Toshiba KD1009 User Manual

GENERAL PRECA UTIONS FOR INSTALLATION/SERVICING/
MAINTENANCE

1. When installing the Paper Feed Pedestal KD-1009 to the Copier, be sure to follow the instructions
described in the “Unpacking/Set-Up Procedure for the KD-1009” booklet which comes with each unit of
the KD-1009.

2. The KD-1009 should be installed by an authorized/qualified person.

3. When transporting/installing KD-1009, employ two persons and be sure to use the positions as indi­cated below. KD-1009 is fairly heavy and weight approximately 17 kg (37.5 lb), therefore pay full
attention when handling it.

4. Before starting installation, servicing or maintenance work, be sure to turn off and unplug the copier
first.

5. The KD-1009 is supplied with power from the copier , requiring no additional power source.

6. The KD-1009 should be grounded to the specified positions on the machine frame.

7. When servicing or maintaining the KD-1009, be careful about the rotating or operating sections such as
gears, pulleys, sprockets, cams, belts, etc.

8. When parts are disassembled, reassembly is basically the reverse of disassembly unless otherwise
noted in this manual or other related documents. Be careful not to reassemble small parts such as
screws, washers, pins, E-rings, toothed washers to the wrong places.

9. Basically, the machine should not be operated with any parts removed or disassemb led.

10. Delicate parts for preventing safety hazard problems (such as thermofuses, door switches sensors,
etc. if any) should be handled/installed/adjusted correctly.

11. During servicing or maintenance work, be sure to check the nameplate and other cautionary labels (if
any) to see if they are clean and firmly stuck. If not, take appropriate actions.

12. Use suitable measuring instruments and tools.

13. 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.
Caution: Before using the wrist band, pull out the power cord plug of the copier and make sure that

there is no uninsulated objects in the vicinity.

14. For the recov ery and disposal of used KD-1009, consumable parts and packing materials, it is recom­mended that the relevant local regulations/rules should be followed.

© Copyright 2000

TOSHIBA TEC CORPORA TION

CONTENTS

1. SPECIFICATIONS ........................................................................................... 1-1

2. OVERVIEW ...................................................................................................... 2-1

2.1 Front Sectional Vie w ......................................................................................................... 2-1

2.2 Layout of Electrical Parts.................................................................................................. 2-2

2.3 Electrical Parts ................................................................................................................. 2-3

2.4 Harness Diagram .............................................................................................................. 2 -5

2.5 Circuit Diagram ................................................................................................................. 2- 9

2.6 Assembly of PC Board ..................................................................................................... 2- 12

2.7 Timing Chart ..................................................................................................................... 2-13

3. GENERAL OPERATION .................................................................................. 3-1

3.1 Description of Operation ................................................................................................... 3-1

3.2 Error Detection.................................................................................................................. 3- 2

3.3 Flow Chart .................................................................................................................. ...... 3- 3

4. DRIVE SYSTEM AND FEEDING OPERATION............................................... 4-1

4.1 Configuration and Drive System........................................................................................ 4- 1

5. DISASSEMBLY AND REPLACEMENT ........................................................... 5-1

5.1 Installation and Removal of Cassettes and Covers ........................................................... 5- 1

5.2 PC Board .......................................................................................................................... 5 -2

5.3 Upper and Lower Transport Roller (Plastic Rollers) ............................................................ 5-2

5.4 Motors .............................................................................................................................. 5-3

5.5 Feed/Separation/Pickup Roller .......................................................................................... 5 -4

5.6 Switches and Sensors ...................................................................................................... 5-6

6. PERIODIC MAINTENANCE ............................................................................ 6-1

October 2000 © TOSHIBA TEC I KD-1009 CONTENTS

1. SPECIFICATIONS

Feeding method Automatic feeding: 1 cassette installed from the front

(One extra cassette (option) are available for the models with a DP2500, DP4500/

3500)

Paper Size: A5 – A3

Thickness: 64 – 80g/m

Transportation speed Approx. 260mm/sec. (Models with a DP1600/2500)

Approx. 400mm/sec. (Models with a DP4500/3500)
Capacity of cassette Stack height: 60.5mm (approx. 550 sheets)
Dimensions 530 (W) × 536 (D) × 305 (H) mm
Weight Approx. 17 kg (one cassette)
Po wer supply 5V, 24V (supplied from the copier)

2

October 2000 © TOSHIBA TEC 1 - 1 KD-1009 SPECIFICATION

2. OVERVIEW

2.1 Front Sectional View

10

16 17

8

9

15

261823192524

12

56

4
3

7

12
13

14
11
20
21
22
27

28

NO . NAME NO. NAME

1 Upper cassette tray-up sensor (S4)
2 Upper cassette paper empty sensor (S6)
3 Upper feed sensor (S2)
4 Upper transport roller
5 Upper cassette feed clutch (C2)
6 Upper cassette feed roller
7 Upper cassette separation roller
8 Upper cassette

9 Lower cassette
10 Upper cassette tray-up motor (M2)
11 Lower feed sensor (S3)
12 Upper cassette elevator coupling
13 Lower transport roller
14 T ransport clutch (C1)

October 2000 © TOSHIBA TEC 2 - 1 KD-1009 OVERVIEW

1 5 Upper cassette pickup roller
1 6 Upper cassette tray
17 Upper cassette elevator
18 Lower cassette tray-up sensor (S5)
1 9 Lower cassette paper empty sensor (S7)
2 0 Lower cassette feed clutch (C3)
21 Lower cassette feed roller
22 Lower cassette separation roller
2 3 Lower cassette pickup roller
2 4 Lower cassette tray
25 Lower cassette tray-up motor (M3)
26 Lower cassette elevator
27 Lower cassette elevator coupling
28 Adjuster

2.2 Layout of Electrical Parts

*

16

Front side

8

2

6

4

9

18

7

11

5

15

1

*

17

12

10

NO. NAME NO. NAME

1 Side cover open/close switch (S1)

2 Upper cassette detection switch (S8)

3 Lower cassette detection switch (S9)

4 Upper feed sensor (S2)

5 Lower feed sensor (S3)

6 Upper cassette tray-up sensor (S4)

7 Lower cassette tray-up sensor (S5)

8 Upper cassette paper empty sensor (S6)

9 Lower cassette paper empty sensor (S7)

*16 Upper cassette paper stock sensor (S10)
*17 Lower cassette paper stock sensor (S11)

3

10 T ransport clutch (C1)
1 1 Upper cassette feed clutch (C2)
1 2 Lower cassette feed clutch (C3)
13 Upper cassette tray-up motor (M2)
14 Lower cassette tray-up motor (M3)
1 5 PFP motor (M1)

18 PC board (PWA)

14

13

* for the DP4500/3500 only

Rear side

KD-1009 OVERVIEW 2 - 2 October 2000 © TOSHIBA TEC

2.3 Electrical Parts

(1) Motor

SYMBOL NAME FUNCTION REMARKS

(M1) PFP-MTR Drives feeding and trans- Brushless motor

PFP motor portation

(M2) T-UP-U-MTR Lifts up the upper cassette tray Brush motor

Upper cassette tray-up motor

(M3) T-UP-L-MTR Lifts up the lower cassette tray Brush motor

Lower cassette tray-up motor

(2) Electromagnetic clutch

SYMBOL NAME FUNCTION REMARKS

(C1) TR-CLT Drives transportation

Transport clutch

(C2) FED-U-CL T Drives roller to pick up paper

Upper cassette feed clutch from the upper cassette

(C3) FED-L-CL T Drives roller to pick up paper

Lower cassette feed clutch from the lower cassette

(3) Switches and Sensors

SYMBOL NAME FUNCTION REMARKS

(S1) SIDE-COV -SW Side cover open/close Push switch

Side cover open/close switch detection

(S2) FED-U-SNR Detects paper from the upper Photo interrupter

Upper feed sensor cassette

(S3) FED-L-SNR Detects paper from the lower Photo interrupter

Lower feed sensor cassette

(S4) T OP-U-SNR Detects if the upper cassette Photo interrupter

Upper cassette tray-up sensor has been raised

(S5) TOP-L-SNR Detects if the lower cassette Photo interrupter

Lower cassette tray-up sensor has been raised

(S6) EMP-U-SNR Detects lack of paper in the Photo interrupter

Upper cassette paper empty sensor upper cassette

(S7) EMP-L-SNR Detects lack of paper in the Photo interrupter

Lower cassette paper empty sensor lower cassette

(S8) CST -U-SW Detects the availability of the Push switch

Upper cassette detection switch upper cassette

(S9) CST -L-CST Detects the availability of the Push switch

Lower cassette detection switch lower cassette

October 2000 © TOSHIBA TEC 2 - 3 KD-1009 OVERVIEW

* for the DP4500/3500 only

SYMBOL SPEC. NAME FUNCTION REMARKS

*(S10) PST-U-SNR Detects that the paper stock is Photo interrupter

Upper cassette paper stock sensor going short of the upper cassette

*(S11) PST-L-SNR Detects that the paper stock is Photo interrupter

Lower cassette paper stock sensor going short of the lower cassette

(4) PC board

SYMBOL SPEC. NAME FUNCTION REMARKS

PWA PWA-F-PFP-519 Drives feeding and moves trays

PC board

KD-1009 OVERVIEW 2 - 4 October 2000 © TOSHIBA TEC

2.4 Harness Diagram

Copier

Copier

(PREMAGE165/255)

(DP1600/2500)

PFP

CN508

TR-CLT

CN507

T-UP-U-MTR

CN511

FED-U-SNR

CN510 CN520 CN520

FED-L-SNR

CN500
CN501

CN505

T-UP-L-MTR

CN509

SIDE-COV-SW

CN500
CN501

CN241
CN242

PFP-MTR

M

CN503

CN243CN247

CN244

PFP

PC board

CN502

CN246

Copier

Copier

(DP4500/3500)

(PREMAGE455/355)

CN318

FED-U-CLT

PFC

CN318

FED-L-CLT

CN567
CN568

TOP-U-SNR

CN567
CN568

CN314

CN316 CN516

ADPT

CN315

EMP-U-SNR

CN314

TOP-L-SNR

EMP-L-SNR

CN315 CN316 CN517

CN335

CST-U-SW

CN336

CST-L-SW

ADPT

CN248

October 2000 © TOSHIBA TEC 2 - 5 KD-1009 OVERVIEW

A1

CLK-C

A2

CLK-B

A3

SCSW-C

PFPRST

SCSW-B

Copier (DP1600/2500)

LCFCNT

DRV7
DRV6
DRV5
DRV4
DRV3
DRV2
DRV1
DRV0

VDD

GND
SIZE-0
SIZE-1
SIZE-2
SIZE-3

RETS-0
RETS-1
RETS-2
RETS-3
RETS-4
RETS-5
RETS-6
RETS-7

A4
A5
A6
A7
A8

A9
A10
A11
A12
A13
A14
A15

B1

B2

B3

B4

B5

B6

B7

B8

B9
B10
B11
B12
B13
B14
B15

CN206

CN206

A1
A2
A3
A4
A5
A6
A7
A8

A9
A10
A11
A12
A13
A14
A15

B1

B2

B3

B4

B5

B6

B7

B8

B9
B10
B11
B12
B13
B14
B15

Copier (PREMAGE 165/255)

+24V
+24V

DG
DG

1
2
3
4

CN207

CN207

1
2
3
4

11
13
15
17
19
21
23
25
27
29
30
28
26
24
22
20
18
16
14
12
10

1
3
5
7
9

8
6
4
2

1
2
3
4

CN500

CN500

CN501

CN501

11
13
15
17
19
21
23
25
27
29
30
28
26
24
22
20
18
16
14
12
10

1
3
5
7
9

8
6
4
2

+24V

1

+24V

2

GND

3

GND

4

A1
A2
A3
A4
A5
A6
A7
A8

A9
A10
A11
A12
A13
A14
A15

B1

B2

B3

B4

B5

B6

B7

B8

B9
B10
B11
B12
B13
B14
B15

1
2
3
4

CN241

CN242

A1
A2
A3
A4
A5
A6
A7
A8

A9
A10
A11
A12
A13
A14
A15

CN241

B1

B2

B3

B4

B5

B6

B7

B8

B9
B10
B11
B12
B13
B14
B15

+24V

1

+24V

2

DG

3

DG

4

PFPCNT
CLK-C
CLK-B
SCSW-C
DRV7
DRV6
DRV5
DRV4
DRV3
DRV2
DRV1
DRV0
PFPRST
VDD
GND
SIZE-0
SIZE-1
SIZE-2
SIZE-3
RETS-0
RETS-1
RETS-2
RETS-3
RETS-4
RETS-5
RETS-6
RETS-7
SCSW-B

PFP

PC board

KD-1009 OVERVIEW 2 - 6 October 2000 © TOSHIBA TEC

CLK-C

A1

CLK-B

A2

SCSW-C

PFPRST

Copier (DP4500/3500)

SCSW-B

Copier (PREMAGE 455/355)

DRV7
DRV6
DRV5
DRV4
DRV3
DRV2
DRV1
DRV0

VDD

GND
+24V
+24V

DG

DG
SIZE-0
SIZE-1
SIZE-2

RETS-0
RETS-2
RETS-3
RETS-4
RETS-5
RETS-7
RETS-5
RETS-6
RETS-7

LCCNT

A3
A4
A5
A6
A7
A8

A9
A10
A11
A12
A13
A14
A15
A16

B1

B2

B3

B4

B5

B6

B7

B8

B9
B10
B11
B12
B13
B14
B15
B16 B16

CN312

CN312

A1
A2
A3
A4
A5
A6
A7
A8

A9
A10
A11
A12
A13
A14

B3

B4

B5

B6

B7

B8

B9
B10
B11
B12
B13
B14
B15

11
13
15
17
19
21
23
25
27
29

30
28
26
24
22
20
18
16
14
12
10

1
3
5
7
9

8
6
4
2

CN567

CN567

11
13
15
17
19
21
23
25
27
29

30
28
26
24
22
20
18
16
14
12
10

PFPCNT

CN241

A1
A2
A3
A4
A5
A6
A7
A8

A9
A10
A11
A12
A13
A14
A15

CN241

B1

B2

B3

B4

B5

B6

B7

B8

B9
B10
B11
B12
B13
B14
B15

CLK-C
CLK-B
SCSW-C
DRV7
DRV6
DRV5
DRV4
DRV3
DRV2
DRV1
DRV0
PFPRST
VDD
GND

SIZE-0
SIZE-1
SIZE-2
RETS-0
RETS-2
RETS-3
RETS-4
RETS-5
RETS-7
RETS-5
RETS-6
RETS-7
SCSW-B

1
3
5
7
9

8
6
4
2

A1
A2
A3
A4
A5
A6
A7
A8

A9
A10
A11
A12
A13
A14
A15

B1

B2

B3

B4

B5

B6

B7

B8

B9
B10
B11
B12
B13
B14
B15

1
2
3
4

CN568

CN568

+24V

1

+24V

2

GND

3

GND

4

1
2
3
4

1

CN242

2
3
4

+24V
+24V
DG
DG

PFP

PC board

October 2000 © TOSHIBA TEC 2 - 7 KD-1009 OVERVIEW

GND

FEDU

VDD
GND

FEDL

VDD
GND

COV-SW

1
2
3
4
5
6
7
8

CN243

CN243

1
2
3
4
5
6
7
8

8
7
6
5
4
3
2
1

CN520

1
2
3
4
5

CN520

6
7
8

GND
FEDU
VDD
GND
FEDL
VDD
GND
COV-SW

CN511

3
2 FED-U-SNR
1

CN510

3
2 FED-L-SNR
1

2
1

CN509

SIDE-COV-SW

CN244

CN244

CN246

CN246

CN247

CN247

CN248

CN248

1
2
3
4
5
6
7
8

1
2
3
4
5
6
7
8

14

GND

13

CST

12
11
10

9
8
7
6
5
4
3
2
1

GND

13

CST

12
11
10

9
8
7
6
5
4
3
2
1

TRMU-B

1

TRMU-A

2

TRMU-B

3

TRMU-A

4

+24V

5

FEDCLT

6

+24V

FEDCLT35

MOT-BRK

7
8

DG

1

DG

2

+24

3

+24

4
5

VDD

6

DIR

7

PLLOK

8
99

MOT-OFF

10 10

GND

11 11

14
13

GND

12

SIZCUO

11

VDD

10

PHU1

9

GND

8

+24V

7

PCLTU

VDD

6

TUPU

5

GND

4

VDD

3

PEMPU

2

GND

1

PFP PC Board

GND

13
12

SIZCUO

VDD

11

PUL1

10

GND

9
8

+24V

7

PCLTU

VDD

6

TUPU

5

GND

4

VDD

3

PEMPU

2

GND

1

1
2

1
2

CN335

CST-U-SW

CN336

CST-L-SW

4
3
2
1
7
6
5
4
3
2
1

CN502 CN503

PFP-MTR

(6)

1

CN516B
2
3

CN316B

4
5
1
2

CN516A

3
4
5

CN316A

6

(7)

(6)

1

CN517B
2
3

CN316B

4
5
1
2

CN517A

3
4
5

CN316A

6

(7)

(1)

(1)

(1)

(1)

CN505

1

T-UP-L-MTR

2

VCC

6

PHU1

5

GND

4

+24V

3

PCLTU

2

VCC

7

LPSON

6

GND

5

VCC

4

PESON

3

GND

2

VCC

6

PHU1

5

GND

4

+24V

3

PCLTU

2

VCC

7

LPSON

6

GND

5

VCC

4

PESON

3

GND

2

1
2

1
2

CN507

1

T-UP-U-MTR

2

CN318

FED-U-CLT

1
2 TOP-U-SNR
3

CN318

FED-L-CLT

1
2 TOP-L-SNR
3

CN508

1
2

1
2
3

CN314

1
2
3

1
2
3

CN314

1
2 EMP-L-SNR
3

TR-CLT

CN344

*PST-U-SNR

CN315

CN344

*PST-L-SNR

CN315

* for the DP4500/3500 only

KD-1009 OVERVIEW 2 - 8 October 2000 © TOSHIBA TEC