General Precautions for Installation/Servicing/Maintenance for the KK-1600
The installation and service should be done by a qualified service technician.
1. When installing the KK-1600 to the Plain Paper Copier, be sure to follow the instructions described in
the “Unpacking/Set-Up Procedure for the KK-1600” booklet which comes with each unit of the
KK-1600.
2. The KK-1600 should be installed by an authorized/qualified person.
3. Before starting installation, servicing or maintenance work, be sure to turn off and unplug the copier
first.
4. When servcing or maintaining the KK-1600, be careful about the rotating or operation sections such
as gear, pulleys, sprockets, cams, belts, etc.
5. When parts are disassembled, reassembly is basically the reverse of disassembly unless otherwise
noted in this manual or other related materials. Be careful not to reassemble small parts such as
screws, washers, pins, E-rings, toothed washers to the wrong places.
6. Basically, the machine should not be operated with any parts removed or disassembled.
7. Delicate parts for preventing safety hazard problems (such as breakers, thermofuses, fuses, door
switches, sensors, etc. if any) should be handled/installed/adjusted correctly.
8. Use suitable measuring instruments and tools.
9. During servicing or maintenance work, be sure to check the serial No. plate and other cautionary
labels (if any) to see if they are clean and firmly fixed. If not, take appropriate actions.
10. The PC board must be stored in an anti-electrostatic bag and handled carefully using a wristband,
because the ICs on it may be damaged due to static electricity. Before using the wrist band, pull out
the power cord plug of the copier and make sure that there is no uninsulated charged objects in the
vicinity.
11. For the recovery and disposal of used KK-1600, consumable parts and packing materials, it is rec-
ommended that the relevant local regulations/rules should be followed.
12. After completing installation, servicing and maintenance of the KK-1600, return the KK-1600 to its
original state, and check operation.
Copyright 2000
TOSHIBA TEC CORPORATION
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1. SPECIFICATIONS
Type of stapling
: Flat clinch method
No. of sheets stapled : 52g/m2 paper, 2 sheets to 80g/m2 paper, 50 sheets
52g/m2 paper, 2 sheets to 80g/m2 paper, 48 sheets + 200g/m2, 2 sheets
Paper thickness : Max. 5.5 mm
: 5000 staples
Staple capacity
Dimensions
Weight
: 257 (W) x 423 (D) x 173 (H) mm
: Approx. 3.4 kg
Power supply
: 100V - 240V (Supplied from copier)
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KK-1600 SPECIFICATIONS
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2. OUTLINE
2.1 Names of Various Components
STP power code
STP power lamp
STP base
STP 02-01-01
STP staple cartridge
STP staple unit
STP 02-01-02
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KK-1600 OUTLINE
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2.2 Layout of Electrical Parts
STP AC adapter
STP LED PWA
STP1
STP 02-02-01
M1
SW2
SW1
STP2
SEN2
SEN1
STP 02-02-02
KK-1600 OUTLINE
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Symbols and functions of various devices
Symbol
SW1
Name
Function
STPCOV-SW
Detects the open/close state of the cover dur-
ing staple replacement, etc.
STP cover open switch
EMPTY-SW
SW2
SEN1
SEN2
M1
Detects the presence or absence of staples.
STP staple empty switch
PSET-SEN
Detects the loading of the paper to be stapled.
Detects the home position of the drive section.
Drive the stapler.
STP paper set sensor
HP-SEN
STP home position sensor
STP motor
STP1
STP2
LED
STP CONT PWA
STP sensor PWA
STP LED PWA
PWA which controls the stapler.
PWA which relays the sensor signals and mo-
tor drive signals.
PWA on which the power lamp (LED) is installed.
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KK-1600 OUTLINE
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2.3 Harness Connection Diagram
J2
1
24V
STP cover open switch
Staple unit
COVER
J1
2
24V
1
2
AC
GND
adapter
J3
CN1
CN2
CN3
1
2
GND
H.P
1
2
3
4
5
6
7
1
2
3
4
5
6
7
M
STP motor
5V
AC IN
1
2
STP staple
empty switch
GND
Empty
STP
sensor
PWA
STP
CONT
PWA
CW
STP home
position sensor
CCW
J4
J5
5V
GND
Set
1
2
3
STP paper set sensor
STP LED PWA
GND
LED
1
2
STP 02-03-01
KK-1600 OUTLINE
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2.4 Board Assembly
J1
STPL CONTROLLER
C11
JP16
2
1
2
3
D9
J5
1
D2
D3
FU1
9
D10
Q2
1
C4
JP13
Q7
D
D8
JP5
JP14
S
JP11
JP12
8
JP2
JP1
D5
G
Q5
S
D7
D4
G
Q6
S
1
Q1
JP10
J4
MADE IN JAPAN
D
D
G
G
JP6
J3
Q4
S
7
1
1
3
W
STP 02-04-01
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KK-1600 OUTLINE
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3. OPERATIONAL DESCRIPTION
3.1 General Description
Upon detecting the loading of paper, the STP operates the motor for staple operation. The AC input
supplied from the copier is converted to a DC voltage (24V) through the AC adapter in the STP and used
as a power supply for the STP.
3.2 Block Diagram
STP cover open switch
+24V
AC
adapter
STP paper set sensor
STP LED PCB
STP
CONT
PWA
Staple unit
M
STP motor
STP
sensor
PWA
STP staple empty switch
STP home position sensor
STP 03-02-01
The STP consists of the AC adapter, STP CONT PWA, sensors, power indicator LED, staple unit, etc.
The staple unit consists of the STP motor, STP Sensor PWA for relaying the sensor signals, mechanical
drive section, etc.
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KK-1600 OPERATIONAL DESCRIPTION
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3.3 Detection of Abnormal Status
• Cover Open/Close Detection
The STP cover open switch turns OFF when the cover is opened. Since the switch is connected to the
power supply, the power supply to the STP is cut when the switch turns OFF. For this reason, all the
operation is disabled while the cover is open. When the STP cover is closed, the delivery of the power
supply is resumed to light the STP power lamp and enable stapling.
• Staple Empty Detection
Upon detecting a staple empty state, the STP staple empty switch resets the motor drive circuit so that
the motor does not operate even if the STP paper set sensor detects the presence of paper. This error
state is reset when staples are supplied causing the STP paper set sensor to detect the presence of
staples.
KK-1600 OPERATIONAL DESCRIPTION
3 - 2
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3.4 Flow Chart
Copier power ON
Open
STP cover open
switch
STP power lamp OFF
Close
STP power lamp ON
Load paper into STP.
(STP paper set sensor ON)
STP staple
empty switch
OK?
NG
Stampling stopped
Supply staples
OK
STP motor operates
to start stapling.
STP 03-04-01
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KK-1600 OPERATIONAL DESCRIPTION
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4. MECHANICAL DESCRIPTION
4.1 Mechanism Drawing
Paper set
STP paper set sensor
STP 04-01-01
4.2 Staple Operation
The staple operation of the STP is performed only by the rotation of the STP motor through the combina-
tion of the gears and cams.
The loading of paper is detected when the paper detection lever is pushed. When paper is loaded into the
stapler, the paper detection lever is pushed causing the STP paper set sensor to detect the presence of
paper.
When the presence of paper is detected, if staples are available, the STP motor is operated to drive the
gears and cams to perform staple operation. If no staples are available, the STP does not operate until
staples are supplied. When one time of staple operation is finished, the STP returns to its original state
and stands by until the next presence of paper is detected.
Staples are loaded in the cartridge and its capacity is about 5,000 staples. When the cartridge is sup-
plied with staples or a new cartridge is installed, perform staple operation without staples (7 to 8 times) to
feed staples to a position where stapling is possible.
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KK-1600 MECHANICAL DESCRIPTION
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5. CIRCUIT DESCRIPTION
5.1 PWA Block Diagram
5V
1
1
2
24V
Q3
switching
regulator
STP cover open
switch
STP LED PWA
2
GND
5V
FU1
1
2
3
5V
1
STP paper set
sensor
STP AC adapter
2
3
GND
GND
PAPER_SENS
STPL_H/P
HOOK_SW
1
GND
5V
2
3
4
5
STP sensor PWA
24V
GND
CW
CCW
Motor drive
circuit
6
7
Motor
controll
circuit
Motor drive
circuit
STP 05-01-01
5.2 Functional Description
The STP operates the stapler through the STP controller PWA. When the power of the copier is turned
on, a power supply is also delivered to the STP to enable stapling. When paper is loaded into the stapler,
the STP paper set sensor detects the presence of paper (changing from “High” to “Low”), and 200 ms
later the CW signal turns ON (changing from “Low” to “High”) to operate the STP motor forward. When
the motor operates, the gears and cams of the stapler operate for stapling. When the STP home position
sensor detects the home position of the stapler (changing from “High” to “Low”) after the CW signal is
activated, the CW signal turns OFF.
If the STP home position sensor remains at “High” level (a failure to return to the home position) for some
reason even if a fixed time (approx. 900 ms) has elapsed after the CW signal turns ON, the CW signal
turns OFF and 100 ms later the CCW signal is turned ON (changing from “Low” to “High”) to operate the
STP motor reversely. In practice, however, if the STP has locked up mechanically, an overload occurs so
that the fuse installed on the STP CONT PWA will blow or the protective circuit of the AC adapter will
function to cut the delivery of the power supply (shutdown).
If the stapler is not at the home position when the power is turned on (“High” level), about 60 ms later the
CCW signal is turned ON (changing from “Low” to “High”) to operate the motor reversely allowing the
stapler to return to the home position.
October 2000 ©TOSHIBA TEC
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KK-1600 CIRCUIT DESCRIPTION
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5.3 Signal Description
Signal Name
STPCOV
Part Name
Functional Description
Status
Note
STP cover open Detects the open/close
Open: Power off
Microswitch
switch
state of the cover during
staple replacement, etc.
Detects the loading of the
paper to be stapled.
STPPSET
STPHP
STP paper set
sensor
Low: Paper loaded
Low: Home position
Low: No staples
Photo sensor
Photo sensor
Microswitch
STP home
Detects the home position
of the drive section.
position sensor
STP staple
empty switch
STPEMP
Detects the presence or
absence of staples.
The STP cover open switch detects the open or close state of the cover. A microswitch is used for the
switch. A power supply is delivered to the stapler when the cover is closed, and cut off when open.
The STP paper set sensor detects the loading of paper. A photo sensor is used for the switch. The signal
goes LOW when the paper to be stapled is loaded.
The STP home position sensor detects the home position of the stapler. A photo sensor is used for the
sensor. It is mounted on the STP sensor PWA and detects the home position every stapling.
The STP staple empty switch detects the presence or absence of staples. A microswitch is used for the
sensor. When staples have run out or no cartridge is mounted, the signal is detected at “Low” level.
KK-1600 CIRCUIT DESCRIPTION
5 - 2
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5.4 Timing Charts
• Staple operation
858ms
200ms
H
L
STP paper set sensor
H
L
STP staple empty switch
STP home position sensor
CW
H
L
H
L
H
L
CCW
• Staple operation (When staples have run out during operation)
200ms
200ms
H
STP paper set sensor
L
No staples
H
L
STP staple empty switch
STP home position sensor
CW
H
L
H
L
H
L
CCW
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KK-1600 CIRCUIT DESCRIPTION
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• Reverse operation (When the motor has locked up)
200ms
900ms
H
STP paper set sensor
L
H
STP staple empty switch
L
H
STP home position sensor
L
H
CW
L
H
CCW
L
100ms
• Reverse operation (When the stapler is not at the home position at power on time)
H
POWER ON
L
H
STP paper set sensor
L
H
STP staple empty switch
L
H
STP home position sensor
L
H
CW
L
H
CCW
L
60ms
KK-1600 CIRCUIT DESCRIPTION
5 - 4
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6. DISASSEMBLY AND REPLACEMENT
[A] STP cover/STP staple cartridge
1. Pull STP cover to release one hook and open
STP cover.
STP cover
314-1
Fig. 6-1
2. Release 2 hooks and detach STP cover.
STP cover
Hook
314-2
Fig. 6-2
Fig. 6-3
Fig. 6-4
3. Release 2 hooks and remove STP staple car-
tridge.
STP staple cartridge
321-1
[B] STP bottom cover F
1. Remove one screw and detach connector cover.
Connector cover
Screw
315
October 2000 © TOSHIBA TEC
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KK-1600 DISASSEMBLY AND REPLACEMENT
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2. Remove 2 screws and remove connector plate.
3. Release 2 hooks and detach connector.
Hook
Screw
Connector plate
316-1
Fig. 6-5
Manual pocket
4. Release the power cable from the hook of the
manual pocket.
Power cable
316-2
Fig. 6-6
5. Remove 2 screws, release 2 hooks, and remove
stapler.
Hook
Stapler
317
Screw
Fig. 6-7
6. Remove one screw and detach STP bottom
cover F.
Screw
STP bottom cover F
318
Fig. 6-8
KK-1600 DISASSEMBLY AND REPLACEMENT
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[C] STP bottom cover R
Screw
STP bottom cover R
Screw
1. Remove stapler. (See Fig. 6-4 to 6-7)
2. Remove 4 screws and detach STP bottom cover
R.
319
Fig. 6-9
[D] STP staple cover
STP staple cover
1. Detach STP cover. (See Fig. 6-1 and 6-2)
2. Remove STP staple cartridge. (See Fig. 6-3)
3. Remove stapler. (See Fig. 6-4 to 6-7)
4. Detach STP bottom cover R. (See Fig. 6-9)
5. Remove one screw, release 5 hooks, and de-
tach STP staple cover.
Hook
Hook
Screw
321-2
Fig. 6-10
[E] STP cover open switch
Clamp
Clamp
1. Detach STP cover. (See Fig. 6-1 and 6-2)
2. Remove STP staple cartridge. (See Fig. 6-3)
3. Remove stapler. (See Fig. 6-4 to 6-7)
4. Detach STP bottom cover. (See Fig. 6-9)
5. Detach STP staple cover. (See Fig. 6-10)
6. Detach one connector from STP controller PWA
(J2) and release 3 clamps.
Connector
321-3
Fig. 6-11
7. Remove one screw and remove STP cover open
switch.
STP cover open switch
Screw
321-4
Fig. 6-12
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KK-1600 DISASSEMBLY AND REPLACEMENT
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[F] AC adapter
1. Remove stapler. (See Fig. 6-4 to 6-7)
2. Detach STP bottom cover R. (See Fig. 6-9)
3. Detach AC adapter jack from STP controller
PWA (J1).
Power cord
AC adapter
AC adapter jack
4. Detach power cord and remove AC adapter.
322-1
Fig. 6-13
[G] STP LED PWA
STP controller PWA
connector
1. Remove stapler. (See Fig. 6-4 to 6-7)
2. Detach STP bottom cover R. (See Fig. 6-9)
3. Remove AC adapter. (See Fig. 6-13)
4. Detach one connector from STP controller PWA
(J5) and release 2 clamps.
clamp
J5
322-2
Fig. 6-14
5. Remove one screw and remove STP LED PWA.
Screw
STP LED PWA
322-3
Fig. 6-15
[H] STP base stay assembly
STP controller PWA
J2
J1
1. Remove stapler. (See Fig. 6-4 to 6-7)
2. Detach STP bottom cover R. (See Fig. 6-9)
3. Detach AC adapter jack and the connectors
from STP controller PWA (J1/J2/J5).
4. Release 4 clamps.
J5
AC adapter jack
323
Fig. 6-16
KK-1600 DISASSEMBLY AND REPLACEMENT
6 - 4
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5. Remove 7 screws and remove STP base stay
assembly.
Screw
Screw
STP base
stay assembly
324
Fig. 6-17
[I] STP base
Screw
1. Detach STP cover. (See Fig. 6-1 and 6-2)
2. Remove STP staple cartridge. (See Fig. 6-3)
3. Remove stapler. (See Fig. 6-4 to 6-7)
4. Detach STP bottom cover F. (See Fig. 6-8)
5. Detach STP bottom cover R. (See Fig. 6-9)
6. Detach STP staple cover. (See Fig. 6-10)
7. Remove STP cover open switch.(See Fig.6-11
and 6-12)
STP stay
325
Fig. 6-18
8. Remove AC adapter. (See Fig. 6-13)
9. Remove STP LED PWA. (See Fig. 6-14 and
6-15)
8. Remove STP base stay assembly. (See Fig. 6-
16 and 6-17)
9. Remove 2 screws and remove STP stay.
Screw
[J] STP controller PWA
1. Remove stapler. (See FIG. 6-4 to 6-7)
2. Detach STP bottom cover R. (See FIG. 6-9)
3. Detach AC adapter jack and all connectors from
STP controller PWA.
AC adapter
jack
4. Remove 2 screws and remove STP controller
PWA.
STP
controller PWA
326
Fig. 6-19
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[K] STP staple unit
STP controller PWA
1. Remove stapler. (See Fig. 6-4 to 6-7)
2. Detach STP bottom cover R. (See Fig. 6-9)
3. Remove STP base stay assembly. (See Fig. 6-
16 and 6-17)
Clamp
J3
J4
4. Detach the connectors from STP controller PWA
(J3/J4) and release 2 clamps.
327
Fig. 6-20
5. Remove 2 screws and remove STP staple unit.
STP staple unit
Screw
328
Fig. 6-21
KK-1600 DISASSEMBLY AND REPLACEMENT
6 - 6
October 2000 © TOSHIBA TEC
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