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

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

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

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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

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

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

Introduction

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

(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

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

Product specifications

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

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

) bond.

) 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

)

Media specifications

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

)

10 1 Product information

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

Basic functions

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.

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.

Basic functions

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

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)

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

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

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

Basic functions

18 2 Theory of operation

Removal and

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.

Removal and replacement strategy

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

Bins a nd covers

Face -up bin

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

Pull the bin away from the product (callout 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).

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

Figure 5. Bins remo val

Bins and covers

Front co ve r

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

F oot cover

Remove the front and back covers.

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

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.

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.

Bins and covers

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

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

I nterna l assemblies

F lipper a ssembly

Remove the front and back covers.

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

(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

on each side of the assembly.

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

Note

Sheet metal edges may be sharp.

Internal assemblies

+ 58 hidden pages