HP 8150, 8100 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 De vices

Service Manual _____________

Part number: C4265-90907 First Edition, November 2000

Warranty

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

Hewlett-Packard makes no warranty of any kind with respect to this information. HEWLETT-PACKARD SPECIFICALLY DISCLAIMS THE IMPLIED WARRANTY OF MERCHANTA BILITY 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

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.

Tr ueType 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

EYCAP

shown in K

. Two examples are S

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.

ELECT

, and - V

ALUE

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.

C4265-90907

iii

C4265-90907

.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

C4265-90907

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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

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C4265-90907

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

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

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

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

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iii

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

DC Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Laser and Scanner Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Paper Motion Monitoring and Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . .187

Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Engine Test Microswitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Image Formation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Toner Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Drum Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Drum Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Image Writing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Image Developing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Image Transferring and Media Separation . . . . . . . . . . . . . . . . . . . . . . . . . 198

Image Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Paper Paths and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Printer, Duplexer, and Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Paper Size Switches (Trays 2 and 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Printing from Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Printing from Trays 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Printing from the Envelope Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Printing with the Duplexer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

2000-sheet Input Tray (Tray 4) Components . . . . . . . . . . . . . . . . . . . . . . . 205

2000-Sheet Input Tray Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

2 x 500-sheet Input Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210

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

7-bin Tabletop Mailbox Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

7-bin Tabletop Mailbox Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

8-bin Mailbox Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

8-bin Mailbox Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Finisher Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Stapler Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Main Functional Cycles of the Stapler (Internal Paper Path) . . . . . . . . . . . 229

Communication Link (Daisy Chain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Paper Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Printer Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

IEEE 1284 Parallel Cable Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Copy Module Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Copy Module System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Function and Layout of the Copy Processor. . . . . . . . . . . . . . . . . . . . . . . . 237

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C4265-90907

Copy Module Power Up Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Copy Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Copy Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Printer components of copy module power up process . . . . . . . . . . . . . . . 242

Notes About the MFP Printer Product ID . . . . . . . . . . . . . . . . . . . . . . . . . . 242

ADF Simplex Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

ADF Duplex Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Flatbed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Copy Module Image Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Communication with the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Communication Channels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Print Job Interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Paper Path and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

6 Removal and Replaceme nt

Removal and Replacement Strategy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . . . . 252

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

User Installable Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

Hardware Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Printer Assembly Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 264

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Delivery Unit (for Face-down Bin). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Diverter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

Diverter Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Lower Right Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Fan 1, Laser/Scanner and Housing (Exhaust) . . . . . . . . . . . . . . . . . . . . . . 284

Fan 2, Low Voltage Power Supply (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . 286

Fan 3, Formatter Fan and Housing (Intake) . . . . . . . . . . . . . . . . . . . . . . . 287

Fan 4, Delivery Unit (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

Fan 5, Tray 1 (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Tray 1 Pickup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

Formatter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Fusing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Laser/Scanner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

Main Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Main Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Paper Input Unit (PIU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

PCA, DC Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Output Paper Sensor PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

High Voltage Power Supply (HVPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

Low Voltage Power Supply (LVPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

Registration Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

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Tray 1 Feed Roller and Separation Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

Tray 2 and 3 Pickup, Feed, and Separation Rollers. . . . . . . . . . . . . . . . . . 326

Paper Input Unit Sensor (PS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

Registration Sensor (PS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Face-up Solenoid Assembly (SL3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

Transfer Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

Tray 2 and 3 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

2000-sheet Input Tray Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . 335

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Paper Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Main Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Front LED PCA Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

Pickup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

Pickup, Feed, and Separation Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

Paper Quantity Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356

Paper Size Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356

Vertical Transfer Unit (VTU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

Tension Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

Locating Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

Casters and Stabilizing Feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

Adjustable Foot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

2 x 500-sheet Input Tray Removal and Replacement. . . . . . . . . . . . . . . . . . . . 364

Orientation of the 2 x 500-sheet Input Tray . . . . . . . . . . . . . . . . . . . . . . . . 365

Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

Vertical Transfer Unit (VTU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

Front Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

Trays 4 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377

Pickup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

Paper Deck Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381

Pickup, Feed, and Separation Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

Tray-Size Sensing PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387

Main Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388

Storage Paper Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

Front Door (Storage Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

Foot Tip and Adjustable Foot Tip (Stabilizing Feet) . . . . . . . . . . . . . . . . . . 393

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Locating Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394

Front LED PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

Envelope Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396

7-bin Tabletop Mailbox Removal and Replacement . . . . . . . . . . . . . . . . . . . . . 397

Orientation of the 7-bin Tabletop Mailbox. . . . . . . . . . . . . . . . . . . . . . . . . . 398

Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

Right Door Assembly (Paper Path Cover) . . . . . . . . . . . . . . . . . . . . . . . . . 410

Face-down Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414

Empty Bin Sensor PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417

Full Bin and Interlock Sensor PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

LED PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421

Face-up Sensors PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422

Reversing Mechanism Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

Face-up/Diverter Assembly (Flipper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425

Short Tray 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428

Solenoid Reversing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429

Flipper Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431

Latching Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

Cover Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433

8-bin Mailbox Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435

Front and Back Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436

Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438

Paper Bins and Blind Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439

Flipper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440

Delivery Head Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443

Transport Belt Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444

Input Paper Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

Metal Tape and Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450

Anticurl Strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452

Delivery Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454

Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459

Diagnostic LED PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

User Status LED PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462

Adjustable and Fixed Casters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464

Attachment Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465

Stapler Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 466

Mailbox with Stapler, Stapler Removal or Installation. . . . . . . . . . . . . . . . . 467

Back Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469

Stapler Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471

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vii

Top Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474

Stapler Bed Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475

Hinges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477

Duplexer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478

HP Digital Copier Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 479

Installing the HP Digital Copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480

Install the Optional Output Accessory. . . . . . . . . . . . . . . . . . . . . . . . . . . . .483

Install the Copy Connect EIO Board into the Printer . . . . . . . . . . . . . . . . . 484

Install the Copy Connect Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485

Hardware Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487

Orientation of the HP Digital Copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489

Copy Module Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490

Separation Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490

Pick Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491

Copy Module Skins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495

Document Holding Pad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495

Paper Chute Flip-out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496

Output Tray Flip-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497

Output Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497

Flatbed (FB) Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498

ADF Latch Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

ADF Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502

Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504

Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .509

Front Panel Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510

Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512

Copy Module Power Supply/Main Board Assemblies. . . . . . . . . . . . . . . . . . . . 514

Copy Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514

Power Supply and Main Board Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515

RFI Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517

Control PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523

Back PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524

Copy Module ADF Unit Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525

Optical Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525

ADF Lamp PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527

ADF Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529

Sensor Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530

ADF Motor Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533

ADF Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534

LED Assembly PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536

ADF Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537

Copy Module Flatbed Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538

Front Panel Frame Ground Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538

Output Tray Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539

Glass Plate Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540

viii Table of Contents

C4265-90907

Home Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542

Carrier Unit Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544

Carrier Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547

Felt Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551

Feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552

Frame Ground Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553

Front Lamp PCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554

Junction PCA and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555

Front Panel Ribbon Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557

Carrier Belt and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559

7 Troubleshooting

Troubleshooting Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562

Printer System Troubleshooting Process . . . . . . . . . . . . . . . . . . . . . . . . . . 565

Printer/Paper-Handling Troubleshooting Process . . . . . . . . . . . . . . . . . . . 566

Copy Module Troubleshooting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 568

Troubleshooting the Print System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570

Preliminary Operating Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570

Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571

Interface Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571

Network Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573

Verify Host System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575

Verify Network and Server Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .575

General Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576

Miscellaneous Problems and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . 576

Paper Curl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581

Troubleshooting the Printer and Paper-handling Devices. . . . . . . . . . . . . . . . . 582

Engine Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585

Event Log Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586

Printer Message Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595

Engine Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596

Input Device Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608

Output Device Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616

Finisher Devices Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628

Paper Handling Controller Error Messages . . . . . . . . . . . . . . . . . . . . . . . . 632

Paper Jams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634

Paper Path Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636

Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639

Configuration Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641

File Directory Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644

Usage Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .645

Check the Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650

Image Quality Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651

Repetitive Defect Ruler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664

Image System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666

High-Voltage Power Supply Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667

C4265-90907

Self-Diagnostics on Paper-handling Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 669

2000-sheet Input Tray Standalone Diagnostics . . . . . . . . . . . . . . . . . . . . . 669

2 x 500-sheet Input Tray Standalone Diagnostics . . . . . . . . . . . . . . . . . . .673

7-bin Tabletop Mailbox Standalone Diagnostics. . . . . . . . . . . . . . . . . . . . . 677

8-bin Mailbox Standalone Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 682

Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 690

Troubleshooting the Copy Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703

Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706

Testing the Copy Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716

Copy Processor LED Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716

Copy Module Boot Up Icon Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 718

Copy Module Offline Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719

Other Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721

Service Mode Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723

8 Parts and Diagr ams

How to Use the Part Lists and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726

Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726

Common Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726

Illustrations and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727

Printer and paper-handling components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728

Printer Parts and Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730

Paper-Handling Devices Parts and Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . 744

Input Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744

Output Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751

HP Digital Copier Parts and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762

Alphabetical Parts List (Printer and Paper-handling Devices). . . . . . . . . . . . . . 777

Alphabetical Parts List (Copy Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 787

Numerical Parts List (Printer and Paper-handling devices). . . . . . . . . . . . . . . . 791

Numerical Parts List (Copy Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

Index

x Table of Contents

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List of Tables

Table 1-1. Common features of the HP LaserJet 8100 Series and the

HP LaserJet 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 (HP LaserJet 8100 series and

HP LaserJet 8150 series) - - - - - - - - - - - - - - - - - - - - 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 - - - - - - - - - - - - - - - - - - - - - - 88 Table 2-6. Specifications for Copy Module - - - - - - - - - - - - - - - - - 89 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

C4265-90907

List of Tables xi

Table 3-26. Key to Figure 3-6 - - - - - - - - - - - - - - - - - - - - - - - - 155 Table 4-1. Cleaning the Printer- - - - - - - - - - - - - - - - - - - - - - - 160 Table 4-2. Cleaning the Document Cover, Document Holder, and

Flatbed Glass- - - - - - - - - - - - - - - - - - - - - - - - - - 162 Table 4-3. Cleaning the ADF- - - - - - - - - - - - - - - - - - - - - - - - 163 Table 5-1. Printer Sensors, Solenoids, Clutches, Motors, and Fans - - - - - 201 Table 5-2. Paper Size Switches - - - - - - - - - - - - - - - - - - - - - - 203 Table 5-3. 2000-sheet Input Tray Sensors, Switches, Clutches

and Motors - - - - - - - - - - - - - - - - - - - - - - - - - - - 206 Table 5-4. 2000-sheet Input Tray Paper Quantity Switches - - - - - - - - - 208 Table 5-5. 2000-sheet Input Tray Paper Size Switches - - - - - - - - - - - 208 Table 5-6. 2 x 500-sheet Input Tray Sensors, Switches, and Motors- - - - - 211 Table 5-7. 2 x 500-sheet Input Tray Switches- - - - - - - - - - - - - - - - 212 Table 5-8. 7-bin Tabletop Mailbox Sensors, Switches, and Motors - - - - - 215 Table 5-9. 8-bin Mailbox Sensors, Switches, Motors, and

Controller PCA - - - - - - - - - - - - - - - - - - - - - - - - - 221 Table 5-10. Stapler Motors, Sensors, and Switches - - - - - - - - - - - - - 227 Table 5-11. Printer Timing- - - - - - - - - - - - - - - - - - - - - - - - - - 232 Table 5-12. Parallel Cable Pin Assignments - - - - - - - - - - - - - - - - - 234 Table 6-1. Hardware Table- - - - - - - - - - - - - - - - - - - - - - - - - 262 Table 6-2. Hardware Table- - - - - - - - - - - - - - - - - - - - - - - - - 487 Table 7-1. Paper Curl - - - - - - - - - - - - - - - - - - - - - - - - - - - 581 Table 7-2. Power On Defects or Blank Display - - - - - - - - - - - - - - - 582 Table 7-3. Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 584 Table 7-4. HP LaserJet 8150 Series Event Log Page 2 - - - - - - - - - - - 587 Table 7-5. Engine Error Messages - - - - - - - - - - - - - - - - - - - - - 596 Table 7-6. 2000-sheet Input Tray Error Messages - - - - - - - - - - - - - 608 Table 7-7. 2 x 500-sheet Input Tray Error Messages - - - - - - - - - - - - 612 Table 7-8. Envelope Feeder Error Messages- - - - - - - - - - - - - - - - 615 Table 7-9. 7-bin Tabletop Mailbox Error Messages - - - - - - - - - - - - - 617 Table 7-10. 8-bin Mailbox Error Messages- - - - - - - - - - - - - - - - - - 622 Table 7-11. Stapler Error Messages- - - - - - - - - - - - - - - - - - - - - 628 Table 7-12. Duplexer Error Messages - - - - - - - - - - - - - - - - - - - - 631 Table 7-13. Paper Handling Controller Error Messages - - - - - - - - - - - 632 Table 7-14. General Paper Path Troubleshooting Questions - - - - - - - - - 633 Table 7-15. Key to Figure 7-16 - - - - - - - - - - - - - - - - - - - - - - - 640 Table 7-16. Printer Devices Troubleshooting- - - - - - - - - - - - - - - - - 648 Table 7-17. Image Quality- - - - - - - - - - - - - - - - - - - - - - - - - - 649 Table 7-18. Blank (White) Page - - - - - - - - - - - - - - - - - - - - - - - 651 Table 7-19. Black Pages - - - - - - - - - - - - - - - - - - - - - - - - - - 651 Table 7-20. Fading Print - - - - - - - - - - - - - - - - - - - - - - - - - - 652 Table 7-21. Dropout- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 654 Table 7-22. Black Lines (parallel or perpendicular to path) - - - - - - - - - - 654 Table 7-23. Toner Smear - - - - - - - - - - - - - - - - - - - - - - - - - - 655 Table 7-24. Background Scatter- - - - - - - - - - - - - - - - - - - - - - - 656 Table 7-25. Repetitive Defects - - - - - - - - - - - - - - - - - - - - - - - 657 Table 7-26. Line at Edge of Paper- - - - - - - - - - - - - - - - - - - - - - 658

xii List of Tables

C4265-90907

Table 7-27. Misshapen Characters, Voids - - - - - - - - - - - - - - - - - - 659 Table 7-28. Faulty Registration - - - - - - - - - - - - - - - - - - - - - - - 660 Table 7-29. Image Skew - - - - - - - - - - - - - - - - - - - - - - - - - - 660 Table 7-30. Bubble Print - - - - - - - - - - - - - - - - - - - - - - - - - - 661 Table 7-31. White Stripes Parallel to Path - - - - - - - - - - - - - - - - - - 662 Table 7-32. Partial Blank Page - - - - - - - - - - - - - - - - - - - - - - - 662 Table 7-33. Compressed Print- - - - - - - - - - - - - - - - - - - - - - - - 663 Table 7-34. Blank Portion in the Middle of the Page (Tray 4 Input only) - - - - 663 Table 7-35. DIP Switch Settings- - - - - - - - - - - - - - - - - - - - - - - 671 Table 7-36. 2000-sheet Input Tray LED Status Interpretation- - - - - - - - - 672 Table 7-37. DIP Switch Settings for troubleshooting test procedures - - - - - 674 Table 7-38. Patterns of LED flashing (2-second pause between

each pattern) - - - - - - - - - - - - - - - - - - - - - - - - - - 676 Table 7-39. DIP switch settings for troubleshooting test - - - - - - - - - - - 677 Table 7-40. Patterns of Flashing LEDs - - - - - - - - - - - - - - - - - - - 679 Table 7-41. 8-bin Mailbox LED Status Interpretation - - - - - - - - - - - - - 685 Table 7-42. Power On Checks - - - - - - - - - - - - - - - - - - - - - - - 704 Table 7-43. Display and Communication Checks - - - - - - - - - - - - - - 705 Table 7-44. Boot Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - 707 Table 7-45. Equipment Errors - - - - - - - - - - - - - - - - - - - - - - - - 708 Table 7-46. Temporary Errors- - - - - - - - - - - - - - - - - - - - - - - - 710 Table 7-47. Error Conditions - - - - - - - - - - - - - - - - - - - - - - - - 713 Table 7-48. Copy Processor LED Test Results - - - - - - - - - - - - - - - 717 Table 7-49. Icon Conditions - - - - - - - - - - - - - - - - - - - - - - - - - 718 Table 7-50. Other Tests- - - - - - - - - - - - - - - - - - - - - - - - - - - 721 Table 8-1. Printer and Paper-Handling Components - - - - - - - - - - - - 728 Table 8-2. Printer Covers and Doors - - - - - - - - - - - - - - - - - - - - 731 Table 8-3. Printer Internal Components (1 of 4) - - - - - - - - - - - - - - 733 Table 8-4. Printer Internal Components (2 of 4)- - - - - - - - - - - - - - - 735 Table 8-5. Printer internal Components (3 of 4)- - - - - - - - - - - - - - - 737 Table 8-6. Printer Internal Components (4 of 4)- - - - - - - - - - - - - - - 739 Table 8-7. Detail of Assemblies - - - - - - - - - - - - - - - - - - - - - - 741 Table 8-8. PCB Assembly Locations - - - - - - - - - - - - - - - - - - - - 742 Table 8-9. Face-up Solenoid Assembly- - - - - - - - - - - - - - - - - - - 743 Table 8-10. 2000-sheet Input Tray Components (1 of 2) - - - - - - - - - - - 745 Table 8-11. 2000-sheet Input Tray Components (2 of 2) - - - - - - - - - - - 747 Table 8-12. 2 x 500-sheet Input Tray Internal Components- - - - - - - - - - 749 Table 8-13. 7-bin Tabletop Mailbox Internal Components - - - - - - - - - - 752 Table 8-14. 8-bin Mailbox Components (1 of 3) - - - - - - - - - - - - - - - 755 Table 8-15. 8-bin Mailbox Components (2 of 3) - - - - - - - - - - - - - - - 757 Table 8-16. 8-bin Mailbox Components (3 of 3) - - - - - - - - - - - - - - - 759 Table 8-17. Stapler Internal Components - - - - - - - - - - - - - - - - - - 761 Table 8-18. Covers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 764 Table 8-19. Flatbed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 765 Table 8-20. Glass Plate and PCA Assembly- - - - - - - - - - - - - - - - - 767 Table 8-21. Carrier Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - 769 Table 8-22. ADF Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - 770

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Table 8-23. Optical Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - 773 Table 8-24. Document Cover Assembly - - - - - - - - - - - - - - - - - - - 774 Table 8-25. Screws (1 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - 775 Table 8-26. Screws (2 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - 775 Table 8-27. Screws (3 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - 776 Table 8-28. Screws (4 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - 776 Table 8-29. Alphabetical Parts List – Printer and Paper-handling Devices - - 777 Table 8-30. Alphabetical Parts List – Copy Module- - - - - - - - - - - - - - 787 Table 8-31. Numerical Parts List – Printer and Paper-handling Devices - - - 791 Table 8-32. Numerical Parts List – Copy Module- - - - - - - - - - - - - - - 801

xiv List of Tables

C4265-90907

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 specificati on - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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, and

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 Distrib ution 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

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Figure 5-10 Image Writing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 195 Figure 5-11 Image Development - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 198 Figure 5-12 Image Transferring and Media Se paration- - - - - - - - - - - - - - - - - 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 Path - - - - - - - - - - - - - - - - - - - - - - 207 Figure 5-17 2000-sheet Input Tray Sensors, Switches, Clutches, and Motors - 209 Figure 5-18 2 x 500-sheet Input Tray Paper Pa th- - - - - - - - - - - - - - - - - - - - - 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

xvi List of Figures

C4265-90907

Figure 6-23 Fan 4, Delivery Unit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 292 Figure 6-24 Fan 5 Removal (1 of 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 293 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 Assembly, 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

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Figure 6-70 2000-sheet Input Tray Main Cable Harness - - - - - - - - - - - - - - - - 351 Figure 6-71 2000-sheet Input Tray Controller PCA- - - - - - - - - - - - - - - - - - - - 352 Figure 6-72 2000-sheet Input Tray Front LED PCA - - - - - - - - - - - - - - - - - - - 355 Figure 6-73 2000-sheet Input Tray Pickup 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 and Paper Quantity

Switch (1 of 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 364 Figure 6-77 2000-sheet Input Tray Paper Size and Paper Quantity Switch

Assemblies (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 Adjustable 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 6-102 2 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

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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 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 Sensor PCA (1 of 2)- - - - - - - - - - - - - - - - - 428 Figure 6-137Full Bin and Interlock Sensor 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-b in Mailbox - - - - - - - - - - - - - - - - - - - - - - - - 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 Transp ort Belt Motor - - - - - - - - - - - - - - - - - - - - - - 454 Figure 6-1618-bin Mailbox Input Paper Guide (1 of 2) - - - - - - - - - - - - - - - - - - 456

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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 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 Adju stable and Fixed Casters- - - - - - - - - - - - - - - - 474 Figure 6-1798-bin Mailbox Att achment 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

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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 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 Assembl y - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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

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Figure 6-256Frame Ground Spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 564 Figure 6-257Front Lamp PCA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 565 Figure 6-258Junction PCA Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 566 Figure 6-259Junction PCA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 567 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 Communications Link (C-link) Cables, Supported Daisy Chain

Connections583 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- - - - - - - - - - - - - - - - - - - - - - - - - - - - 648 Figure 7-15 Paper Path Test Source and Output Selection- - - - - - - - - - - - - - 650 Figure 7-16 Sample Menu Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 653 Figure 7-17 Sample printer Configuration Page (1 of 2) - - - - - - - - - - - - - - - - 655 Figure 7-18 Sample Copy Module Configuration Page - - - - - - - - - - - - - - - - - 656 Figure 7-19 Sample File Directory Page - - - - - - - - - - - - - - - - - - - - - - - - - - - 657 Figure 7-20 Sample Usage Page - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 659 Figure 7-21 Repetitive Defect Ruler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 678 Figure 7-22 High Voltage Power Supply Contacts - - - - - - - - - - - - - - - - - - - - 681 Figure 7-23 8-bin Mailbox LEDs Description - - - - - - - - - - - - - - - - - - - - - - - - 695 Figure 7-24 8-bin Mailbox Power Supply Test Mode Switch - - - - - - - - - - - - - 696 Figure 7-25 Printer Sensors and Switches- - - - - - - - - - - - - - - - - - - - - - - - - - 704 Figure 7-26 Printer Motor, Clutches, and Solenoids - - - - - - - - - - - - - - - - - - - 705 Figure 7-27 DC Controller Inputs and Outputs (1 of 5) - - - - - - - - - - - - - - - - - 706 Figure 7-28 DC Controller Inputs and Outputs (2 of 5) - - - - - - - - - - - - - - - - - 707 Figure 7-29 DC Controller Inputs and Outputs (3 of 5) - - - - - - - - - - - - - - - - - 708 Figure 7-30 DC Controller Inputs and Outputs (4 of 5) - - - - - - - - - - - - - - - - - 709 Figure 7-31 DC Controller Inputs and Outputs (5 of 5) - - - - - - - - - - - - - - - - - 710 Figure 7-32 Mailbox with Stapler Wiring Diagram- - - - - - - - - - - - - - - - - - - - - 711 Figure 7-33 2000-sheet Input Tray Controller PCA Inputs- - - - - - - - - - - - - - - 712 Figure 7-34 2000-sheet Input Tray Controller PCA Outputs- - - - - - - - - - - - - - 713 Figure 7-35 2000-sheet Input Tray Main Wiring Diagram - - - - - - - - - - - - - - - 714 Figure 7-36 8-bin Mailbox Main Wiring Diagra m- - - - - - - - - - - - - - - - - - - - - - 715 Figure 7-37 Copy Processor LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 730 Figure 7-38 Locations of ADF Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - 733

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Figure 8-1 HP LaserJet 8150 MFP Paper-Handling Components- - - - - - - - - 742 Figure 8-2 Printer Covers and Doors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 744 Figure 8-3 Printer Internal Components (1 of 4) - - - - - - - - - - - - - - - - - - - - - 746 Figure 8-4 Printer Internal Components (2 of 4) - - - - - - - - - - - - - - - - - - - - - 748 Figure 8-5 Printer Internal Components (3 of 4) - - - - - - - - - - - - - - - - - - - - - 750 Figure 8-6 Printer Internal Components (4 of 4) - - - - - - - - - - - - - - - - - - - - - 752 Figure 8-7 Detail of Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 754 Figure 8-8 PCB Assembly Location Diagram - - - - - - - - - - - - - - - - - - - - - - - 756 Figure 8-9 Face-up Solenoid Assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - 757 Figure 8-10 2000-sheet Input Tray Components (1 of 2)- - - - - - - - - - - - - - - - 758 Figure 8-11 2000-sheet Input Tray Components (2 of 2)- - - - - - - - - - - - - - - - 760 Figure 8-12 2 x 500-sheet Input Tray Internal Components- - - - - - - - - - - - - - 762 Figure 8-13 7-bin Tabletop Mailbox Intern al Components - - - - - - - - - - - - - - - 765 Figure 8-14 8-bin Mailbox Components (1 of 3) - - - - - - - - - - - - - - - - - - - - - - 768 Figure 8-15 8-bin Mailbox Components (2 of 3) - - - - - - - - - - - - - - - - - - - - - - 770 Figure 8-16 8-bin Mailbox Components (3 of 3) - - - - - - - - - - - - - - - - - - - - - - 772 Figure 8-17 Stapler Internal Components - - - - - - - - - - - - - - - - - - - - - - - - - - 774 Figure 8-18 Assembly Location Diagram- - - - - - - - - - - - - - - - - - - - - - - - - - - 776 Figure 8-19 Covers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 777 Figure 8-20 Flatbed- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 779 Figure 8-21 Glass Plate and PCA Assembly - - - - - - - - - - - - - - - - - - - - - - - - 781 Figure 8-22 Carrier Unit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 783 Figure 8-23 ADF Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 784 Figure 8-24 Optical Unit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 787 Figure 8-25 Document Cover Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - 788 Figure 8-26 Screws (1 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 789 Figure 8-27 Screws (2 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 789 Figure 8-28 Screws (3 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 790 Figure 8-29 Screws (4 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 790

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