Panasonic WORKIO DP-150 User manual

Service Manual Section
DP-150
Parts Manual Section
DP-150
© 2000 Matsushita Graphic Communication Systems, Inc.
All rights reserved. Unauthori ed copying and
distribution is a violation of law.
Service Manual
Digital Copier
DP-150

Table of Contents
General
Description
MechanismMaintenance
PCB Connector and Signal Information
Troubleshooting
Installation
WARNING
Section I General Description
1.1 Specifications ................................................................................ 1-1
1.2 Features......................................................................................... 1-3
1.3 New Functions ............................................................................... 1-3
1.4 Systems ......................................................................................... 1-4
1.5 Control Panel................................................................................. 1-5
1.6 Component Location ..................................................................... 1-6
1. Outer View................................................................................. 1-6
2. Inner View.................................................................................. 1-6
3. Fan/ Motor Location................................................................... 1-7
4. Sensor Location......................................................................... 1-7
5. Solenoid/Switch Location .......................................................... 1-8
6. PCB Location............................................................................. 1-8
1.7 Copy Process ................................................................................ 1-9
1.8 Precautions for Consumables ..................................................... 1-10
Section II Mechanism
2.1 Main Drive...................................................................................... 2-1
2.2 Operations ..................................................................................... 2-2
1. Sheet Bypass ............................................................................ 2-2
2. Paper Feed Unit ........................................................................ 2-4
3. Toner Cartridge ......................................................................... 2-6
4. Fuser Unit .................................................................................. 2-9
5. Optics Unit ............................................................................... 2-12
6. Laser Unit ................................................................................ 2-15
DP-150

Section III Maintenance
3.1 Precautions for Preventive Maintenance Service .......................... 3-1
3.2 Maintenance Chart ........................................................................ 3-3
3.3 Cleaning Method ........................................................................... 3-4
3.4 Disassembly and Re-assembly ..................................................... 3-7
1. Sheet Bypass ............................................................................ 3-8
2. Developer Unit/Drum unit ........................................................ 3-13
3. Fuser Unit ................................................................................ 3-18
4. Optics Unit ............................................................................... 3-21
5. Main Body................................................................................ 3-27
3.5 Adjustment................................................................................... 3-28
1. Exposure Adjustment .............................................................. 3-29
2. Skew/Side position Adjustment (Printer unit) .......................... 3-30
3. Skew/Lead edge position Adjustment (Scanner unit).............. 3-31
4. Void Registration Adjustment .................................................. 3-31
3.6 Updating the Firmware ................................................................ 3-32
Section IV PCB Connector and Signal Information
4.1 Glossary of Electrical Abbreviations .............................................. 4-1
4.2 Main CPU PCB .............................................................................. 4-3
4.3 LVPS PCB ................................................................................... 4-13
Section V Troubleshooting
5.1 Service Mode................................................................................. 5-1
1. Service Mode Functions ............................................................ 5-1
2. F4 Mode : Input/Output Check .................................................. 5-3
3. F5 Mode : Copier Function Programming ................................. 5-5
4. F6 Mode : Adjustment and Programming .................................. 5-6
5. F7 Mode : Electronic Counter .................................................... 5-8
6. F8 Mode : Copier Operating Adjustment ................................... 5-9
7. F9 Mode : Service Mode ......................................................... 5-10
5.2 Self-diagnostics/Machine Malfunctions ....................................... 5-11
1. User Error :U code................................................................... 5-11
2. Paper Jam : J code.................................................................. 5-12
3. Machine Error : E code ............................................................ 5-13
Schematic Diagram

WARNING
This service information is designed for experienced repair technicians only and
is not designed for use by the general public.
It does not contain warnings or cautions to advise non-technical individuals of
potential dangers in attempting to service a product.
Products powered by electricity should be serviced or repaired only by experienced
professional technicians. Any attempt to service or repair the product or products
dealt with in this service information by anyone else could result serious injury or
death.
For U.S.A
This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference when the equipment
is operated in a commercial environment. This equipment generates, uses, and
can radiate radio frequency energy and, if not installed and used in accordance
with the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment on a residential area is likely to
cause harmful interference in which case the user will be required to correct the
interference at his/her own expense.
Any unauthorized changes or modifications to this equipment would void the users
authority to operate this device.
For U.S.A
This manual was developed and is supplied to authorized servicing dealers by
Panasonic Document Imaging Co. for the sole purpose of providing information
necessary for the equipment’s proper support. It is intended that this information
be confidential and may not reproduced without prior written consent from
Panasonic Document imaging Co. Panasonic Document imaging Co. reserves
the right to change any information enclosed herein without prior notification.
This manual was developed and is supplied to authorized servicing dealers by
Panasonic Co. for the sole purpose of providing information necessary for the
equipment’s proper support. It is intended that this information be confidential
and may not be reproduced without prior written consent from Panasonic Co.
Panasonic Co. reserves the right to change any information enclosed herein without
prior notification.

For U.S.A
For your safety
Caution
This product utili es a laser.
Use of controls or adjustments or performance of procedures other than
those specified herein may result in ha ardous radiation exposure.
Product complies with DHHS Rules 21
CFR Subchapter J in effect of date
of manufacture.
Utsunomiya, Tochigi, Japan
Product complies with DHHS Rules 21
CFR Subchapter J in effect of date
of manufacture.
Taytay, Ri al, Philippines
FFPTE2479
DANGER-Invisible laser
radiation when open and
interlock defeated.
AVOID DIRECT EXPOSURE
TO BEAM.
Label when manufactured in Japan.
Label when manufactured in Philippines.

For your safety
Caution
This product utili es a laser.
Use of controls or adjustments or performance of procedures other than
those specified herein may result in ha ardous radiation exposure.
CAUTIO
Invisible laser radiation when
open and interlocks defeated.
AVOID EXPOSURE TO BEAM.
VORSICHT:
Unsichtbare Laserstrahlung, wenn
Abdeckung geoffnet und
Sicherheitsverriegelung uberbruckt.
NICHT DEM STRAHL AUSSETZEN.
PELIGRO:
Cuando se abre y se invalida el bloqueo, se
producen radiaciones invisibles de laser.
EVITESE LA EXPOSICION
DIRECTA A TALES RAYOS.
FFPTE2584
ATTE TIO :
Rayonnement laser invisible
dangereux en cas d'ouverture et
lorsque la securite est neutralisee.
EXPOSITION DANGEREUSE AU FAISCEAU.

For Sweden, and Denmark
VARNING!
Explosionsfara vid felaktigt batteribyte.
Använd samma batterityp eller ekvivalent typ som rekommenderas av
apparattillverkaren. Kassera använt batteri enligt fabrikantens instruktion.
ADVARSEL!
Lithiumbatteri—Eksplosionsfare ved
fejlagtig håndtering.
Udskiftning må kun ske med batteri
af samme fabrikat og type.
Lever det brugte batteri tilbage til
leverrandoren.
CAUTION!
Danger of explosion if battery is incorrectly replaced. Replace only with the
same or equivalent recommended by the manufacturer. Dispose of used
batteries according to the manufacturer’s instructions.
For Holland
Batterij niet
weggooien, maar
inleveren als KCA.
NL
Caution: Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer.
Dispose of used batteries according to the manufacturer’s instructions.

For U.K.
FOR YOUR SAFETY PLEASE READ THE FOLLOWING TEXT CAREFULLY.
This appliance is supplied with a moulded three pin mains plug for your safety and
convenience. A 13 amp fuse is fitted in this plug.
Should the fuse need to be replaced please ensure that the replacement fuse has a rating
of 13 amps and that it is approved by ASTA or BSI to BS1362.
Check for the ASTA mark or the BSI mark on the body of the fuse.
If the plug contains a removable fuse cover you must ensure that it is refitted when the fuse
is replaced.
If you lose the fuse cover the plug must not be used until a replacement cover is obtained.
A replacement fuse cover can be purchased from your local Panasonic Dealer.
IF THE FITTED MOULDED PLUG IS UNSUITABLE FOR THE SOCKET OUTLET IN YOUR
OFFICE THEN THE FUSE SHOULD BE REMOVED AND THE PLUG CUT OFF AND
DISPOSED OF SAFELY.
THERE IS A DANGER OF SEVERE ELECTRICAL SHOCK IF THE CUT OFF PLUG IS
INSERTED INTO ANY 13 AMP SOCKET.
If a new plug is to be fitted please observe the wiring code as shown below.
If in any doubt please consult a qualified electrician.
WARNING: THIS APPLIANCE MUST BE EARTHED.
IMPORTANT: The wires in this mains lead are coloured in accordance with the following
code:
Green and Yellow :Earth
Blue :Neutral
Brown :Live
As the colours of the wires in the main lead of this appliance may not correspond with the
coloured markings identifying the terminals in your plug, proceed as follows:
The wire which is coloured GREEN-AND-YELLOW must be connected to the terminal in the
plug which is marked by letter E or by the safety EARTH symbol “ ” or coloured GREEN or
GREEN-AND-YELLOW.
The wire which is coloured BLUE must be connected to the terminal in the plug which is
marked with the letter N or coloured BLACK.
The wire which is coloured BROWN must be connected to the terminal in the plug which is
marked with the letter L or coloured RED.
How to replace the fuse.
Open the fuse compartment with a screwdriver and replace the fuse.
Fuse
Fuse

1-1
Introduction
Section I General Description
1. 1 Specifications
<General Specifications>
Type: Desk top (scanner and printer)
Copy Process: Laser recording method + Electrostatic photographic
method
Development Process: Mono-component
Image Control: Digital control
Photoreceptor: OPC
Fusing System: Heat and Pressure
Maximum Copy Size: Legal (8.5" X 14") B4 (257mm X 364mm)
Paper Feed: Front loading universal
Sheet bypass
Paper Capacity: Paper tray : 250 sheets
Sheet bypass : 50 sheets/25 sheets
(when duplexing)
Copy Size: Legal, Letter-R, Invoice
A4R, A5
Exit Tray Capacity: 200 sheets
Ambient conditions: Temperature : 50-86˚ F/10-30˚C
Relative humidity : 30-80% (non condensing)
Noise Level: Standaby : 32dB
Operation : 54dB
Warm Up Time: Approximately 20 seconds
Power Source: AC 120V+/-10%, 8.0A, 50/60Hz
AC 220V - 240V+/-10%, 4.5A, 50Hz
Dimensions: 19.5" (W) X 17.2" (D) X 10.7" (H)
496 (W) X 438 (D) X 273 (H) mm
Weight: 41lb/18.6kg
Paper Weight Range: Normal paper : 20lb/80g/m2
Ranges : 16 - 24lb/60 - 90g/m2(paper tray)
15 - 34lb/55 - 130g/m2(sheet bypass)
Special Paper: OHP, Label (Xerographic)
(Via sheet bypass)

1-2
<Copy specifications>
Resolution: 600 dpi
Gradation: 256 steps (photo mode)
First Copy Time: 7.9 sec. (LETTER R/A4R: manual exposure)
Ratios: Enlargement (fixed ratio) :1.29 (For North America)
1.41 (Except North America)
Reduction (fixed ratio) : 0.79, 0.65, 0.61
(For North America)
0.87, 0.82, 0.71
(Except North America)
Zoom : 50 % to 200 %
(by 1 % step)
Continuous Copy Speed: Letter R/A4R : 15 sheets/minute
Continuous Copy Count: 99 sheets
* Specifications are subject to change without notice.

1-3
Introduction
1. 2 Features
1. Advanced digital technology
1) This copier uses advanced digital technology to ensure high reliability and
offers such advanced functions as toner save.
2. Quick operation
First copy time of 7.9 seconds.
1. 3 New Functions
1. Toner save mode
This feature unable you to get higher copy yield on your toner save mode.
2. Zoom (50% to 200%)
Making copies with variable zoom ratios from 50% to 200% by 1% step.

1-4
1. 4 Systems
Control panel
Open/close
Right Cover
Sheet Bypass
Front Cover
Paper Tray

1-5
Introduction
PHOTO
FP-D150FP AUTO
DARK
141% A5 A4
LIGHT
CLEAR/STOP
10 1
START
C/
ENERGY
SAVER
100%
82% FLS¥B4 A4
FLS¥B4 A5
71% A4 A5
58%
%
ZOOM
(50~200%)
1. 5 Control Panel
• DP-150
Auto/Photo Select Key Display
Energy
Saver Key Clear/Stop
Key
Exposure
control
Key Select
Key Paper Tray Key Zoom Key
Ten
Key Start Key

1-6
Heat Roller
Pressure Roller
Drum
Transfer Roller
Sheet Bypass
Pick-up Roller
Sheet Bypass
Feed Roller
Sheet Bypass
DFP Roller
Registration
Roller
Paper Feed Roller
1. 6 Component Location
1. Outer View
2. Inner View
Control Panel
Right Cover
Sheet Bypass
Front Cover
Paper Tray

1-7
Introduction
3. Fan/Motor Location
Optics Drive Motor
Exhaust Fan
Main Motor
4. Sensor Location
Optics Home Position
Paper Tray
Paper Pass
Size Detection
Toner Level
Paper Exit

1-8
5. Solenoid/Switch Location
6. PCB Location CCD
Main CPU
High Voltage
Power Supply
(HVPS)
Lamp Inverter
Control
Panel
LVPS &
ACD
Paper Feed
Solenoid
Registration
Solenoid
Sheet Bypass
Solenoid
Power Switch
Discharge LED

1-9
Introduction
1. 7 Copy Process
(1) Primary charge
(7) Discharge
(6) Cleaning
(5) Fusing
Paper exit
Paper feed
(4) Separation
(4) Transfer
(3) Developing
Toner
(2) Image exposure
Original –DC
Discharge lamp:
Transfer/Separation Fusing: Cleaning:
Primary Charge: Image Exposure: Developing:
Drum surface
approximately-680V DC
Charge corona
Drum
Latent
charge
image
Illumination
Discharge
lamp
Heat roller
Fuser lamp
Paper
Pressure
roller
Separation Needle
Transfer
roller
Cleaning
blade
Drum
Drum
Fuser temperature
approximately 190˚C
Photoelectric
conversion
Drum
Magnetic
roller
Latent charge
image ( - )
Toner
(+)
Bias voltage: DC –400V
AC 1.5kVP-P

1-10
1. 8 Precautions for Consumables
(1) Photoreceptor drum
•Do not touch the surface of the drum with your hands.
•Stand the drum with the drum gear up for storage.
•Be careful not to put water, oil, saliva and/or dirt on the drum.
•Do not hit or scratch the surface of the drum.
•Do not store the drum in a hot and humid area.
•Avoid the direct sunlight or other strong light.
•
Do not expose the drum to the chemical gas or vapor.
•
Cover the drum anytime it is removed from the copier.
•
Do not use the corona cleaner unless dirty copy appears.
(The corona cleaner may damage the corona wire surface.)
(2) Developer
•Be careful not to let foreign matter into the
magnet roller unit.
•Do not touch the sleeve surface with your
hands.
•Do not stand the cartridge on end.
•Do not bang the cartridge.
•Do not store the cartridge in a hot and/or
humid area.
•Shake the cartridge as illustrated several times and install it into the copier.
(3) Safety and hygiene
•Be careful not to inhale the toner.
Toner can easily dust and become airborne, so handle carefully.
•When installing the developer, be careful not to let toner cloud. If you inhale it
by accident, wash out your mouth well. If toner sticks to your skin, wash it off
with soap.
•Regarding toner on clothes, vacuum or brush before washing with soap. Do
not use benzine, alcohol or thinner. Their use may be responsible for stains
by melting the components of toner.
•Use a vacuum for the toner on the floor or table and wipe it off with a cloth with
a neutral detergent.
•Keep toner away from flames. It is not inflammable but will burn if exposed to
flames.
•Waste consumables (photoreceptor and developer) should be recycled.
•When using solvents such as IPA, read and follow the instruction carefully.
Use gloves and eye protection.
Corona Cleaner

Mechanism
2-1
Section II Mechanism
2. 1 Main Drive
The driving mechanism of the machine is as follows.
Motor name Driving method Driving unit
Main motor DC24V driving •Rotation of the photoreceptor drum
•
Developer unit, Paper feed unit, Paper transport unit,
Fuser unit, Paper exit unit
Main motor
Developer
drive gear
Paper
exit
drive
gear Fuser drive
gear
Developer
coupling
Paper
feed
drive
gear

2-2
2. 2 Operations
1.Sheet Bypass
1)Construction of the sheet bypass
•Sheet bypass consists of a sheet bypass paper feed unit and a registration roller
unit.
Component name Description
1Sheet bypass paper feed Feed the paper from the sheet bypass pick up
roller roller to the registration roller.
2Sheet bypass pick up Send the paper from the sheet bypass tray to
roller the paper feed roller.
3Sheet bypass DFP roller Avoid feeding two sheets of paper at the same
time.
4Registration roller Time the lead edge of the paper with the
developed image on the drum.
5Registration roller Let the paper hit between registration rollers
and register it.
6Paper pass sensor To detect proper registration of the copy paper
at the registration rollers.
64512
3