HP C4779A, С4788A Service Manual

HP 3,000-sheet Stapler/Stacker (C4788A)
HP 3,000-sheet Stacker (C4779A)

Service Manual Supplement

for Paper-Handling Accessories

HP 3,000-Sheet Stapler/Stacker
(C4788A)
HP 3,000-Sheet Stacker (C4779A)

Service Manual

Copyright Information

© 1999 Hewlett-Packard
Company

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

Part Number: C4788-90904
First Edition, January 1999

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
MERCHANTABILITY AND
FITNESS FOR A PARTICULAR
PURPOSE

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liable for any dire ct, indirect,
incidental, consequential, or
other damage alleged in
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use of this information.

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GOVERNMENT USERS:
RESTRICTED RIGHTS
COMMERCIAL COMPUTER
SOFTWARE: “Use, duplication,
or disclosure by the
Government is subject to
restrictions as set forth in
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at DFARS 52.227-7013.”

Trademark Credits

E

NERGY STAR is a U.S.
registered service mark of the
United States Environmental
Protection Agency.

All other products mentioned
herein may be trademarks of
their respective companies.

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

Contents

1 Product informa tion

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Product features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Product specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Media specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Theory of operation

Basic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

C-link communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Device configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Paper path sensors and jam detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3 Removal and replacement

Removal and replacement strategy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Required tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Bins and covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Face-up bin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Stapler bin/Stacker bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Back cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Foot cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Stapler door assembly with label/stacker door assembly. . . . . . . . . . . . . . . . . 24

Controller PCA cover (with label) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Internal assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Flipper assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Carriage assembly (Stapler/Stacker only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Accumulator assembly (Stapler/Stacker only) . . . . . . . . . . . . . . . . . . . . . . . . . 29

Offset module (Stacker only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Stapler (Stapler/Stacker only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Controller PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

LED PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Interlock switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Safety switch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Attachment assembly (rod, bracket, cables). . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Flipper ribbon cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Stationary caster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

EN

3

Adjustable caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 Troubleshooting

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Basic troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Verifying power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Printing the configuration page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Evaluating the configuration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Printing the event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Evaluating the event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Calibrating the staple position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Troubleshooting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Paper path test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Standalone diagnostic tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Service LED flashing patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

User LED status interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Printer messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Control panel messages and errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

HP 3,000-Sheet Stapler/Stacker error messages. . . . . . . . . . . . . . . . . . . . . . . 60

HP 3,000-Sheet Stacker error messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5 Parts and diagrams

How to use the parts lists and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Ordering parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Refilling the stapler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Ordering staples cartridges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Bins and covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Internal assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4 Contents

EN

1

Left side

Front

Right side

Back

Face-up bin

Stapler bin/Stacker bin

Product information

Introduction

The 3,000-Sheet Stapler/Stacker and the 3,000-Sheet Stacker from
Hewlett-Packard are powerful enhancements to the capablilties of
your high-capacity laser printer.

The HP 3,000-Sheet Stapler/Stacker is an optional multi-speed
output device designed to handle different printer speeds. It staples
up to 50 sheets of plain paper at a time and can hold a total of 3,125
sheets—3,000 sheets in the stapler bin and 125 sheets, not stapled,
in the face-up bin.

The HP 3,000-Sheet Stacker is another optional multi-speed output
device designed to handle different printer speeds. The Stacker
stacks up to 3,000 sheets of plain paper in the stacker bin, has job
offset capabilities for easy handling, and has job separation (first
page offset) for shared environments. The Stacker includes a face-up
bin that holds another 125 sheets.

Figure 1. Stapler/Stacker

EN

Introduction

5

P roduct feature s

Table 1. Output capacity (unstaple d)

Letter- or A4-sized paper

Ledger- or A3-sized paper Up to 1,500 sheets of 20 lb or lighter paper in the stapler bin or

Up to 3,000 sheets of 20 lb [75 g/m
lighter paper in the stapler bin or stacker bin
Up to 125 sheets of 20 lb or lighter paper in the face-up bin

stacker bin
Up to 125 sheet of 20 lb or lighter paper in the face-up bin

2

(grams per square meter)] or

Table 2. Stapling (Stapler/Stacker only)

Two to 50 sheets of 20 lb bond or equivalent stack height—approximately 5 millimeters (mm)

Multiple staple positions:

●

One angled

●

One, two, three, or six staples

●

Custom stapling with up to seven staples

Table 3. Stacking (Stacker only)

Job offset Whole print jobs or mopies are offset from each other.

Job separation Only the first page of print job or mopy is offset.

6 1 Product information

EN

P roduct specifications

Table 4. Physical dimensions

Weig h t 65 pounds [29.5 kg (kilograms)]

Packaging weight 16.9 pounds (7.7 kg)

Height 39.84 inches (1012 mm) includes face-up bin

38 inches (965 mm) without face-up bin

Depth 19.45 inches (494 mm)

Width
(front cover-to-back cover)

21.14 inches (537 mm)

Table 5. Electrical specifications

External power supply Input: automatic 100/240 Vac (volts alternating current)

Power consumption 60.0 watts (Stapler/Stacker)

38.8 watts (Stacker)

Rated power 1.2 amps (110 volts)

0.5 amps (220 volts)

Sleep mode Less than 2.0 watts

Off mode Less than 2.0 watts

EN

Product specifications

7

Table 6. Environme ntal specifications

Temperature (operating) 0 to 45 degrees C (Celsius)

Temperature (storage) -40 to 70 degrees C

Humidity (operating) 20 to 80% RH (relative humidity)

Humidity (storage) 15 to 80% RH

Electrostatic discharge
(ESD)

15 to 25 kV (kilovolts)

Table 7. Acoustic emissions

Operating 5.0 bels or less

Idle 4.0 bels or less

Stacking 50 dB (decibels)

8 1 Product information

EN

M edia specifica t ions

The following table lists supported paper sizes and output bin
capacities for the HP 3,000-Sheet Stapler/Stacker and the HP 3,000­Sheet Stacker.

Table 8. Bin specifica tions

Bin Capacity Paper size Weight

Stacker Bin
(Optional Bin 1)

Face-up Bin Up to 125 sheets of

Up to 3,000 sheets of
letter- or A4-sized, 20

lb (80 g/m
Note: The stacker bin

capacity varies
depending on the
paper size and
weight. For example,
the bin capacity is
reduced to 1,500
sheets if you use
11x17-inch, 20 lb
bond.

20 lb (80 g/m

2

) bond.

2

) bond

Letter
A4
Legal
Ledger (11x17 inch)
A3
JIS B4
JIS B5
A5
Executive
JIS Executive
8K
16K
Custom sizes:
Minimum—190 mm length x
148 mm width
Maximum—460 mm length x
297 mm width

Note:

Envelopes, labels, and
transparencies are NOT
supported in the stacker bin.

The face-up bin supports any paper sizes and
weights that the printer supports. See the printer user
guide for information about supported sizes and
weights.

16 to 28 lb bond (60
to 110 g/m

2

)

EN

Media specifications

9

The following table lists supported paper sizes and capacities for the
stapler in the HP 3,000-Sheet Stapler/Stacker.

Table 9. Stapler Specifications

Capacity Paper Weight

Maximum 5 mm
stack height. For
example, 50 sheets
of 20 lb bond.

Note:

The stapling
capacity varies
depending on the
paper's thickness.

Letter
A4
Legal
Ledger (11 by 17 in)
A3
JIS B4
JIS B5
A5
Executive
JIS Executive
8K
16K

Note:

Envelopes, labels, and
transparancies are NOT
supported in the stapler.

16 to 28 lb bond (60
to 110 g/m

2

)

10 1 Product information

EN

2

Theory of operation

Ba sic functions

C -link communication

Communication and control of the C-link devices is accomplished
through the paper-handling controller embedded on the formatter
PCA (printed circuit assembly) in the printer. The C-link devices have
their own power supplies and controller boards that receive signals
and commands from the paper-handling controller.

Figure 2. C-link cab ling

EN

Basic functions

11

D evice configur ation

The HP 3,000-Sheet Stapler/Stacker and the HP 3,000-Sheet Stack er
attach to printers’ left sides.

3,000-Sheet Stapler/Stacker

Set the default offset action and default stapler action at the printer
control panel under Configuration of Stkr.

The options for default offset action are:

●

No Print jobs or mopies are stacked without separation

(although stapling options override this setting).

●

Yes Print jobs or mopies are offset from each other.

The options for default stapler action are:

●

No Staple Print jobs of mopies are delivered to the stapler bin

without being stapled.

●

One Angled
Staple

Print jobs or mopies are stapled with one staple at a
40° angle.

●

(#) Staples Print jobs or mopies are stapled with the configured

●

Custom Staples Print jobs or mopies are stapled with the configured

3,000-Sheet Stacker

Set the default offset action at the printer control panel under
Configuration of Stkr. The options for default offset action are:

●

No Print jobs or mopies are stacked without separation.

●

Yes Print jobs or mopies are offset from each other.

●

Job Separator Print jobs or mopies are separated by offsetting the

12 2 Theory of operation

number (1, 2, 3, or 6) of staples.

number of staples as defined by the network
administrator.

first page.

EN

Pow er supply

A universal power supply is activ ated when the printer’s power s witch
is turned on. The printer’s paper handling controller sends a power-on
signal to the power supply through the controller PCA.

The power supply provides +26 V (volts) for motors and +5 V for
sensors and controller electronics. The power supply is also acitva ted
when the controller PCA is set to service mode.

Pow er- on seque nce

During the power-on sequence, an internal self-test is performed. All
motors, electronics, and main assemblies are tested.

After successful power-on sequence, the user LED (light-emitting
diode) is lit green.

If the power-on sequence is NOT successful, a jam condition or a
hardware malfunction is indicated through the printer control panel
and the user LED is lit amber.

EN

Basic functions

13

Paper pa th sensors and ja m detection

The paper path sensors detect paper jams as follows:

●

Flipper entry sensor 1 (FLEntry1) and flipper entry sensor
(FLEntry):

• paper in the flipper at power on or after clearing a paper jam
(when either sensor is activated at power on or after clearing a
jam)

• paper jammed before entering the flipper (when the printer
sends a message that pages are being sent to the Stapler/
Stacker or Stacker, but FLEntry1 is never activated)

• paper jammed in the flipper (when FLEntry1 is activated, but
FLEntry is not, or when FLEntry1 is never deactivated, or
when FLEntry is never deactivated)

●

Flipper exit sensor (FLExit)

• paper in the flipper at power on or after clearing a paper jam
(when FLExit is activated at power on or after clearing a jam)

• paper jammed in the last part of flipping (FLExit never
activated)

• paper jammed entering the accumulator (FLExit never
deactivated)

●

Gear wheel sensor (GWSens)—Stapler/Stacker only

• paper jammed in the accumulator (GWSens never activated)

●

Accumulator exit sensor (ACExit)—Stapler/Stacker only

• paper in the accumulator at power on or after clearing a paper
jam (when ACExit is activated at power on or after clearing a
jam)

• paper jammed in the accumulator (when ACExit is not
deactivated after eject)

●

Exit (Exit)—Stacker only

• paper jammed in the offset module (Exit never activated)

14 2 Theory of operation

EN

Paper pa th

Pape r input

The device receives paper from the printer at different speeds—106,
117, or 147 mm/second—depending on the printer in use.

Flipper

Paper arrival is sensed by FLEntry1, which activates the flipper
motors. For face-up printing, the flipper simply delivers paper sensed
by FLEntry to the face-up bin. Otherwise, the flipper changes page
orientation from face-up to face-down and delivers paper sensed by
FLExit to the accumulator assembly (Stapler/Stacker) or offset
module (Stacker).

Accumula tor asse mb ly (S taple r/S tacke r ON LY )

The accumulator assembly collects and registers print jobs/mopies
from the flipper (sensed by GWSens), sends them to the carriage
assembly for stapling, and deliv ers them to the stapler bin (sensed b y
ACExit).

O ffset module (S tacker O NLY)

EN

The offset module collects and registers print jobs/mopies from the
flipper (sensed by FLExit), offsets them (if selected), and delivers
them to the stacker bin (sensed by Exit).

Basic functions

15

Face-up paper path

Flipper entry sensor

(FLEntry)

Flipper entry sensor 1 (FLEntry1)

Face-down paper path

Path through accumulator

Accumulator exit sensor

(ACExit)

Gear wheel sensor

(GWSens)

Accumulator

Interlock switch
Paper input from

the printer

Flipper

Flipper exit sensor
(FLExit)

Stapler/Carriage

Controller PCA

Power supply

Figure 3. Stapler/S tacker pape r path and sensors

16 2 Theory of operation

EN

Face-up paper path

Flipper entry sensor

(FLEntry)

Flipper entry sensor 1 (FLEntry1)

Face-down paper path

Path through offset

module

Exit sensor (Exit)

Offset module

Interlock switch
Paper input from

the printer

Flipper

Flipper exit sensor
(FLExit)

Controller PCA

Power supply

Figure 4. Stacke r paper path a nd sensors

EN

Basic functions

17

18 2 Theory of operation

EN

Removal and

3

replacement

R emoval and replace ment str ate gy

This chapter documents removal and replacement of field
replaceable units (FRUs) only.

Replacement is generally the rev erse of remo val. Occasionally, notes
are included to provide direction for difficult or critical replacement
procedures.

Removal of some FRUs does not require that all covers and bins be
removed first from the Stacker or Stapler/Stacker. The disassembly
procedure described here details initial removal of all bins and cov ers
for unobstructed views of internal components.

EN

Removal and replacement strategy

19

WARNING! Unplug the power cord from the power outlet before attempting to

service the HP 3,000-Sheet Stacker or HP 3,000-Sheet Stapler/
Stacker . Otherwise, se vere injury can result. Certain functional checks
must be performed during troubleshooting with power supplied to the
product. However, the power supply should be disconnected during
disassembly.

CAUTION The HP 3,000-Sheet Stapler/Stacker and the HP 3,000-Sheet Stack er

contain parts that are electrostatic discharge (ESD) sensitive.

Note Disconnecting the attachment assembly from the bottom of the printer

and moving the product away from the printer can make removal of
FRUs easier.

R equired tools

Torx TX-10 and TX-20 screwdrivers and a small flatblade screwdriver
are the only tools you need to disassemble the Stacker and the
Stapler/Stacker.

20 3 Removal and replacement

EN

Bins a nd covers

2

3

2

1

2

2

2

4

Face -up bin

Lift slightly the end of the bin (callout 1).

1

Pull the bin away from the product (callout 2).

2

CAUTION

When replacing the bin, make sure you position it under the bin-full flag
(callout 3). Placing it over the bin-full flag and then attempting to f orce
the bin into its slots can damage the flag.

S taple r bin/Sta c ker bin

Unhook the plastic tabs underneath the bin (callout 4).

1

Carefully lift the bin straight up until it is released from the frame.

2

Figure 5. Bins remo val

EN

Bins and covers

21

Front co ve r

2

2

2

1

2

3

1 Use the TX-20 screwdriver to remove three screws (callout 1).
2 Lift the cover straight up until it is released from the product.

Ba ck co ver

1 Use the TX-20 screwdriver to remove three screws (callout 2).
2 Press and hold in the interlock switch (callout 3) while lifting the

cover straight up until the cover is released from the product.

Figure 6. Front a nd back cove rs remova l

22 3 Removal and replacement

EN

F oot cover

Remove the front and back covers.

1

Grasp the foot cov er on one side , rotate it out slightly, and then lift

2

it up to clear the locating pin. Repeat this step for the opposite
side of the foot cover.

Lift up the cover and pull it away from the product.

3

Figure 7. Foot co ver removal

To r eins tall

The cover can be difficult to replace correctly. Make sure you line up
the ridges on the bottom of the cover with the grooves on the product.

EN

Bins and covers

23

S taple r door assembly with la bel/sta ck er door

2

1

2

2

assembly

1 Open the door assembly and, on a Stapler/Stacker, center the

stapler unit.

2 Use the TX-20 screwdriver to remove two screws (callout 1) from

inside the door, one at the front and one at the bac k of the device.

Note The screws remain attached to the plastic screwholders.

3 Rotate the door down until the flat sides of the hinges are parallel

to the floor and pull the door straight away from the product.

C ontroller P CA cover ( with label)

1 Use the TX-20 screwdriver to remov e the upper and lower scre ws

(callout 2) from the cover.

2 Rotate the cover to clear the tabs at the back of the product and

lift the cover away from the product.

Figure 8. Staple r door assembly/Stacke r door asse mbly and controller

PCA cove r remova l

24 3 Removal and replacement

EN

I nterna l assemblies

2

2

1

2

F lipper a ssembly

Remove the front and back covers.

1

At the back of the product, disconnect the flipper ribbon cable

2

(callout 1) by pressing the black tabs on the connector to release
the cable.

Use the TX-20 screwdriver to remov e four screws (callout 2), two

3

on each side of the assembly.

Figure 9. Flipper assembly re moval ( 1 of 2)

Note

EN

Sheet metal edges may be sharp.

Internal assemblies

25

4 Use both hands to grasp the assembly on each side and, with a

2

1

firm tug, lift the assembly straight up to clear the tabs (callout 1;
one of the two tabs is shown) on each side of the assembly.

5 Pull the assembly straight away from the product, being careful of

the bin-full flag.

Figure 10. F lipper assembly re moval (2 of 2 )

26 3 Removal and replacement

EN

C arr iage asse mb ly ( Staple r/Sta cker only)

2

1

Remove the front cover, the back cover, and the controller PCA

1

cover.
Disconnect the ribbon cable (callout 1) from the controller PCA by

2

pressing the black tabs to release the cable.

Figure 11. Carriage assembly removal (1 of 2)

Push the ribbon cable up through the hole.

3

EN

Internal assemblies

27

4 Use the TX-20 screwdriver to remove two screws (callout 1), one

2

1

on each side of the assembly.

5 Lift the assembly to clear the tabs on each side of the assembly

and pull the assembly straight away from the frame.

Figure 12. Carriage assembly removal (2 of 2)

28 3 Removal and replacement

EN

Accumulator a ssembly (S tapler/ Stacker only)

2

1

Remove the front cov er, the back cover, the controller PCA co v er,

1

the flipper assembly, and the carriage assembly.

Note

While it is possible to remove the accumulator assembly without first
removing the carriage assembly, HP strongly recommends that the
carriage assembly be removed before removing the accumulator
assembly. Otherwise, you might find it very difficult to reposition the
accumulator assembly with the carriage assembly in the way.

Disconnect the ribbon cable (callout 1) from the controller PCA by

2

pressing the black tabs to release the cable.

Figure 13. Accumula tor asse mbly remova l (1 of 2)

Push the ribbon cable up through the hole.

3

EN

Internal assemblies

29

4 Use the TX-20 screwdriver to remov e four screws (callout 1), two

2

1

on each side of the assembly.

Figure 14. Accumula tor asse mbly remova l (2 of 2)

5 Lift the accumulator assembly up to clear the tabs at each side

and rotate the top of the assembly down while pulling it aw ay from
the product.

30 3 Removal and replacement

EN

O ffset module (Sta cker only)

2

2

1

2

Remove the front cov er, the back cover, the controller PCA co v er,

1

and the flipper assembly.
Disconnect the ribbon cable (callout 1) from the controller PCA by

2

pressing the black tabs to release the cable.
Push the ribbon cable up through the hole.

3

Use the TX-20 screwdriver to remov e four screws (callout 2), two

4

on each side of the module.

Figure 15. O ffset module remova l

Lift the offset module to clear the tabs at each side and rotate the

5

top of the module away from the product while pulling it away
from the product.

EN

Internal assemblies

31

S taple r (Sta pler/ Stacke r only)

1 Remove the carriage assembly from the 3,000-Sheet Stapler/

Stacker and place it on a work surface.

2 Remove the staples cartridge from the stapler.
3 Disconnect the cable from its connector and unthread the cable

from the cable guides.

Figure 16. Stapler removal (1 of 3)

32 3 Removal and replacement

EN

Use the TX-10 screwdriver to remove the grounding screw

2

2

2

1

4

(callout 1) and release the grounding cable.
Use the TX-20 screwdriver to remove two screws and their

5

washers (callout 2) from the stapler.

Note

Keep the washers with the screws to make sure they are reinstalled.

Figure 17. Stapler removal (2 of 3)

The stapler is affixed tightly to the carriage assembly. Once the two
screws have been remo ved, the stapler is held in place by the two metal
tabs located on the side of the stapler opposite the screws.

Use firm pressure to slide the stapler toward the tab side of the

6

stapler, clearing the tabs.

Note

EN

Internal assemblies

33

7 Lift the stapler away from the carriage.

2

2

1

2

Note In the figure below, the stapler has been removed from the carriage

assembly and is rotated to show the tabs (callout 1) and tab slots
(callout 2).

Figure 18. Stapler removal (3 of 3)

To r eins tall

Place the tabs in the tab holes and use firm pressure to slide the
stapler toward the screws side of the stapler, lining up the screw
holes. Do not attempt to replace the screws until the screw holes are
lined up.

34 3 Removal and replacement

EN

C ontroller P CA

2

1

2

2

2

2

2

3

Remove the controller PCA cover.

1

Release the seven cables, including the C-link cable, from their

2

connectors (callout 1) on the stapler/stacker controller PCA (or
six from the stacker controller PCA).

Use the TX-20 screwdriver to remove three screws (callout 2).

3

Figure 19. S taple r/Stacker controller PCA or Stacker controller PCA removal

Note

Note

CAUTION

EN

You might have to squeeze the three locating pins to allow the holes
on the controller PCA to clear the pins.

Pull the controller PCA from the product.

4

See Chapter 4—Troubleshooting—for information about the service
LEDs (callout 3).

Placing the controller PCA on a metal surface can damage the
controller. Place the controller PCA on an ESD mat.

Internal assemblies

35

LE D P CA

2

2

1

2

1 Remove the front cover.
2 Use the TX-10 screwdriver to remove one screw (callout 1) from

the LED PCA.

3 Disconnect the cable (callout 2) to release the LED PCA.

Figure 20. LED PCA removal

36 3 Removal and replacement

EN

Pow er supply

2

2

2

2

1

3

Remove the controller PCA cover.

1

Unplug the power cable (callout 1) from the power supply.

2

Disconnect the cable from the controller PCA (callout 2).

3

Use the TX-20 screwdriver to remove one screw (callout 3) from

4

the bracket that holds the power supply in place.

Figure 21. Pow er supply removal

Lift the bracket and the power supply out and away from the

5

product.

EN

Internal assemblies

37

I nter lock switch

2

1

2

2

2

3

1 Remove the back cover.
2 Disconnect two cables (callout 1) from the interlock switch.
3 Squeeze the interlock switch on the top and bottom (callout 2),

and slide the interlock through the hole (callout 3).

Figure 22. I nterlock switch remova l

38 3 Removal and replacement

EN

S afe ty switch assembly

2

2

2

1

2

3

Remove the front cover, the back cover, and the carriage

1

assembly.
Press the two tabs on the sides of the safety switch assembly

2

cover (callout 1) to release it from the frame and lift the cover
away from the assembly.

Disconnect two cables (callout 2) from the safety switch

3

assembly.
Press the tabs on the bottom of the safety switch assembly (one

4

tab on each side—callout 3) to release it from the frame and lift
the assembly away from the product.

Figure 23. S afety switch assemb ly removal

EN

Internal assemblies

39

Atta chment a ssembly (rod, bracket, cables)

2

1

1 Unplug the attachment assembly’ s C-link cable from the controller

PCA and power cable from the power supply.

2 Use the TX-20 screwdriver to remov e f our scre ws (callout 1) from

the attachment assembly.

3 Guide both cables through the hole and pull the assembly away

from the product.

Figure 24. Atta chment assembly remo val

40 3 Removal and replacement

EN

F lipper r ibbon cable

2

2

2

1

Remove the back cover and the controller PCA cover.

1

Disconnect the cable (callout 1) at both ends by pressing the

2

black tabs on the connectors.
Open the three cable clips (callout 2; two of the three cable clips

3

are shown) to release the cable.

Figure 25. F lipper ribbon cable remova l

EN

Internal assemblies

41

S tationa ry caste r

2

1

1 Remove front or back co v er, depending upon the caster you want

to replace.

2 Lay the Stapler/Stack er on its front or back side so that the caster

being replaced is off the floor.

3 Use the TX-20 screwdriver to remove one screw (callout 1) from

the inside of the frame.

4 Rotate the caster 90° to clear the tabs and pull the caster away

from the product.

Figure 26. S tationary ca ster remo val

42 3 Removal and replacement

EN

Adjusta ble ca ster

2

1

Remove the front cover, the back cover, and the foot cover.

1

Lay the Stapler/Stack er on its front or back side so that the caster

2

being replaced is off the floor.
Use a flatblade screwdriver to snap the e-clip off of the adjusting

3

knob (callout 1).

Figure 27. Adjusta ble caster re moval

Slide the caster out of its position.

4

EN

Internal assemblies

43

44 3 Removal and replacement

EN

4

Troubleshooting

Introduction

This section provides a systematic approach to identifying the causes
of malfunctions and errors on the output paper handling devices—the
HP 3,000-Sheet Stapler/Stacker and the HP 3,000-Sheet Stacker—
that attach to the printer. The troubleshooting process addresses the
major problems, allowing you to identify malfunctions and errors in the
devices.

Note

This chapter provides troubleshooting information, the standalone
diagnostics tool, control panel messages, and the event log error
messages for the HP 3,000-Sheet Stapler/Stacker and the HP 3000­Sheet Stacker. For troubleshooting information about the printer, see
the printer’s service manual.

EN

Introduction

45

Ba sic troubleshooting

Ve r ifying po wer

Confirm that the printer is turned on and that a message appears on
the control panel display. The message should indicate Ready,
Offline, or Powersave On for a normal operating condition. The user
LED on the Stapler/Stacker or Stack er should be lit g reen when there
is a ready message on the control panel display.

P r inting the configuration page

Use the configuration page to verify proper installation of the paper­handling devices, firmware versions, and important printer
information.

To print a configur ation pa ge

1 Press M

display.

2 Press I
3 Press S

until Information Menu appears on the control panel

ENU

until Print Configuration appears.

TEM

to print the configuration page.

ELECT

E valua ting the configuration page

After printing the configuration page, make sure it shows that the
Stapler/Stacker or Stacker is installed.

If the product does not appear on the configuration, check the cable
connections. Make sure that the C-link cables and power cables are
correctly installed and are functional and that the power cables supply
power to the paper-handling devices.

46 4 Troubleshooting

EN

P r inting the eve nt log

If the control panel display does not indicate a normal operating
condition, an error message will be displayed and logged in the event
log. You can access the event log through the printer’s Test Menu to
display more specific information about the current error message.

The printer's internal event log stores the most recent error messages
and can be printed or displayed at any time . If the printer cannot print
or move any paper, follow the steps below to display the event log.
Otherwise, print the event log.

To display the event log

1

Press M

ENU

until

Information Menu

appears on the control panel

display.
Press I

2

Press

3

Press – V

4

Write down the error messages.

5

until

TEM

Select

ALUE

Show Event Log

to show the event log.

+ to scroll through the event log.

appears.

To print the eve nt log

1

2
3

Press M
display.

Press I
Press S

ENU

TEM

ELECT

until

Information Menu

until

Print Event Log

to print the event log.

appears on the control panel

appears.

E valua ting the eve nt log

The event log can point to specific problems in the product.

Check the event log for specific error trends in the last 10,000

●

printed pages.
Ask the customer for any observed error trends.

●

Record any specific error trends.

●

See the alphabetical and numerical event log tables.

●

See the section about error messages later in this chapter for

●

recommended courses of action.

EN

Basic troubleshooting

47

C alibrating the staple position

Note Recalibrate the staple position only if the accumulator assembly, the

carriage assembly , or the controller PCA is replaced. Non-volatile RAM
(NVRAM) located in the controller PCA keeps in memory the
configured compensation values for the staple position. When the
device is in service mode, you can access the fle xible calibration menu.

To calibrate the staple position

1 Turn the printer off.
2 Enter service mode (see “To set the device in service mode” later

in this chapter). As the device powers on, the NVRAM receives
the calibration values.

3 After successful power on, exit service mode (see “To exit service

mode” later in this chapter).

4 Turn the printer on and wait until Ready appears on the control

panel display. The user LED, located at the top of the front cover,
should blink green.

until Configuration of Stkr appears on the control

5 Press M

panel display.

ENU

6 Press I
7 Press – V
8 Press S
9 Press M
10 Press I

until Default of Staples appears.

TEM

+ until One Staple appears.

ALUE

.

ELECT

until Information Menu appears.

ENU

until Print Paper Path Test appears.

TEM

11 Print a ten-page job to the stapler bin (optional bin 1).
12 Check the staple position of the 10-page print job against the

staple position in Figure 28—Staple position.

• If the positons are not comparable, then the device should be
recalibrated; continue with step 13 below.

• If the positions match or are close to a match, the device does
not require recalibration; proceed to step 18.

13 Press M
14 Press I
15 Press – V
16 Press S

until Configuration of Stkr appears.

ENU

until X Compensation/Y Compensation appears.

TEM

+ to set the correct compensation (in millimeters).

ALUE

.

ELECT

48 4 Troubleshooting

EN

Repeat steps 9 through 16 until you are comfortable with the

X-axis

Y-axis

–+

–+

Staple position

17

staple position.
Press M

18

Press I

19

Press – V

20

Press S

21

Press GO.

22

ENU

TEM

ALUE

ELECT

until

Configuration of Stkr

until

Calibra Values

+ until

appears.

Set

.

appears.

appears.

If you set compensation values, the printer should return to Ready
automatically and the user LED should return to the solid green
status.

Because you set calibration values, the printer should not allow
access to the compensation values in service mode.

If you did not set compensation values, repeat steps 1 through 4 and
steps steps 18 through 22.

Figure 28. S taple position

EN

Basic troubleshooting

49

Troubleshooting tools

Paper pa th test

Using the information from the event log, you can verify a specific
printer paper path with the paper path test. The paper path test menu
allows you to select the paper source and the output destination.

Note See Chapter 2—Theory of operation—for graphic representations of

the paper path.

To perfor m a pa per path test

1 Press M

until Information Menu appears on the control panel

ENU

display.

2 Press I

S

ELECT

3 Press – V

S

ELECT

4 Press – V

S

ELECT

5 Press – V

press S

6 Press – V

S

ELECT

until Print Paper Path Test appears and then press

TEM

.

+ to choose the correct input tray and then press

ALUE

.

+ to choose the correct destination and then press

ALUE

.

+ to choose the correct duplex mode and then

ALUE

.

ELECT

+ to choose the number of copies and then press

ALUE

.

To stop the paper path test, press C

ANCEL JOB

on the control panel.

50 4 Troubleshooting

EN

Timing

Figure 29 shows timeouts related to jam declarations. The number in
parentheses is the jam’s error log code.

Note

Figure 29. D evice timing

Jam codes used in the drawing and in the explanation are in
hexadecimal representation.

The time is the maximum time allowed between two events. The
figure shows the flow of a normal sheet, from entry to the
accumulator/offset module.

EN

The printer sends a delivery notice for each sheet. When the device
detects the signal, a timeout of three seconds begins.

F LEntry 1 se nsor and F LEntr y sensor

If the sheet does not arrive to the FLEntry 1 sensor within three
seconds, the device declares a jam 02.

When the sheet arrives at the FLEntry 1 sensor, which means that the
sheet is being pushed by the printer and pulled by the device, the
timer is reset to timeout in one second. If the sheet does not arrive at
FLEntry sensor in one second, the device declares a jam 03.

Next, the FLEntry 1 sensor is deactivated. Since this event depends
on the paper length and the printer speed, it is independent of time.
The device counts steps in the receiving stepper motor. With the
proper relation of steps to length, the device knows when the sheet

Troubleshooting tools

51

leaves the printer rollers. At that time, the device switches to high
speed and begins a timeout of one second. If the sheet fails to leave
the FLEntry 1 sensor in one second, the device declares a jam 04.

Once FLEntry 1 is deactivated, a timeout of .75 seconds begins to the
next event—deactivation of the FLEntry sensor. If the FLEntry sensor
is not deactivated, the device declares a jam 05. If the FLEntry sensor
is deactivated, a timeout of 1.5 seconds begins for activation of the
FLExit sensor.

F LExit se nsor

If the FLExit sensor is not activated within the timeout, the device
declares a jam 0A.

FLExit sensor deactivatation depends on the internal paper path
speed and the paper length. The device declares a jam when internal
step counter exceeds 133% of number of steps that represent the
paper length.

If the FLExit sensor is not deactivated, which can occur when sheet
stops in the paper path because of an obstruction or slipping, the
device declares a jam 0B.

When the FLExit sensor is deactivated correctly, a timeout of 1.5
seconds begins for activation of the registration wheel's sensor.

G WS ens se nsor/E xit sensor

If the GWSens sensor (in the Stapler/Stacker) or the Exit sensor (on
the Stacker) is not activated within the timeout, the device declares a
jam 12.

52 4 Troubleshooting

EN

S tanda lone diagnostic tool

The standalone diagnostic routines differ between the 3,000-Sheet
Stapler/Stacker and the 3,000-Sheet Stacker.

The standalone diagnostic tool tests the device's motors and
functionality without the C-link commands from the printer.

The device has a “user LED” and a set of “service LEDs.”

User LED—the single LED located at the top of the front cover

●

provides information about the power-on status and attachment/
alignment to the printer.

Service LEDs (see Figure 19, callout 3)—three LEDs (green,

●

yellow, and red) located near the bottom of the controller PCA,
toward the back of the device, provide additional technical
information about the device.

Note

Note

To interpret the LED patterns, see the tables later in this chapter.
When service mode is entered, the Stapler/Stacker performs a

power-up sequence. While in service mode, the stapler test/stacker
test, stacker bin test, face-up bin full sensor test, and stacker bin full
test can be performed.

To set the device in ser vice mode

Make sure the printer is turned off before performing this test. If the
printer is on when service mode is enabled, some C-link signals might
affect the test performance.

Unplug the C-link cable that connects the device to the printer.

1

Unplug the power cable that connects the device to the printer

2

and plug the power cable directly into a grounded power source.
Remove the controller PCA cover (see Chapter 3—Removal and

3

Replacement—for removal and replacement procedures).
Slide the service mode switch on the controller PCA to the “ON”

4

position (toward you).
Press and hold in the interlock switch.

5

EN

To exit service mode

Release the interlock switch and slide the service mode switch on

1

the controller PCA back to the normal position.
Reinstall the controller PCA cover and C-link and power cables.

2

Troubleshooting tools

53

Note The user LED blinks green when the printer is turned on after setting

and exiting service mode. Perform steps 18 through 22 under
“Calibrating the staple position” earlier in this chapter to return to
normal operation.

S tapler test/ stacker te st

For the stapler test/stacker test, use letter- or A4-sized paper. Feed
the paper straight, centered, and slowly to av oid skews and jams. If a
jam occurs, release the interlock switch and depress it again to reset
the device.

Note Any stapler settings or offset settings configured at the printer control

panel are ignored during the stapler test/stacker test.
1 Feed two sheets of paper into the paper input area. The sheets

are sent to the face-up bin.

2 Feed two sheets at a time into the paper input area.

• In the 3,000-Sheet Stapler/Stacker, the sheets are stapled
as shown below and sent to the stacker bin:

next two sheets: no staples
next two sheets: 1 staple

• In the 3,000-Sheet Stacker, the sheets are routed as follows:

54 4 Troubleshooting

next two sheets: 2 staples
next two sheets: 3 staples
next two sheets: 6 staples
next two sheets: 1 staple, angled at 40°

next two sheets restart the cycle: to the face-up bin

next two sheets: to the stacker bin, offset in

one direction

next two sheets: to the face-up bin
next two sheets: to the stacker bin, offset in

the opposite direction

next two sheets restart the cycle: to the face-up bin

EN

S tacke r bin test

Block the upper optical sensor and observe the movement of the
stacker bin.

Face -up bin full se nsor test

Lift and hold up the bin-full flag until the user LED blinks amber. The
user LED should blink amber within a few seconds.

S tacke r Bin Full S ensor Test

Block the upper optical sensor until the stacker bin reaches the
bottom of its motion, triggering the stacker bin full sensor; the user
LED should blink amber.

EN

Troubleshooting tools

55

S er vice LED flashing pa tterns

The blinking of the service LEDs will be 0.5 seconds on and 0.5
seconds off, during the coding sequence. After a two-second delay
the sequence will be repeated.

Table 10. S ervice LE D flashing patterns

LED blinking
pattern (number

LED Meaning

Solid green Device OK
Blinking green Device detached from the printer 1
Blinking yellow Staple jam 1

Jam in flipper 2
Jam in paper path 3
Jam in accumulator 4
Jam in carriage 5

Blinking red Stapler malfunction 1

Flipper malfunction 2
Malfunction in paper path 3

of blinks)

Accumulator/offset module malfunction 4
Carriage malfunction 5
Controller PCA malfunction 6

U ser LE D status inte rpreta tion

The blinking of the user LED is continuous.

Table 11. User LED status interpretation

Color Solid/blinking Meaning

Off N/A Printer in powersave mode or de vice not

receiving power

Green Solid Device is on and ready
Green Blinking Device is in service mode
Amber Solid Device has a hardware malfunction
Amber Blinking Device is not correctly attached to

printer, one or more bins are full, or

device has a paper jam or a staple jam

56 4 Troubleshooting

EN

P rinte r messages

C ontrol pane l message s and e rrors

Be sure to read the exact text of the control panel message , including
the error message number and the text, in order to locate the error
message in the tables.

The printer has enhanced information in the control panel.
Printer messages displayed on the control panel display provide five

categories of information. Each message category is assigned a
priority. If more than one condition occurs at the same time, the
highest priority message is displayed. When it has been cleared, the
next priority message will be displayed, and so on. The displayed
messages and their priorities are:

Printer status

●

Warning messages

●

Error messages

●

Critical error messages

●

External paper-handling device messages

●

Co ntrol panel and e vent log me ssage forma t

The format of control panel messages is:

13.xy—paper jam in input/output device

●

Input/output device condition—xy.zz

●

66.xy.zz—input/output device failure

●

The format of event log messages is:

13.xy zz—input/output device paper jam

●

65.xy.zz—input/output device condition

●

66.xy.zz—input/output device hardware malfunction

●

EN

Printer messages

57

For both the control panel and event log messages:

●

x is the C-link device number in the daisy chain:

0 Paper handling controller
1 First C-link device
2 Second C-link device
3 Third C-link device
4 Fourth C-link device
5 Fifth C-link device

●

y is the C-link device type:

0 Paper handling controller
1 Input device
2 Output device
3 Finishing device
4 Other supported device (not in use)
5 Other supported device (not in use)

●

zz is the error code. See the error message tables later in this
chapter for more information.

Shown below are examples of control panel messages with their
corresponding event log messages and meanings. Recommended
actions are not shown; see the error message tables later in this
chapter for recommended actions.

Control panel message Event log Meaning

13.11 Paper Jam in Input
Device

66.22.09 Output Device
Failure

13.11.1B A paper jam occurred in the first C-link device
configured. It is an input device (2,000-Sheet
Input Tray or 2 x 500-Sheet Input Tray) with an
error code 1B. This is normally a timeout at an
entry or exit sensor.

66.22.09 A hardware malfunction occurred in t he second
C-link device configured. It is an output device
(Mailbox) with an error code 09. This is an
external memory error.

58 4 Troubleshooting

EN

Note

Print a configuration page to properly identify the input or output device
configured. Notice that the error format only identifies the C-link device
number and the device type; it does not identify which input or output
device is used in the system.

Figure 30. E rror for m at for paper handling

EN

Printer messages

59

HP 3,000-Sheet Stapler/Stacker error messages

Operating errors

Table 12. Operating errors in the Stapler/Stacker

Event
Control pane l
messages

●

Output bin
full

●

Clear
paper from
face up

●

Output bin
full

●

Clear
paper from
optional
bin 1

log erro r

message

N/A Blinking

N/A Blinking

User
LED

amber
(print job
or mopy in
progress)

amber
(print job
or mopy in
progress)

Service
LED Description

N/A Face up bin is full;

125 sheets have
been collected in
the face-up bin.

N/A Stapler bin is full;

3,000 sheets have
been collected in
the stapler bin.

-Or­More than 1,500
sheets of A3- or 11­by-17-inch-sized
paper have been
collected in the
stapler bin.

Recommended
action

Remove paper from
the face-up bin.

Remove paper from
the stapler bin.

Stapler low

N/A N/A N/A There are only 20

on staples

●

Check
stapler
device

●

Clear
jammed
staple

Stapler out

N/A Blinking

of staples

Too many

N/A Blinking

pages in job
to staple

60 4 Troubleshooting

Blinking
amber

Blinking
yellow

(one blink)

yellow

(one blink)

yellow

(one blink)

to 50 staples left.
A staple is jammed

in the stapler.

The cartridge is out
of staples.

The maximum
height of stack to
be stapled has
been exceeded.
Print job is
completed, but not
stapled.

Refill the stapler.

Clear the jammed
staple.

Refill the stapler.

Do not configure
the equipment to
staple stacks that
are thicker than the
maximum height
allowed; follow the
guidelines listed in
the user’s guide.

EN

Open Doors

Table 13. O pen doors in the Stapler/ Stacker

Event
Control pane l
messages

log erro r

message

User
LED

Service
LED Description

Recommended
action

Stkr: Attach
to printer

Stkr: Close
stapler door

N/A Blinking

amber

N/A Blinking

amber

Blinking
green

Blinking
green

The device is
detached from the
printer.

The stapler door is
open.

Attach the device to
the printer and
verify the user LED
is green.

Close the stapler
door.

EN

Printer messages

61

Pape r jams

Table 14. Paper jams in the Stapler/Stacker

Event
Control pane l
messages

Stkr: Detach
and Clear Jam

log erro r

message

13.13 01

or

13.23 01

13.13 02

or

13.23 02

13.13 03

or

13.23 03

User
LED

Blinking
amber

Blinking
amber

Blinking
amber

Service
LED Description

Blinking
yellow

(two
blinks)

Blinking
yellow

(two
blinks)

Blinking
yellow

(two
blinks)

When powering on
or after clearing a
jam, a paper jam is
present at the
flipper entry area.

Paper never
reached the flipper
entry sensors.

Paper jammed at
flipper entry sensor.

Recommended
action

●

Clear the paper
jam.

●

Pow er cycle the
the printer and
the computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

62 4 Troubleshooting

EN

Table 14. Paper jams in the Stapler/Stacker

Event
Control pane l
messages

Stkr: Detach
and Clear Jam

(continued)

log erro r

message

13.13 04

or

13.23 04

13.13 05

or

13.23 05

13.13 06

or

13.23 06

13.13 09

or

13.23 09

User
LED

Blinking
amber

Blinking
amber

Blinking
amber

Blinking
amber

Service
LED Description

Blinking
yellow

(two
blinks)

Blinking
yellow

(two
blinks)

Blinking
yellow

(two
blinks)

Blinking
yellow

(three
blinks)

Paper jammed in
the flipper area.

Paper jammed on
the flipper area.

Self-adjustment
routine incomplete.

When powering on
or after clearing a
jam, a paper jam is
present in the
paper path.

Recommended
action

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

●

Check for
mechanical
interferences in
the flipper's
rollers area.

●

If the problem
persists,
replace the
flipper
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

EN

Printer messages

63

Table 14. Paper jams in the Stapler/Stacker

Event
Control pane l
messages

Stkr: Detach
and Clear Jam

(continued)

log erro r

message

13.13 0A

or

13.23 0A

13.13 0B

or

13.23 0B

13.13 11

or

13.23 11

13.13 12

or

13.23 12

User
LED

Blinking
amber

Blinking
amber

Blinking
amber

Blinking
amber

Service
LED Description

Blinking
yellow

(three
blinks)

Blinking
yellow

(three
blinks)

Blinking
yellow

(four
blinks)

Blinking
yellow

(four
blinks)

Paper jammed
when flipping and
not reaching the
exit sensor.

Paper jammed
when entering the
accumulator.

When powering on
or after clearing a
jam, a paper jam is
present in the
accumulator
assembly.

Paper jammed in
the paper path
between the flipper
and the
accumulator.

Recommended
action

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

●

Clear the paper
jam. Make sure
you remove all
shreds of paper
from the path.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

Replace the
accumulator
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

Replace the
accumulator
assembly.

64 4 Troubleshooting

EN

Table 14. Paper jams in the Stapler/Stacker

Event
Control pane l
messages

Stkr: Detach
and Clear Jam

(continued)

Stkr: Detach
and clear
staple jam

log erro r

message

13.13 13

or

13.23 13

13.13 19

or

13.23 19

User
LED

Blinking
amber

Blinking
amber

Service
LED Description

Blinking
yellow

(four
blinks)

Blinking
yellow

(five
blinks)

A paper jam
occurred when
trying to eject a
print job or mopy.

Paper jammed
between the
carriage and the
stack of paper to be
stapled.

Recommended
action

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

Replace the
accumulator
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer.

●

Verify unit
calibration (Y
compensation).

●

Replace the
stapler
assembly.

H ardwa re ma lfunctions

Table 15. Hardware malfunctions in the Stapler/Stacker

Event
Control pane l
messages

●

Stkr: Call
Service

●

Stkr:
Error 04

●

66.13.17

or

66.23.17
Output
device
failure

EN

log erro r

message

66.13.17

or

66.23.17

User
LED

Solid
amber

Service
LED Description

Blinking
red

(four
blinks)

The accumulator
assembly
malfunctioned.

-Or-

The DC motor
retainer or sensor is
damaged.

Recommended
action

●

Replace the
accumulator
assembly.

●

If the problem
perisists,
replace the
controller PCA.

Printer messages

65

Table 15. Hardware malfunctions in the Stapler/Stacker

Event
Control pane l
messages

●

Stkr: Call
Service

●

Stkr:
Error 04

●

66.13.18

log erro r

message

66.13.18

or

66.23.18

User
LED

Solid
amber

Service
LED Description

Blinking
red

(four
blinks)

The accumulator
assembly
malfunctioned.

-Or-

or

66.23.18
Output
device
failure

●

Stkr: Call
Service

●

Stkr:
Error 05

●

66.13.25

66.13.25

or

66.23.25

Solid
amber

Blinking
red

(five
blinks)

The bearing
bracket or gear
wheel sensor is
damaged.

The stapler is
damaged.

or

66.23.25
Output
device
failure

●

Stkr: Call
Service

●

Stkr:
Error 06

●

66.13.33

or

66.23.33

66.13.33

or

66.23.33

Solid
amber

Blinking
red

(six blinks)

The controller PCA
is damaged.

-Or-

There is a RAM
error.

Output
device
failure

●

Stkr: Call
Service

●

Stkr:
Error 06

●

66.13.34

or

66.23.34

66.13.34

or

66.23.34

Solid
amber

Blinking
red

(six blinks)

The controller PCA
is damaged.

-Or-

There is an
EEPROM error.

Output
device
failure

Recommended
action

●

Replace the
accumulator
assembly.

●

If the problem
persists,
replace the
controller PCA.

●

Replace the
stapler.

●

Replace the
controller PCA.

●

Pow er cycle the
printer and the
computer.

●

If the problem
persists,
replace the
controller PCA.

●

Pow er cycle the
printer and the
computer.

●

If the problem
persists,
replace the
controller PCA.

66 4 Troubleshooting

EN

Table 15. Hardware malfunctions in the Stapler/Stacker

Event
Control pane l
messages

●

Stkr: Call
Service

●

Stkr:
Error 06

●

66.13.35

or

66.23.35

log erro r

message

66.13.35

or

66.23.35

User
LED

Solid
amber

Service
LED Description

Blinking
red

(six blinks)

The controller PCA
is damaged.

-Or-

ROM has been
corrupted.

Output
device
failure

●

Stkr: Call
Service

●

Stkr:
Error 06

●

66.13.36

or

66.23.36

66.13.36

or

66.23.36

Solid
amber

Blinking
red

(six blinks)

The controller PCA
is damaged.

-Or-

The C-link register
is damaged.

Output
device
failure

●

Stkr: Call
Service

●

Stkr:
Error 06

●

66.13.37

or

66.23.37
Output

66.13.37

or

66.23.37

Solid
amber

Blinking
red

(six blinks)

The controller PCA
is damaged.

-Or-

The DAC (digit al-to­analog converter) is
damaged.

device
failure

Recommended
action

●

Pow er cycle the
printer and the
computer.

●

If the problem
persists,
replace the
controller PCA.

●

Pow er cycle the
printer and the
computer.

●

If the problem
persists,
replace the
controller PCA.

●

Pow er cycle the
printer and the
computer.

●

Replace the
controller PCA.

●

Replace the
flipper
assembly.

EN

Printer messages

67

HP 3,000-Sheet Stacker error messages

Operating errors

Table 16. Operating errors in the Stacker

Event
Control pane l
messages

●

Output bin
full

●

Clear
paper from
face up

●

Output bin
full

●

Clear
paper from
optional
bin 1

log erro r

message

N/A Blinking

N/A Blinking

User
LED

amber
(print job
or mopy in
progress)

amber
(print job
or mopy in
progress)

Service
LED Description

N/A Face up bin is full;

N/A Stacker bin is full;

125 sheets have
been collected in
the face-up bin.

3,000 sheets have
been collected in
the stacker bin.

-Or­More than 1,500

sheets of A3- or 11­by-17-inch-sized
paper have been
collected in the
stacker bin.

Recommended
action

Remove paper from
the face-up bin.

Remove paper from
the stacker bin.

O pen doors

Table 17. O pen doors in the Stac ker

Event
Control pane l
messages

Stkr: Attach
to printer

68 4 Troubleshooting

log erro r

message

N/A Blinking

User
LED

amber

Service
LED Description

Blinking
green

The device is
detached from the
printer.

Recommended
action

Attach the device to
the printer and
verify the user LED
is green.

EN

Pape r jams

Table 18. Paper jams in the Stacker

Event
Control pane l
messages

Stkr: Detach
and Clear Jam

log erro r

message

13.12 01

or

13.22 01

13.12 02

or

13.22 02

13.12 03

or

13.22 03

User
LED

Blinking
amber

Blinking
amber

Blinking
amber

Service
LED Description

Blinking
yellow

(two
blinks)

Blinking
yellow

(two
blinks)

Blinking
yellow

(two
blinks)

When powering on
or after clearing a
jam, a paper jam is
still present at the
flipper entry area.

Paper never
reached the flipper
entry sensors.

Paper jammed at
flipper entry sensor.

Recommended
action

●

Clear the paper
jam.

●

Pow er cycle the
the printer and
the computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

EN

Printer messages

69

Table 18. Paper jams in the Stacker

Event
Control pane l
messages

Stkr: Detach
and Clear Jam

(continued)

log erro r

message

13.12 04

or

13.22 04

13.12 05

or

13.22 05

13.12 06

or

13.22 06

13.12 09

or

13.22 09

User
LED

Blinking
amber

Blinking
amber

Blinking
amber

Blinking
amber

Service
LED Description

Blinking
yellow

(two
blinks)

Blinking
yellow

(two
blinks)

Blinking
yellow

(two
blinks)

Blinking
yellow

(three
blinks)

Paper jammed in
the flipper area.

Paper jammed in
the flipper area.

Self-adjustment
routine incomplete.

When powering on
or after clearing a
jam, a paper jam is
present in the
paper path.

Recommended
action

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

●

Check for
mechanical
interferences in
the flipper's
rollers area.

●

If the problem
persists,
replace the
flipper
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

70 4 Troubleshooting

EN

Table 18. Paper jams in the Stacker

Event
Control pane l
messages

Stkr: Detach
and Clear Jam

(continued)

log erro r

message

13.12 0A

or

13.22 0A

13.12 0B

or

13.22 0B

13.12 21

or

13.22 21

13.12 22

or

13.22 22

User
LED

Blinking
amber

Blinking
amber

Blinking
amber

Blinking
amber

Service
LED Description

Blinking
yellow

(three
blinks)

Blinking
yellow

(three
blinks)

Blinking
yellow

(four
blinks)

Blinking
yellow

(four
blinks)

Paper jammed
when flipping and
not reaching the
exit sensor.

Paper jammed
when entering the
offset module.

When powering on
or after clearing a
jam, a paper jam is
present in the offset
module.

Paper jammed
between the path
and the offset
module.

Recommended
action

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

If the problem
persists,
replace the
flipper
assembly.

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

Replace the
offset module.

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

Replace the
offset module.

EN

Printer messages

71

Table 18. Paper jams in the Stacker

Event
Control pane l
messages

Stkr: Detach
and Clear Jam

(continued)

log erro r

message

13.12 23

or

13.22 23

User
LED

Blinking
amber

Service
LED Description

Blinking
yellow

(four
blinks)

Paper stopped and
jammed in the
offset module

H ardwa re M alfunctions

Table 19. Hardware malfunctions in the Stacker

Event
Control pane l
messages

●

Stkr: Call
Service

●

Stkr:
Error 06

●

66.12.33

or

66.22.33
Output
device
failure

●

Stkr: Call
Service

●

Stkr:
Error 06

●

66.12.34

or

66.22.34
Output
device
failure

log erro r

message

66.12.33

or

66.22.33

66.12.34

or

66.22.34

User
LED

Solid
amber

Solid
amber

Service
LED Description

Blinking
red

(six blinks)

Blinking
red

(six blinks)

The controller PCA
is damaged.

-Or-

There is a RAM
error.

The controller PCA
is damaged.

-Or-

There is an
EEPROM error.

Recommended
action

●

Clear the paper
jam.

●

Pow er cycle the
printer and the
computer, if
neccesary.

●

Replace the
offset module.

Recommended
action

●

Pow er cycle the
printer and the
computer.

●

If the problem
persists,
replace the
controller PCA.

●

Pow er cycle the
printer and the
computer.

●

If the problem
persists,
replace the
controller PCA.

72 4 Troubleshooting

EN

Table 19. Hardware malfunctions in the Stacker

Event
Control pane l
messages

●

Stkr: Call
Service

●

Stkr:
Error 06

●

66.12.35

or

66.22.35
Output

log erro r

message

66.12.35

or

66.22.35

User
LED

Solid
amber

Service
LED Description

Blinking
red

(six blinks)

The controller PCA
is damaged.

-Or-

ROM has been
corrupted.

device
failure

●

Stkr: Call
Service

●

Stkr:
Error 06

●

66.12.36

or

66.22.36
Output

66.12.36

or

66.22.36

Solid
amber

Blinking
red

(six blinks)

The controller PCA
is damaged.

-Or-

The C-link register
is damaged.

device
failure

●

Stkr: Call
Service

●

Stkr:
Error 06

●

66.12.37

or

66.22.37
Output
device

66.12.37

or

66.22.37

Solid
amber

Blinking
red

(six blinks)

The controller PCA
is damaged.

-Or-

The DAC (digit al-to­analog converter) is
damaged.

failure

●

Stkr: Call
Service

●

Stkr:
Error 07

●

66.12.41

or

66.22.41
Output

66.12.41

or

66.22.41

Solid
amber

Blinking
red

(seven
blinks)

The offset module
is damaged.

-Or-

The offset encoder
failed.

device
failure

Recommended
action

●

Pow er cycle the
printer and the
computer.

●

If the problem
persists,
replace the
controller PCA.

●

Pow er cycle the
printer and the
computer.

●

If the problem
persists,
replace the
controller PCA.

●

Pow er cycle the
printer and the
computer.

●

Replace the
controller PCA.

●

Replace the
flipper
assembly.

●

Pow er cycle the
printer and the
computer.

●

Replace the
offset module.

EN

Printer messages

73

74 4 Troubleshooting

EN

5

Parts and diagrams

H ow to use the parts lists a nd diag rams

The figures in this chapter illustrate the major assemblies in the HP
3,000-Sheet Stapler/Stacker and HP 3,000-Sheet Stack er . Each table
following an exploded assembly diagram lists the reference
designator, the associated part number for the item, and a description
of the part.

Parts that have no ref erence designator or part number are not FR Us
and cannot be ordered through Product Support Division Materials.

EN

How to use the parts lists and diagrams

75

O rdering parts

All standard part numbers listed are stocked and can be ordered from
HP’s Product Support Division Materials.

●

Hewlett-Packard Co.
Product Support Division Materials
8050 Foothills Blvd.
Roseville, CA 95678
Parts Direct Ordering: 800-227-8164 (U.S. only)

●

Hewlett-Packard Co.
Product Support Division Materials
Wolf-Hirth Strasse 33
D-7030 Boblingen, Germany
(497031) 14-2253

You can also contact Hewlett-Packard in the U.S. at 916-783-8040 to
find out part numbers for the products. Contact a local HP Parts
Coordinator for other local phone numbers.

76 5 Parts and diagrams

EN

R efilling the stapler

Staples cartridges are available through a local authorized HP dealer.
In the U.S., you can find a dealer near you (or if your dealer is
temporarily out of stock) by calling the HP Customer Information
Center at 800-752-0900.

When you order refill staples, you receive three staples cartridges;
each staple cartridge contains 5,000 staples. The product number for
ordering staples cartridges is C4791A.

O rder ing staple s cartr idges

The staples cartridges can be ordered from Hewlett-Packard at the
following phone numbers:

U.S.: 800-538-8787

●

Canada: 800-387-3154

●

Toronto: 516-671-8383
United Kingdom: 0734-441212

●

Germany: 0130-3322

●

Contact a local HP Parts Coordinator for other local phone numbers.

EN

How to use the parts lists and diagrams

77

5

4

3

2

6

1

Figure 31 Bins a nd covers

78 5 Parts and diagrams

7

EN

Bins a nd covers

Table 20. Bins a nd covers

Reference Description Part number

1 Front cover C4788-60505
2 Foot cover C4788-60525
3 Stapler bin (for Stapler/Stacker)

Stacker bin (for Stacker)
4 Face-up bin C4788-60512
5 Back cover C4788-60504
6 Stapler door assembly with label (for Stapler/

Stacker)

Stacker door assembly (for Stacker)
7 Controller PCA cover (with label) (for Stapler/

Stacker)

Controller PCA cover (with label) (for Stacker)

C4788-60513
C4779-60505

C4788-60507
C4779-60502

C4788-60508
C4779-60503

EN

Bins and covers

79

9

8

20

21

10

22

15

16

Figure 32 Internal assemblies

19

18

13

17

14

11

12

80 5 Parts and diagrams

EN

I nterna l assemblies

Table 21. Internal assemblies

Reference Description Part number

8 LED PCA C4788-60510
9 Flipper assembly C4788-60501
10 Flipper ribbon cable C4788-60524
11 Stapler (applies only to Stapler/Stacker) C4788-60519
12 Stapler refill housing C4788-60522
13 Carriage assembly (applies only to Stapler/Stacker) C4788-60503
14 Attachment assembly (rod, bracket, cables) C4788-60523
15 Adjustable caster C4788-60516
16 Stationary caster C4788-60515
17 Power supply C4788-60511
18 Stapler controller PCA (for Stapler/Stacker)

Stacker controller PCA (for Stacker)
19 Offset module (for Stacker) C4779-60501
20 Accumulator assembly (for Stapler/Stacker) C4788-60502
21 Interlock C4788-60514
22 Safety switch assembly C4788-60517

C4788-60509
C4779-60504

EN

Internal assemblies

81

82 5 Parts and diagrams

EN

Printed on at least
50% Total Recycled Fiber with
at least 10% Post-Consumer Paper

Copyright© 1999
Hewlett-Packard Co.
Printed in USA 1/99

Manual Part No.
C4788-90904

*C4788-90904*
*C4788-90904*

C4788-90904