Toshiba KD1009 User manual

GENERAL PRECAUTIONS FOR INSTALLATION/SERVICING/
MAINTENANCE
1. When installing the Paper Feed Pedestal KD-1009 to the Copier, be sure to follow the instructions
describedinthe“Unpacking/Set-UpProcedurefortheKD-1009”bookletwhichcomeswitheachunitof
theKD-1009.
2. TheKD-1009should be installed byanauthorized/qualified person.
3. When transporting/installing KD-1009, employ two persons and be sure to use the positions as indi-
cated below. KD-1009 is fairly heavy and weight approximately 17 kg (37.5 lb), therefore pay full
attentionwhenhandling it.
4. Before starting installation, servicing or maintenance work, be sure to turn off and unplug the copier
first.
5. TheKD-1009 is supplied with powerfromthecopier,requiring no additionalpowersource.
6. TheKD-1009 should be grounded to the specified positions on the machine frame.
7. WhenservicingormaintainingtheKD-1009,becarefulabouttherotatingoroperatingsectionssuchas
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 disassembled.
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. Fortherecovery and disposalof used KD-1009,consumablepartsand packingmaterials, it isrecom-
mendedthat the relevant localregulations/rules should be followed.
© Copyright 2000
TOSHIBATEC CORPORATION

October 2000 © TOSHIBA TEC IKD-1009 CONTENTS
CONTENTS
1. SPECIFICATIONS ........................................................................................... 1-1
2. OVERVIEW ...................................................................................................... 2-1
2.1 FrontSectionalView ......................................................................................................... 2-1
2.2 Layout of Electrical Parts.................................................................................................. 2-2
2.3 Electrical Parts ................................................................................................................. 2-3
2.4 HarnessDiagram .............................................................................................................. 2-5
2.5 CircuitDiagram ................................................................................................................. 2-9
2.6 Assembly of PC Board ..................................................................................................... 2-12
2.7 TimingChart..................................................................................................................... 2-13
3. GENERAL OPERATION .................................................................................. 3-1
3.1 DescriptionofOperation ................................................................................................... 3-1
3.2 ErrorDetection.................................................................................................................. 3-2
3.3 FlowChart ........................................................................................................................ 3-3
4. DRIVE SYSTEM AND FEEDING OPERATION............................................... 4-1
4.1 ConfigurationandDrive System........................................................................................ 4-1
5. DISASSEMBLY AND REPLACEMENT........................................................... 5-1
5.1 Installation and Removal of Cassettes and Covers ........................................................... 5-1
5.2 PCBoard .......................................................................................................................... 5-2
5.3 Upperand LowerTransport Roller (Plastic Rollers) ............................................................ 5-2
5.4 Motors .............................................................................................................................. 5-3
5.5 Feed/Separation/PickupRoller.......................................................................................... 5-4
5.6 Switchesand Sensors ...................................................................................................... 5-6
6. PERIODIC MAINTENANCE ............................................................................ 6-1

October 2000 © TOSHIBA TEC 1 - 1 KD-1009 SPECIFICATION
1. SPECIFICATIONS
Feedingmethod Automatic feeding: 1 cassette installed from the front
(Oneextracassette (option)areavailableforthe modelswithaDP2500,DP4500/
3500)
Paper Size: A5 – A3
Thickness: 64 – 80g/m2
Transportationspeed Approx.260mm/sec.(ModelswithaDP1600/2500)
Approx.400mm/sec.(ModelswithaDP4500/3500)
Capacity of cassette Stackheight:60.5mm(approx. 550 sheets)
Dimensions 530 (W) × 536 (D) × 305 (H) mm
Weight Approx. 17 kg (one cassette)
Powersupply 5V,24V (supplied from the copier)

October 2000 © TOSHIBA TEC 2 - 1 KD-1009 OVERVIEW
2. OVERVIEW
2.1 Front SectionalView
NO. NAME NO. NAME
12
3
4
56
7
8
9
10
11
12
13
14
20
22
16 17
27
261823192524 28
21
15
1 Uppercassette tray-up sensor (S4)
2 Uppercassette paper empty sensor(S6)
3 Upperfeedsensor(S2)
4 Uppertransportroller
5 Upper cassette feed clutch (C2)
6 Uppercassettefeed roller
7 Uppercassetteseparationroller
8 Uppercassette
9 Lowercassette
10 Upper cassette tray-upmotor (M2)
11 Lower feed sensor (S3)
12 Upper cassette elevator coupling
13 Lowertransportroller
14 Transportclutch (C1)
15 Upper cassette pickuproller
16 Upper cassette tray
17 Upper cassette elevator
18 Lower cassette tray-up sensor(S5)
19 Lower cassette paperempty sensor (S7)
20 Lower cassette feed clutch (C3)
21 Lower cassette feed roller
22 Lower cassette separation roller
23 Lower cassette pickuproller
24 Lower cassette tray
25 Lower cassette tray-upmotor (M3)
26 Lower cassette elevator
27 Lower cassette elevatorcoupling
28 Adjuster

KD-1009 OVERVIEW 2 - 2 October 2000 © TOSHIBA TEC
2.2 Layout of Electrical Parts
15
18
13
14
10
12
17
1
9
4
68
11 16
2
*
5
7
3
*
NO. NAME NO. NAME
1 Side cover open/close switch (S1)
2 Upper cassette detection switch (S8)
3 Lower cassette detection switch (S9)
4 Upperfeedsensor(S2)
5 Lowerfeedsensor(S3)
6 Uppercassette tray-up sensor (S4)
7 Lowercassette tray-up sensor (S5)
8 Uppercassette paper empty sensor(S6)
9 Lowercassette paper empty sensor(S7)
10 Transportclutch (C1)
11 Upper cassette feed clutch (C2)
12 Lower cassette feed clutch (C3)
13 Upper cassette tray-upmotor (M2)
14 Lower cassette tray-upmotor (M3)
15 PFP motor (M1)
*16 Upper cassette paper stock sensor (S10)
*17 Lower cassette paper stock sensor (S11)
18 PC board (PWA)
*for the DP4500/3500 only
Rearside
Frontside

October 2000 © TOSHIBA TEC 2 - 3 KD-1009 OVERVIEW
2.3 Electrical Parts
(1)Motor
(2)Electromagnetic clutch
(3)Switches and Sensors
SYMBOL NAME FUNCTION REMARKS
(M1) PFP-MTR Drivesfeedingand trans- Brushless motor
PFP motor portation
(M2) T-UP-U-MTR Lifts up the upper cassette tray Brush motor
Uppercassette tray-up motor
(M3) T-UP-L-MTR Lifts up the lower cassette tray Brushmotor
Lowercassette tray-up motor
SYMBOL NAME FUNCTION REMARKS
(C1) TR-CLT Drives transportation
Transport clutch
(C2) FED-U-CLT Drives roller to pick up paper
Upper cassette feed clutch from the upper cassette
(C3) FED-L-CLT Drives roller to pick up paper
Lower cassette feed clutch from the lower cassette
SYMBOL NAME FUNCTION REMARKS
(S1) SIDE-COV-SW Sidecover open/close Push switch
Side cover open/close switch detection
(S2) FED-U-SNR Detectspaper from the upper Photo interrupter
Upperfeedsensor cassette
(S3) FED-L-SNR Detectspaper from the lower Photointerrupter
Lowerfeedsensor cassette
(S4) TOP-U-SNR Detects if the upper cassette Photointerrupter
Uppercassettetray-up sensor has been raised
(S5) TOP-L-SNR Detects if the lower cassette Photointerrupter
Lowercassettetray-up sensor has been raised
(S6) EMP-U-SNR Detects lack of paper in the Photointerrupter
Uppercassette paper empty sensor upper cassette
(S7) EMP-L-SNR Detects lack of paper in the Photointerrupter
Lowercassette paper empty sensor lowercassette
(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

KD-1009 OVERVIEW 2 - 4 October 2000 © TOSHIBA TEC
(4)PCboard
SYMBOL SPEC. NAME FUNCTION REMARKS
PWA PWA-F-PFP-519 Drives feeding and moves trays
PCboard
*for the DP4500/3500 only
SYMBOL SPEC. NAME FUNCTION REMARKS
*(S10) PST-U-SNR Detects that the paper stock is Photointerrupter
Upper cassette paper stock sensor going short of the upper cassette
*(S11) PST-L-SNR Detects that the paper stock is Photointerrupter
Lower cassette paper stock sensor going short of the lower cassette

October 2000 © TOSHIBA TEC 2 - 5 KD-1009 OVERVIEW
2.4 Harness Diagram
PFP
PFC
PFP
PC board
Copier
(PREMAGE165/255)
CN508
TR-CLT
CN507
T-UP-U-MTR
CN511
FED-U-SNR
CN510 CN520 CN520
CN241
CN242
CN500
CN501
CN500
CN501
Copier
(PREMAGE455/355)
CN567
CN568
CN567
CN568
CN502
CN503
FED-L-SNR
CN318
FED-U-CLT CN316 CN516
ADPT
ADPT
CN314
TOP-U-SNR
CN315
EMP-U-SNR
CN314
TOP-L-SNR
CN318
FED-L-CLT
CN315 CN316 CN517
EMP-L-SNR
CN335
CST-U-SW
CN336
CST-L-SW
CN509
CN243CN247
CN248 CN244
CN246
SIDE-COV-SW
CN505
M
T-UP-L-MTR
PFP-MTR
Copier
(DP1600/2500)
Copier
(DP4500/3500)

KD-1009 OVERVIEW 2 - 6 October 2000 © TOSHIBA TEC
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
LCFCNT
CLK-C
PFPCNT
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
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
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
CN206
CN206
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
CN500
CN500
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
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
CN241
CN241
+24V
+24V
DG
DG
+24V
+24V
DG
DG
PFP
PC board
Copier (PREMAGE 165/255)
1
2
3
4
1
2
3
4
CN207
CN207
1
2
3
4
1
2
3
4
CN501
CN501
1
2
3
4
1
2
3
4
CN242
+24V
+24V
GND
GND
Copier(DP1600/2500)

October 2000 © TOSHIBA TEC 2 - 7 KD-1009 OVERVIEW
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
LCCNT
CLK-C
PFPCNT
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
A1
A2
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
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
B16 B16
CN312
CN312
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
CN567
CN567
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
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
CN241
CN241
+24V
+24V
DG
DG
+24V
+24V
DG
DG
PFP
PC board
Copier (PREMAGE 455/355)
1
2
3
4
1
2
3
4
CN568
CN568
1
2
3
4
1
2
3
4
CN242
+24V
+24V
GND
GND
Copier(DP4500/3500)

KD-1009 OVERVIEW 2 - 8 October 2000 © TOSHIBA TEC
GND
FEDU
VDD
GND
FEDL
VDD
GND
COV-SW
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
CN243
CN243
TRMU-B
TRMU-A
TRMU-B
TRMU-A
+24V
FEDCLT
+24V
FEDCLT35
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
CN244
CN244
DG
DG
+24
+24
VDD
DIR
PLLOK
MOT-BRK
MOT-OFF
GND
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
99
10 10
11 11
CN246
4
3
2
1
7
6
5
4
3
2
1
CN502 CN503
CN246
GND
SIZCUO
VDD
PHU1
GND
+24V
PCLTU
VDD
TUPU
GND
VDD
PEMPU
GND
14
13
12
11
10
9
8
7
6
5
4
3
2
1
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CN247
CN247
(6)
1
2
3
4
5
1
2
3
4
5
6
(7)
(1)
6
5
4
3
2
7
6
5
4
3
2
(1)
CN516B
CN316B
CN516A
CN316A
CN520
CN520
3
CN511
2 FED-U-SNR
13
CN510
2 FED-L-SNR
12
CN509
1SIDE-COV-SW
1
CN505
2T-UP-L-MTR
1
CN507
2T-UP-U-MTR
1
CN508
2TR-CLT
1
CN335
2CST-U-SW
1
CN344
2
3
1
CN315
2
*PST-U-SNR
*PST-L-SNR
3
1
CN314
2 TOP-U-SNR
3
1
CN318
2FED-U-CLT
VCC
PHU1
GND
+24V
PCLTU
VCC
LPSON
GND
VCC
PESON
GND
GND
SIZCUO
VDD
PUL1
GND
+24V
PCLTU
VDD
TUPU
GND
VDD
PEMPU
GND
13
12
11
10
9
8
7
6
5
4
3
2
1
13
12
11
10
9
8
7
6
5
4
3
2
1
CN248
CN248
(6)
1
2
3
4
5
1
2
3
4
5
6
(7)
(1)
6
5
4
3
2
7
6
5
4
3
2
(1)
CN517B
CN316B
CN517A
CN316A
1
CN336
2CST-L-SW
1
CN344
2
3
1
CN315
2 EMP-L-SNR
3
1
CN314
2 TOP-L-SNR
3
1
CN318
2FED-L-CLT
VCC
PHU1
GND
+24V
PCLTU
VCC
LPSON
GND
VCC
PESON
GND
PFP-MTR
PFP PC Board
GND
FEDU
VDD
GND
FEDL
VDD
GND
COV-SW
GND
CST
GND
CST
*for the DP4500/3500 only

October 2000 © TOSHIBA TEC 2 - 9 KD-1009 OVERVIEW
2.5 Circuit Diagram

KD-1009 OVERVIEW 2 - 10 October 2000 © TOSHIBA TEC

October 2000 © TOSHIBA TEC 2 - 11 KD-1009 OVERVIEW

KD-1009 OVERVIEW 2 - 12 October 2000 © TOSHIBA TEC
2.6 Assembly of PC Board
CN243 CN242 CN241
CN244
CN246
CN247 CN248
CN249 CN250
18
711
118
11
14
A1
B15
C1
47/50
IC2
M3
C2
5161
A1
B1
100/25
HC244FL
IC5
HC244FL
IC8
1114
IC7
IC4
8428KS
MC74HC273AFL
MC74HC273AFL
IC6
62308FT
13
M3
HC244FL
PD
RV
C3
10/50
C4
10/50
R1
M3
IC1
8428KS
IC3
10K

October 2000 © TOSHIBA TEC 2 - 13 KD-1009 OVERVIEW
2.7 Timing Chart
(1) DP1600 (A4 sized sheet fed from the upper cassette)
MAIN-MTR
PFP-MTR
FED-U-CLT
TR-CLT FED-U-SNR
PFU-FED-CLT
PFU-FED-SNR
RGST-SNR
RGST-CLT
EXIT-SNR
CW
CCW
CW
CCW
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF

KD-1009 OVERVIEW 2 - 14 October 2000 © TOSHIBA TEC
(2) DP2500 (A4 sized sheet fed from the upper cassette)
MAIN-MTR
PFP-MTR
FED-U-CLT
TR-CLT FED-U-SNR
PFU-FED-CLT
PFU-FED-SNR
RGST-SNR
RGST-CLT
EXIT-SNR
CW
CCW
CW
CCW
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF

October 2000 © TOSHIBA TEC 2 - 15 KD-1009 OVERVIEW
(3) DP4500/3500 (A4 sized sheet fed from the upper cassette)
MAIN-MTR
PFP-MTR
FED-U-CLT
TR-CLT FED-U-SNR
PFU-FED-CLT
PFU-FED-SNR
RGST-SNR
RGST-CLT
EXIT-SNR
CW
CCW
CW
CCW
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF