HP 8100 DN, 8100 N, 8100 Service Manual

HP LaserJet 8100, 8100 N, 8100 DN

English

and Paper Handling Devices Service Manual

Service Manual

HP LaserJet 8100 (C4214A) HP LaserJet 8100 N (C4215A) HP LaserJet 8100 DN (C4216A) Paper Handling Devices

Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws.

Publication number C4214-91000

First edition, October 1998

Trademark Credits

Adobe and PostScript are trademarks of Adobe Systems Incorporated which may be registered in certain jurisdictions.

Windows is a U.S. registered trademark of Microsoft Corporation.

Warranty

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

Hewlett-Packard makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties or merchantability and fitness for a particular purpose.

Hewlett-Packard shall not be liable for errors co ntained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material.

WARNING

Electrical Shock Hazard To avoid electrical shock, use

only supplied power cords and connect only to properly grounded wall outlets.

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

Conventions

This manual uses the following conventions: The names of major printer parts and assemblies are Capitalized.

Color is used to emphasize items which are important to the material

under discussion.

italic

Bold is used for emphasis, particularly in situations where would be confusing.

type

Italic type

Note Notes contain important information set off from the text.

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.

The illustration below shows the orientation of the paper-handling accessories as they are referred to in this publication.

is used to indicate related documents or emphasis.

C4214-91000 iii

Chapter Descriptions

1 Product Information

Contains printer features and product overview, tray capacities and sizes, media specifications, service approach, how to get technical assistance, and required safety and compliance statements.

2 Site Requirements

Contains space and environmental requirements.

3 Operating Overview

Contains details about control panel menus, restoring factory defaults, and resetting and testing the printer.

4 Maintenance and Adjustments

Contains cleaning and preventive maintenance information, and adjustment procedures for all paper trays.

5 Functional Overview

Contains block diagrams and basic theory of operation for the printer systems, paper paths, and paper handling devices. Contains basic cabling information.

6 Removal and Replacement

Contains step-by-step procedures for replacing field replaceab le units (FRUs) in the printer and paper-handling devices.

7 Troubleshooting

Contains a preliminary troubleshooting table, a table with descriptions and recommended actions for all control panel messages, image defect samples, paper handling problems, and troubleshooting checks and tools.

iv C4214-91000

8 Parts and Diagrams

Contains exploded view drawings and part number listings for all replaceable parts in the printer and paper-handling devices.

Contains two replaceable parts tables: one sorted alphabetically by part name, and one sorted numerically by part number. Both tables are cross referenced to the diagrams in the chapter.

Subject Index

Contains an alphabetical, cross referenced listing of information f ound in the main body of the manual.

C4214-91000 v

vi C4214-91000

Table of Contents

1 Product Information

Printer Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Paper Capacities and Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Model and Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Media Selection Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Envelopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Adhesive Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Transparencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Storing Print Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Shipping Print Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

External View of HP LaserJet 8100/N/DN Engine . . . . . . . . .14

Formatter Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Paper-handling Devices, Accessories, and Options . . . . . . . . . . .17

Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Hard Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Determining Memory Requirements. . . . . . . . . . . . . . . . . . . .24

Service Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Ordering Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Exchange Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Toner Cartridge Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Refilled Toner Cartridges and Non-HP Staple Cartridges . . .28

Recycling Toner Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . .28

Technical Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

HP FIRST (Fax Information Retrieval Support Technology). .29

Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

World Wide Web. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

HP Reseller Sales and Service Support Line (US Only). . . . .30

Other Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Regulatory Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

FCC Regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Environmental Product Stewardship. . . . . . . . . . . . . . . . . . . .34

Material Safety Data Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . .36

Environmental Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Safety Statements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

C4214-91000 vii

2 Site Requirements

Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Space Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

3 Operating Overview

Using the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Control Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Settings and Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Printer Driver Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Paper Source Default . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Performing a Cold Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Setting the Display Language. . . . . . . . . . . . . . . . . . . . . . . . .54

Control Panel Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Quick Copy Jobs Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Private/Stored Jobs Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Paper Handling Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Print Quality Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Printing Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Configuration Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

I/O Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

EIO Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Resets Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Setting Page Count, Maintenance Count,

and Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Setting the Cold Reset Default Paper Size. . . . . . . . . . . . . . .80

Testing the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Paper Path Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Configuration Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

4 Maintenance and Adjustments

Cleaning the Printer and Accessories. . . . . . . . . . . . . . . . . . . . . .86

Cleaning the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Cleaning Spilled Toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Tray Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

2000-sheet Input Tray Adjustment Procedure. . . . . . . . . . . . . . . .92

viii C4214-91000

5 Functional Overview

Printer Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . .96

Power Distribution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

AC Power Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Overcurrent/Overvoltage Protection . . . . . . . . . . . . . . . . . . . .98

High Voltage Power Distribution. . . . . . . . . . . . . . . . . . . . . . .99

Formatter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

DC Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Laser and Scanner Drive . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Paper Motion Monitoring and Control. . . . . . . . . . . . . . . . . .103

Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Engine Test Microswitch. . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Image Formation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Toner Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

Drum Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Drum Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Image Writing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

Image Developing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Image Transferring and Media Separation . . . . . . . . . . . . . .114

Image Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

Paper Paths and Components . . . . . . . . . . . . . . . . . . . . . . . . . .116

Printer, Duplexer, and Envelope Feeder. . . . . . . . . . . . . . . .116

Paper Size Switches (Trays 2 and 3) . . . . . . . . . . . . . . . . . .119

Printing from Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Printing from Trays 2 and 3. . . . . . . . . . . . . . . . . . . . . . . . . .119

Printing from the Envelope Feeder. . . . . . . . . . . . . . . . . . . .120

Printing with the Duplexer. . . . . . . . . . . . . . . . . . . . . . . . . . .120

2000-sheet Input Tray (Tray 4) Components . . . . . . . . . . . .121

2000-Sheet Input Tray Operation . . . . . . . . . . . . . . . . . . . . .123

2 x 500-sheet Input Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . .126

2 x 500-sheet Input Tray Operation . . . . . . . . . . . . . . . . . . .128

7-bin Tabletop Mailbox Components . . . . . . . . . . . . . . . . . .130

7-bin Tabletop Mailbox Operation. . . . . . . . . . . . . . . . . . . . .132

8-bin Mailbox Components. . . . . . . . . . . . . . . . . . . . . . . . . .136

8-bin Mailbox Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Finisher Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Stapler Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Main Functional Cycles of the Stapler (Internal Paper Path)145

Communication Link (Daisy Chain). . . . . . . . . . . . . . . . . . . .146

Paper Jam Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Printer Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

IEEE 1284 Parallel Cable Information. . . . . . . . . . . . . . . . . . . . .150

C4214-91000 Table of Contents ix

6 Removal and Replacement

Removal and Replacement Strategy. . . . . . . . . . . . . . . . . . . . . .152

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153

User Installable Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . .154

Memory and Personality Upgrade . . . . . . . . . . . . . . . . . . . .154

Duplexer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

Envelope Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

2000-sheet or 2 x 500-sheet Input Tray . . . . . . . . . . . . . . . .157

8-bin Mailbox/5-bin Mailbox with Stapler . . . . . . . . . . . . . . .158

7-bin Tabletop Mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159

Hardware Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162

Engine Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . .164

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165

Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167

Delivery Unit (for Face-down Bin). . . . . . . . . . . . . . . . . . . . .176

Diverter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179

Diverter Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .180

Lower Right Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . .181

Fan 1, Laser/Scanner and Housing (Exhaust) . . . . . . . . . . .184

Fan 2, Low Voltage Power Supply (Exhaust) . . . . . . . . . . . .186

Fan 3, Formatter Fan and Housing (Intake) . . . . . . . . . . . . .187

Fan 4, Delivery Unit (Exhaust) . . . . . . . . . . . . . . . . . . . . . . .188

Fan 5, Tray 1 (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189

Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191

Tray 1 Pickup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .194

Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198

Formatter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200

Fusing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202

Laser/Scanner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .204

Main Gear Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206

Main Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209

Paper Input Unit (PIU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210

PCA, DC Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211

Output Paper Sensor PCA . . . . . . . . . . . . . . . . . . . . . . . . . .212

High Voltage Power Supply (HVPS). . . . . . . . . . . . . . . . . . .219

Low Voltage Power Supply (LVPS) . . . . . . . . . . . . . . . . . . .220

Registration Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221

Tray 1 Feed Roller and Separation Pad . . . . . . . . . . . . . . . .224

Tray 2 and 3 Pickup, Feed, and Separation Rollers. . . . . . .226

Paper Input Unit Sensor (PS2) . . . . . . . . . . . . . . . . . . . . . . .227

Registration Sensor (PS1) . . . . . . . . . . . . . . . . . . . . . . . . . .229

Face-up Solenoid Assembly (SL3) . . . . . . . . . . . . . . . . . . . .231

Transfer Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .232

Tray 2 and 3 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . .234

2000-sheet Input Tray Removal and Replacement. . . . . . . . . . .235

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236

x C4214-91000

Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237

Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238

Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239

Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240

Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241

Paper Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243

Main Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246

Front LED PCA Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . .248

Pickup Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252

Pickup, Feed, and Separation Rollers . . . . . . . . . . . . . . . . .254

Paper Quantity Switch Assembly . . . . . . . . . . . . . . . . . . . . .257

Paper Size Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . .257

Vertical Transfer Unit (VTU) . . . . . . . . . . . . . . . . . . . . . . . . .259

Tension Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261

Locating Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262

Casters and Stabilizing Feet. . . . . . . . . . . . . . . . . . . . . . . . .263

Adjustable Foot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264

2 x 500-sheet Input Tray Removal and Replacement. . . . . . . . .265

Orientation of the 2 x 500-sheet Input Tray . . . . . . . . . . . . .266

Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267

Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268

Vertical Transfer Unit (VTU) . . . . . . . . . . . . . . . . . . . . . . . . .269

Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272

Front Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275

Trays 4 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278

Pickup Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280

Paper Deck Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . .282

Pickup, Feed, and Separation Rollers . . . . . . . . . . . . . . . . .284

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285

Tray-Size Sensing PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . .286

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288

Main Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289

Storage Paper Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291

Front Door (Storage Area) . . . . . . . . . . . . . . . . . . . . . . . . . .292

Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293

Foot Tip and Adjustable Foot Tip (Stabilizing Feet) . . . . . . .294

Locating Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295

Front LED PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296

7-bin Tabletop Mailbox Removal and Replacement . . . . . . . . . .297

Orientation of the 7-bin Tabletop Mailbox. . . . . . . . . . . . . . .298

Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299

Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302

Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309

C4214-91000 Table of Contents xi

Right Door Assembly (Paper Path Cover) . . . . . . . . . . . . . .310

Face-down Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314

Empty Bin Sensor PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . .317

Full Bin and Interlock Sensor PCA . . . . . . . . . . . . . . . . . . . .319

LED PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321

Face-up Sensors PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322

Reversing Mechanism Motor . . . . . . . . . . . . . . . . . . . . . . . .323

Face-up/Diverter Assembly (Flipper) . . . . . . . . . . . . . . . . . .325

Short Tray 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328

Solenoid Reversing Mechanism . . . . . . . . . . . . . . . . . . . . . .329

Flipper Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330

Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331

Latching Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .332

Cover Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333

8-bin Mailbox Removal and Replacement. . . . . . . . . . . . . . . . . .334

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335

Front and Back Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . .336

Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338

Paper Bins and Blind Cover . . . . . . . . . . . . . . . . . . . . . . . . .339

Flipper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340

Delivery Head Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343

Transport Belt Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .344

Input Paper Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .346

Metal Tape and Housing Assembly . . . . . . . . . . . . . . . . . . .348

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350

Anticurl Strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352

Delivery Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .354

Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359

Diagnostic LED PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .360

User Status LED PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .362

Adjustable and Fixed Casters. . . . . . . . . . . . . . . . . . . . . . . .364

Attachment Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365

Stapler Assembly Removal and Replacement . . . . . . . . . . . . . .366

Mailbox with Stapler, Stapler Removal or Installation. . . . . .367

Back Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369

Stapler Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371

Top Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374

Stapler Bed Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375

Hinges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .377

xii C4214-91000

7 Troubleshooting

Troubleshooting Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .380

Troubleshooting the Printing System . . . . . . . . . . . . . . . . . . . . .384

Preliminary Operating Checks . . . . . . . . . . . . . . . . . . . . . . .384

General Troubleshooting Information . . . . . . . . . . . . . . . . . . . . .385

Miscellaneous Problems and Solutions . . . . . . . . . . . . . . . .385

Paper Curl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390

Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391

Engine Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .394

Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .395

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .395

General Paper Path Troubleshooting . . . . . . . . . . . . . . . . . . . . .399

Paper Jams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400

Paper Path Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402

Printer Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405

Control Panel Messages and Errors. . . . . . . . . . . . . . . . . . .405

Printer Message Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . .408

Self - Diagnostics on Paper-handling Devices . . . . . . . . . . . . . .445

2000-sheet Input Tray Stand-alone Diagnostics. . . . . . . . . .445

2 x 500-sheet Input Tray Standalone Diagnostics . . . . . . . .449

7-bin Tabletop Mailbox Standalone Diagnostics. . . . . . . . . .453

8-bin Mailbox Stand-alone Diagnostics. . . . . . . . . . . . . . . . .458

Information Pages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .466

Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .466

Configuration Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .468

Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473

Interface Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . .473

Image Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .475

Check the Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . .476

Image Quality Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477

Repetitive Defect Ruler. . . . . . . . . . . . . . . . . . . . . . . . . . . . .490

Image System Troubleshooting . . . . . . . . . . . . . . . . . . . . . .492

High-Voltage Power Supply Check. . . . . . . . . . . . . . . . . . . .493

Network Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .495

Verify Host System Operation. . . . . . . . . . . . . . . . . . . . . . . .497

Verify Network and Server Operation. . . . . . . . . . . . . . . . . .497

Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .498

8 Parts and Diagrams

How to Use the Part Lists and Diagrams . . . . . . . . . . . . . . . . . .512

Ordering Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .512

Accessories and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .513

Common Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .513

Illustrations and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . .513

Alphabetical Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549

Numerical Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .559

C4214-91000 Table of Contents xiii

xiv C4214-91000

List of Figures

Figure 1-1 Sample Model and Serial Number Label for the Printer - - - - - - 6 Figure 1-2 Dimensions of Paper Handling Devices - - - - - - - - - - - - - - 8 Figure 1-3 HP LaserJet 8100/N/DN Engine - Front and Right

Side View with Tray 1 Open- - - - - - - - - - - - - - - - - - - 14 Figure 1-4 Rear and Left Side View - - - - - - - - - - - - - - - - - - - - 16 Figure 1-5 HP LaserJet 8100/N/DN Optional Paper Handling Devices- - - - 17 Figure 1-6 Sample 4% Page Coverage- - - - - - - - - - - - - - - - - - - 27 Figure 2-1 Printer Space Requirements (Top view) - - - - - - - - - - - - - 45 Figure 2-2 Printer Space Requirements (Side view)- - - - - - - - - - - - - 45 Figure 2-3 Printer Space Requirements (with Mailbox and Input Device) - - 46 Figure 3-1 Control Panel Layout - - - - - - - - - - - - - - - - - - - - - - 50 Figure 3-2 Configuration Page (varies with installed options) - - - - - - - - 82 Figure 3-3 Menu Map Page (varies with installed options)- - - - - - - - - - 83 Figure 4-1 Image Area Margins - - - - - - - - - - - - - - - - - - - - - - 90 Figure 4-2 Tray Position Adjustment - - - - - - - - - - - - - - - - - - - - 91 Figure 4-3 Tray 4 Position Adjustment - - - - - - - - - - - - - - - - - - - 92 Figure 5-1 Printer Functional Block Diagram - - - - - - - - - - - - - - - - 96 Figure 5-2 Low Voltage Power Distribution System - - - - - - - - - - - - - 97 Figure 5-3 Low Voltage Power Supply - - - - - - - - - - - - - - - - - - - 98 Figure 5-4 High Voltage Power Supply Contacts - - - - - - - - - - - - - - 99 Figure 5-5 Normal Mode vs EconoMode - - - - - - - - - - - - - - - - - - 102 Figure 5-6 Image Formation Block Diagram - - - - - - - - - - - - - - - - 105 Figure 5-7 Photosensitive Drum - - - - - - - - - - - - - - - - - - - - - - 107 Figure 5-8 Drum Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - 108 Figure 5-9 Primary Charging Roller- - - - - - - - - - - - - - - - - - - - - 109 Figure 5-10 Image Writing- - - - - - - - - - - - - - - - - - - - - - - - - - 110 Figure 5-11 Image Development - - - - - - - - - - - - - - - - - - - - - - 113 Figure 5-12 Image Transferring and Media Separation- - - - - - - - - - - - 114 Figure 5-13 Image Fusing- - - - - - - - - - - - - - - - - - - - - - - - - - 115 Figure 5-14 Printer Paper Paths- - - - - - - - - - - - - - - - - - - - - - - 116 Figure 5-15 Printer Sensors, Solenoids, Clutches, Motors, and Fans - - - - - 118 Figure 5-16 2000-sheet Input Tray Paper Path- - - - - - - - - - - - - - - - 121 Figure 5-17 2000-sheet Input Tray Sensors, Switches, Clutches, and Motors- 123 Figure 5-18 2 x 500-sheet Input Tray Paper Path - - - - - - - - - - - - - - 126 Figure 5-19 2 x 500-sheet input Tray Sensors and Switches - - - - - - - - - 127 Figure 5-20 7-bin Tabletop Mailbox Components (1 of 2)- - - - - - - - - - - 130 Figure 5-21 7-bin Tabletop Mailbox Components (2 of 2)- - - - - - - - - - - 131 Figure 5-22 7-bin Tabletop Mailbox Block Diagram- - - - - - - - - - - - - - 135 Figure 5-23 8-bin Mailbox Paper Path - - - - - - - - - - - - - - - - - - - - 136 Figure 5-24 8-bin Mailbox Sensors, Switches, Motors, and Controller PCA - - 138 Figure 5-25 Finisher Paper Path- - - - - - - - - - - - - - - - - - - - - - - 142

C4214-91000 xv

Figure 5-26 Stapler Motors, Sensors, and Switches - - - - - - - - - - - - - 142 Figure 5-27 Stapler Cycles - - - - - - - - - - - - - - - - - - - - - - - - - 145 Figure 5-28 Recommended C-link Configuration (Daisy Chain)- - - - - - - - 147 Figure 5-29 General Timing Diagram - - - - - - - - - - - - - - - - - - - - 149 Figure 5-30 Parallel Cable Pin Assignments (C2946A)- - - - - - - - - - - - 150 Figure 6-1 Phillips vs. Posidriv Screwdrivers - - - - - - - - - - - - - - - - 153 Figure 6-2 Disk Drive - - - - - - - - - - - - - - - - - - - - - - - - - - - 155 Figure 6-3 Control Panel (1 of 2) - - - - - - - - - - - - - - - - - - - - - - 165 Figure 6-4 Control Panel (2 of 2) - - - - - - - - - - - - - - - - - - - - - - 166 Figure 6-5 AC Access Cover- - - - - - - - - - - - - - - - - - - - - - - - 168 Figure 6-6 Back Cover- - - - - - - - - - - - - - - - - - - - - - - - - - - 169 Figure 6-7 Front Cover (1 of 2)- - - - - - - - - - - - - - - - - - - - - - - 170 Figure 6-8 Front Cover (2 of 2)- - - - - - - - - - - - - - - - - - - - - - - 171 Figure 6-9 Left Lower Cover - - - - - - - - - - - - - - - - - - - - - - - - 172 Figure 6-10 Top Cover (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - 173 Figure 6-11 Top Cover (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - 174 Figure 6-12 Delivery Unit (1 of 2) - - - - - - - - - - - - - - - - - - - - - - 176 Figure 6-13 Delivery Unit (2 of 2) - - - - - - - - - - - - - - - - - - - - - - 177 Figure 6-14 Diverter Assembly - - - - - - - - - - - - - - - - - - - - - - - 179 Figure 6-15 Diverter Door Assembly- - - - - - - - - - - - - - - - - - - - - 180 Figure 6-16 Lower Right Door Assembly (1 of 3)- - - - - - - - - - - - - - - 181 Figure 6-17 Right Lower Door Assembly (2 of 3)- - - - - - - - - - - - - - - 182 Figure 6-18 Right Lower Door Assembly (3 of 3)- - - - - - - - - - - - - - - 183 Figure 6-19 Fan 1, Laser/Scanner (1 of 2) - - - - - - - - - - - - - - - - - - 184 Figure 6-20 Fan 1, Laser/Scanner (2 of 2) - - - - - - - - - - - - - - - - - - 185 Figure 6-21 Fan 2, Low Voltage Power Supply- - - - - - - - - - - - - - - - 186 Figure 6-22 Fan 3, Formatter Fan - - - - - - - - - - - - - - - - - - - - - - 187 Figure 6-23 Fan 4, Delivery Unit- - - - - - - - - - - - - - - - - - - - - - - 188 Figure 6-24 Fan 5 Removal (1 of 2) - - - - - - - - - - - - - - - - - - - - - 189 Figure 6-25 Fan 5 Removal (2 of 2) - - - - - - - - - - - - - - - - - - - - - 190 Figure 6-26 Tray 1 Removal (1 of 3)- - - - - - - - - - - - - - - - - - - - - 191 Figure 6-27 Tray 1 Removal (2 of 3)- - - - - - - - - - - - - - - - - - - - - 192 Figure 6-28 Tray 1 Removal (3 of 3)- - - - - - - - - - - - - - - - - - - - - 193 Figure 6-29 Tray 1 Pickup Unit Removal (1 of 4)- - - - - - - - - - - - - - - 194 Figure 6-30 Tray 1 Pickup Unit Removal (2 of 4)- - - - - - - - - - - - - - - 195 Figure 6-31 Tray 1 Pickup Unit Removal (3 of 4)- - - - - - - - - - - - - - - 196 Figure 6-32 Tray 1 Pickup Unit Removal (4 of 4)- - - - - - - - - - - - - - - 197 Figure 6-33 Feeder Assembly (1 of 2) - - - - - - - - - - - - - - - - - - - - 198 Figure 6-34 Feeder Assembly (2 of 2) - - - - - - - - - - - - - - - - - - - - 199 Figure 6-35 Formatter Assembly - - - - - - - - - - - - - - - - - - - - - - 201 Figure 6-36 Fusing Assembly - - - - - - - - - - - - - - - - - - - - - - - - 202 Figure 6-37 Laser/Scanner Assembly - - - - - - - - - - - - - - - - - - - - 204 Figure 6-38 Main Gear Assembly (1 of 3) - - - - - - - - - - - - - - - - - - 206 Figure 6-39 Main Gear Assembly (2 of 3) - - - - - - - - - - - - - - - - - - 207 Figure 6-40 Main Gear Assembly (3 of 3) - - - - - - - - - - - - - - - - - - 208 Figure 6-41 Main Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - 209 Figure 6-42 Paper Input Unit - - - - - - - - - - - - - - - - - - - - - - - - 210

xvi C4214-91000

Figure 6-43 DC Controller PCA - - - - - - - - - - - - - - - - - - - - - - - 211 Figure 6-44 Output Paper Sensor PCA (1 of 4) - - - - - - - - - - - - - - - 212 Figure 6-45 Output Paper Sensor PCA (2 of 4) - - - - - - - - - - - - - - - 213 Figure 6-46 Output Paper Sensor PCA (3 of 4) - - - - - - - - - - - - - - - 214 Figure 6-47 Output Paper Sensor PCA (4 of 4) - - - - - - - - - - - - - - - 215 Figure 6-48 Paper Size PCA (1 of 3)- - - - - - - - - - - - - - - - - - - - - 216 Figure 6-49 Paper Size PCA (2 of 3)- - - - - - - - - - - - - - - - - - - - - 217 Figure 6-50 Paper Size PCA (3 of 3)- - - - - - - - - - - - - - - - - - - - - 218 Figure 6-51 High Voltage Power Supply - - - - - - - - - - - - - - - - - - - 219 Figure 6-52 Low Voltage Power Supply - - - - - - - - - - - - - - - - - - - 220 Figure 6-53 Registration Assembly (1 of 3) - - - - - - - - - - - - - - - - - 221 Figure 6-54 Registration Assembly (2 of 3) - - - - - - - - - - - - - - - - - 222 Figure 6-55 Registration Assembly (3 of 3) - - - - - - - - - - - - - - - - - 223 Figure 6-56 Tray 1 Feed Roller - - - - - - - - - - - - - - - - - - - - - - - 224 Figure 6-57 Tray 1 Separation Pad - - - - - - - - - - - - - - - - - - - - - 225 Figure 6-58 Tray 2 and 3, Pickup, Feed, and Separation Rollers - - - - - - - 226 Figure 6-59 Paper Input Unit Sensor (PS2) - - - - - - - - - - - - - - - - - 228 Figure 6-60 Registration Sensor (PS1) - - - - - - - - - - - - - - - - - - - 230 Figure 6-61 Face-up Solenoid Assembly, SL3 - - - - - - - - - - - - - - - - 231 Figure 6-62 Transfer Roller Assembly - - - - - - - - - - - - - - - - - - - - 232 Figure 6-63 2000-sheet Input Tray Orientation- - - - - - - - - - - - - - - - 236 Figure 6-64 2000-sheet Input Tray Front Cover - - - - - - - - - - - - - - - 237 Figure 6-65 2000-sheet Input Tray Back Cover - - - - - - - - - - - - - - - 238 Figure 6-66 2000-sheet Input Tray Left Cover - - - - - - - - - - - - - - - - 239 Figure 6-67 2000-sheet Input Tray Right Cover - - - - - - - - - - - - - - - 240 Figure 6-68 2000-sheet Input Tray Main Drive Assembly- - - - - - - - - - - 241 Figure 6-69 2000-sheet Input Tray Paper Tray- - - - - - - - - - - - - - - - 243 Figure 6-70 2000-sheet Input Tray Main Cable Harness - - - - - - - - - - - 245 Figure 6-71 2000-sheet Input Tray Controller PCA- - - - - - - - - - - - - - 246 Figure 6-72 2000-sheet Input Tray Front LED PCA - - - - - - - - - - - - - 249 Figure 6-73 2000-sheet Input Tray Pickup Assembly- - - - - - - - - - - - - 250 Figure 6-74 2000-sheet Input Tray Power Supply - - - - - - - - - - - - - - 252 Figure 6-75 2000-sheet Input Tray Rollers: Pickup, Feed, and Separation - - 255 Figure 6-76 2000-sheet Input Tray Paper Size and Paper Quantity Switch - - 258 Figure 6-77 2000-sheet Input Tray Paper Size and Paper Quantity Switch

Assemblies (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - 258 Figure 6-78 2000-sheet Input Tray Vertical Transfer Unit (VTU) - - - - - - - 259 Figure 6-79 2000-sheet Input Tray Tension Springs - - - - - - - - - - - - - 261 Figure 6-80 2000-sheet Input Tray Locating Pins - - - - - - - - - - - - - - 262 Figure 6-81 2000-sheet Input Tray Casters - - - - - - - - - - - - - - - - - 263 Figure 6-82 2000-sheet Input Tray Adjustable Foot - - - - - - - - - - - - - 264 Figure 6-83 Orientation of the 2 x 500-sheet Input Tray - - - - - - - - - - - 266 Figure 6-84 Back Cover- - - - - - - - - - - - - - - - - - - - - - - - - - - 267 Figure 6-85 Left Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - 268 Figure 6-86 Vertical Transfer Unit (VTU) (1 of 3) - - - - - - - - - - - - - - - 269 Figure 6-87 Vertical Transfer Unit (VTU) (2 of 3) - - - - - - - - - - - - - - - 270 Figure 6-88 Vertical Transfer Unit (VTU) (3 of 3) - - - - - - - - - - - - - - - 271

C4214-91000 List of Figures xvii

Figure 6-89 Right Cover (1 of 3)- - - - - - - - - - - - - - - - - - - - - - - 272 Figure 6-90 Right Cover (2 of 3)- - - - - - - - - - - - - - - - - - - - - - - 273 Figure 6-91 Right Cover (3 of 3)- - - - - - - - - - - - - - - - - - - - - - - 274 Figure 6-92 Front Top Cover (1 of 3) - - - - - - - - - - - - - - - - - - - - 275 Figure 6-93 Front Top Cover (2 of 3) - - - - - - - - - - - - - - - - - - - - 276 Figure 6-94 Front Top Cover (3 of 3) - - - - - - - - - - - - - - - - - - - - 277 Figure 6-95 Trays 4 and 5 (1 of 2) - - - - - - - - - - - - - - - - - - - - - - 278 Figure 6-96 Trays 4 and 5 (2 of 2) - - - - - - - - - - - - - - - - - - - - - - 279 Figure 6-97 Pickup Assembly (1 of 2) - - - - - - - - - - - - - - - - - - - - 280 Figure 6-98 Pickup Assembly (2 of 2) - - - - - - - - - - - - - - - - - - - - 281 Figure 6-99 Paper Deck Drive Assembly (1 of 2)- - - - - - - - - - - - - - - 282 Figure 6-100 Paper Deck Drive Assembly (2 of 2)- - - - - - - - - - - - - - - 283 Figure 6-101 Pickup, Feed, and Separation Rollers - - - - - - - - - - - - - - 284 Figure 6-102 2 x 500-sheet Input Tray Controller PCA- - - - - - - - - - - - - 285 Figure 6-103 Tray-Size Sensing PCA (1 of 2) - - - - - - - - - - - - - - - - - 286 Figure 6-104 Tray-Size Sensing PCA (2 of 2) - - - - - - - - - - - - - - - - - 287 Figure 6-105 Power Supply- - - - - - - - - - - - - - - - - - - - - - - - - - 288 Figure 6-106 Main Cable (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - 289 Figure 6-107 Main Cable (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - 290 Figure 6-108 Storage Paper Tray - - - - - - - - - - - - - - - - - - - - - - - 291 Figure 6-109 Front Door (Storage Area) - - - - - - - - - - - - - - - - - - - 292 Figure 6-110 Casters- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 293 Figure 6-111 Foot Tip and Adjustable Foot Tip - - - - - - - - - - - - - - - - 294 Figure 6-112 Locating Pins - - - - - - - - - - - - - - - - - - - - - - - - - - 295 Figure 6-113 Front LED PCA - - - - - - - - - - - - - - - - - - - - - - - - - 296 Figure 6-114 Orientation of the 7-bin Tabletop Mailbox - - - - - - - - - - - - 298 Figure 6-115 Front cover (1 of 3) - - - - - - - - - - - - - - - - - - - - - - - 299 Figure 6-116 Front cover (2 of 3) - - - - - - - - - - - - - - - - - - - - - - - 300 Figure 6-117 Front cover (3 of 3) - - - - - - - - - - - - - - - - - - - - - - - 301 Figure 6-118 Back cover (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - 302 Figure 6-119 Back cover (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - 303 Figure 6-120 Top cover (1 of 4)- - - - - - - - - - - - - - - - - - - - - - - - 304 Figure 6-121 Top cover (2 of 4)- - - - - - - - - - - - - - - - - - - - - - - - 305 Figure 6-122 Top cover (3 of 4)- - - - - - - - - - - - - - - - - - - - - - - - 306 Figure 6-123 Top cover (4 of 4)- - - - - - - - - - - - - - - - - - - - - - - - 307 Figure 6-124 Mailbox Controller PCA - - - - - - - - - - - - - - - - - - - - - 308 Figure 6-125 Mailbox Power Supply - - - - - - - - - - - - - - - - - - - - - 309 Figure 6-126 Right Door Assembly (Paper Path Cover) (1 of 5) - - - - - - - - 310 Figure 6-127 Right Door Assembly (Paper Path Cover) (2 of 5) - - - - - - - - 311 Figure 6-128 Right Door Assembly (Paper Path Cover) (3 of 5) - - - - - - - - 311 Figure 6-129 Right Door Assembly (Paper Path Cover) (3 of 5) - - - - - - - - 312 Figure 6-130 Right Door Assembly (Paper Path Cover) (4 of 5) - - - - - - - - 313 Figure 6-131 Face-down Bins (1 of 3)- - - - - - - - - - - - - - - - - - - - - 314 Figure 6-132 Face-down Bins (2 of 3)- - - - - - - - - - - - - - - - - - - - - 315 Figure 6-133 Face-down Bins (3 of 3)- - - - - - - - - - - - - - - - - - - - - 316 Figure 6-134 Empty Bin Sensor PCA (1 of 2) - - - - - - - - - - - - - - - - - 317 Figure 6-135 Empty Bin Sensor PCA (2 of 2) - - - - - - - - - - - - - - - - - 318

xviii C4214-91000

Figure 6-136 Full Bin and Interlock Sensor PCA (1 of 2)- - - - - - - - - - - - 319 Figure 6-137 Full Bin and Interlock Sensor PCA (2 of 2)- - - - - - - - - - - - 320 Figure 6-138 LED PCA - - - - - - - - - - - - - - - - - - - - - - - - - - - - 321 Figure 6-139 Face-up Sensors PCA - - - - - - - - - - - - - - - - - - - - - 322 Figure 6-140 Reversing Mechanism Motor (1 of 2) - - - - - - - - - - - - - - 323 Figure 6-141 Reversing Mechanism Motor (2 of 2) - - - - - - - - - - - - - - 324 Figure 6-142 Face-up/Diverter Assembly (Flipper) (1 of 3)- - - - - - - - - - - 325 Figure 6-143 Face-up/Diverter Assembly (Flipper) (2 of 3)- - - - - - - - - - - 326 Figure 6-144 Face-up/Diverter Assembly (Flipper) (3 of 3)- - - - - - - - - - - 327 Figure 6-145 Short Tray 7 - - - - - - - - - - - - - - - - - - - - - - - - - - 328 Figure 6-146 Solenoid Reversing Mechanism - - - - - - - - - - - - - - - - - 329 Figure 6-147 Flipper Solenoid - - - - - - - - - - - - - - - - - - - - - - - - 330 Figure 6-148 7-bin Tabletop Mailbox Handle - - - - - - - - - - - - - - - - - 331 Figure 6-149 Latching Mechanism - - - - - - - - - - - - - - - - - - - - - - 332 Figure 6-150 Cover Latch - - - - - - - - - - - - - - - - - - - - - - - - - - 333 Figure 6-151 Orientation of the 8-bin Mailbox - - - - - - - - - - - - - - - - - 335 Figure 6-152 8-bin Mailbox Covers (Front and Back) - - - - - - - - - - - - - 336 Figure 6-153 8-bin Mailbox Top Cover - - - - - - - - - - - - - - - - - - - - 337 Figure 6-154 8-bin Mailbox Power Supply- - - - - - - - - - - - - - - - - - - 338 Figure 6-155 8-bin Mailbox Paper Bins and Blind Cover - - - - - - - - - - - - 339 Figure 6-156 8-bin Mailbox Flipper Assembly (1 of 3) - - - - - - - - - - - - - 340 Figure 6-157 8-bin Mailbox Flipper Assembly (2 of 3) - - - - - - - - - - - - - 341 Figure 6-158 8-bin Mailbox Flipper Assembly (3 of 3) - - - - - - - - - - - - - 342 Figure 6-159 8-bin Mailbox Delivery Head Motor - - - - - - - - - - - - - - - 343 Figure 6-160 8-bin Mailbox Transport Belt Motor - - - - - - - - - - - - - - - 344 Figure 6-161 8-bin Mailbox Input Paper Guide (1 of 2)- - - - - - - - - - - - - 346 Figure 6-162 8-bin Mailbox Input Paper Guide (2 of 2)- - - - - - - - - - - - - 347 Figure 6-163 8-bin Mailbox Metal Tape and Housing Assembly (1 of 2) - - - - 348 Figure 6-164 8-bin Mailbox Metal Tape and Housing Assembly (2 of 2) - - - - 349 Figure 6-165 8-bin Mailbox Controller PCA (1 of 2) - - - - - - - - - - - - - - 350 Figure 6-166 8-bin Mailbox Controller PCA (2 of 2) - - - - - - - - - - - - - - 351 Figure 6-167 8-bin Mailbox Anticurl Strings (1 of 2) - - - - - - - - - - - - - - 352 Figure 6-168 8-bin Mailbox Anticurl Strings (2 of 2) - - - - - - - - - - - - - - 353 Figure 6-169 8-bin Mailbox Delivery Head Assembly (1 of 4) - - - - - - - - - 354 Figure 6-170 8-bin Mailbox Delivery Head Assembly (2 of 4) - - - - - - - - - 355 Figure 6-171 8-bin Mailbox Delivery Head Assembly (3 of 4) - - - - - - - - - 356 Figure 6-172 8-bin Mailbox Delivery Head Assembly (4 of 4) - - - - - - - - - 357 Figure 6-173 8-bin Mailbox Interlock Switch- - - - - - - - - - - - - - - - - - 359 Figure 6-174 8-bin Mailbox Diagnostic LED PCA (1 of 2) - - - - - - - - - - - 360 Figure 6-175 8-bin Mailbox Diagnostic LED PCA (2 of 2) - - - - - - - - - - - 361 Figure 6-176 8-bin Mailbox User Status LED PCA (1 of 2)- - - - - - - - - - - 362 Figure 6-177 8-bin Mailbox User Status LED PCA (2 of 2)- - - - - - - - - - - 363 Figure 6-178 8-bin Mailbox Adjustable and Fixed Casters - - - - - - - - - - - 364 Figure 6-179 8-bin Mailbox Attachment Assembly- - - - - - - - - - - - - - - 365 Figure 6-180 Mailbox with Stapler, Stapler Removal or Installation- - - - - - - 367 Figure 6-181 C-link Cable on Mailbox with Stapler - - - - - - - - - - - - - - 368 Figure 6-182 Back Plate (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - 369

C4214-91000 List of Figures xix

Figure 6-183 Back Plate (2 of 2) - - - - - - - - - - - - - - - - - - - - - - - 370 Figure 6-184 Stapler Controller PCA (1 of 3) - - - - - - - - - - - - - - - - - 371 Figure 6-185 Stapler Controller PCA (2 of 3) - - - - - - - - - - - - - - - - - 372 Figure 6-186 Stapler Controller PCA (3 of 3) - - - - - - - - - - - - - - - - - 373 Figure 6-187 Top Cover Assembly - - - - - - - - - - - - - - - - - - - - - - 374 Figure 6-188 Stapler Bed Assembly - - - - - - - - - - - - - - - - - - - - - 375 Figure 6-189 Hinges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 377 Figure 7-1 HP LaserJet Troubleshooting Process (1 of 2) - - - - - - - - - 382 Figure 7-2 HP LaserJet Troubleshooting Process (2 of 2) - - - - - - - - - 383 Figure 7-3 Fan Location and Airflow - - - - - - - - - - - - - - - - - - - - 393 Figure 7-4 Engine Test Button - - - - - - - - - - - - - - - - - - - - - - - 394 Figure 7-5 Sample Event Log - - - - - - - - - - - - - - - - - - - - - - - 396 Figure 7-6 Paper Path Jam Locations - - - - - - - - - - - - - - - - - - - 401 Figure 7-7 Paper Path Test Source and Output Selection- - - - - - - - - - 403 Figure 7-8 Error Format for Paper Handling - - - - - - - - - - - - - - - - 407 Figure 7-9 8-bin Mailbox LEDs Description - - - - - - - - - - - - - - - - - 458 Figure 7-10 8-bin Mailbox Power Supply Test Mode Switch - - - - - - - - - 459 Figure 7-11 Sample Menu Map - - - - - - - - - - - - - - - - - - - - - - - 467 Figure 7-12 Sample Configuration Page (1 of 2) - - - - - - - - - - - - - - - 469 Figure 7-13 Sample Configuration Page (2 of 2) - - - - - - - - - - - - - - - 470 Figure 7-14 Communications Link (C-link) Cables, Supported Daisy Chain

Connections - - - - - - - - - - - - - - - - - - - - - - - - - - 473 Figure 7-15 Repetitive Defect Ruler - - - - - - - - - - - - - - - - - - - - - 491 Figure 7-16 High Voltage Power Supply Contacts - - - - - - - - - - - - - - 494 Figure 7-17 Sample JetDirect Configuration Page - - - - - - - - - - - - - - 496 Figure 7-18 Printer Sensors and Switches - - - - - - - - - - - - - - - - - - 499 Figure 7-19 Printer Motor, Clutches, and Solenoids - - - - - - - - - - - - - 500 Figure 7-20 DC Controller Inputs and Outputs (1 of 5) - - - - - - - - - - - - 501 Figure 7-21 DC Controller Inputs and Outputs (2 of 5) - - - - - - - - - - - - 502 Figure 7-22 DC Controller Inputs and Outputs (3 of 5) - - - - - - - - - - - - 503 Figure 7-23 DC Controller Inputs and Outputs (4 of 5) - - - - - - - - - - - - 504 Figure 7-24 DC Controller Inputs and Outputs (5 of 5) - - - - - - - - - - - - 505 Figure 7-25 Mailbox with Stapler Wiring Diagram - - - - - - - - - - - - - - 506 Figure 7-26 2000-sheet Input Tray Controller PCA Inputs - - - - - - - - - - 507 Figure 7-27 2000-sheet Input Tray Controller PCA Outputs - - - - - - - - - 508 Figure 7-28 2000-sheet Input Tray Main Wiring Diagram- - - - - - - - - - - 509 Figure 7-29 8-bin Mailbox Main Wiring Diagram - - - - - - - - - - - - - - - 510 Figure 8-1 HP LaserJet 8100/8100N/8100DN Printer and Paper-Handling

Components - - - - - - - - - - - - - - - - - - - - - - - - - - 514 Figure 8-2 Printer Covers and Doors - - - - - - - - - - - - - - - - - - - - 518 Figure 8-3 Printer Internal Components (1 of 4)- - - - - - - - - - - - - - - 520 Figure 8-4 Printer Internal Components (2 of 4)- - - - - - - - - - - - - - - 522 Figure 8-5 Printer Internal Components (3 of 4)- - - - - - - - - - - - - - - 524 Figure 8-6 Printer Internal Components (4 of 4)- - - - - - - - - - - - - - - 526 Figure 8-7 Detail of Assemblies - - - - - - - - - - - - - - - - - - - - - - 528 Figure 8-8 PCB Assembly Location Diagram - - - - - - - - - - - - - - - - 530 Figure 8-9 Face-up Solenoid Assembly- - - - - - - - - - - - - - - - - - - 531

xx C4214-91000

Figure 8-10 2000-sheet Input Tray Components (1 of 2) - - - - - - - - - - - 532 Figure 8-11 2000-sheet Input Tray Components (2 of 2) - - - - - - - - - - - 534 Figure 8-12 8-bin Mailbox Components (1 of 3) - - - - - - - - - - - - - - - 536 Figure 8-13 8-bin Mailbox Components (2 of 3) - - - - - - - - - - - - - - - 538 Figure 8-14 8-bin Mailbox Components (3 of 3) - - - - - - - - - - - - - - - 540 Figure 8-15 Stapler Internal Components - - - - - - - - - - - - - - - - - - 542 Figure 8-16 2 x 500-sheet Input Tray Internal Components- - - - - - - - - - 545 Figure 8-17 7-bin Tabletop Mailbox Internal Components - - - - - - - - - - 547

C4214-91000 List of Figures xxi

xxii C4214-91000

List of Tables

Table 1-1. Common features of the HP LaserJet 8100, HP LaserJet 8100 N,

and HP LaserJet 8100 DN - - - - - - - - - - - - - - - - - - - - 2 Table 1-2. Comparison of Printer Features - - - - - - - - - - - - - - - - - - 3 Table 1-3. Paper Capacities and Sizes - - - - - - - - - - - - - - - - - - - - 4 Table 1-4. Dimensions of Printer and Paper-handling Devices - - - - - - - - 7 Table 1-5. Dimensions of Output Devices - - - - - - - - - - - - - - - - - - 8 Table 1-6. Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - 9 Table 1-7. Acoustic Emissions - - - - - - - - - - - - - - - - - - - - - - - 10 Table 1-8. Accessories and Options - - - - - - - - - - - - - - - - - - - - 18 Table 1-9. Minimum Memory Requirements - - - - - - - - - - - - - - - - 25 Table 2-1. Printer and Toner Cartridge Environmental Conditions - - - - - - 47 Table 3-1. Control Panel Keys - - - - - - - - - - - - - - - - - - - - - - - 50 Table 3-2. Indicator Lights - - - - - - - - - - - - - - - - - - - - - - - - - 51 Table 3-3. Factory Default Settings- - - - - - - - - - - - - - - - - - - - - 55 Table 3-4. Information Menu - - - - - - - - - - - - - - - - - - - - - - - - 58 Table 3-5. Information Menu - - - - - - - - - - - - - - - - - - - - - - - - 58 Table 3-6. Information Menu - - - - - - - - - - - - - - - - - - - - - - - - 59 Table 3-7. Paper Handling Menu- - - - - - - - - - - - - - - - - - - - - - 60 Table 3-8. Print Quality Menu - - - - - - - - - - - - - - - - - - - - - - - 62 Table 3-9. Printing Menu- - - - - - - - - - - - - - - - - - - - - - - - - - 64 Table 3-10. Configuration Menu - - - - - - - - - - - - - - - - - - - - - - - 67 Table 3-11. I/O Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72 Table 3-12. EIO Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - 74 Table 3-13. Resets Menu - - - - - - - - - - - - - - - - - - - - - - - - - - 76 Table 3-14. Service Mode Menu Items - - - - - - - - - - - - - - - - - - - 77 Table 3-15. Key to Figure 3-2 - - - - - - - - - - - - - - - - - - - - - - - - 82 Table 3-16. Key to Figure 3-3 - - - - - - - - - - - - - - - - - - - - - - - - 83 Table 4-1. Cleaning the Printer- - - - - - - - - - - - - - - - - - - - - - - 88 Table 5-1. Printer Sensors, Solenoids, Clutches, Motors, and Fans - - - - - 117 Table 5-2. Paper Size Switches - - - - - - - - - - - - - - - - - - - - - - 119 Table 5-3. 2000-sheet Input Tray Sensors, Switches, Clutches and Motors - 122 Table 5-4. 2000-sheet Input Tray Paper Quantity Switches - - - - - - - - - 124 Table 5-5. 2000-sheet Input Tray Paper Size Switches - - - - - - - - - - - 124 Table 5-6. 2 x 500-sheet Input Tray Sensors, Switches, and Motors- - - - - 127 Table 5-7. 2 x 500-sheet Input Tray Switches- - - - - - - - - - - - - - - - 128 Table 5-8. 7-bin Tabletop Mailbox Sensors, Switches, and Motors - - - - - 131 Table 5-9. 8-bin Mailbox Sensors, Switches, Motors, and Controller PCA - - 137 Table 5-10. Stapler Motors, Sensors, and Switches - - - - - - - - - - - - - 143 Table 5-11. Printer Timing- - - - - - - - - - - - - - - - - - - - - - - - - - 148 Table 6-1. Hardware Table- - - - - - - - - - - - - - - - - - - - - - - - - 162 Table 7-1. Major Steps for Troubleshooting- - - - - - - - - - - - - - - - - 380

C4214-91000 xxiii

Table 7-2. Paper Curl - - - - - - - - - - - - - - - - - - - - - - - - - - - 390 Table 7-3. Power On Defects or Blank Display - - - - - - - - - - - - - - - 391 Table 7-4. Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 393 Table 7-5. General Paper Path Troubleshooting Questions - - - - - - - - - 399 Table 7-6. Engine Error Messages - - - - - - - - - - - - - - - - - - - - - 409 Table 7-7. 2000-sheet Input Tray Error Messages - - - - - - - - - - - - - 421 Table 7-8. 2 x 500-sheet Input Tray Error Messages - - - - - - - - - - - - 425 Table 7-9. Envelope Feeder Error Messages - - - - - - - - - - - - - - - - 428 Table 7-10. 7-bin Tabletop Mailbox Error Messages - - - - - - - - - - - - - 429 Table 7-11. 8-bin Mailbox Error Messages- - - - - - - - - - - - - - - - - - 434 Table 7-12. Stapler Error Messages - - - - - - - - - - - - - - - - - - - - - 440 Table 7-13. Duplexer Error Messages - - - - - - - - - - - - - - - - - - - - 443 Table 7-14. Paper Handling Controller Error Messages - - - - - - - - - - - 444 Table 7-15. DIP Switch Settings- - - - - - - - - - - - - - - - - - - - - - - 447 Table 7-16. 2000-sheet Input Tray LED Status Interpretation- - - - - - - - - 448 Table 7-17. DIP Switch Settings for troubleshooting test procedures - - - - - 450 Table 7-18. Patterns of LED flashing (2-second pause between each pattern) 452 Table 7-19. DIP switch settings for troubleshooting test - - - - - - - - - - - 453 Table 7-20. Patterns of Flashing LEDs - - - - - - - - - - - - - - - - - - - 455 Table 7-21. 8-bin Mailbox LED Status Interpretation - - - - - - - - - - - - - 461 Table 7-22. Printer Devices Troubleshooting- - - - - - - - - - - - - - - - - 472 Table 7-23. Image Quality- - - - - - - - - - - - - - - - - - - - - - - - - - 475 Table 7-24. Blank (White) Page - - - - - - - - - - - - - - - - - - - - - - - 477 Table 7-25. Black Pages - - - - - - - - - - - - - - - - - - - - - - - - - - 477 Table 7-26. Fading Print - - - - - - - - - - - - - - - - - - - - - - - - - - 478 Table 7-27. Dropout- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 480 Table 7-28. Black Lines (parallel or perpendicular to path) - - - - - - - - - - 480 Table 7-29. Toner Smear - - - - - - - - - - - - - - - - - - - - - - - - - - 481 Table 7-30. Background Scatter- - - - - - - - - - - - - - - - - - - - - - - 482 Table 7-31. Repetitive Defects - - - - - - - - - - - - - - - - - - - - - - - 483 Table 7-32. Line at Edge of Paper- - - - - - - - - - - - - - - - - - - - - - 484 Table 7-33. Misshapen Characters, Voids - - - - - - - - - - - - - - - - - - 485 Table 7-34. Faulty Registration - - - - - - - - - - - - - - - - - - - - - - - 486 Table 7-35. Image Skew - - - - - - - - - - - - - - - - - - - - - - - - - - 486 Table 7-36. Bubble Print - - - - - - - - - - - - - - - - - - - - - - - - - - 487 Table 7-37. White Stripes Parallel to Path - - - - - - - - - - - - - - - - - - 488 Table 7-38. Partial Blank Page - - - - - - - - - - - - - - - - - - - - - - - 488 Table 7-39. Compressed Print- - - - - - - - - - - - - - - - - - - - - - - - 489 Table 7-40. Blank Portion in the Middle of the Page (Tray 4 Input only)- - - - 489 Table 8-1. Printer and Paper-Handling Components - - - - - - - - - - - - 515 Table 8-2. Printer Covers and Doors - - - - - - - - - - - - - - - - - - - - 519 Table 8-3. Printer Internal Components (1 of 4)- - - - - - - - - - - - - - 521 Table 8-4. Printer Internal Components (2 of 4)- - - - - - - - - - - - - - - 523 Table 8-5. Printer internal Components (3 of 4)- - - - - - - - - - - - - - - 525 Table 8-6. Printer Internal Components (4 of 4)- - - - - - - - - - - - - - - 527 Table 8-7. Detail of Assemblies - - - - - - - - - - - - - - - - - - - - - - 529 Table 8-8. PCB Assembly Locations - - - - - - - - - - - - - - - - - - - - 530

xxiv C4214-91000

Table 8-9. Face-up Solenoid Assembly- - - - - - - - - - - - - - - - - - - 531 Table 8-10. 2000-sheet Input Tray Components (1 of 2) - - - - - - - - - - - 533 Table 8-11. 2000-sheet Input Tray Components (2 of 2) - - - - - - - - - - - 535 Table 8-12. 8-bin Mailbox Components (1 of 3) - - - - - - - - - - - - - - - 537 Table 8-13. 8-bin Mailbox Components (2 of 3) - - - - - - - - - - - - - - - 539 Table 8-14. 8-bin Mailbox Components (3 of 3) - - - - - - - - - - - - - - - 541 Table 8-15. Stapler Internal Components - - - - - - - - - - - - - - - - - - 543 Table 8-16. 2 x 500-sheet Input Tray Internal Components- - - - - - - - - - 545 Table 8-17. 7-bin Tabletop Mailbox Internal Components - - - - - - - - - - 547 Table 8-18. Alphabetical Parts List - - - - - - - - - - - - - - - - - - - - - 549 Table 8-19. Numerical Parts List - - - - - - - - - - - - - - - - - - - - - - 559

C4214-91000 List of Tables xxv

xxvi C4214-91000

Product Information

Chapter Contents

Printer Features - - - - - - - - - - - - - - - - - - - - - - 2 Paper Capacities and Sizes - - - - - - - - - - - - - - - - 4 Identification - - - - - - - - - - - - - - - - - - - - - - - - 6 Specifications - - - - - - - - - - - - - - - - - - - - - - - 7 Media Selection Guidelines - - - - - - - - - - - - - - - -11 Product Overview - - - - - - - - - - - - - - - - - - - - -14 Paper-handling Devices, Accessories, and Options - - - - -17 Service Approach - - - - - - - - - - - - - - - - - - - - -26 Technical Assistance- - - - - - - - - - - - - - - - - - - -29 Warranty- - - - - - - - - - - - - - - - - - - - - - - - - -31 Regulatory Information- - - - - - - - - - - - - - - - - - -33

C4214-91000 Chapter Contents 1

Printer Features

Table 1-1. Common features of the HP LaserJet 8100, HP LaserJet 8100 N, and HP LaserJet 8100 DN

Feature Description

Print Speed 32 ppm letter or A4

Duplex Speed 12 ppm letter or A4

Text and G raphics Resolu tion 600 dpi with FastRes

17 ppm ledger (11 x 17) 18 ppm A3 20 ppm legal

20.5 ppm B4

8.4 ppm ledger (11 x 17) or A3

9.0 ppm legal or B4

FastRes 1200 provides 1200 dpi quality at full speed plus Resolution Enhancement technology (REt)

Standard Printer Languages: Enhanced PCL 6

PCL 5e for compatibility PostScript

Duty Cycle (Monthly Usage) Up to 150,000 images

Internal Typefaces 45 PCL, 35 PostScript

Cartridge Slots None

Power Control PowerSave Mode

Control Panel 6 Keys, 3 LEDs, LCD Display

(2-line, 16 characters per line)

EconoMode (draft quality)

Yes

™

Level 2 emulation

2 Chapter 1 Product Information C4214-91000

+ 582 hidden pages