HP 8100, 8150 Service Manual

LaserJet

8100 and 8150

print systems and paper

handling devices

service manual

HP LaserJet 8150 and 8100 Series Print Systems and Paper Handling Devices

Service Manual _____________

Part number: C4265-90963 First Edition, August 2001

Warranty

The information contained in this document is subject to change without notice.

Hewlett-Packard makes no warranty of any kind with respect to thi s informatio n . HEWLETT-PACKARD SPECIFICALLY DISCLAIMS THE IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Hewlett-Packard shall not be liable for any direct, indirect, incidental, consequential, or other damage alleged in connection with the furnishing or use of this information.

Trademark Credits

Adobe is a trademark of Adobe Systems Incorporated which may be registered in certain jurisdictions.

Arial is a U.S. registered trademark of the Monotype Corporation.

CompuServe trademark of CompuServe, Inc.

NERGY STAR is a U.S.

registered service mark of the United States Environmental Protection Agency.

Microsoft trademark of Microsoft Corporation.

PANTONE check-standard trademark for color.

PostScript is a trademark of Adobe Systems, Incorporated, which may be registered in certain jurisdictions.

TrueType is a U.S. trademark of Apple Computer, Inc.

UNIX is a registered trademark in the United States and other countries, licensed exclusively through X/Open Company Limited.

Windows, MS Windows, and Windows NT are U.S. registered trademarks of Microsoft Corporation.

is a U.S.

is a U.S. registered

Pantone, Inc.’s

Hewlett-Packard Company 11311 Chinden Boulevard Boise, Idaho 83714 U.S.A.

Conventions

This is a combined Service Manual for both the HP LaserJet 8100 series printer and the HP LaserJet 8150 series printer. The HP LaserJet 8150 series printer shares most characteristics of the HP LaserJet 8100 series printer, except where stated.

This manual uses the following conventions:

Color is used to emphasize items that are important to the material under discussion.

Bold is used for emphasis, particularly in situations where italic type would be

confusing. Italic type is used to indicate related documents or emphasis. DISPLAY type indicates text as seen on the printer control panel display. Commands you use on a computer keyboard or on the printer control panel are

shown in K

COURIER type indicates text that you type on a computer keyboard exactly as shown.

Hint Hints are used to suggest an action that might simplify the process.

Note Notes contain important information set off from the text.

EYCAP. Two examples are SELECT, and - VALUE +.

CAUTION Caution messages alert you to the possibility of damage to equipment

or loss of data.

WARNING! Warning messages alert you to the possibility of personal injury.

C4265-90963 iii

iv C4265-90963

1 Product Information

Printer Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Features of the HP Digital Copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

External View of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

External View of HP Digital Copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Model and Serial Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Paper-handling Devices, Accessories, and Options . . . . . . . . . . . . . . . . . . . . . 38

Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Hard Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Determining Memory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Paper Capacities and Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Printer and Paper-handling Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Media Selection Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Printer Media Selection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Copy Module Media Selection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Service Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Exchange Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Toner Cartridge Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Refilled Toner Cartridges and Non-HP Staple Cartridges . . . . . . . . . . . . . . 63

Recycling Toner Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Technical Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

HP FIRST (Fax Information Retrieval Support Technology) . . . . . . . . . . . . 64

Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

World Wide Web. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

HP Reseller Sales and Service Support Line (US Only) . . . . . . . . . . . . . . . 65

Other Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Regulatory Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

FCC Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Environmental Product Stewardship. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Material Safety Data Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Environmental Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Declarations of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

C4265-90963 Table of Contents i

2 Site Requirements

Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Printer and Paper-handling Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Copy Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

3 Operating Overview

Using the Printer Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Control Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Settings and Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Printer Driver Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Paper Source Default . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Performing a Cold Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Setting the Display Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Printer Control Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

HP LaserJet 8100 Series Quick Copy Jobs Menu . . . . . . . . . . . . . . . . . . . 101

HP LaserJet 8100 Series Private/Stored Jobs Menu . . . . . . . . . . . . . . . . . 101

HP LaserJet 8150 Series Quick Copy Menu . . . . . . . . . . . . . . . . . . . . . . . 102

HP LaserJet 8150 Series Private/Stored Jobs Menu . . . . . . . . . . . . . . . . . 102

Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Paper Handling Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Print Quality Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Printing Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Configuration of MBM Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

I/O Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

EIO Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Duplex Registration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Resets Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Using the HP Digital Copier Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

HP Digital Copier Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

HP Digital Copier Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Loading Documents into the ADF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Loading Documents onto the Flatbed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Printer Service Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Setting Page Count, Maintenance Count,and Serial Number . . . . . . . . . . 143

Setting the Cold Reset Default Paper Size. . . . . . . . . . . . . . . . . . . . . . . . . 144

HP Digital Copier Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

HP Digital Copier Administrator Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Remote Upgrade of the Printer Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Upgrade HP Digital Copier Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Testing the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Paper Path Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Configuration Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

ii Table of Contents C4265-90963

4 Maintenance and Adjustments

Cleaning the Printer and Paper Handling Accessories . . . . . . . . . . . . . . . . . . . 158

Cleaning Spilled Toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Cleaning the HP Digital Copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Vacuum Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Cleaning ADF and Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Cleaning the Document Cover, Document Holder, and Flatbed Glass . . . 162

Cleaning the ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Copy Module Optics Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Cleaning the ADF Lamp and Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Lubricating the ADF Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Cleaning the Carrier Unit and Mechanical Assemblies. . . . . . . . . . . . . . . .166

Lubricating the Carrier Unit Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Lubricating the Top of the Carrier Guide Rail . . . . . . . . . . . . . . . . . . . . . . . 166

Lubricating the Flatbed Motor Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Cleaning the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Maintaining the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Maintaining the Copy Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

HP Digital Copier Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Adjusting Printer Input Trays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Adjusting for Edge-to-Edge Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Adjusting Input Trays for Normal Printing. . . . . . . . . . . . . . . . . . . . . . . . . . 170

Adjusting the 2000-sheet Printer Input Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Adjusting Duplex Registration of the Paper Trays. . . . . . . . . . . . . . . . . . . . . . . 174

Adjusting the Copy Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Types of Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

When to Calibrate or Adjust the Copy Module . . . . . . . . . . . . . . . . . . . . . . 175

Calibration Target . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Entering the Calibration Menu in Service Mode . . . . . . . . . . . . . . . . . . . . . 176

How to Perform an Offset Adjustment Calibration . . . . . . . . . . . . . . . . . . .177

How to Perform a Density Calibration Adjustment . . . . . . . . . . . . . . . . . . . 177

How to Perform an ADF Vertical Magnification Adjustment . . . . . . . . . . . . 177

5 Functional Overview

Printer Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Power Distribution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

AC Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Overcurrent/Overvoltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

High Voltage Power Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Formatter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

DC Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Laser and Scanner Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Paper Motion Monitoring and Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Engine Test Microswitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

C4265-90963 iii

Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Image Formation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Toner Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Drum Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Drum Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Image Writing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Image Developing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Image Transferring and Media Separation . . . . . . . . . . . . . . . . . . . . . . . . . 199

Image Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Paper Paths and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Printer, Duplexer, and Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Paper Size Switches (Trays 2 and 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Printing from Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Printing from Trays 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Printing from the Envelope Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Printing with the Duplexer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

2000-sheet Input Tray (Tray 4) Components . . . . . . . . . . . . . . . . . . . . . . . 207

2000-Sheet Input Tray Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

2 x 500-sheet Input Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

2 x 500-sheet Input Tray Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

7-bin Tabletop Mailbox Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

7-bin Tabletop Mailbox Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

8-bin Mailbox Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

8-bin Mailbox Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Finisher Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Stapler Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Main Functional Cycles of the Stapler (Internal Paper Path) . . . . . . . . . . . 232

Communication Link (Daisy Chain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Paper Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Printer Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

IEEE 1284 Parallel Cable Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Copy Module Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Copy Module System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Function and Layout of the Copy Processor. . . . . . . . . . . . . . . . . . . . . . . . 240

Copy Module Power Up Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Copy Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Copy Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Printer components of copy module power up process . . . . . . . . . . . . . . . 245

Notes About the MFP Printer Product ID . . . . . . . . . . . . . . . . . . . . . . . . . . 245

ADF Simplex Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

ADF Duplex Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Flatbed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Copy Module Image Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Communication with the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Communication Channels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Print Job Interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Paper Path and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

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6 Removal and Replaceme nt

Removal and Replacement Strategy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . . . . 256

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

User Installable Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Hardware Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Printer Assembly Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 268

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Delivery Unit (for Face-down Bin). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Diverter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Diverter Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

Lower Right Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Fan 1, Laser/Scanner and Housing (Exhaust) . . . . . . . . . . . . . . . . . . . . . . 288

Fan 2, Low Voltage Power Supply (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . 290

Fan 3, Formatter Fan and Housing (Intake) . . . . . . . . . . . . . . . . . . . . . . . 291

Fan 4, Delivery Unit (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

Fan 5, Tray 1 (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Tray 1 Pickup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Formatter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

Fusing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Laser/Scanner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

Main Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Main Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

Paper Input Unit (PIU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

PCA, DC Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

Output Paper Sensor PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

High Voltage Power Supply (HVPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Low Voltage Power Supply (LVPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

Registration Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Tray 1 Feed Roller and Separation Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

Tray 2 and 3 Pickup, Feed, and Separation Rollers. . . . . . . . . . . . . . . . . . 330

Paper Input Unit Sensor (PS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

Registration Sensor (PS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Face-up Solenoid Assembly (SL3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

Transfer Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Tray 2 and 3 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

2000-sheet Input Tray Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . 341

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

C4265-90963 v

Paper Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

Main Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

Front LED PCA Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

Pickup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

Pickup, Feed, and Separation Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

Paper Quantity Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

Paper Size Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

Vertical Transfer Unit (VTU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

Tension Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

Locating Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

Casters and Stabilizing Feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

Adjustable Foot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

2 x 500-sheet Input Tray Removal and Replacement. . . . . . . . . . . . . . . . . . . . 372

Orientation of the 2 x 500-sheet Input Tray . . . . . . . . . . . . . . . . . . . . . . . . 373

Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

Vertical Transfer Unit (VTU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376

Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

Front Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

Trays 4 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385

Pickup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387

Paper Deck Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

Pickup, Feed, and Separation Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

Tray-Size Sensing PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

Main Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396

Storage Paper Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398

Front Door (Storage Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

Foot Tip and Adjustable Foot Tip (Stabilizing Feet) . . . . . . . . . . . . . . . . . . 401

Locating Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

Front LED PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

Envelope Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

7-bin Tabletop Mailbox Removal and Replacement . . . . . . . . . . . . . . . . . . . . . 405

Orientation of the 7-bin Tabletop Mailbox. . . . . . . . . . . . . . . . . . . . . . . . . . 406

Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407

Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410

Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417

Right Door Assembly (Paper Path Cover) . . . . . . . . . . . . . . . . . . . . . . . . . 418

Face-down Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

Empty Bin Sensor PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426

Full Bin and Interlock Sensor PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428

vi Table of Contents C4265-90963

LED PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

Face-up Sensors PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431

Reversing Mechanism Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

Face-up/Diverter Assembly (Flipper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434

Short Tray 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437

Solenoid Reversing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438

Flipper Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439

Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440

Latching Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441

Cover Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442

8-bin Mailbox Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444

Front and Back Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445

Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448

Paper Bins and Blind Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449

Flipper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450

Delivery Head Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453

Transport Belt Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454

Input Paper Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456

Metal Tape and Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

Anticurl Strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462

Delivery Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464

Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469

Diagnostic LED PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470

User Status LED PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472

Adjustable and Fixed Casters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474

Attachment Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475

Stapler Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 476

Mailbox with Stapler, Stapler Removal or Installation. . . . . . . . . . . . . . . . . 477

Back Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479

Stapler Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481

Top Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484

Stapler Bed Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485

Hinges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487

Duplexer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488

HP Digital Copier Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 489

Installing the HP Digital Copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490

Install the Optional Output Accessory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493

Install the Copy Connect EIO Board into the Printer . . . . . . . . . . . . . . . . . 494

Install the Copy Connect Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495

Hardware Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497

Orientation of the HP Digital Copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499

Copy Module Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

Separation Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

Pick Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

C4265-90963 vii

Copy Module Skins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505

Document Holding Pad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505

Paper Chute Flip-out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506

Output Tray Flip-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507

Output Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507

Flatbed (FB) Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508

ADF Latch Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511

ADF Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512

Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514

Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519

Front Panel Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520

Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522

Copy Module Power Supply/Main Board Assemblies. . . . . . . . . . . . . . . . . . . . 524

Copy Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524

Power Supply and Main Board Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525

RFI Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527

Control PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533

Back PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534

Copy Module ADF Unit Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535

Optical Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535

ADF Lamp PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537

ADF Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539

Sensor Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540

ADF Motor Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543

ADF Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544

LED Assembly PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546

ADF Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547

Copy Module Flatbed Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549

Front Panel Frame Ground Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549

Output Tray Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550

Glass Plate Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551

Home Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553

Carrier Unit Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555

Carrier Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558

Felt Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562

Feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563

Frame Ground Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564

Front Lamp PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565

Junction PCA and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566

Front Panel Ribbon Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568

Carrier Belt and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570

viii Table of Contents C4265-90963

7 Troubleshooting

Troubleshooting Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574

Printer System Troubleshooting Process . . . . . . . . . . . . . . . . . . . . . . . . . . 577

Printer/Paper-Handling Troubleshooting Process . . . . . . . . . . . . . . . . . . . 578

Copy Module Troubleshooting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 580

Troubleshooting the Print System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582

Preliminary Operating Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582

Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583

Interface Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583

Network Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585

Verify Host System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587

Verify Network and Server Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587

General Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588

Miscellaneous Problems and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . 588

Paper Curl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593

Troubleshooting the Printer and Paper-handling Devices. . . . . . . . . . . . . . . . . 594

Engine Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597

Event Log Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598

Printer Message Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607

Engine Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608

Input Device Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620

Output Device Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628

Finisher Devices Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640

Paper Handling Controller Error Messages . . . . . . . . . . . . . . . . . . . . . . . . 644

Paper Jams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646

Paper Path Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648

Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651

Configuration Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653

File Directory Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656

Usage Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657

Check the Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662

Image Quality Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663

Repetitive Defect Ruler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676

Image System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678

High-Voltage Power Supply Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679

Self-Diagnostics on Paper-handling Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 681

2000-sheet Input Tray Standalone Diagnostics . . . . . . . . . . . . . . . . . . . . . 681

2 x 500-sheet Input Tray Standalone Diagnostics . . . . . . . . . . . . . . . . . . .685

7-bin Tabletop Mailbox Standalone Diagnostics. . . . . . . . . . . . . . . . . . . . . 689

8-bin Mailbox Standalone Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694

Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702

Troubleshooting the Copy Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715

Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718

Testing the Copy Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728

Copy Processor LED Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728

Copy Module Boot Up Icon Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 730

C4265-90963 ix

Copy Module Offline Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731

Other Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733

Service Mode Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735

8 Parts and Diagr ams

How to Use the Part Lists and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738

Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738

Common Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738

Illustrations and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 739

Printer and paper-handling components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740

Printer Parts and Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742

Paper-Handling Devices Parts and Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . 756

Input Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756

Output Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 763

HP Digital Copier Parts and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 774

Alphabetical Parts List (Printer and Paper-handling Devices). . . . . . . . . . . . . . 789

Alphabetical Parts List (Copy Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799

Numerical Parts List (Printer and Paper-handling devices). . . . . . . . . . . . . . . . 803

Numerical Parts List (Copy Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813

x Table of Contents C4265-90963

List of Tables

Table 1-1. Common features of the HPLJ 8100 Series and HPLJ 8150 Series 26 Table 1-2. Comparison of HP LaserJet 8100 Series Printer Features - - - - 27 Table 1-3. Comparison of HP LaserJet 8150 Series Printer Features - - - - 28 Table 1-4. Accessories and Options - - - - - - - - - - - - - - - - - - - - 40 Table 1-5. Minimum Memory Requirements - - - - - - - - - - - - - - - - 49 Table 1-6. Paper Capacities and Sizes- - - - - - - - - - - - - - - - - - - 50 Table 1-7. Paper Weight Equivalence - - - - - - - - - - - - - - - - - - - 55 Table 1-8. Declaration of Conformity - - - - - - - - - - - - - - - - - - - - 72 Table 2-1. Printer and Toner Cartridge Environmental Conditions - - - - - - 84 Table 2-2. Dimensions of printer and Paper-handling Devices - - - - - - - 85 Table 2-3. Dimensions of Output Devices - - - - - - - - - - - - - - - - - 86 Table 2-4. Electrical Specifications - - - - - - - - - - - - - - - - - - - - 87 Table 2-5. Acoustic Emissions - - - - - - - - - - - - - - - - - - - - - - 89 Table 2-6. Specifications for Copy Module - - - - - - - - - - - - - - - - - 90 Table 3-1. Control Panel Keys - - - - - - - - - - - - - - - - - - - - - - - 92 Table 3-2. Indicator Lights - - - - - - - - - - - - - - - - - - - - - - - - - 93 Table 3-3. Factory Default Settings- - - - - - - - - - - - - - - - - - - - - 97 Table 3-4. HP LaserJet 8100 Series Quick Copy Jobs Menu - - - - - - - - 101 Table 3-5. HP LaserJet 8100 Series Private/Stored Jobs Menu - - - - - - - 101 Table 3-6. HP LaserJet 8150 Series Job Retention Menu- - - - - - - - - - 102 Table 3-7. Information Menu - - - - - - - - - - - - - - - - - - - - - - - - 104 Table 3-8. Paper Handling Menu- - - - - - - - - - - - - - - - - - - - - - 105 Table 3-9. Print Quality Menu - - - - - - - - - - - - - - - - - - - - - - - 108 Table 3-10. Printing Menu- - - - - - - - - - - - - - - - - - - - - - - - - - 110 Table 3-11. Configuration Menu - - - - - - - - - - - - - - - - - - - - - - - 113 Table 3-12. MBM Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - 118 Table 3-13. I/O Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119 Table 3-14. EIO Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - 121 Table 3-15. Duplex Registration Menu- - - - - - - - - - - - - - - - - - - - 123 Table 3-16. Resets Menu - - - - - - - - - - - - - - - - - - - - - - - - - - 125 Table 3-17. Status Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - 127 Table 3-18. Menu Tabs - - - - - - - - - - - - - - - - - - - - - - - - - - - 128 Table 3-19. Context-sensitive Help - - - - - - - - - - - - - - - - - - - - - 133 Table 3-20. Default Configurations - - - - - - - - - - - - - - - - - - - - - 133 Table 3-21. Functions of Buttons and LEDs - - - - - - - - - - - - - - - - - 134 Table 3-22. Start Button LED States- - - - - - - - - - - - - - - - - - - - - 135 Table 3-23. Default Settings- - - - - - - - - - - - - - - - - - - - - - - - - 136 Table 3-24. Service Mode Menu Items - - - - - - - - - - - - - - - - - - - 141 Table 3-25. Key to Figure 3-5 - - - - - - - - - - - - - - - - - - - - - - - - 154 Table 3-26. Key to Figure 3-6 - - - - - - - - - - - - - - - - - - - - - - - - 155 Table 4-1. Cleaning the Printer- - - - - - - - - - - - - - - - - - - - - - - 160

C4265-90963 List of Tables xi

Table 4-2. Cleaning the Document Cover, Document Holder, Flatbed Glass- 162 Table 4-3. Cleaning the ADF- - - - - - - - - - - - - - - - - - - - - - - - 163 Table 5-1. Printer Sensors, Solenoids, Clutches, Motors, and Fans - - - - - 202 Table 5-2. Paper Size Switches - - - - - - - - - - - - - - - - - - - - - - 204 Table 5-3. 2000-sheet Input Tray Sensors, Switches, Clutches and Motors - 208 Table 5-4. 2000-sheet Input Tray Paper Quantity Switches - - - - - - - - - 210 Table 5-5. 2000-sheet Input Tray Paper Size Switches - - - - - - - - - - - 210 Table 5-6. 2 x 500-sheet Input Tray Sensors, Switches, and Motors- - - - - 213 Table 5-7. 2 x 500-sheet Input Tray Switches- - - - - - - - - - - - - - - - 214 Table 5-8. 7-bin Tabletop Mailbox Sensors, Switches, and Motors - - - - - 217 Table 5-9. 8-bin Mailbox Sensors, Switches, Motors, and Controller PCA - - 223 Table 5-10. Stapler Motors, Sensors, and Switches - - - - - - - - - - - - - 229 Table 5-11. Printer Timing- - - - - - - - - - - - - - - - - - - - - - - - - - 235 Table 5-12. Parallel Cable Pin Assignments - - - - - - - - - - - - - - - - - 237 Table 6-1. Hardware Table- - - - - - - - - - - - - - - - - - - - - - - - - 266 Table 6-2. Hardware Table- - - - - - - - - - - - - - - - - - - - - - - - - 497 Table 7-1. Paper Curl - - - - - - - - - - - - - - - - - - - - - - - - - - - 593 Table 7-2. Power On Defects or Blank Display - - - - - - - - - - - - - - - 594 Table 7-3. Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 596 Table 7-4. HP LaserJet 8150 Series Event Log Page 2 - - - - - - - - - - - 599 Table 7-5. Engine Error Messages - - - - - - - - - - - - - - - - - - - - - 608 Table 7-6. 2000-sheet Input Tray Error Messages - - - - - - - - - - - - - 620 Table 7-7. 2 x 500-sheet Input Tray Error Messages - - - - - - - - - - - - 624 Table 7-8. Envelope Feeder Error Messages- - - - - - - - - - - - - - - - 627 Table 7-9. 7-bin Tabletop Mailbox Error Messages - - - - - - - - - - - - - 629 Table 7-10. 8-bin Mailbox Error Messages- - - - - - - - - - - - - - - - - - 634 Table 7-11. Stapler Error Messages - - - - - - - - - - - - - - - - - - - - - 640 Table 7-12. Duplexer Error Messages - - - - - - - - - - - - - - - - - - - - 643 Table 7-13. Paper Handling Controller Error Messages - - - - - - - - - - - 644 Table 7-14. General Paper Path Troubleshooting Questions - - - - - - - - - 645 Table 7-15. Key to Figure 7-16 - - - - - - - - - - - - - - - - - - - - - - - 652 Table 7-16. Printer Devices Troubleshooting- - - - - - - - - - - - - - - - - 660 Table 7-17. Image Quality- - - - - - - - - - - - - - - - - - - - - - - - - - 661 Table 7-18. Blank (White) Page - - - - - - - - - - - - - - - - - - - - - - - 663 Table 7-19. Black Pages - - - - - - - - - - - - - - - - - - - - - - - - - - 663 Table 7-20. Fading Print - - - - - - - - - - - - - - - - - - - - - - - - - - 664 Table 7-21. Dropout- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 666 Table 7-22. Black Lines (parallel or perpendicular to path) - - - - - - - - - - 666 Table 7-23. Toner Smear - - - - - - - - - - - - - - - - - - - - - - - - - - 667 Table 7-24. Background Scatter- - - - - - - - - - - - - - - - - - - - - - - 668 Table 7-25. Repetitive Defects - - - - - - - - - - - - - - - - - - - - - - - 669 Table 7-26. Line at Edge of Paper- - - - - - - - - - - - - - - - - - - - - - 670 Table 7-27. Misshapen Characters, Voids - - - - - - - - - - - - - - - - - - 671 Table 7-28. Faulty Registration - - - - - - - - - - - - - - - - - - - - - - - 672 Table 7-29. Image Skew - - - - - - - - - - - - - - - - - - - - - - - - - - 672 Table 7-30. Bubble Print - - - - - - - - - - - - - - - - - - - - - - - - - - 673 Table 7-31. White Stripes Parallel to Path - - - - - - - - - - - - - - - - - - 674

xii List of Tables C4265-90963

Table 7-32. Partial Blank Page - - - - - - - - - - - - - - - - - - - - - - - 674 Table 7-33. Compressed Print- - - - - - - - - - - - - - - - - - - - - - - - 675 Table 7-34. Blank Portion in the Middle of the Page (Tray 4 Input only)- - - - 675 Table 7-35. DIP Switch Settings- - - - - - - - - - - - - - - - - - - - - - - 683 Table 7-36. 2000-sheet Input Tray LED Status Interpretation- - - - - - - - - 684 Table 7-37. DIP Switch Settings for troubleshooting test procedures - - - - - 686 Table 7-38. Patterns of LED flashing (2-second pause between each pattern) 688 Table 7-39. DIP switch settings for troubleshooting test - - - - - - - - - - - 689 Table 7-40. Patterns of Flashing LEDs - - - - - - - - - - - - - - - - - - - 691 Table 7-41. 8-bin Mailbox LED Status Interpretation - - - - - - - - - - - - - 697 Table 7-42. Power On Checks - - - - - - - - - - - - - - - - - - - - - - - 716 Table 7-43. Display and Communication Checks - - - - - - - - - - - - - - 717 Table 7-44. Boot Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - 719 Table 7-45. Equipment Errors - - - - - - - - - - - - - - - - - - - - - - - - 720 Table 7-46. Temporary Errors - - - - - - - - - - - - - - - - - - - - - - - - 722 Table 7-47. Error Conditions - - - - - - - - - - - - - - - - - - - - - - - - 725 Table 7-48. Copy Processor LED Test Results - - - - - - - - - - - - - - - 729 Table 7-49. Icon Conditions - - - - - - - - - - - - - - - - - - - - - - - - - 730 Table 7-50. Other Tests- - - - - - - - - - - - - - - - - - - - - - - - - - - 733 Table 8-1. Printer and Paper-Handling Components - - - - - - - - - - - - 740 Table 8-2. Printer Covers and Doors - - - - - - - - - - - - - - - - - - - - 743 Table 8-3. Printer Internal Components (1 of 4) - - - - - - - - - - - - - - 745 Table 8-4. Printer Internal Components (2 of 4)- - - - - - - - - - - - - - - 747 Table 8-5. Printer internal Components (3 of 4)- - - - - - - - - - - - - - - 749 Table 8-6. Printer Internal Components (4 of 4)- - - - - - - - - - - - - - - 751 Table 8-7. Detail of Assemblies - - - - - - - - - - - - - - - - - - - - - - 753 Table 8-8. PCB Assembly Locations - - - - - - - - - - - - - - - - - - - - 754 Table 8-9. Face-up Solenoid Assembly- - - - - - - - - - - - - - - - - - - 755 Table 8-10. 2000-sheet Input Tray Components (1 of 2) - - - - - - - - - - - 757 Table 8-11. 2000-sheet Input Tray Components (2 of 2) - - - - - - - - - - - 759 Table 8-12. 2 x 500-sheet Input Tray Internal Components- - - - - - - - - - 761 Table 8-13. 7-bin Tabletop Mailbox Internal Components - - - - - - - - - - 764 Table 8-14. 8-bin Mailbox Components (1 of 3) - - - - - - - - - - - - - - - 767 Table 8-15. 8-bin Mailbox Components (2 of 3) - - - - - - - - - - - - - - - 769 Table 8-16. 8-bin Mailbox Components (3 of 3) - - - - - - - - - - - - - - - 771 Table 8-17. Stapler Internal Components - - - - - - - - - - - - - - - - - - 773 Table 8-18. Covers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 776 Table 8-19. Flatbed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 777 Table 8-20. Glass Plate and PCA Assembly - - - - - - - - - - - - - - - - - 779 Table 8-21. Carrier Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - 781 Table 8-22. ADF Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - 782 Table 8-23. Optical Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - 785 Table 8-24. Document Cover Assembly - - - - - - - - - - - - - - - - - - - 786 Table 8-25. Screws (1 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - 787 Table 8-26. Screws (2 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - 787 Table 8-27. Screws (3 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - 788 Table 8-28. Screws (4 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - 788

C4265-90963 xiii

Table 8-29. Alphabetical Parts List – Printer and Paper-handling Devices - - 789 Table 8-30. Alphabetical Parts List – Copy Module- - - - - - - - - - - - - - 799 Table 8-31. Numerical Parts List – Printer and Paper-handling Devices - - - 803 Table 8-32. Numerical Parts List – Copy Module- - - - - - - - - - - - - - - 813

xiv List of Tables C4265-90963

List of Figures

Figure 1-1 Copy System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29 Figure 1-2 Printer - Front and Right Side View with Tray 1 Open - - - - - - - - - - 31 Figure 1-3 Rear and Left Side View - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33 Figure 1-4 Front view of HP Digital Copier- - - - - - - - - - - - - - - - - - - - - - - - - - 34 Figure 1-5 Rear view of HP Digital Copier - - - - - - - - - - - - - - - - - - - - - - - - - - 34 Figure 1-6 Preferred Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35 Figure 1-7 Digital Copier Tabletop Configuration - - - - - - - - - - - - - - - - - - - - - 36 Figure 1-8 Sample Model and Serial Number Label for the printer - - - - - - - - - 37 Figure 1-9 Paper Handling Devices and Accessories - - - - - - - - - - - - - - - - - - 38 Figure 1-10 Paper size specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56 Figure 1-11 Paper orientation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59 Figure 1-12 Areas of the Paper that Should Not Be Perforated - - - - - - - - - - - - 60 Figure 1-13 Sample 5% Page Coverage- - - - - - - - - - - - - - - - - - - - - - - - - - - - 62 Figure 2-1 Printer Space Requirements (Top view) - - - - - - - - - - - - - - - - - - - 81 Figure 2-2 Printer Space Requirements (Side view) - - - - - - - - - - - - - - - - - - - 81 Figure 2-3 Printer Space Requirements (with Mailbox and Input Device) - - - - 82 Figure 2-4 Printer and Copy Module Space requirements - - - - - - - - - - - - - - - 83 Figure 2-5 Dimensions of Paper Handling Devices- - - - - - - - - - - - - - - - - - - - 87 Figure 3-1 Control Panel Layout- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92 Figure 3-2 Front Panel Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 127 Figure 3-3 Button/LED Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 134 Figure 3-4 Copy Module Service Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - 145 Figure 3-5 Configuration Page (varies with installed options)- - - - - - - - - - - - 154 Figure 3-6 Menu Map Page (varies with printer models and installed options) 155 Figure 4-1 Cleaning the Document Cover, Document Holder, Flatbed Glass- 162 Figure 4-2 Parts of the ADF - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 163 Figure 4-3 Image Area Margins - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 170 Figure 4-4 Tray Position Adjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171 Figure 4-5 Tray 4 Position Adjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - 172 Figure 4-6 Creating an Offset Target- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 176 Figure 5-1 Printer Functional Block Diagram - - - - - - - - - - - - - - - - - - - - - - - 180 Figure 5-2 Low Voltage Power Distribution System - - - - - - - - - - - - - - - - - - 181 Figure 5-3 Low Voltage Power Supply- - - - - - - - - - - - - - - - - - - - - - - - - - - - 182 Figure 5-4 High Voltage Power Supply Contacts - - - - - - - - - - - - - - - - - - - - 184 Figure 5-5 Normal Mode vs. EconoMode- - - - - - - - - - - - - - - - - - - - - - - - - - 187 Figure 5-6 Image Formation Block Diagram- - - - - - - - - - - - - - - - - - - - - - - - 190 Figure 5-7 Photosensitive Drum - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 192 Figure 5-8 Drum Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 193 Figure 5-9 Primary Charging Roller- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 194 Figure 5-10 Image Writing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 195 Figure 5-11 Image Development - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 198

C4265-90963 List of Figures xv

Figure 5-12 Image Transferring and Media Separation- - - - - - - - - - - - - - - - - 199 Figure 5-13 Image Fusing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 200 Figure 5-14 Printer Paper Paths- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 201 Figure 5-15 Printer Sensors, Solenoids, Clutches, Motors, and Fans - - - - - - - 204 Figure 5-16 2000-sheet Input Tray Paper Pa th - - - - - - - - - - - - - - - - - - - - - - 207 Figure 5-17 2000-sheet Input Tray Sensors, Switches, Clutches, and Motors - 209 Figure 5-18 2 x 500-sheet Input Tray Paper Path- - - - - - - - - - - - - - - - - - - - - 212 Figure 5-19 2 x 500-sheet input Tray Sensors and Switches - - - - - - - - - - - - - 213 Figure 5-20 7-bin Tabletop Mailbox Components (1 of 2) - - - - - - - - - - - - - - - 216 Figure 5-21 7-bin Tabletop Mailbox Components (2 of 2) - - - - - - - - - - - - - - - 217 Figure 5-22 7-bin Tabletop Mailbox Block Diagram - - - - - - - - - - - - - - - - - - - 221 Figure 5-23 8-bin Mailbox Paper Path- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 222 Figure 5-24 8-bin Mailbox Sensors, Switches, Motors, and Controller PCA- - - 224 Figure 5-25 Finisher Paper Path- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 228 Figure 5-26 Stapler Motors, Sensors, and Switches - - - - - - - - - - - - - - - - - - - 229 Figure 5-27 Stapler Cycles- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 232 Figure 5-28 Recommended C-link Configuration (Daisy Chain) - - - - - - - - - - - 234 Figure 5-29 General Timing Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 236 Figure 5-30 Copy Module System Block Diagram - - - - - - - - - - - - - - - - - - - - 238 Figure 5-31 Copy Processor and key components - - - - - - - - - - - - - - - - - - - - 240 Figure 5-32 Image path (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 249 Figure 5-33 Locations of ADF Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - 252 Figure 5-34 ADF Sensors functional diagram- - - - - - - - - - - - - - - - - - - - - - - - 253 Figure 6-1 Phillips vs. Posidriv Screwdrivers - - - - - - - - - - - - - - - - - - - - - - - 257 Figure 6-2 Disk Drive- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 259 Figure 6-3 Control Panel (1 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 269 Figure 6-4 Control Panel (2 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 270 Figure 6-5 AC Access Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 272 Figure 6-6 Back Cover- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 273 Figure 6-7 Front Cover (1 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 274 Figure 6-8 Front Cover (2 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 275 Figure 6-9 Left Lower Cover- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 276 Figure 6-10 Top Cover (1 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 277 Figure 6-11 Top Cover (2 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 278 Figure 6-12 Delivery Unit (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 280 Figure 6-13 Delivery Unit (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 281 Figure 6-14 Diverter Assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 283 Figure 6-15 Diverter Door Assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 284 Figure 6-16 Lower Right Door Assembly (1 of 3) - - - - - - - - - - - - - - - - - - - - - 285 Figure 6-17 Right Lower Door Assembly (2 of 3) - - - - - - - - - - - - - - - - - - - - - 286 Figure 6-18 Right Lower Door Assembly (3 of 3) - - - - - - - - - - - - - - - - - - - - - 287 Figure 6-19 Fan 1, Laser/Scanner (1 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - 288 Figure 6-20 Fan 1, Laser/Scanner (2 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - 289 Figure 6-21 Fan 2, Low Voltage Power Supply - - - - - - - - - - - - - - - - - - - - - - 290 Figure 6-22 Fan 3, Formatter Fan- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 291 Figure 6-23 Fan 4, Delivery Unit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 292 Figure 6-24 Fan 5 Removal (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 293

xvi List of Figures C4265-90963

Figure 6-25 Fan 5 Removal (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 294 Figure 6-26 Tray 1 Removal (1 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 295 Figure 6-27 Tray 1 Removal (2 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 296 Figure 6-28 Tray 1 Removal (3 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 297 Figure 6-29 Tray 1 Pickup Unit Removal (1 of 4) - - - - - - - - - - - - - - - - - - - - - 298 Figure 6-30 Tray 1 Pickup Unit Removal (2 of 4) - - - - - - - - - - - - - - - - - - - - - 299 Figure 6-31 Tray 1 Pickup Unit Removal (3 of 4) - - - - - - - - - - - - - - - - - - - - - 300 Figure 6-32 Tray 1 Pickup Unit Removal (4 of 4) - - - - - - - - - - - - - - - - - - - - - 301 Figure 6-33 Feeder Assembly (1 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 302 Figure 6-34 Feeder Assembly (2 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 303 Figure 6-35 Formatter Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 305 Figure 6-36 Fusing Assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 306 Figure 6-37 Laser/Scanner Assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 308 Figure 6-38 Main Gear Assembly (1 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - - 310 Figure 6-39 Main Gear Assembly (2 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - - 311 Figure 6-40 Main Gear Assembly (3 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - - 312 Figure 6-41 Main Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 313 Figure 6-42 Paper Input Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 314 Figure 6-43 DC Controller PCA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 315 Figure 6-44 Output Paper Sensor PCA (1 of 4) - - - - - - - - - - - - - - - - - - - - - - 316 Figure 6-45 Output Paper Sensor PCA (2 of 4) - - - - - - - - - - - - - - - - - - - - - - 317 Figure 6-46 Output Paper Sensor PCA (3 of 4) - - - - - - - - - - - - - - - - - - - - - - 318 Figure 6-47 Output Paper Sensor PCA (4 of 4) - - - - - - - - - - - - - - - - - - - - - - 319 Figure 6-48 Paper Size PCA (1 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 320 Figure 6-49 Paper Size PCA (2 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 321 Figure 6-50 Paper Size PCA (3 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 322 Figure 6-51 High Voltage Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - 323 Figure 6-52 Low Voltage Power Supply- - - - - - - - - - - - - - - - - - - - - - - - - - - - 324 Figure 6-53 Registration Assembly (1 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - 325 Figure 6-54 Registration Assembly (2 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - 326 Figure 6-55 Registration Assembly (3 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - 327 Figure 6-56 Tray 1 Feed Roller- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 328 Figure 6-57 Tray 1 Separation Pad- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 329 Figure 6-58 Tray 2 and 3, Pickup, Feed, and Separation Rollers - - - - - - - - - - 330 Figure 6-59 Paper Input Unit Sensor (PS2) - - - - - - - - - - - - - - - - - - - - - - - - - 333 Figure 6-60 Registration Sensor (PS1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 335 Figure 6-61 Face-up Solenoid Assem bly, SL3 - - - - - - - - - - - - - - - - - - - - - - - 336 Figure 6-62 Transfer Roller Assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 337 Figure 6-63 2000-sheet Input Tray Orientation- - - - - - - - - - - - - - - - - - - - - - - 342 Figure 6-64 2000-sheet Input Tray Front Cover - - - - - - - - - - - - - - - - - - - - - - 343 Figure 6-65 2000-sheet Input Tray Back Cover - - - - - - - - - - - - - - - - - - - - - - 344 Figure 6-66 2000-sheet Input Tray Left Cover - - - - - - - - - - - - - - - - - - - - - - - 345 Figure 6-67 2000-sheet Input Tray Right Cover - - - - - - - - - - - - - - - - - - - - - - 346 Figure 6-68 2000-sheet Input Tray Main Drive Assembly - - - - - - - - - - - - - - - 347 Figure 6-69 2000-sheet Input Tray Paper Tray- - - - - - - - - - - - - - - - - - - - - - - 349 Figure 6-70 2000-sheet Input Tray Main Cable Harness - - - - - - - - - - - - - - - - 351 Figure 6-71 2000-sheet Input Tray Controller PCA- - - - - - - - - - - - - - - - - - - - 352

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Figure 6-72 2000-sheet Input Tray Front LED PCA - - - - - - - - - - - - - - - - - - - 355 Figure 6-73 2000-sheet Input Tray Picku p Assembly - - - - - - - - - - - - - - - - - - 356 Figure 6-74 2000-sheet Input Tray Power Supply- - - - - - - - - - - - - - - - - - - - - 358 Figure 6-75 2000-sheet Input Tray Rollers: Pickup, Feed, and Separation - - - 361 Figure 6-76 2000-sheet Input Tray Paper Size, Paper Quantity Switch (1 of 2) 364 Figure 6-77 2000-sheet Input Tray Paper Size, Paper Quantity Switch (2 of 2) 365 Figure 6-78 2000-sheet Input Tray Vertical Transfer Unit (VTU) - - - - - - - - - - 366 Figure 6-79 2000-sheet Input Tray Tension Springs- - - - - - - - - - - - - - - - - - - 368 Figure 6-80 2000-sheet Input Tray Locating Pins- - - - - - - - - - - - - - - - - - - - - 369 Figure 6-81 2000-sheet Input Tray Casters - - - - - - - - - - - - - - - - - - - - - - - - - 370 Figure 6-82 2000-sheet Input Tray Adjustab le Foot - - - - - - - - - - - - - - - - - - - 371 Figure 6-83 Orientation of the 2 x 500-sheet Input Tray - - - - - - - - - - - - - - - - 373 Figure 6-84 Back Cover- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 374 Figure 6-85 Left Cover- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 375 Figure 6-86 Vertical Transfer Unit (VTU) (1 of 3) - - - - - - - - - - - - - - - - - - - - - 376 Figure 6-87 Vertical Transfer Unit (VTU) (2 of 3) - - - - - - - - - - - - - - - - - - - - - 377 Figure 6-88 Vertical Transfer Unit (VTU) (3 of 3) - - - - - - - - - - - - - - - - - - - - - 378 Figure 6-89 Right Cover (1 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 379 Figure 6-90 Right Cover (2 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 380 Figure 6-91 Right Cover (3 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 381 Figure 6-92 Front Top Cover (1 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 382 Figure 6-93 Front Top Cover (2 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 383 Figure 6-94 Front Top Cover (3 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 384 Figure 6-95 Trays 4 and 5 (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 385 Figure 6-96 Trays 4 and 5 (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 386 Figure 6-97 Pickup Assembly (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 387 Figure 6-98 Pickup Assembly (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 388 Figure 6-99 Paper Deck Drive Assembly (1 of 2) - - - - - - - - - - - - - - - - - - - - - 389 Figure 6-100Paper Deck Drive Assembly (2 of 2) - - - - - - - - - - - - - - - - - - - - - 390 Figure 6-101Pickup, Feed, and Separation Rollers - - - - - - - - - - - - - - - - - - - - 391 Figure 6-1022 x 500-sheet Input Tray Controller PCA - - - - - - - - - - - - - - - - - - 392 Figure 6-103Tray-Size Sensing PCA (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - 393 Figure 6-104Tray-Size Sensing PCA (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - 394 Figure 6-105 Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 395 Figure 6-106Main Cable (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 396 Figure 6-107Main Cable (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 397 Figure 6-108 Storage Paper Tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 398 Figure 6-109Front Door (Storage Area) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 399 Figure 6-110Casters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 400 Figure 6-111Foot Tip and Adjustable Foot Tip - - - - - - - - - - - - - - - - - - - - - - - 401 Figure 6-112Locating Pins - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 402 Figure 6-113Front LED PCA- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 403 Figure 6-114 Orientation of the 7-bin Tabletop Mailbox- - - - - - - - - - - - - - - - - - 406 Figure 6-115Front Cover (1 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 407 Figure 6-116Front Cover (2 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 408 Figure 6-117Front Cover (3 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 409 Figure 6-118Back Cover (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 410

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Figure 6-119Back Cover (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 411 Figure 6-120Top Cover (1 of 4)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 412 Figure 6-121Top Cover (2 of 4)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 413 Figure 6-122Top Cover (3 of 4)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 414 Figure 6-123Top Cover (4 of 4)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 415 Figure 6-124Mailbox Controller PCA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 416 Figure 6-125Mailbox Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 417 Figure 6-126Right Door Assembly (Paper Path Cover) (1 of 5)- - - - - - - - - - - - 418 Figure 6-127Right Door Assembly (Paper Path Cover) (2 of 5)- - - - - - - - - - - - 419 Figure 6-128Right Door Assembly (Paper Path Cover) (3 of 5)- - - - - - - - - - - - 420 Figure 6-129Right Door Assembly (Paper Path Cover) (4 of 5)- - - - - - - - - - - - 421 Figure 6-130Right Door Assembly (Paper Path Cover) (5 of 5)- - - - - - - - - - - - 422 Figure 6-131Face-down Bins (1 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 423 Figure 6-132Face-down Bins (2 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 424 Figure 6-133Face-down Bins (3 of 3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 425 Figure 6-134Empty Bin Sensor PCA (1 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - 426 Figure 6-135Empty Bin Sensor PCA (2 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - 427 Figure 6-136Full Bin and Interlock Se nsor PCA (1 of 2)- - - - - - - - - - - - - - - - - 428 Figure 6-137Full Bin and Interlock Se nsor PCA (2 of 2)- - - - - - - - - - - - - - - - - 429 Figure 6-138LED PCA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 430 Figure 6-139Face-up Sensors PCA- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 431 Figure 6-140Reversing Mechanism Motor (1 of 2)- - - - - - - - - - - - - - - - - - - - - 432 Figure 6-141Reversing Mechanism Motor (2 of 2)- - - - - - - - - - - - - - - - - - - - - 433 Figure 6-142Face-up/Diverter Assembly (Flipper) (1 of 3) - - - - - - - - - - - - - - - 434 Figure 6-143Face-up/Diverter Assembly (Flipper) (2 of 3) - - - - - - - - - - - - - - - 435 Figure 6-144Face-up/Diverter Assembly (Flipper) (3 of 3) - - - - - - - - - - - - - - - 436 Figure 6-145Short Tray 7 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 437 Figure 6-146Solenoid Reversing Mechanism - - - - - - - - - - - - - - - - - - - - - - - - 438 Figure 6-147Flipper Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 439 Figure 6-148 7-bin Tabletop Mailbox Handle - - - - - - - - - - - - - - - - - - - - - - - - - 440 Figure 6-149Latching Mechanism - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 441 Figure 6-150Cover Latch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 442 Figure 6-151Orientation of the 8-bin Mailbo x - - - - - - - - - - - - - - - - - - - - - - - - 444 Figure 6-1528-bin Mailbox Covers (Front and Back) - - - - - - - - - - - - - - - - - - - 445 Figure 6-1538-bin Mailbox Top Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 447 Figure 6-1548-bin Mailbox Power Supply- - - - - - - - - - - - - - - - - - - - - - - - - - - 448 Figure 6-1558-bin Mailbox Paper Bins and Blind Cover- - - - - - - - - - - - - - - - - 449 Figure 6-1568-bin Mailbox Flipper Assembly (1 of 3)- - - - - - - - - - - - - - - - - - - 450 Figure 6-1578-bin Mailbox Flipper Assembly (2 of 3)- - - - - - - - - - - - - - - - - - - 451 Figure 6-1588-bin Mailbox Flipper Assembly (3 of 3)- - - - - - - - - - - - - - - - - - - 452 Figure 6-1598-bin Mailbox Delivery Head Motor - - - - - - - - - - - - - - - - - - - - - - 453 Figure 6-1608-bin Mailbox Transport Belt Mot or - - - - - - - - - - - - - - - - - - - - - - 454 Figure 6-1618-bin Mailbox Input Paper Guide (1 of 2) - - - - - - - - - - - - - - - - - - 456 Figure 6-1628-bin Mailbox Input Paper Guide (2 of 2) - - - - - - - - - - - - - - - - - - 457 Figure 6-163 8-bin Mailbox Metal Tape and Housing Assembly (1 of 2) - - - - - - 458 Figure 6-164 8-bin Mailbox Metal Tape and Housing Assembly (2 of 2) - - - - - - 459 Figure 6-1658-bin Mailbox Controller PCA (1 of 2) - - - - - - - - - - - - - - - - - - - - 460

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Figure 6-1668-bin Mailbox Controller PCA (2 of 2) - - - - - - - - - - - - - - - - - - - - 461 Figure 6-1678-bin Mailbox Anticurl Strings (1 of 2) - - - - - - - - - - - - - - - - - - - - 462 Figure 6-1688-bin Mailbox Anticurl Strings (2 of 2) - - - - - - - - - - - - - - - - - - - - 463 Figure 6-1698-bin Mailbox Delivery Head Assembly (1 of 4) - - - - - - - - - - - - - 464 Figure 6-1708-bin Mailbox Delivery Head Assembly (2 of 4) - - - - - - - - - - - - - 465 Figure 6-1718-bin Mailbox Delivery Head Assembly (3 of 4) - - - - - - - - - - - - - 466 Figure 6-1728-bin Mailbox Delivery Head Assembly (4 of 4) - - - - - - - - - - - - - 467 Figure 6-1738-bin Mailbox Interlock Switch - - - - - - - - - - - - - - - - - - - - - - - - - 469 Figure 6-1748-bin Mailbox Diagnostic LED PCA (1 of 2) - - - - - - - - - - - - - - - - 470 Figure 6-1758-bin Mailbox Diagnostic LED PCA (2 of 2) - - - - - - - - - - - - - - - - 471 Figure 6-1768-bin Mailbox User Status LED PCA (1 of 2) - - - - - - - - - - - - - - - 472 Figure 6-1778-bin Mailbox User Status LED PCA (2 of 2) - - - - - - - - - - - - - - - 473 Figure 6-1788-bin Mailbox Adjustable and Fixed Casters- - - - - - - - - - - - - - - - 474 Figure 6-1798-bin Mailbox Attachment Assembly - - - - - - - - - - - - - - - - - - - - - 475 Figure 6-180 Mailbox with Stapler, Stapler Removal or Installation - - - - - - - - - 477 Figure 6-181C-link Cable on Mailbox with Stapler- - - - - - - - - - - - - - - - - - - - - 478 Figure 6-182Back Plate (1 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 479 Figure 6-183Back Plate (2 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 480 Figure 6-184Stapler Controller PCA (1 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - 481 Figure 6-185Stapler Controller PCA (2 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - 482 Figure 6-186Stapler Controller PCA (3 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - 483 Figure 6-187Top Cover Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 484 Figure 6-188Stapler Bed Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 485 Figure 6-189Hinges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 487 Figure 6-190 Optional Output Accessory- - - - - - - - - - - - - - - - - - - - - - - - - - - - 493 Figure 6-191Copy Connect EIO Board (slot 3) - - - - - - - - - - - - - - - - - - - - - - - 494 Figure 6-192 View with HP Digital Copier Stand (preferred configuration) - - - - 495 Figure 6-193View with HP Digital Copier on Tabletop - - - - - - - - - - - - - - - - - - 495 Figure 6-194Orientation of the HP Digital Copier- - - - - - - - - - - - - - - - - - - - - - 499 Figure 6-195Separation Pad Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 500 Figure 6-196Pick Roller Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 501 Figure 6-197Pick Rollers (1 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 502 Figure 6-198Pick Rollers (2 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 503 Figure 6-199Document Holding Pad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 505 Figure 6-200Paper Chute Flip-out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 506 Figure 6-201Output Tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 507 Figure 6-202FB Cover Assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 508 Figure 6-203Thumb Screw for Document Cover Assembly - - - - - - - - - - - - - - 509 Figure 6-204Removing the Cover from the Posts - - - - - - - - - - - - - - - - - - - - - 510 Figure 6-205ADF Latch Cap - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 511 Figure 6-206ADF Cover (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 512 Figure 6-207ADF Cover (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 513 Figure 6-208Front Panel (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 514 Figure 6-209Front Panel (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 515 Figure 6-210 Front Panel Cable Clamp and Front Panel Frame Ground Plate - 516 Figure 6-211Front Panel Ribbon Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - 517 Figure 6-212Unplugging the Ribbon Cable- - - - - - - - - - - - - - - - - - - - - - - - - - 518

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Figure 6-213Panel Cover (bottom view)- - - - - - - - - - - - - - - - - - - - - - - - - - - - 519 Figure 6-214Front Panel Brackets (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - 520 Figure 6-215Front Panel Brackets (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - 521 Figure 6-216Upper Cover (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 522 Figure 6-217Upper Cover (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 523 Figure 6-218Copy Processor Board- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 524 Figure 6-219 Power Supply and Main Board Tray (1 of 2)- - - - - - - - - - - - - - - - 525 Figure 6-220 Power Supply and Main Board Tray (2 of 2)- - - - - - - - - - - - - - - - 526 Figure 6-221RFI Cover (inside/rear view)- - - - - - - - - - - - - - - - - - - - - - - - - - - 527 Figure 6-222RFI Cover (outside/front view) - - - - - - - - - - - - - - - - - - - - - - - - - 528 Figure 6-223Control PCA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 529 Figure 6-224Card Cage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 530 Figure 6-225EEPROM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 531 Figure 6-226Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 532 Figure 6-227 Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 533 Figure 6-228Back PCA- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 534 Figure 6-229Optical Unit (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 535 Figure 6-230Optical Unit (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 536 Figure 6-231ADF Lamp PCA (1 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 537 Figure 6-232ADF Lamp PCA (2 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 538 Figure 6-233ADF Lamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 539 Figure 6-234Sensor Unit Assembly (1 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - 540 Figure 6-235Sensor Unit Assembly (2 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - 541 Figure 6-236Sensor Unit Assembly (3 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - 542 Figure 6-237ADF Motor Unit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 543 Figure 6-238ADF Belt- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 544 Figure 6-239LED Assembly PCA- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 546 Figure 6-240ADF Unit (shown without Optical Unit)- - - - - - - - - - - - - - - - - - - - 547 Figure 6-241Front Panel Frame Ground Spring - - - - - - - - - - - - - - - - - - - - - - 549 Figure 6-242Output Tray Brackets- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 550 Figure 6-243Glass Plate Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 551 Figure 6-244Idle Roller Coil Spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 552 Figure 6-245Home Position Sensor (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - 553 Figure 6-246Home Position Sensor (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - 554 Figure 6-247Dust Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 555 Figure 6-248Lamp (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 556 Figure 6-249Lamp (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 557 Figure 6-250Carrier Unit (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 558 Figure 6-251Carrier Unit (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 559 Figure 6-252Carrier Belt- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 560 Figure 6-253Unplugging the Ribbon Cable- - - - - - - - - - - - - - - - - - - - - - - - - - 561 Figure 6-254Felt Pad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 562 Figure 6-255Feet- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 563 Figure 6-256Frame Ground Spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 564 Figure 6-257Front Lamp PCA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 565 Figure 6-258Junction PCA Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 566 Figure 6-259Junction PCA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 567

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Figure 6-260Front Panel Ribbon Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - 568 Figure 6-261Unplugging the Ribbon Cable- - - - - - - - - - - - - - - - - - - - - - - - - - 569 Figure 6-262Carrier Belt and Motor (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - 570 Figure 6-263Carrier Belt and Motor (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - 571 Figure 7-1 Troubleshooting Process - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 575 Figure 7-2 Print System Troubleshooting Process - - - - - - - - - - - - - - - - - - - 577 Figure 7-3 Printer and Paper-Handling Troubleshooting Process (1 of 2) - - - 578 Figure 7-4 Printer and Paper-Handling Troubleshooting Process (2 of 2) - - - 579 Figure 7-5 Copy Module Troubleshooting Process (1 of 2) - - - - - - - - - - - - - 580 Figure 7-6 Copy Module Troubleshooting Process (2 of 2) - - - - - - - - - - - - - 581 Figure 7-7 C-link Cables, Supported Daisy Chain Connections - - - - - - - - - - 583 Figure 7-8 Sample JetDirect Configuration Page - - - - - - - - - - - - - - - - - - - - 586 Figure 7-9 Fan Location and Airflow- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 596 Figure 7-10 Engine Test Button - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 597 Figure 7-11 Sample Event Log, page one - - - - - - - - - - - - - - - - - - - - - - - - - - 600 Figure 7-12 HP LaserJet 8150 Series Sample Event Log, page two- - - - - - - - 601 Figure 7-13 Error Format for Paper Handling- - - - - - - - - - - - - - - - - - - - - - - - 606 Figure 7-14 Paper Path Jam Locations- - - - - - - - - - - - - - - - - - - - - - - - - - - - 647 Figure 7-15 Paper Path Test Source and Output Selection - - - - - - - - - - - - - - 649 Figure 7-16 Sample Menu Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 652 Figure 7-17 Sample printer Configuration Page (1 of 2) - - - - - - - - - - - - - - - - 654 Figure 7-18 Sample Copy Module Configuration Page - - - - - - - - - - - - - - - - - 655 Figure 7-19 Sample File Directory Page - - - - - - - - - - - - - - - - - - - - - - - - - - - 656 Figure 7-20 Sample Usage Page - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 658 Figure 7-21 Repetitive Defect Ruler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 677 Figure 7-22 High Voltage Power Supply Contacts - - - - - - - - - - - - - - - - - - - - 680 Figure 7-23 8-bin Mailbox LEDs Description - - - - - - - - - - - - - - - - - - - - - - - - 694 Figure 7-24 8-bin Mailbox Power Supply Test Mode Switch - - - - - - - - - - - - - 695 Figure 7-25 Printer Sensors and Swit ches- - - - - - - - - - - - - - - - - - - - - - - - - - 703 Figure 7-26 Printer Motor, Clutches, and Solenoids - - - - - - - - - - - - - - - - - - - 704 Figure 7-27 DC Controller Inputs and Outputs (1 of 5) - - - - - - - - - - - - - - - - - 705 Figure 7-28 DC Controller Inputs and Outputs (2 of 5) - - - - - - - - - - - - - - - - - 706 Figure 7-29 DC Controller Inputs and Outputs (3 of 5) - - - - - - - - - - - - - - - - - 707 Figure 7-30 DC Controller Inputs and Outputs (4 of 5) - - - - - - - - - - - - - - - - - 708 Figure 7-31 DC Controller Inputs and Outputs (5 of 5) - - - - - - - - - - - - - - - - - 709 Figure 7-32 Mailbox with Stapler Wiring Diagram- - - - - - - - - - - - - - - - - - - - - 710 Figure 7-33 2000-sheet Input Tray Controller PCA Inputs- - - - - - - - - - - - - - - 711 Figure 7-34 2000-sheet Input Tray Controller PCA Outputs- - - - - - - - - - - - - - 712 Figure 7-35 2000-sheet Input Tray Main Wiring Diagram - - - - - - - - - - - - - - - 713 Figure 7-36 8-bin Mailbox Main Wiring Diagra m- - - - - - - - - - - - - - - - - - - - - - 714 Figure 7-37 Copy Processor LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 728 Figure 7-38 Locations of ADF Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - 731 Figure 8-1 HP LaserJet 8150 MFP Paper-Handling Components- - - - - - - - - 740 Figure 8-2 Printer Covers and Doors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 742 Figure 8-3 Printer Internal Components (1 of 4) - - - - - - - - - - - - - - - - - - - - - 744 Figure 8-4 Printer Internal Components (2 of 4) - - - - - - - - - - - - - - - - - - - - - 746 Figure 8-5 Printer Internal Components (3 of 4) - - - - - - - - - - - - - - - - - - - - - 748

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Figure 8-6 Printer Internal Components (4 of 4) - - - - - - - - - - - - - - - - - - - - - 750 Figure 8-7 Detail of Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 752 Figure 8-8 PCB Assembly Location Diagram - - - - - - - - - - - - - - - - - - - - - - - 754 Figure 8-9 Face-up Solenoid Assembl y- - - - - - - - - - - - - - - - - - - - - - - - - - - 755 Figure 8-10 2000-sheet Input Tray Components (1 of 2)- - - - - - - - - - - - - - - - 756 Figure 8-11 2000-sheet Input Tray Components (2 of 2)- - - - - - - - - - - - - - - - 758 Figure 8-12 2 x 500-sheet Input Tray Internal Components- - - - - - - - - - - - - - 760 Figure 8-13 7-bin Tabletop Mailbox Intern al Components - - - - - - - - - - - - - - - 763 Figure 8-14 8-bin Mailbox Components (1 of 3) - - - - - - - - - - - - - - - - - - - - - - 766 Figure 8-15 8-bin Mailbox Components (2 of 3) - - - - - - - - - - - - - - - - - - - - - - 768 Figure 8-16 8-bin Mailbox Components (3 of 3) - - - - - - - - - - - - - - - - - - - - - - 770 Figure 8-17 Stapler Internal Components - - - - - - - - - - - - - - - - - - - - - - - - - - 772 Figure 8-18 Assembly Location Diagram- - - - - - - - - - - - - - - - - - - - - - - - - - - 774 Figure 8-19 Covers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 775 Figure 8-20 Flatbed- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 777 Figure 8-21 Glass Plate and PCA Asse mb ly - - - - - - - - - - - - - - - - - - - - - - - - 779 Figure 8-22 Carrier Unit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 781 Figure 8-23 ADF Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 782 Figure 8-24 Optical Unit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 785 Figure 8-25 Document Cover Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - 786 Figure 8-26 Screws (1 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 787 Figure 8-27 Screws (2 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 787 Figure 8-28 Screws (3 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 788 Figure 8-29 Screws (4 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 788

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