PANASONIC DP-CL18 Service Manual

DP-CL18

ORDER No.KM60503633CE

Color Laser Printer

DP-CL18

CONTENTS

Page Page

1 Introduction 5

1.1. Specifications

1.2. Options, Accessories and Supplies

1.3. Printer Panel

1.4. External View

1.5. Main Components Layout

1.6. PCB, Switches and Sensors Identification

2 About Lead Free Solder

2.1. Suggested PbF Solder

2.2. How to recognize that PbF Free solder is used

3 Installation, Setup, and Repacking

3.1. Installation Requirements

3.2. Setup

3.3. Repacking

4 User Mode Operation

4.1. User Mode Printer Panel Operation

4.2. User Mode Main Menu

4.3. Check then Print Selection 1 Menu

4.4. Memory Print Item Menu

4.5. Confidential Print Selection 1 Menu

4.6. System Information Item Menu

4.7. Color Calibration Item Menu

4.8. Maintenance Item Menu

4.9. Tray Item Menu

4.10. Print Item Menu

4.11. PCL Item Menu

4.12. PostScript Item Menu

4.13. N/W Protocol Setup Item Menu

4.14. Receive Setting Item Menu

4.15. Adjust to Media Item Menu

4.16. System Item Menu

4.17. Mono Page Detect Item Menu

5 HDD Maintenance Mode Operation

5.1. HDD Maintenance Mode Operation

5.2. HDD Maintenance Mode Menu Table

5.3. HDD Maintenance Mode Main Menu

5.4. HDD Information Item Menu

5.5. Check Disk Item Menu

5.6. Quick Format Item Menu

5.7. HDD Format Item Menu

5.8. HDD Deletion Item Menu

6 Service Mode Operation

6.1. Service Mode Control Panel Operation

6.2. Service Mode Menu Table

6.3. Service Main Menu

6.4. Print Report Item Menu

6.5. Position Setting Item Menu

6.6. STR Setting Item Menu

6.7. DEV. Bias Item Menu

6.8. FSR Temp. Setting Item Menu

6.9. Maintenance Item Menu

10 11 13

15 16

21 22 24

30 32 33 34 35 36 37 38 39 41 42 43 44 46 47 48 48

49 50 51 52 53 54 55 55

56 57 65 66 75 76 77 78 79

6.10. ENG Serial Number Item Menu 5 7 8

6.11. Controller Setting Item Menu

6.12. Panel Test Item Menu

6.13. Engine Test Item Menu

6.14. Color Correction Item Menu

6.15. Flag Setting Item Menu

6.16. Printing Network Configuration Report

7 Mechanical Function

7.1. Drive Mechanism General Description

7.2. Accumulator Tension Unit (ATU) Drive Mechanism

7.3. Print Process

8 Removal and Replacement Procedures

8.1. Fuser Unit

8.2. Accumulator Unit (Acc. Unit)

8.3. Front Door Cover and STR (Second Transfer Roller) Bias

Assembly

8.4. Right Cover

8.5. Rear, Left and Top Covers

8.6. Color Registration Sensor

8.7. Engine Control Board, Toner Cartridge Holder, Cartridge

Drive Unit, Paper Pickup Motor, Main Drive Unit, Bias Unit, Fan Motor and Fan Motor Duct

8.8. LSU (Laser Scanning Unit)

8.9. Paper Exit

8.10. IH (Inductive Heater) Unit

8.11. Paper Feed Unit

8.12. Power Supply Unit (Power Supply Board and IH Power

Board)

8.13. Main Control Board

8.14. High Voltage Board and Reg. Thermistor Sensor

8.15. Accumulator Tension Unit

8.16. Print Cartridge Unit Holder

8.17. Fuser Fan Motor

8.18. Front Door Open Detection and Right Cover Open

Detection Switches

8.19. MPT (Multipurpose Print Tray) Home Position Sensor and

MPT Paper Detection Sensor Boards

8.20. Waste Toner Cartridge Full Sensor

8.21. Standard Paper Cassette

9 Block and Connection Diagrams

9.1. Block Diagram

9.2. Connection Diagram

10 Electrical Circuit General Description

10.1. General Description

10.2. Explanation of Connector

11 Adjustment

11.1. Print Position Calibration

11.2. Color Density Adjustment

11.3. Skew Adjustment

12 Preventative Maintenance

12.1. General

80 81 82 83 93 93 94

95 98

108

116

116 117

117 119 119 122

123 133 133 137 140

144 146 147 148 152 153

153

154 154 155

161

161 163

165

165 169

198

198 199 207

210

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12.2. Recommended Tools 210

12.3. Recommend Cleaning

12.4. Maintenance Tables

13 Tr oubleshooting

13.1. Initial Troubleshooting Flowchart

13.2. Warning/Error Message

13.3. Jam and HDD Error

13.4. Print Quality

13.5. Printer Error (Call Service)

13.6. No Message

13.7. No Printing

14 Replacemen t Parts List with Lubrication Guide

210 211

212

212 213 228 240 256 283 284

287

14.1. Covers

14.2. Left Side Parts

14.3. Right Side Parts

14.4. Front and Top Side Parts

14.5. Rear Side Parts (Power Supply, Main Control and High Voltage Boards)

14.6. Cassette

14.7. Packing Material

14.8. Toner Cartridge Dummy Case

14.9. Print Cartridge Dummy Case

14.10. PbF Solder Service Part Number

287 290 297 301

307 310 313 313 313 314

1 Introduction

1.1. Specifications

DP-CL18

1.2. Options, Accessories and Supplies

Model No. Description Remarks DQ-UR3K Black Toner Cartridge 6K Average Life (6,000 pages *1) DQ-UR3C Cyan Toner Cartridge 6K Average Life (6,000 pages *1) DQ-UR3M Magenta Toner Cartridge 6K Average Life (6,000 pages *1) DQ-UR3Y Yellow Toner Cartridge 6K Average Life (6,000 pages *1) DQ-UR4C Cyan Toner Cartridge 3K Average Life (3,000 pages *1) DQ-UR4M Magenta Toner Cartridge 3K Average Life (3,000 pages *1) DQ-UR4Y Yellow Toner Cartridge 3K Average Life (3,000 pages *1) DQ-UP3K Black Print Cartridge Average Life (15,000 pages *1) DQ-UP3C Color Print Cartridge Average Life (15,000 pages *1) DQ-FU3 Fuser Unit Average Life (100,000 pages *1) DQ-BF3 Waste Toner Cartridge Average Life (14,000 pages *1) DQ-BE3 Accumulator Unit Average Life (100,000 pages *1) DQ-BR3 Transfer Roller Average Life (100,000 pages *1) DA-DS1 Optional Paper Feeder KX-CLAD1 Automatic Duplex Unit KX-CLEM3 128MB DIMM KX-CLEM4 256MB DIMM KX-CLHD2 Hard Disk Drive DA-MC2 Upgrade Kit for DP-CL18 (PS3)

DP-CL18

The rated life expectancy of each consumable is based on printing under specific operating conditions such as page coverage for a particular page size (5% coverage per color at 600 x 600 dpi resolution on A4 size paper). The actual consumable life will vary depending on its use and other printing variables including page coverage, page size, media type, print resolution, continues or intermittent printing, number of color planes, ambient temperature and humidity.

DP-CL18

1.3. Printer Panel

1.3.1. Panel Operation

1.3.2. LED Indicator

Three indicators show the following printer’s status:

Indicator Printer Status

DP-CL18

Blink

Off

Power

On Line

Ready Error

Printer is turned on.

Printer is in the Power Save mode.

Printer is turned off.

Printer is ready for printing. (Printer warms up and starts printing automatically when it receives print data.)

Printer is in the Off Line.

Printer is in the normal condition. Printer is not in error conditions.

Printer is receiving data, printing or data remains in the memory. Printer is in the Menu mode.

Ready Error

Printer recoverable errors (media jam, media empty, etc.) has occurred.

An internal error (Call for Service Error) has occured.

DP-CL18

1.4. External View

1.5. Main Components Layout

DP-CL18

1.6. PCB, Switches and Sensors Identification

DP-CL18

Sensor/Switch/Board Name Description Paper Size Detection For detecting the current selected paper size at the standard paper cassette. Toner Empty Sensor Board For detecting whether the toner is low (or empty) or not. Temp./Humidity Sensor Board For sensing the ambient temperature and humidity. Paper Full Sensor Board This board has the paper full sensor. The paper full sensor is fo r detecting whether the output

Toner Cartridge Access Cover Detection Switch

ADU Jam Detection Sensor Board For detecting whether the paper is ejected from the ADU (Option Automatic Duplex Unit) within

ADU Detection Sensor Switch For detecting whether the ADU is installed. MPT Paper Detection Sensor Board For detecting whether the paper is set on the MPT (multi-purpose paper tray). MPT Home Position Sensor Board For detecting the home position of the MPT pickup roller. Paper Empty/Registration Sensor Board This board has the paper empty and registration sensors. The paper empty sensor is for

OPC Cam Home Position Sensor Board For detecting the home position of the OPC drum. Acc. Cam Home Position Sensor Board For detecting the home position of the accumulator cam and controlling the printing process. Front/Right Door Open Detection Switch For detecting whether the front door or right cover is opened.

paper tray is full. For detecting whether the toner cartridge access cover is closed. If the toner cartridge access

cover is opened, printing is not possible.

the proper time.

detecting whether the paper is set on the standard paper cassette. The registration sensor is for detecting whether the sheet of paper arrived at the registration roller after being properly picked and traveling through the paper feed rollers.

DP-CL18

Sensor/Switch/Board Name Description

LSU Safety Interlock Switch When the front door or right cover is opened (or both are opened), the power that is supplied to

the laser diode drive circuit in the laser unit is shut off because this switch is opened

Front/Right Door Interlock Switch When the front door or right cover is opened (or both are opened), the printing is not done

because this switch is opened. Waste Toner Cartridge Full Sensor Board For detecting whether the waste toner cartridge is full. Color Registration Sensor Board For reading the Color Registration Check Pattern to calculate adjustment for the fine Color

Registration Adjustment.

2 About Lead Free Solder

DP-CL18

2.1. Suggested PbF Solder

We recommend you to use the following solder when re-soldering component for repair. Before using other Pb free solder than the following solder, be sure to confirm a solder maker you appoint has made license agreements to be required when using Pb free solder legally.

Supplier: Senju Metal Industry Co., Ltd. (http://www.senju-m.co.jp) Part Description in Senju: ECO SOLDER RMA02 P3 M705 Series

Note:

When the recommended PbF solder is not available at Senju Metal Industry Co., Ltd., see section 14.10 PbF Solder Service Part Number.

DP-CL18

2.2. How to recognize that PbF Free solder is used

2.2.1. Main Control Board

(Top View)

Marked PbF

2.2.2. ROM Board

(Top View)

Marked PbF

2.2.3. Engine Control Board

Marked PbF

DP-CL18

2.2.4. Paper Empty/Registration Sensor Board

Marked PbF

DP-CL18

2.2.5. Multi-purpose (MPT) Paper Detection Sensor Board

2.2.6. ADU Jam Detection Sensor Board

Marked PbF

2.2.7. Paper Full Sensor Board

Marked PbF

2.2.8. OPC Cam Home Sensor Board

Marked PbF

2.2.9. Accumulator Cam Home Position Sensor Board

2.2.10. Waste Toner Full Detection Board

Marked PbF

2.2.11. Toner Empty Sensor Board

Marked PbF

2.2.12. Multi-purpose (MPT) Home Position Sensor Board

DP-CL18

2.2.13. Color Registration Sensor Board

2.2.14. Exit FG Board

Marked PbF

DP-CL18

2.2.15. LCD Board

Marked PbF

3 Installation, Setup, and Repacking

3.1. Installation Requirements

3.1.1. Environment

1. Temperature Range :10 °C - 32.5 °C(50°F - 90.5 °F) (Temperature fluctuation ± 10 °C per hour or less)

2. Humidity Range :20% RH - 80% RH (Humidity fluctuation ± 20 °C per hour or less)

3. Weight : Gross; Approx. 33 kg (72.77 lbs.), Net; Approx. 30 kg (66.15 lbs) excluding packing material

4. Place the unit on a stable, level surface.

5. Do not install the unit under the following conditions. a. Extremely high or low temperature b. Extremely high or low humidity c. Direct exposure to sunlight d. Areas of high dust concentration e. Areas of poor ventilation f. Areas exposed to chemical fumes g. Areas with extreme vibration h. Directly in air conditioning flow

DP-CL18

3.1.2. Minimum Space Requirements

1. Right : 33 cm (13")

2. Left : 11 cm (4.3")

3. Rear : 15 cm (5.9")

Note:

When you install a consumable component or replace it with a new one, additional space may be required.

DP-CL18

3.2. Setup

3.2.1. Removing the Packing Material

1. Remove the plastic bag from the printer.

2. Remove any adhesive tape.

Note:

Please do not throw away the packing materials. They may be required to ship or transport the printer. To provide optimum print quality, the unit must be kept upright and level at all times.

3.2.2. Installing the Toner Cartridge

1.Open the toner cartridge access cover ( toner door) and remove the sealing tapes.

2.Open the plastic bags and take out the toner cartridges. Shake the toner cartridges several times.

3.Insert the toner cartridges in the appropriately labeled slots. From right to left, the order of the color toner cartridges is Black (1), Cyan (2), Magenta (3), Yellow (4).

(4) (3) (2) (1)

4.Close the toner cartridge access cover ( toner door).

3.2.3. Installing the Print Cartridge

1.Open the right cover (right side door).

2.Unlock and open the print cartridge holder.

Note: To prevent damage to the print cartridge,

• Do not touch the green drum surface.

• Do not expose to light for more than 45 sec.

• Do not expose to direct sunlight.

4.Remove the seal covers.

5.Holding the color print cartridge with the protective tray, match the arrow marks ( ) then insert the color print cartridge half way into the printer.

6.Firmly push the color print cartridge until it snaps into place.

• Store the protective tray, seal covers, packing materials and cartons for repacking in future.

10.Close the right side cover (door).

3.Open the plastic bags and take out the print cartridges.

Black print cartridge

Color print cartridge

Green drum

Protective tray

( )

7.Repeat steps 4 - 6 for the black print cartridge.

( )

Protective tray

9.Close the print cartridge holder until it clicks (1) and locks it (2).

8.Install the waste toner cartridge (1) and slide the green lever (2).

DP-CL18

3.3. Repacking

Prepare the unit before shipping.

Note:

It is highly recommended that users keep the original carton and All packing materials. Please follow these instructions when moving the printer.

· Please use the original carton and all of the original packing material.

· Improper repacking of the printer may result in a charge to repair the unit or a cleaning charge to remove spilled toner.

· Since the printer uses dry toner, extreme care must be taken when handling. The printer should be handled in the upright

(vertical) position.

· Original carton and packing materials

· Newspaper or drop cloth

· Shipping tape and scissors

DP-CL18

Turn off the printer, remove the power code and all interface cables.

Open the right cover (right side door).

Slide the green lever for the waste toner cartridge to the right (RELEASE).

Unlock the two levers (1) and open the print cartridge holder (2).

Pull out the color print cartridge halfway and remove it (2) while pressing the green stopper (1) on the left side.

Remove the waste toner cartridge.

Be sure the green lever is in the RELEASE position so that upper openings to waste toner cartridge are completely closed.

Insert the waste toner cartridge into a plastic bag and seal the end of the bag tightly.

Note:

To prevent damage to the print cartridge;

- Do not touch the green drum surface.

- Do not expose to light for more than 45 minutes.

- Do not expose to direct sunlight.

DP-CL18

Close the PC shutter and wipe off any loose toner on the color print cartridge using a toner vacuum. Do not use a standard office vacuum; the toner will not be retained by typical vacuum dust collectors.

Caution 1:

If replacing the upper seal cover though the toner is on the color print cartridge, the toner will be scattered when removing the upper seal cover. The scattered toner may be attached to the OPC drum and the poor print quality will be caused.

Caution 2:

If the print cartridge is wiped using a toner vacuum when the PC shutter is opening, the toner in the print cartridge is sucked and charged. This charge is discharged to the OPC drum and the OPC drum may be damaged. Wipe off the toner on the print cartridge using care that the PC shutter is not opened.

Move the PC shutter in this arrow direction to close the PC shutter.

Replace the protective tray (1), upper seal covers (2-4)

and protective caps (5).

Be sure the three sealing levers of the print cartridge are exposed through the lower seal cover.

PC Shutter

Lever

Insert the color print car tridge into the black plastic bag and seal the end of the bag tightly with adhesive tape.

Lower Seal Cover

Pull out the black print cartridge.

Note:

To prevent damage to the print cartridge;

- Do not touch the green drum surface.

- Do not expose to light for more than 45 minutes.

- Do not expose to direct sunlight.

Close the PC shutter and wipe off any loose toner on the black print cartridge using a toner vacuum. Do not use a standard office vacuum; the toner will not be retained by typical vacuum dust collectors.

Caution 1:

If replacing the upper seal cover though the

Caution 2:

toner is on the black print cartridge, the toner will be scattered when removing the upper seal cover. The scattered toner may be attached to the OPC drum and the poor print quality will be caused.

PC Shutter

Move the PC shutter in this arrow direction to close the PC shutter.

DP-CL18

Replace the protective tray (1), upper seal cover (2) and protective cap (3).

Be sure the sealing lever of the print cartridge is exposed through the lower seal cover .

Lever

Lower Seal Cover

Insert the black print cartridge into the black plastic bag and seal the end of the bag tightly with adhesive tape.

Remove the media from the multi-purpose tray. Push the multi-purpose tray (1) and close the tray cover (2).

Pull the media tray (1) out of the printer. Remove the media (2) from the media tray and install the tray pad (3) into the media tray.

Close the print cartridge holder [(1)-(2)] and lock it. Close the right cover (3) (right side door).

Note:

Be sure the accumulator unit is kept in the printer.

Accumulator unit

Install the media tray into the printer.

Close (1) and insert (2) the paper support into the printer.

Confirm all toner cartr idges are completely installed in the printer.

DP-CL18

If the hard disk drive option has been installed in the printer, confirm the hard disk drive is fastened with two screws provided. If it is not installed, proceed to step 26.

Remove the two thumb screws from the main control board.

Pull out the main control board while holding the green handle.

Install the main control board back into the

printer, as shown.

Tighten the two thumb screws.25

Reconfirm the hard disk drive is fastened with two screws. If it is not fastened, fasten it with two screws.

Repack the printer in the original shipping box.

Make sure that you keep the printer upright and level when moving.

SAFETY CAUTION

The printer weighs about 30 K (66 lbs.). It must be handled by two people.

Place the printer in the plastic bag on the lower cushion and wrap the printer with the plastic bag.(1)

(2)

Place the middle on the lower cushion, upper cushion on the printer and middle cushion. Place the waste toner cartridge, black print cartridge and color print car tridge and accessory box on the

(3)

upper cushion.

Color print cartridge

Black print cartridge

DP-CL18

Waste toner cartridge

Accessory Box

Place the top carton and install the 4 joints.(4)

DP-CL18

4 User Mode Operation

4.1. User Mode Printer Panel Operation

4.1.1. Panel Operation

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