulses Bin No. Pulses Bin No. Pulses
proof 470 7 354 14 260
1 436 8 342 15 248
2 422 9 328 16 234
3 408 10 314 17 220
4 394 11 302 18 208
5 382 12 288 19 194
6 368 13 274 20 180
Staple failure is detected if the paper sensor is not de-energized after the
machine finishes returning the stapled paper to the bin.
300 pls
340 pls
400 pls
280 pls
436 pls
470 pls
280 pls
280 pls
OFF OFF OFF ON ON OFF ON ON
Paper Exit Signal from Copier
Entrance
Sensor
Registration
Sensor
Exit
Sensor
Jam Detection Timing
Jam
Sensor
*1
By-pass Tray
Gate Motor
Tray Gate HP
Sensor
Tray Gate Upper
Position Sensor
Main Motor
Stop Signal
from Copier
Papers in
copier exit Sorter Jam
STM 3-19 FT8780/8880
2.10.2 Machine Operation in Jam Conditions
a. When a paper jam occurs in the copier, the sorter stapler stops after
delivering papers in the sorter to the appropriate bins.
b. When a paper jam occurs in the sorter stapler, the by-pass tray gate
motor energizes and papers in the copier are delivered to the by-pass
tray.
c. When a staple failure is detected, the machine stops staple operation.
2.10.3 Jam Reset
a. If a paper jam occurs at the diagonal transport unit, the jam condition is
reset when the diagonal transport door is closed after removing the
misfed paper.
b. If a paper jam occurs in the sorter, the jam condition is reset when the
vertical transport door or the horizontal transport door is closed after
removing the misfed paper.
c. If a staple failure occurs, the jam condition is reset when the sorter front
door is closed after removing the unstapled paper.
2.10.4 Jam Recovery
Copies on the bin are counted by the jam sensor.
When the start key is pressed after misfed paper is removed, the machine
delivers the copies from the continuance bin.
FT8780/8880 3-20 STM
SECTION 4
MENU READER
1. SPECIFICATIONS
- Item - - Specification -
Job Sheet
1. Material:
2. Size:
3. Weight:
4. Markers:
Paper
2.6" x 5.9"
22 lbs to 43 lbs
Black pencil, #2 is recommended.
Marker (Black)
Ball-point pen (Black)
Job Sheet Feed Method: Fed in and out automatically
Reading Time: Approximately 2.5 seconds
Power Source: +24 volts and +5 volts (from copier)
Dimensions:
(W x D x H)
4.4" x 6.5" x 1.8"
Weight: 1.42 lb
Rev. 7/92
STM 4-1 FT8780/8880
2. OVERALL MACHINE CONTROL

The menu readers operation is controlled by the copier.
Mark
Detection
Sensor
Signal
Amplification
LED
Indlcator
LED
Drive
Sheet
Detection
Sensor
+15V
+5V
+15V
+24V
+5V
Copier
Motor
CPU
Power
Supply
Voltage
Monitor
External
Reset
Level
Conversion
ROM
Address
Latch
+24V
Motor
Drive
Menu
Reader
FT8780/8880 4-2 STM
3. DATA FORMAT
Menu Reader Copier
b7 b6 b5 b4 b3 b2 b1 b0 DATA CONTENTS
B C D 0 0 0 0 Copy Quantity x 1
Size 4 Size 3 Size 2 Size 1 0 0 1 1 Paper Size
Enlarge 3 Enlarge 2 Enlarge 1 100% 0 1 0 0 Reproduction Ratio-1
Reduce 4 Reduce 3 Reduce 2 Reduce 1 0 1 0 1 Reproduction Ratio-2
0 2 : 1 2 : 2 1 : 2 0 1 1 0 Duplex
0 0 Stack Sort 0 1 1 1 Sorter
0 0 0 Staple 1 0 0 0 Staple
0 0 0 Reserve-1 1 0 0 1 Reserve-1
0
Reserve
2-2
Reserve
2-2
Reserve
2-1
1 0 1 0 Reserve-2
----- ------ ------ ------ 1 1 0 1
------ ------ ------ ------ 1 1 1 0
1 1 1 1 Control Data
Copier Menu Reader
b7 b6 b5 b4 b3 b2 b1 b0 DATA CONTENTS
------ ------ ------ ------ 0 0 0 0 Insert Sheet OK/NG
------ ------ ------ ------ 0 0 0 1
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
------ ------ ------ ------ 1 1 1 0
1 1 1 1 1 1 1 1 Send OK
The contents of the reserve bytes are different in each market.
STM 4-3 FT8780/8880
4. BASIC OPERATION
4.1 JOB SHEET READING

When a job sheet is inserted, the sheet detection sensor [A] detects the
leading edge of the job sheet. The job sheet is then fed in by the upper and
lower transport rollers [B, C].
[A]
[C]
[B]
FT8780/8880 4-4 STM

The mark detection sensor [A] detects the reference line [D] and reads the
job sheet. The mark detection sensor is composed of 4 photosensors. The
sensor on the right [B] detects the reference line and reference marks [E],
and the other sensors [C] read the job sheet data.
The menu reader CPU monitors signals from the mark detection sensor and
measures the time between each reference mark. There are 25 reference
marks along the sheet edge. After the 25th reference mark is read, the job
sheet is fed out by the upper and lower transport rollers [F, G].
The operation panel status changes after the job sheet is read, and the job
sheet information is sent to the copier CPU.
[A]
[C]
[B]
[D]
[E]
[F]
[G]
STM 4-5 FT8780/8880
4.2 MENU READER INDICATOR LIGHTS
Red Light Green Meaning
1 OFF ON A job sheet can be inserted.
2 ON OFF
A job sheet is being read or the copier
Start key stays red.
3 Blinks OFF
A job sheet read error has occurred; the
menu reader stops reading. Check the job
sheet to make sure it is marked correctly
and insert it again.
Note: The red light blinks for 6 seconds;
then, it stays on.
4 OFF Blinks
A conversion error has occurred; insert the
job sheet again.
Note: The green light blinks for 6 seconds;
then, it stays on.
5 Blinks Blinks
The RAM contents have been changed or
the menu reader has failed to read the
ROM contents.
Note: Turn the main switch off and on.
FT8780/8880 4-6 STM
4.3 PROCESSING ERRORS
Reference Line
If the reference line does not reach the mark detection sensor within 2.6
seconds after the job sheet is fed in, the job sheet is fed out. (Feeding out
takes 1.6 seconds.) The red light blinks for 6 seconds; then, the job sheet
can be reinserted.
Reference Mark
If the mark detection sensor detects the reference line and then fails to detect
a reference mark within 0.2 seconds, or if it fails to detect a reference mark
within 0.1 seconds, the job sheet is fed out and the red light blinks for 6
seconds; then, the job sheet can be reinserted.
NOTE: Occasionally, the job sheet feeds out to the rear side of the menu
reader after a failure to detect the reference mark number.
Marking
When two or more selections are made for the same item, the menu reader
cannot process the job sheet and the red light blinks (indicating an error).
NOTE: 1. When an item is not marked on the job sheet, the menu reader
automatically reads as follows:
-- Item -- -- Indicator --
Copy Quantity 1
Reproduction Ration 100%
2. The job sheet may jam inside the menu reader if it is smaller
than the specified size.
CAUTION: Sensors were set at the factory and cannot be adjusted in
the field.
STM 4-7 FT8780/8880
SECTION 5
FINISHER
(SR300)
1. OVERALL MACHINE INFORMATION
1.1 SPECIFICATION
Paper Size: Maximum: 11" x 17"
Minimum: 51/2" x 81/2" sideways
Paper Weight: Standard copying/Stack mode
14 ~ 43 lb
Staple mode
17 ~ 21 lb
Paper Capacity: Standard copying/Stack mode
2,000 sheets:
81/2" x 11" or smaller size (20 lb)
1,000 sheets:
81/2" x 14" or larger size (20 lb)
Staple mode
See the following table:
Size
Number
of Originals
81/2" x 11"
or smaller size
81/2" x 14" 11" x 17"
2 ~ 10 sheets 100 sets 100 sets 100 sets
31 ~ 40 sheets 50 sets 25 sets --
41 ~ 50 sheets 40 sets 20 sets --
Stapler Capacity: 81/2" x 11" or smaller size (20 lb):
from 2 to 50 sheets
81/2" x 14" (20 lb):
from 2 to 50 sheets
11" x 17" (20 lb):
from 2 to 30 sheets
Staple Replenishment: Cartridge exchange (5,000 pieces/cartridge)
Power Source: DC 24 V (from copier)
Power Consumption: 60 VA (average)
STM 5-1 FT8780/8880
Stapling Position:

Dimensions: 24.4" x 27.5" x 36.4"
Weight: 110 lb
Staple Cartridge: Staple Cartridge Type C,
EDP # 208171
Rev. 2/94
a
b
a a
b
b
a = 0.2" 0.08" (5 2 mm)
b = 0.2" 0.1" (5 2.5 mm)
a = 0.2" 0.08" (5 2 mm)
b = 0.2" 0.1" (5 2.5 mm)
a = 0.2" 0.08" (5 2 mm)
b = 5.20" 0.08" (132 2 mm)
(81/2" x 11" or larger size)
b = 10.5" 0.08" (265 2 mm)
(81/2" x 14" or larger size)
(1 staple) (2 staples)
FT8780/8880 5-2 STM
1.2 MECHANICAL COMPONENT LAYOUT

12
13
11
10
9
8
7
6
5
4
1
3
2
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. Junction Gate
11. Entrance Rollers
12. Upper Transport Rollers
13. Exit Rollers
STM 5-3 FT8780/8880
1.3 ELECTRICAL COMPONENT DESCRIPTION
Point (waterproof paper) when using this table.
Motors
Transport Drive Drives transport rollers. 12
Shift Tray Lift Moves the shift tray up or down. 4
Exit Drive Drives the exit and shift tray positioning rollers. 5
Exit Unit Lift Lifts the exit roller unit. 1
Stack Feed-out Drives the stack feed-out belt. 8
Jogger Moves the jogger fences. 10
Stapler Drive Moves the stapler unit. 11
Shift Moves the shift tray side to side. 21
Staple Drives the staple hammer. 18
Sensors
Entrance Detects copy paper entering into the finisher. 3
Jogger Unit Entrance Detects copy paper entering into the jogger unit. 6
Jogger Unit Paper Detects copy paper in the jogger unit. 17
Stack Feed-out Belt HP Detects the home position of the stack feed-out belt. 16
Jogger HP Detects the jogger home position. 23
Exit Detects misfeeds in exit area. 25
Stack Height 1 Detects copy paper stack height in staple mode. 26
Stack Height 2 Detects copy paper stack height in sort/stack mode. 28
Shift Tray Lower Limit Detects the lower limit of the shift tray position. 14
Stapler Hammer HP Detects the staple hammer home position. 19
Exit Unit HP Detects the exit roller upper unit home position. 29
Exit Unit Half Turn Detects the exit roller upper unit position. 27
Shift Tray Half Turn Detects shift tray side to side position. 20
Stapler Unit HP Detects the stapler unit home position. 22
Front Door Safety
(Switch)
Cuts dc power when the front door is opened.
24
Shift Tray Upper Limit
(Switch)
Detects the upper limit of the shift tray position.
2
Solenoids
Positioning Roller Lowers the positioning roller in the jogger unit. 9
Junction Gate Drives the junction gate. 7
Rev. 11/92
FT8780/8880 5-4 STM
PCBs
Transport Drive Motor
Control
Controls the transport drive motor operation.
13
Main Control Controls overall finisher operation. 15
STM 5-5 FT8780/8880
1.4 DRIVE LAYOUT

11
12
13
14
16
15
8
7
9
10
1
2
3
4
5
6
1. Shift Tray Lift Motor
2. Exit Drive Motor
3. Upper Transport Drive Belt
4. Lower Transport Drive Belt
5. Transport Drive Belt
6. Transport Drive Motor
7. Shift Tray Lift Belt
8. Shift Motor
9. Shift Cam
10. Exit Roller
11. Stack Feed-out Motor
12. Jogger Drive Belt
13. Jogger Motor
14. Stapler Drive Motor
15. Stack Feed-out Belt
16. Stapler Drive Belt
FT8780/8880 5-6 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 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]
[C]
[B]
[D]
[E]
[F]
STM 5-7 FT8780/8880
2. SECTIONAL DESCRIPTION
2.1 PAPER DELIVERY SWITCHING

Depending on the selected finishing mode, the copies are directed up or
down by the junction gate [A]. A two-way solenoid is used to control the
junction gate.
(1) When the exit sensor of the copier is actuated while in staple mode, the
solenoid [B] pulls the plunger in the direction of the arrow [C]. The
junction gate directs the copies down to transport them to the jogger unit.
(2) When the exit sensor of the copier is actuated while in the sort/stack
mode, the solenoid pushes the plunger in the direction of the arrow [D].
The junction gate directs the copies upwards to deliver them to the shift
tray.
The junction gate maintains its position until a different finishing mode is
selected.
[A]
[B]
[C] [D]
(1) Staple Mode (2) Sort/Stack Mode
FT8780/8880 5-8 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 the timing belts [C]. When the main switch
is turned on, the tray position is initialized to the upper position. The trays
upper most position is detected when the shift tray pushes up the actuator [D]
to deactuate the stack height sensor 1 [E].
While copying, the actuator is gradually raised as the copy stack increases in
height. In the sort/stack mode, when the stack height sensor 2 [F] remains
actuated for 4 seconds, the shift tray lift motor rotates, lowering the tray unit
for 50 ms.
In staple mode, when the stack height sensor 1 remains deactuated for 4
seconds, the motor rotates lowering the tray until the stack height sensor is
again actuated.
When the tray reaches its lower limit position, the lower limit sensor [G] is
(blocked) 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.
When raising the tray to its upper most position a mechanical safety switch [I]
is installed to prevent the drive gears from being damaged if the stack height
sensor 1 or actuator does not operate properly. When the shift tray pushes
up the shift tray positioning roller [J], the shift tray lift motor stops.
[A]
[E]
[D]
[F]
[B]
[H]
[J]
[C]
[I]
[G]
STM 5-9 FT8780/8880
2.3 SHIFT TRAY SIDE TO SIDE SHIFT MECHANISM

In the sort/stack mode, the shift tray [A] moves side to side to stagger and
separate sets of copies.
The horizontal position of the shift tray is controlled by the shift motor (a 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 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 (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]
[C]
[B]
[E]
[D]
[F]
[G]
[H]
FT8780/8880 5-10 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].
[B]
[C]
[A]
[H]
[G]
[D]
[C]
[F]
[F]
[E]
STM 5-11 FT8780/8880
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 (a stepper motor)
starts rotating to position the front and rear jogger fences [A] 8 mm away from
the selected size 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 3 mm away from the paper
edges. (2)
Just after the positioning roller pushes the copy back, each jogger fence
moves inward 3 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 8 mm
from the copy edge in preparation for the next copy.
8 mm 3 mm
(2) (1) (3)
[A] [B]
FT8780/8880 5-12 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 reflective type photosensor [G] in the staple unit to detect staple
end conditions.
[E]
[C]
[B]
[A]
[F]
[D]
[G]
STM 5-13 FT8780/8880
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] (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 the 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 the front.
After the job is completed, the stapler unit moves back to its home position.
The home position is determined when the stapler unit home position sensor
[C] is actuated.
The staple position can be changed using an SP mode.
[C]
[B]
[A]
FT8780/8880 5-14 STM
2.8 FEED-OUT TO SHIFT TRAY

After being stapled, the stack feed out motor [A] starts rotating. The pawl [B]
on the stack feed-out 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, (see black arrows) the motor stops for 400ms. At this moment,
the exit rollers catch the stapled copies to feed them out to the shift tray.
Then the motor rotates again until the pawl causes the stack feed-out belt
home position sensor [D] to be deactuated.
[C]
[B]
[D]
[A]
[B]
STM 5-15 FT8780/8880
2.8.1 EXIT UNIT

In staple mode, when stapling is completed, the exit unit lift motor [A] starts
rotating to open the exit unit [B]. This is to prevent paper jams when a thick
paper stack is exiting. The exit unit lift motor stops when the exit unit half turn
sensor [C] is actuated. While the paper stack is exiting, the exit unit lift motor
starts rotation again to close the exit unit. The upper and lower exit rollers [D]
catch and feed the stack of copies to the shift tray. The exit unit lift motor
stops when the exit guide home position sensor [E] is actuated.
The exit unit lift motor does not work in sort/stack mode.
The exit drive motor which started rotating to drive the exit rollers [F] when
the first copy activates the entrance sensor is slowed down just before each
single copy sheet is completely fed out. This is to ensure an even copy stack.
[E]
[B]
[C]
[A]
[C]
[D]
FT8780/8880 5-16 STM
3. INSTALLATION
3.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box according to
the following list.
1. Installation Procedure..................................... 1
2. Relay Guide.................................................... 1
3. Shift Tray ........................................................ 1
4. Staple Cartridge.............................................. 1
5. Panhead Screw 4 x 8 ..................................... 10
6. Ground Screw................................................. 1
STM 5-17 FT8780/8880
3.2 INSTALLATION PROCEDURE
CAUTION: Unplug the copier power cord before starting the following
procedure.

1. Remove the strips of filament tape [A] on the finisher and remove the
styrofoam blocks [B]. Remove the fixing screws [C].
2. Open the finisher front door and pull out the transport unit [D]. Then,
remove the strips of filament tape [E] and cut the bind [F] for the stapler
using pliers.
3. Push the transport unit in its original position and close the front door.
[B]
[A]
[E]
[D]
[C]
[F]
[C]
FT8780/8880 5-18 STM

4. Remove the copier right cover [A] (2 screws) and plastic cap [B]. Pass the
4P connector [C], fiber cable [D], and ground wire [E] of the interface
harness through the lower hole [F] of the right cover. Then, reinstall the
right cover.
NOTE: Since the 2P connector is not used for this finisher installation,
keep it in the copier.
5. Install the relay guide [G] (2 screws).
6. Bring the finisher near the main copier and confirm that the height of the
relay guide exit plates [H] are aligned between the finisher entrance
plates [I].
NOTE: If not, adjust the height of the relay guide exit plates (loosen the 2
screws [J]).
[A]
[B]
[F]
[E]
[D]
[C]
[G]
[J]
[I]
[H]
STM 5-19 FT8780/8880

7. Connect the 4P connector [A], fiber cable [B], and fix the ground wire [C]
(1 screw with a star washer).
NOTE: 220/230/240 V market only
The finisher unit meets EN 60 950, Class safety standards,
which do not require an earth connection. However, it should be
grounded to ensure proper operation.
8. Remove the finisher right cover [D] (2 screws).
9. Connect the finisher to the main copier (4 screws) and reinstall the
finisher right cover.
10. Install the finisher shift tray [E] (4 screws).
[C]
[B] [A]
[E]
[D]
FT8780/8880 5-20 STM

11. Open the finisher front door and install the staple cartridge (refer to the
instruction decal on the rear side of the front door):
a) Pull out the transport unit [A].
b) Release the lock lever [B] and turn the stapler counterclockwise until it
locks.
c) Remove the green plastic clip [C] from the staple cartridge, and install
the cartridge in the stapler.
d) Set the stapler to its original position.
e) Push the transport unit in its original position.
12. Plug in the power cord and turn on the copier main switch.
13. Test the operation of the finisher.
NOTE: The stapler will not be stapling for the first 10 or so copies until
the first staple comes to the proper position from the cartridge.
[C]
[B]
[A]
STM 5-21 FT8780/8880
4. SERVICE TABLES
4.1 TEST POINT TABLE (Main Board)
Number Function
TP1 24 V
TP2 GND
TP3 5 V
4.2 FUSE TABLE
Number Rated Current Location
Fuse 1 5A Main PCB
Fuse 1 8A
Transport Drive Motor
Control PCB
FT8780/8880 5-22 STM
4.3 LED TABLE
LED No. ON Status
Main PCB
LED 1 Stack feed-out belt H.P sensor is not actuated.
LED 2 Jogger unit connector is not completely set.
LED 3 Stapler H.P. sensor is actuated.
LED 4 Jogger H.P. sensor is actuated.
LED 5 Jogger unit paper sensor is activated.
LED 6 Jogger unit entrance sensor detects the paper.
LED 7 Shift tray lower limit sensor is actuated.
LED 8 Stack height sensor 2 is actuated.
LED 9 Exit unit H.P. sensor is actuated.
LED 10 Exit unit half turn sensor is not actuated.
LED 11 Stack height sensor 1 is actuated.
LED 12 Shift tray half turn sensor is actuated.
LED 13 Exit sensor is detects the paper.
LED 14 Entrance sensor is activated.
LED 15 Hammer H.P. sensor detects hammer.
LED 16 Staple end sensor is activated.
LED 17 OFF: Motor speed is too low. BNote
LED 18 OFF: Motor speed is too high. BNote
Transport Drive Motor Control PCB
LED 1 Transport drive motor speed is normal.
NOTE: In SP mode, the transport drive motor, stack feed motor, and exit
drive motor speeds are adjusted automatically in order. While each
motor is adjusted, if the motor speed is normal, LED17 and LED18
light. If the motor speed is too high, only LED17 lights. If the motor
speed is too low, only LED18 lights.
STM 5-23 FT8780/8880
4.4 DIP SW TABLE
4.4.1 Motor Test Mode
DIP101 DIP102
Motor
1 2 3 4 1 2 3 4
1 0 0 0 1 1 0 1 Transport Drive Motor
0 1 0 0 1 1 0 1 Exit Drive Motor
0 0 1 0 1 1 0 1 Stack Feed-out Motor
0 0 0 1 1 1 0 1 Shift Tray Lift Motor
0: OFF 1: ON
Factory
Setting
DIP101 DIP102
0 0 0 0 0 0 0 0
After setting the DIP SW102, turn on one of the DIP SW101 to start the
appropriate motor, turn off the DIP SW 101 to stop the motor.
4.4.2 Free Run Test Mode
DIP102
Function
1 2 3 4
1 1 0 0 Motor Free Run
1 1 1 0 Staple Free Run
1 1 1 1 Shift Free Run
0: OFF 1: ON
Free run test mode starts when the SW100 on the main board is pressed,
and stops when the SW101 is pressed.
Operation:
1. Motor Free Run
The motors of the finisher are energized in the following order:
Transport drive motor Exit motor Stack feed out motor
Shift motor Shift tray lift motor Exit unit lift motor
The PCB checks the speed of the transport drive, exit and stack feed
motors, and mechanical lock of the other motors.
2. Staple Free Run
The finisher works as if 5 sets of 5 LT papers are being stapled and
delivered. The machine is then initialized and repeats the same operation.
3. Shift Free Run
The finisher works as if 10 sets of 5 LT papers are being sorted. The shift
tray is lowered for each of the 2 sets and then returns to its home position
to repeat the same operation.
FT8780/8880 5-24 STM
4.5 PM TABLE
NOTE: Amounts mentioned in the PM interval are copy numbers.
C: Clean R: Replace L: Lubricate
ITEM EM 1.5M NOTE
Rollers C Alcohol
Antistatic Brush C Dry cloth
Brush Rollers R 2 large and 2 small rollers
Bushings L Launa oil; if it makes noise
Sensors C Blower brush
4.6 LUBRICATION POINTS
At an EM call or when the parts are getting dry, lubricate the following parts
using a suitable lubricant.
4.6.1 Shift Tray Positioning Roller Arm
Lubricant: Launa--40 oil or equivalent

STM 5-25 FT8780/8880
4.6.2 Jogger/Staple Unit Shafts
Lubricant: Launa--40 oil or equivalent

4.6.3 Shift Tray Drive Gears
Lubricant: Grease G--501

FT8780/8880 5-26 STM
5. REPLACEMENT AND ADJUSTMENT
5.1 EXTERIOR REMOVAL

1. Open the front door [A] and remove the upper cover [B] (2 screws).
2. Remove the upper door bracket [C] (2 screws) and remove the front door
[A].
3. Remove the front shift cover [D] (2 screws).
4. Remove the rear cover [E] (3 screws).
5. Remove the right upper cover [F] (2 screws).
6. Remove the shift tray [G] (4 screws).
7. Remove the front and rear tray cover [H] (1 screw each).
8. Remove the right cover [I] (2 screws).
[H]
[G]
[F]
[E]
[I]
[D]
[B]
[C]
[A]
STM 5-27 FT8780/8880
5.2 SHIFT TRAY UNIT REMOVAL

1. Remove the front door, upper cover, front shift cover, rear cover, right
upper cover, and the right cover.
2. Remove the shift tray lift motor assembly [A] (4screws).
3. Remove the harness holder plate [B] (3 screws).
4. Remove the screw [C] spring [D], bushing [E] and pulley [F].
5. Disconnect the 7 connectors [G].
6. Remove the 6 screws [H].
7. Lift the shift tray unit [I] off from the hooks [J] and remove.
[G]
[H] [F] [E] [D] [C]
[H]
[G]
[I]
[H]
[A]
[B]
FT8780/8880 5-28 STM
5.3 JOGGER UNIT REMOVAL

1. Open the front door.
2. Slide out the jogger unit [A].
3. Remove the four screws [B] fixing the unit to the slide rails [C].
4. Lift the jogger unit off from the slide rails.
[A]
[C]
[B]
STM 5-29 FT8780/8880
5.4 ALIGNMENT BRUSH ROLLER REPLACEMENT

1. Remove the rear cover.
2. Mark the position of the tension bracket [A] and loosen the screw [B].
3. Remove the 2 E-rings [C], slide out the pulley [D] and bushing [E], and
remove the alignment brush roller assembly [F].
4. Remove the screws [G], E-rings [H], pins [I], and remove the brush rollers
[J].
NOTE: 1. When reassembling, put the bracket [A] back to the marked
position.
2. Do not lose the pins [I].
[B]
[A]
[A]
[E]
[C]
[D]
[F]
[C]
[H]
[J]
[G]
[I]
FT8780/8880 5-30 STM
5.5 JOGGER DRIVE BELT REPLACEMENT

1. Open the front door and slide out the staple unit [A].
2. Remove the front and rear jogger fences [B] (2 screws each).
3. Remove the 2 screws [C] fixing the jogger fence sliders [D] to the belt
clampers [E].
4. Mark the position of the tension bracket [F] and remove (1 screw).
5. Remove the jogger drive belt [G] with the belt clampers [C].
NOTE: When reassembling, put the bracket [F] back to the marked
position.
[G]
[E]
[D]
[A]
[B]
[C]
[F]
STM 5-31 FT8780/8880
5.6 EXIT ROLLER REPLACEMENT

1. Remove the upper cover, front door, front shift cover, rear cover, and
right upper cover.
2. Remove the screw [A], spring [B], bushing [C], and pulley [D].
3. Remove the 4 screws [E] fixing the lower exit guide plate [F].
4. Remove the 2 E-rings [G] and remove the exit roller assembly [H].
5. Remove the E-rings [I], pins [J] and replace the exit rollers [K].
NOTE: Do not lose the pins [J].
[E]
[F]
[G]
[H]
[D]
[I]
[C]
[J]
[G]
[K]
[B]
[A]
[E]
FT8780/8880 5-32 STM
5.7 SHIFT TRAY POSITIONING ROLLER REPLACEMENT

1. Raise the stack height sensor actuator [A] and hold it until the shift tray
automatically lowers.
2. Turn off the main switch before the shift tray returns to its home position.
NOTE: If the machine is in a condition that does not allow the shift tray to
be lowered electrically, then remove the shift tray [B].
3. Remove the 2 E-rings [C] and replace the reverse roller [D].
[C]
[A]
[D]
[B]
STM 5-33 FT8780/8880
5.8 SENSOR REPLACEMENT

Stack Height Sensors
1. Remove the upper cover.
2. Remove the stack height sensor actuator [A] (1 screw).
3. Remove the bracket [B] (1 screw).
4. Replace the stack height sensor 1 [C] and the stack height sensor 2 [D].
NOTE: When reinstalling the bracket [B], align the edge of the bracket
with the stay [E].
Exit Unit Home Position Sensor/Exit Unit Half Turn Sensor
1. Remove the upper cover.
2. Remove the exit unit lift motor [F] (2 screws).
3. Replace the exit unit half turn sensor [G].
4. Remove the bracket [H] (1 screw) and replace the exit unit home position
sensor [I].
[E]
[F]
[C]
[B]
[D]
[A]
[G]
[H]
[I]
FT8780/8880 5-34 STM

Jogger Unit Entrance Sensor
1. Remove the jogger entrance guide [A] (1 screw).
2. Remove the sensor bracket [B] (2 screws).
3. Replace the jogger unit entrance sensor [C] (1 screw).
[B]
[C]
[A]
STM 5-35 FT8780/8880

Shift Tray Half Turn Sensor
1. Remove the rear cover.
2. Remove the shift motor bracket [A] (3 screws).
3. Remove the sensor bracket [B] (1 screw) and replace the shift tray half
turn sensor [C].
Jogger Unit Paper Sensor
1. Open the front cover and slide out the staple unit [D].
2. Remove the 2 screws [E] fixing the bracket [F].
3. Slightly pull out the bracket in the direction shown and remove the jogger
unit paper sensor [G] (1 screw).
[A]
[B]
[C] [F]
[E]
[G]
[D]
FT8780/8880 5-36 STM
5.9 BELT TENSION ADJUSTMENT

1. Remove the rear cover and adjust the belt
[A] tension with tightener [a].
Remove the upper cover, the front door, and
the front shift cover. Adjust the belt [B] with
tightener [b].
Standard:6 mm deflection at 50 20 g
pressure.

2. Remove the upper cover and the rear cover.
Loosen the two screws [c] and adjust the
belt [C] tension by changing the motor
position.
pressure.
[D]
[E]
[F]
[B]
[A]
[C]
[H]
[G]
[A, B]
[a, b]
[C]
[c]
STM 5-37 FT8780/8880
3. Remove the rear cover and adjust the belt
[D] [E] [F] tension with tightener [d] [e] [f].
<Standard>
[D]: 6 mm deflection at 60 20 g pressure
[E]: 6 mm deflection at 170 30 g pressure
[F]: 6 mm deflection at 60 20 g pressure

4. Open the front door and slide onto the
jogger unit. Adjust the belt [G] tension with
tightener [g].
pressure

5. Remove the rear cover. Loosen the 2
screws [h] and [i]. Retighten the screw [h]
and then retighten [i]. The belt [H] tension is
automatically adjusted due to spring tension.
[D]
[d]
[f]
[F]
[e]
[E]
[g]
[G]
[i] [h]
[H]
FT8780/8880 5-38 STM

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