Toshiba Printer KK 1600 User Manual

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  
2 - 2  
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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  
2 - 4  
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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.  
October 2000 ©TOSHIBA TEC  
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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.  
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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  
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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  
6 - 2  
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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  
October 2000 © TOSHIBA TEC  
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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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KK-1600 DISASSEMBLY AND REPLACEMENT  
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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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