HP Laserjet M600 series service manual

LASERJET ENTERPRISE 600 M601, M602, AND M603 SERIES PRINTER

Service Manual

HP LaserJet Enterprise 600 M601,

M602, and M603 Series Printer

Service Manual

Copyright and License

© 2011 Copyright Hewlett-Packard

Development Company, L.P.

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

The information contained herein is subject to change without notice.

The only warranties for HP products and services are set forth in the express warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty. HP shall not be liable for technical or editorial errors or omissions contained herein.

Part number: CE988-90945

Edition 1, 11/2011

Trademark Credits

ENERGY STAR and the ENERGY STAR mark are registered U.S. marks.

Conventions used in this guide

TIP: Tips provide helpful hints or shortcuts.

NOTE: Notes provide important information to explain a concept or to complete a task.

CAUTION: Cautions indicate procedures that you should follow to avoid losing data or damaging the product.

WARNING! Warnings alert you to specific procedures that you should follow to avoid personal injury, catastrophic loss of data, or extensive damage to the product.

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iv

Conventions used in this guide

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Table of contents

1 Theory of operation ..........................................................................................................	1
Basic operation ........................................................................................................................	2
Major print systems ...................................................................................................	2
Internal components ..................................................................................................	3
Operating sequence ..................................................................................................	7
Formatter system ......................................................................................................................	8
Sleep mode ..............................................................................................................	8
Input/output .............................................................................................................	8
USB ..........................................................................................................	8
Embedded print server ................................................................................	9
Hard-disk ..................................................................................................	9
CPU .........................................................................................................	9
Memory ...................................................................................................................	9
Random-access memory ..............................................................................	9
Nonvolatile memory ...................................................................................	9
DIMM slot ................................................................................................................	9
PJL overview ...........................................................................................................	10
PML .......................................................................................................................	10
Control panel .........................................................................................................	10
Engine-control system ..............................................................................................................	11
DC controller PCA ...................................................................................................	12
Sensors, solenoids, and switches ...............................................................................	13
Motors and fans ......................................................................................................	14
Failure detection ......................................................................................	14
Motor failure ............................................................................	14
Fan motor failure .......................................................................	14
Engine power supply ................................................................................	15
Fuser-control circuit ....................................................................	15
Low-voltage power supply ..........................................................	17
High-voltage power supply .........................................................	18
Overcurrent/overvoltage protection .............................................	19
Image-formation system ...........................................................................................................	20

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Image-formation process ..........................................................................................	21
Block 1: Latent image formation .................................................................	23
Step 1: Primary charging ...........................................................	23
Step 2: Laser-beam exposure ......................................................	23
Block 2: Developing .................................................................................	24
Step 3: Developing ....................................................................	24
Block 3: Transfer ......................................................................................	25
Step 4: Transfer ........................................................................	25
Step 5: Separation ....................................................................	25
Block 4: Fusing ........................................................................................	26
Step 6: Fusing ...........................................................................	26
Block 5: Drum cleaning .............................................................................	27
Step 7: Drum cleaning ...............................................................	27
Step 8: Drum charge elimination .................................................	27
Laser/scanner system .............................................................................................................	28
Laser failure detection ..............................................................................................	30
Pickup, feed, and delivery system .............................................................................................	31
Pickup-and-feed block ..............................................................................................	32
Fuser/delivery block ................................................................................................	33
Pressure roller pressure release control .......................................................................	33
Paper trays .............................................................................................................	34
Printing from Tray 1 ..................................................................................	34
Printing from Tray 2 ..................................................................................	34
Cassette media size detection and cassette presence detection ......................	34
Jam detection .........................................................................................................	36
1x500-sheet paper feeder .......................................................................................................	40
Pickup-and-feed operation (PF) ..................................................................................	41
Cassette lift operation (PF) ........................................................................................	43
Cassette media size detection and cassette presence detection (PF) ...............................	43
Cassette multiple-feed prevention (PF) ........................................................................	43
Jam detection (PF) ...................................................................................................	43
1x1500-sheet paper deck .......................................................................................................	44
Pickup-and-feed operation (PD) .................................................................................	45
Cassette lift operation (PD) .......................................................................................	47
Media size detection (PD) ........................................................................................	48
Multiple-feed prevention (PD) ....................................................................................	48
Jam detection (PF) ...................................................................................................	48
Envelope feeder .....................................................................................................................	49
Pickup-and-feed operation (EF) ..................................................................................	50
Multiple-feed prevention (EF) .....................................................................................	50
Multiple-feed detection (EF) .......................................................................................	51

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Jam detection (EF) ...................................................................................................	51
Duplexer ...............................................................................................................................	53
Motor and fan control (DP) .......................................................................................	54
Failure detection (DP) ................................................................................	55
Reverse-and-re-pickup operation (DP) .........................................................................	55
Side registration adjustment operation (DP) ................................................................	56
Jam detection (DP) ...................................................................................................	58
2 Removal and replacement ..............................................................................................	59
Introduction ...........................................................................................................................	60
Removal and replacement strategy ...........................................................................................	60
Electrostatic discharge ............................................................................................................	60
Required tools ........................................................................................................................	61
Types of screws .....................................................................................................................	62
Service approach ...................................................................................................................	63
Before performing service ........................................................................................	63
After performing service ...........................................................................................	63
Post-service test .......................................................................................................	63
Print-quality test ........................................................................................	63
Customer replaceable units (CRUs) ...........................................................................................	64
Print cartridge .........................................................................................................	64
Tray 2 ...................................................................................................................	65
Tray 2 separation, pickup, and feed rollers ................................................................	66
Transfer roller ........................................................................................................	69
Fuser .....................................................................................................................	70
Remove the fuser ......................................................................................	70
Formatter cover and formatter cage ...........................................................................	71
Installing a new formatter ..........................................................................	73
Hard drive .............................................................................................................	74
Remove the SSM ......................................................................................	74
Remove the encrypted HHD .......................................................................	76
Installing a replacement hard drive .............................................................	78
SSM firmware upgrade ..............................................................	78
HDD firmware upgrade ..............................................................	79
Memory DIMM .......................................................................................................	80
Remove the memory DIMM .......................................................................	80
Install the memory DIMM ...........................................................................	81
Tray 1 pickup and feed rollers ..................................................................................	82
Tray 1 separation roller ...........................................................................................	85
Rear output bin .......................................................................................................	87
Covers ..................................................................................................................................	88

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Top-accessory cover ................................................................................................	88
Envelope feed accessory covers ................................................................................	89
Duplex accessory or cover .......................................................................................	90
Tray 2 extension door ..............................................................................................	91
Remove the Tray 2 extension door ..............................................................	91
Top cover ...............................................................................................................	92
Remove the top cover ...............................................................................	92
Right-side cover .......................................................................................................	95
Remove the right-side cover .......................................................................	95
Reinstall the right cover .............................................................................	97
Left-side cover .........................................................................................................	98
Remove the left-side cover .........................................................................	98
Right-front cover ....................................................................................................	100
Remove the right-front cover .....................................................................	100
Rear-upper cover ...................................................................................................	103
Remove the rear-upper cover ...................................................................	103
Front cover ...........................................................................................................	105
Remove the front cover ............................................................................	105
Main assemblies ..................................................................................................................	107
Registration assembly ............................................................................................	107
Control-panel assembly ..........................................................................................	109
Remove the control-panel assembly ...........................................................	109
Walk-up USB port and cable ..................................................................................	111
Remove the walk-up USB port and cable ...................................................	111
Inner connecting PCA ............................................................................................	114
Remove the inner connecting PCA ............................................................	114
Reinstall the inner connecting PCA ...........................................................	116
Fan FN102 ..........................................................................................................	117
Remove fan FN102 ................................................................................	117
Fan FN103 ..........................................................................................................	119
Remove fan FN103 ................................................................................	119
Pickup-motor assembly (M101) ...............................................................................	121
Remove the pickup-motor assembly ...........................................................	121
Drum-motor assembly (M102) .................................................................................	123
Remove the drum motor ..........................................................................	123
Lifter-motor assembly (M103) ..................................................................................	125
Remove the lifter motor ...........................................................................	125
DC controller PCA .................................................................................................	128
Remove the DC controller PCA .................................................................	128
Reinstallation tip .....................................................................................	129
Installing a new formatter and a new DC controller ....................................	129

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Pickup-drive assembly ............................................................................................	131
Remove the pickup-drive assembly ............................................................	131
Reinstall the pickup-drive assembly ...........................................................	136
Fuser-motor assembly (M299) .................................................................................	137
Remove the fuser-motor assembly .............................................................	137
Drum-drive assembly ..............................................................................................	139
Remove the drum-drive assembly ..............................................................	139
Reinstall the drum-drive assembly .............................................................	141
Fan FN101 ..........................................................................................................	142
Remove fan FN101 ................................................................................	142
Fan FN301 ..........................................................................................................	144
Remove fan FN301 ................................................................................	144
Environmental sensor (TH3) ....................................................................................	146
Remove the environmental sensor (TH3) ....................................................	146
High voltage power supply ....................................................................................	148
Remove the high-voltage power-supply assembly ........................................	148
Feed-guide assembly .............................................................................................	152
Remove the feed-guide assembly ..............................................................	152
Reinstall the feed-guide assembly .............................................................	154
Tray 1 paper-pickup assembly ................................................................................	155
Remove the Tray 1 pickup assembly .........................................................	155
Feed-roller assembly ..............................................................................................	157
Remove the feed-roller assembly ...............................................................	157
Laser/scanner assembly .........................................................................................	158
Remove the laser/scanner assembly .........................................................	158
Paper-delivery assembly ........................................................................................	161
Remove the paper-delivery assembly .........................................................	161
Reinstall the paper-delivery assembly ........................................................	164
1,500-sheet paper deck (PD) .................................................................................................	165
Separation roller (PD) ............................................................................................	165
Rear cover (PD) .....................................................................................................	167
Right-side cover (PD) ..............................................................................................	168
1,500-sheet paper deck left-side cover .....................................................................	169
Remove the left-side cover .......................................................................	169
Door (PD) .............................................................................................................	172
Motor (PD) ...........................................................................................................	174
Remove the Motor (PD) ...........................................................................	174
Driver PCA (PD) ....................................................................................................	176
Remove the Driver PCA (PD) ....................................................................	176
Lift-drive assembly (PD) ...........................................................................................	178
Remove the Lift-drive assembly (PD) ...........................................................	178

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3 Solve problems .............................................................................................................	181
Solve problems checklist .......................................................................................................	182
Menu map ..........................................................................................................................	184
Preboot menu options ...........................................................................................................	185
Current settings pages ..........................................................................................................	192
Troubleshooting process ........................................................................................................	193
Determine the problem source .................................................................................	193
Pre-troubleshooting checklist ....................................................................	193
Troubleshooting flowchart .......................................................................	194
Power subsystem ...................................................................................................	196
Power-on checks ....................................................................................	196
Overview ...............................................................................	196
Tools for troubleshooting .......................................................................................................	199
Component diagnostics ..........................................................................................	199
LED diagnostics ......................................................................................	199
Understand lights on the formatter .............................................	199
Engine diagnostics .................................................................................	204
Engine test button ....................................................................	204
Formatter test ..........................................................................	204
Print/Stop test .........................................................................	205
Drum rotation test ....................................................................	205
Paper-path test (and automatic sensor test) .................................................	206
Paper path sensors test (automatic) ............................................	206
Manual sensor test .................................................................................	208
Top of page sensor (PS103) .....................................................	210
Pre-feed sensor (PS102) ...........................................................	211
Fuser delivery sensor (PS700) ...................................................	212
Duplex sensor (PS1502) ...........................................................	213
Media width sensors 1/2 (PS106/108) .....................................	214
Output bin full sensor (PS104) ..................................................	215
Tray 1 paper present sensor (PS105) .........................................	216
Tray 2 paper present sensor (PS101) .........................................	217
Tray 2 top of stack sensor (PS107) ............................................	218
Tray 2 paper size switches (SW102) .........................................	219
Tray/Bin manual sensor test ....................................................................	220
Print/stop test ........................................................................................	220
Component tests .....................................................................................	221
Diagrams .............................................................................................................	223
Block diagrams ......................................................................................	223
Main assemblies .....................................................................	223
Main parts .............................................................................	224

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Motors and fans ......................................................................	225
PCAs .....................................................................................	226
500-sheet feeder .....................................................................	226
1,500-sheet feeder ..................................................................	227
Connectors ............................................................................................	229
DC controller PCA connectors ...................................................	229
Product base connectors ...........................................................	231
500-sheet paper tray connectors ...............................................	232
1,500-sheet paper tray connectors ............................................	232
Duplexer connectors ................................................................	233
Envelope feeder connectors ......................................................	233
General timing chart ...............................................................................	234
Circuit diagrams ....................................................................................	235
Internal print-quality test pages ................................................................................	241
Print-quality-troubleshooting pages ............................................................	241
Clean the paper path .............................................................................	242
Set up an auto cleaning page ...................................................	242
Print configuration page ..........................................................................	243
Configuration page .................................................................	243
HP embedded Jetdirect page ....................................................	245
Print quality troubleshooting tools ............................................................................	246
Repetitive image defect ruler ....................................................................	246
Control-panel menus ..............................................................................................	247
Retrieve Job from USB menu ....................................................................	247
Retrieve Job from Device Memory menu ....................................................	247
Supplies menu .......................................................................................	248
Trays menu ............................................................................................	249
Administration menu ...............................................................................	250
Reports menu ..........................................................................	250
General Settings menu .............................................................	250
Retrieve From USB Settings menu ..............................................	253
General Print Settings menu ......................................................	253
Default Print Options menu .......................................................	255
Display Settings menu ..............................................................	255
Manage Supplies menu ...........................................................	256
Manage Trays menu ................................................................	257
Stapler/Stacker Settings menu ..................................................	258
Multi-Bin Mailbox Settings menu ................................................	258
Network Settings menu ............................................................	259
Troubleshooting menu ..............................................................	263
Device Maintenance menu ......................................................................	264

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Backup/Restore menu ..............................................................	264
Calibrate/Cleaning menu ........................................................	264
USB Firmware Upgrade menu ...................................................	265
Service menu ..........................................................................	265
Interpret control-panel messages, status-alert messages, and event code errors ..............	266
10.00.33 ..............................................................................................	266
10.00.35 ..............................................................................................	266
10.00.60 ..............................................................................................	266
10.00.69 ..............................................................................................	267
10.00.91 ..............................................................................................	267
10.0X.Y0 Supply memory error ...............................................................	267
10.23.35 ..............................................................................................	268
10.23.50 ..............................................................................................	268
10.23.51 ..............................................................................................	268
10.23.52 ..............................................................................................	268
10.23.60 ..............................................................................................	268
10.23.70 Printing Past Very Low ..............................................................	269
10.26.15 ..............................................................................................	269
10.26.50 ..............................................................................................	269
10.26.60 ..............................................................................................	270
10.XX.34 Used Supply In Use ..................................................................	270
10.XX.40 Genuine HP Supplies Installed ...................................................	270
10.XX.41 Unsupported Supply In Use .......................................................	271
10.XX.70 Printing past very low ...............................................................	271
10.YY.15 Install <supply> .......................................................................	271
10.YY.35 Incompatible <supply> .............................................................	272
11.00.YY Internal clock error ..................................................................	272
13.00.00 ..............................................................................................	272
13.00.EE ..............................................................................................	273
13.A3.FF ..............................................................................................	273
13.D3.DZ .............................................................................................	273
13.E5.FF ...............................................................................................	273
13.EA.EE ..............................................................................................	274
13.EE.FF ...............................................................................................	274
13.FF.EE ...............................................................................................	274
13.FF.FF ...............................................................................................	274
13.WX.EE .............................................................................................	274
13.WX.FF .............................................................................................	275
13.WX.YZ Fuser Area Jam ......................................................................	275
13.WX.YZ Fuser wrap jam ......................................................................	275
13.WX.YZ Jam below control panel .........................................................	275

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13.WX.YZ Jam in Tray 1 ........................................................................	275
13.WX.YZ Jam in Tray <X> .....................................................................	276
13.WX.YZ Jam inside envelope feeder .....................................................	276
13.WX.YZ Jam inside top cover ...............................................................	276
14.00.XX ..............................................................................................	276
20.00.00 Insufficient memory: <Device> To continue, touch “OK” ...............	277
21.00.00 Page Too Complex ..................................................................	277
32.08.AX ..............................................................................................	277
32.1C.XX ..............................................................................................	278
32.21.00 ..............................................................................................	284
33.01.XX ..............................................................................................	285
33.XX.YY Used board/disk .....................................................................	285
40.00.01 USB I/O buffer overflow To continue, touch “OK” .......................	285
40.00.02 Embedded I/O buffer overflow To continue, touch “OK” ..............	285
40.00.05 Embedded I/O bad transmission To continue, touch “OK” ...........	286
41.02.00 Error ......................................................................................	286
41.03.YZ Unexpected size in envelope feeder To use another tray, touch
"Options" ..............................................................................................	286
41.03.YZ Unexpected size in tray <X> .....................................................	287
41.05.YZ Unexpected type in tray <X> ....................................................	288
41.XX.YZ Error To continue, touch “OK” ...................................................	290
42.XX.YY ..............................................................................................	291
47.00.XX ..............................................................................................	291
47.01.XX ..............................................................................................	291
47.02.XX ..............................................................................................	292
47.03.XX ..............................................................................................	292
47.04.XX ..............................................................................................	292
47.05.00 ..............................................................................................	292
47.06.XX ..............................................................................................	292
47.WX.YZ Printer Calibration Failed To continue, touch “OK” .....................	293
49.XX.YY To continue turn off then on .......................................................	294
50.WX.YZ Fuser error To continue turn off then on .....................................	294
51.00.YY Error ......................................................................................	296
52.XX.00 Error To continue turn off then on ...............................................	296
54.XX.YY Error ......................................................................................	297
55.00.YY DC controller error To continue turn off then on ...........................	298
55.0X.YY DC controller error To continue turn off then on ...........................	298
56.00.YY Error To continue turn off then on ...............................................	298
57.00.0Y Error To continue turn off then on ..............................................	299
58.00.0Y Error To continue turn off then on ..............................................	300
59.00.YY error To continue turn off then on ...............................................	300

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59.A2.0x Error ......................................................................................	301
60.00.0Y Tray <Y> lifting error ...............................................................	302
62.00.00 No system To continue turn off then on .......................................	302
65.X0.A1 Output accessory disconnected .................................................	303
66.80.YY Stapler/Stacker failure .............................................................	303
69.11.YY Error To continue turn off then on ...............................................	305
70.00.00 Error To continue turn off then on ..............................................	305
79.XX.YY Error To continue turn off then on ...............................................	306
80.0X.YY Embedded JetDirect error .........................................................	306
81.YY.ZZ EIO-1 Card Failure ..................................................................	308
82.73.46 OR 82.73.47 .........................................................................	309
98.00.01 Corrupt data in firmware volume ...............................................	310
98.00.02 Corrupt data in solutions volume ...............................................	310
98.00.03 Corrupt data in configuration volume .........................................	310
98.00.04 Corrupt data in job data volume ...............................................	310
99.00.01 Upgrade not performed file is corrupt ........................................	311
99.00.02 Upgrade not performed timeout during receive ...........................	311
99.00.03 Upgrade not performed error writing to disk ...............................	311
99.00.04 Upgrade not performed timeout during receive ...........................	311
99.00.05 Upgrade not performed timeout during receive ...........................	312
99.00.06 Upgrade not performed error reading upgrade ...........................	312
99.00.07 Upgrade not performed error reading upgrade ...........................	312
99.00.08 Upgrade not performed error reading upgrade ...........................	312
99.00.09 Upgrade canceled by user .......................................................	313
99.00.10 Upgrade canceled by user .......................................................	313
99.00.11 Upgrade canceled by user .......................................................	313
99.00.12 Upgrade not performed the file is invalid ...................................	313
99.00.13 Upgrade not performed the file is invalid ...................................	314
99.00.14 Upgrade not performed the file is invalid ...................................	314
99.00.2X ..............................................................................................	314
99.09.60 Unsupported disk ....................................................................	315
99.09.61 Unsupported disk ....................................................................	315
99.09.62 Unknown disk .........................................................................	315
99.09.63 Incorrect disk ..........................................................................	316
99.09.64 Disk malfunction ......................................................................	316
99.09.65 Disk data error ........................................................................	316
99.09.66 No disk installed .....................................................................	316
99.09.67 Disk is not bootable please download firmware ..........................	316
99.XX.YY ..............................................................................................	317
<binname> full Remove all paper from bin ................................................	317
<Supply> low OR Supplies low ................................................................	317

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<Supply> very low OR Supplies very low ..................................................	318
[File System] device failure To clear press “OK” .........................................	318
[File System] file operation failure To clear press “OK” ...............................	318
[File System] file system is full To clear press “OK” .....................................	318
[File System] is not initialized ...................................................................	319
[File System] is write protected .................................................................	319
Accept bad signature .............................................................................	319
Bad optional tray connection ...................................................................	319
Canceling .............................................................................................	320
Canceling... <jobname> .........................................................................	320
Cartridge Low ........................................................................................	320
Cartridge Memory Abnormal ...................................................................	320
Cartridge Out ........................................................................................	320
Checking engine ....................................................................................	321
Checking paper path ..............................................................................	321
Chosen personality not available To continue, touch “OK” ..........................	321
Cleaning do not grab paper ....................................................................	321
Cleaning... ............................................................................................	322
Clearing event log ..................................................................................	322
Clearing paper path ...............................................................................	322
Close stapler/stacker multi bin mailbox door .............................................	322
Close top cover ......................................................................................	322
Cooling device ......................................................................................	323
Creating cleaning page... .......................................................................	323
Data received To print last page press “OK” .............................................	323
Event log is empty ..................................................................................	323
Expected drive missing ...........................................................................	324
External device initializing .......................................................................	324
Face Down Tray Full ...............................................................................	324
FIM Load Error Send full FIM on <X> port .................................................	324
Fuser Kit low ..........................................................................................	324
Fuser Kit very low To continue, touch “OK” ...............................................	325
Genuine HP cartridge installed ................................................................	325
Genuine HP supply installed ....................................................................	325
HP Secure hard drive disabled .................................................................	325
Incompatible <supply> ............................................................................	326
Incompatible supplies .............................................................................	326
Initializing... ..........................................................................................	326
Install fuser unit ......................................................................................	326
Install supplies .......................................................................................	327
Install supply ..........................................................................................	327

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Internal disk device failure To clear press “OK” ..........................................	327
Internal disk file operation failed ..............................................................	327
Internal disk file system is full ...................................................................	328
Internal disk is write protected ..................................................................	328
Internal disk not found ............................................................................	328
Internal disk not functional .......................................................................	328
Internal disk not initialized .......................................................................	328
Internal disk spinning up .........................................................................	329
Job not stapled due to mixed sizes ...........................................................	329
Load Tray <X>: [Type], [Size] ..................................................................	329
Load Tray <X>: [Type], [Size] To use another tray, press “OK” ....................	330
Loading program <XX> ...........................................................................	330
Manually feed output stack Then touch "OK" to print second side ................	330
Manually feed: <Type><Size> .................................................................	330
Manually feed: <Type><Size> To use another tray, press “OK” ...................	331
Moving solenoid ....................................................................................	331
Moving solenoid and motor .....................................................................	331
No job to cancel ....................................................................................	331
NON HP SUPPLY INSTALLED ...................................................................	332
Output Bin Full .......................................................................................	332
Paused… ..............................................................................................	332
Performing Paper Path Test… ...................................................................	332
Please Wait... ........................................................................................	332
Printing Configuration... ..........................................................................	333
Printing Event Log... ................................................................................	333
Printing File Directory... ...........................................................................	333
Printing Font List... ..................................................................................	333
Printing Fuser Test Page... .......................................................................	333
Printing Help Page... ..............................................................................	334
Printing Menu Map... .............................................................................	334
Printing Registration Page… ....................................................................	334
Printing stopped .....................................................................................	334
Printing Supplies Status Page... ................................................................	334
Printing Usage Page... ............................................................................	334
Printing…engine test ...............................................................................	335
Processing duplex job Do not grab paper until job completes ......................	335
Processing job from tray <X>... Do not grab paper until job completes .........	335
Processing... ..........................................................................................	335
Processing... copy <X> of <Y> ................................................................	335
RAM disk device failure To clear press “OK” .............................................	336
RAM disk file operation failed To clear press “OK” ....................................	336

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RAM disk file system is full To clear press “OK” .........................................	336
RAM disk is write protected To clear press “OK” ........................................	336
RAM disk not initialized ..........................................................................	336
Ready ...................................................................................................	337
Ready <IP Address> ...............................................................................	337
Receiving Upgrade .................................................................................	337
Remove one print cartridge .....................................................................	337
Remove USB accessory ...........................................................................	337
Replace <supply> ..................................................................................	338
Replace supplies ....................................................................................	338
Resend external accessory firmware .........................................................	339
Resend Upgrade ....................................................................................	339
Restore Factory Settings ..........................................................................	339
ROM disk device failed To clear press “OK” .............................................	339
ROM disk file operation failed To clear press “OK” ....................................	339
ROM disk file system is full To clear press “OK” .........................................	340
ROM disk is write protected To clear press “OK” .......................................	340
ROM disk not initialized To clear press “OK” ............................................	340
Rotating Motor .......................................................................................	340
Size Mis-Match ......................................................................................	340
Size mismatch in Tray <X> ......................................................................	341
Sleep mode on ......................................................................................	341
Staple Cartridge low ..............................................................................	341
Staple Cartridge very low .......................................................................	341
Stapler/Stacker staple jam ......................................................................	342
Supplies low ..........................................................................................	342
SUPPLY MEMORY WARNING .................................................................	342
The unit has corrupt data .........................................................................	342
Tray <X> empty: [Type], [Size] ................................................................	343
Tray <X> lifting ......................................................................................	344
Tray <X> open .......................................................................................	344
Tray <X> overfilled .................................................................................	345
Type mismatch Tray ................................................................................	345
Unsupported drive installed To continue, touch “OK” ..................................	345
Unsupported supply in use OR Unsupported supply installed To continue,
touch “OK” ...........................................................................................	346
Unsupported tray configuration ................................................................	346
Unsupported USB accessory detected Remove USB accessory ......................	346
Upgrade Error .......................................................................................	346
USB accessory not functional ...................................................................	347
USB hubs are not fully supported Some operations may not work properly ....	347

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USB is write protected To clear press “OK” ...............................................	347
USB needs too much power .....................................................................	347
USB needs too much power Remove USB and Then Turn Off then On ...........	347
USB not initialized ..................................................................................	348
USB storage accessory removed Clearing any associated data ....................	348
USB storage device failure To clear press “OK” .........................................	348
USB storage file operation failed To clear press “OK” ................................	348
USB storage file system is full To clear press “OK” ......................................	348
Used supply installed To continue, touch “OK” OR Used supply in use ..........	349
Waiting for tray <X> to lift ......................................................................	349
Windows Login Required to Use this Feature .............................................	349
Event-log messages ...............................................................................................	350
Print an event log ...................................................................................	351
View an event log ..................................................................................	352
Clear an event log ..................................................................................	352
Clear jams ..........................................................................................................................	353
Jam locations ........................................................................................................	354
Common causes of jams ........................................................................................	355
Clear jams from the input trays ...............................................................................	356
Clear jams from Tray 1 ...........................................................................	356
Clear jams from Tray 2 or an optional 500-sheet tray .................................	356
Clear jams from the optional 1,500-sheet tray ...........................................	357
Clear jams from the optional duplexer .....................................................................	359
Clear jams from the optional envelope feeder ...........................................................	361
Clear jams from the output areas ............................................................................	363
Clear jams from the rear output bin ..........................................................	363
Clear jams from the optional stacker or stapler/stacker ...............................	364
Clear paper jams from the optional stacker or stapler/stacker ......	364
Clear staple jams from the optional stapler/stacker .....................	365
Clear jams from the optional 5-bin mailbox ...............................................	367
Clear jams from the fuser .......................................................................................	369
Clear jams from the print-cartridge (top cover) ..........................................................	373
Change jam recovery ............................................................................................	375
Paper does not feed automatically ..........................................................................................	376
The product does not pick up paper ........................................................................	376
The product picks up multiple sheets of paper ...........................................................	376
Prevent paper jams ................................................................................................	376
Use manual print modes .......................................................................................................	378
Solve image-quality problems ................................................................................................	380
Print-quality examples ............................................................................................	380
Clean the product ................................................................................................................	388

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Clean the paper path ............................................................................................	388
Set up an auto cleaning page ..................................................................	388
Solve performance problems .................................................................................................	389
Solve connectivity problems ...................................................................................................	390
Solve direct-connect problems .................................................................................	390
Solve network problems .........................................................................................	390
Service mode functions .........................................................................................................	391
Service menu ........................................................................................................	391
Product resets .......................................................................................................	392
Restore factory-set defaults .......................................................................	392
Clean Disk and Partial Clean functions ....................................................................	393
Active and repository firmware locations ...................................................	393
Partial Clean .........................................................................................	394
Execute a Partial Clean ............................................................	394
Clean Disk ............................................................................................	395
Execute a Clean Disk ...............................................................	395
Product updates ...................................................................................................................	397
Determine the installed revision of firmware ..............................................................	397
Perform a firmware upgrade ...................................................................................	397
Embedded Web Server ...........................................................................	397
USB storage device (Preboot menu) ..........................................................	398
USB storage device (control-panel menu) ...................................................	399
4 Parts and diagrams ......................................................................................................	401
Order parts by authorized service providers ............................................................................	402
Order parts, accessories, and supplies ....................................................................	402
Supplies part numbers ...........................................................................................	402
Customer-self repair parts .......................................................................................	402
Accessories part numbers .......................................................................................	404
Related documentation and software .......................................................................	405
How to use the parts lists and diagrams ..................................................................................	406
Assembly locations ...............................................................................................................	407
Base product (no optional trays or accessories) .........................................................	407
Covers ................................................................................................................................	410
Product base ........................................................................................................	410
Internal components .............................................................................................................	412
Internal components (1 of 3) ...................................................................................	412
Internal components (2 of 3) ...................................................................................	414
Internal components (3 of 3) ...................................................................................	416
High-voltage power supply .....................................................................................	418
Cassette (Tray 2) ...................................................................................................	420

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Cassette (custom media) .........................................................................................	422
Paper feed roller assembly .....................................................................................	424
Registration assembly ............................................................................................	426
Tray 1 (MP) pickup assembly ..................................................................................	428
Paper delivery assembly ........................................................................................	430
Fuser assembly .....................................................................................................	432
PCAs (product base) ..............................................................................................	434
Input devices .......................................................................................................................	436
1x500-sheet feeder ...............................................................................................	436
Covers (1x500) .....................................................................................	436
Main body (1x500) ................................................................................	438
Cassette (1x500) ...................................................................................	440
PCA (1x500) .........................................................................................	442
1x1500-sheet paper deck ......................................................................................	444
Covers (1x1500) ...................................................................................	444
Front door assembly (1x1500) .................................................................	446
Main body (1x500; 1 of 2) .....................................................................	448
Main body (1x500; 2 of 2) .....................................................................	450
Paper pickup assembly (1x500) ...............................................................	452
PCA (1x1500) .......................................................................................	454
Duplexer .............................................................................................................................	456
Main body (duplexer) ............................................................................................	456
PCA (duplexer) .....................................................................................................	458
Envelope feeder ...................................................................................................................	460
Covers (envelope feeder) .......................................................................................	460
Main body (1 of 2; envelope feeder) .......................................................................	462
Main body (2 of 2; envelope feeder) .......................................................................	464
PCA (envelope feeder) ...........................................................................................	466
Output devices ....................................................................................................................	468
Stapler/stacker multi-bin mailbox (MBM) ..................................................................	468
Covers (MBM) .......................................................................................	468
Main body (MBM) ..................................................................................	470
Main body (MBM; 1 of 2) ........................................................	470
Main body (MBM; 2 of 2) ........................................................	472
PCA (MBM) ...........................................................................................	474
Stacker and Stapler/Stacker (S and S/S) .................................................................	476
Covers (S and S/S) ................................................................................	476
Main body (SS) ......................................................................................	478
Main body (S) .......................................................................................	480
Middle assemblies (S and S/S) ................................................................	482
Stapler/Stacker middle assembly (1 of 2; S/S) ...........................	482

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Stapler/Stacker middle assembly (2 of 2; S/S) ...........................	484
Stacker middle assembly (1 of 2; S) ...........................................	486
Stacker middle assembly (2 of 2; S) ...........................................	488
PCA (S and S/S) ....................................................................................	490
Alphabetical parts list ...........................................................................................................	492
Numerical parts list ..............................................................................................................	501
Appendix A Service and support .....................................................................................	511
Hewlett-Packard limited warranty statement .............................................................................	512
HP's Premium Protection Warranty: LaserJet print cartridge limited warranty statement ..................	514
Data stored on the print cartridge ...........................................................................................	515
End User License Agreement ..................................................................................................	516
Customer self-repair warranty service .....................................................................................	519
Customer support .................................................................................................................	520
Repack the product ..............................................................................................................	521
Appendix B Product specifications ...................................................................................	523
Physical specifications ..........................................................................................................	524
Power consumption, electrical specifications, and acoustic emissions ..........................................	524
Operating environment .........................................................................................................	525
Appendix C Regulatory information .................................................................................	527
FCC regulations ...................................................................................................................	528
Environmental product stewardship program ...........................................................................	529
Protecting the environment ......................................................................................	529
Ozone production .................................................................................................	529
Power consumption ...............................................................................................	529
Toner consumption ................................................................................................	529
Paper use .............................................................................................................	529
Plastics .................................................................................................................	529
HP LaserJet print supplies .......................................................................................	530
Return and recycling instructions .............................................................................	530
United States and Puerto Rico ..................................................................	530
Multiple returns (more than one cartridge) ..................................	530
Single returns ..........................................................................	530
Shipping ................................................................................	530
Non-U.S. returns ....................................................................................	531
Paper ..................................................................................................................	531
Material restrictions ...............................................................................................	531
Disposal of waste equipment by users in private households in the European Union ......	532

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Chemical substances .............................................................................................	532
Material Safety Data Sheet (MSDS) .........................................................................	532
For more information .............................................................................................	532
Declaration of Conformity .....................................................................................................	534
Certificate of Volatility ..........................................................................................................	536
Types of memory ...................................................................................................	536
Volatile memory .....................................................................................	536
Non-volatile memory ..............................................................................	536
Hard-disk-drive memory ..........................................................................	536
Safety statements .................................................................................................................	537
Laser safety ..........................................................................................................	537
Canadian DOC regulations ....................................................................................	537
VCCI statement (Japan) ..........................................................................................	537
Power cord instructions ..........................................................................................	537
Power cord statement (Japan) .................................................................................	537
EMC statement (China) ..........................................................................................	538
EMC statement (Korea) ..........................................................................................	538
EMI statement (Taiwan) ..........................................................................................	538
Product Stability ....................................................................................................	538
Laser statement for Finland .....................................................................................	538
GS statement (Germany) ........................................................................................	539
Substances Table (China) .......................................................................................	540
Restriction on Hazardous Substances statement (Turkey) .............................................	540
Index ...............................................................................................................................	541

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1 Theory of operation

●Basic operation

●Formatter system

●Engine-control system

●Image-formation system

●Laser/scanner system

●Pickup, feed, and delivery system

●1x500-sheet paper feeder

●1x1500-sheet paper deck

●Envelope feeder

●Duplexer

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1

Basic operation

Major print systems

Operation can be divided into the following systems:

●Engine-control system (which includes the power supply and DC controller PCA)

●Laser/scanner system (which forms the latent image on a photosensitive drum)

●Image-formation system (which transfers a toner image onto the print media)

●Pickup, feed, and delivery system (which consists of various rollers and transports the media through the product)

●Options

Figure 1-1 Major product systems

LASER/SCANNER SYSTEM

IMAGE-FORMATION SYSTEM

ENGINE CONTROL

SYSTEM

PICKUP-AND-FEED SYSTEM

OPTION

2

Chapter 1 Theory of operation

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Internal components
Figure 1-2 Internal components, product base
		1	2	3	4	5	6		7	8	9
19	18	17	16	15		14	13	12	11	10

1	Face-down delivery roller	11	Feed roller
2	Fuser sleeve unit	12	Tray 2 separation roller
3	Laser/scanner unit	13	Tray 2 feed roller
4	Photosensitive drum	14	Tray 2 pickup roller
5	Transfer roller	15	Print cartridge
6	Registration shutter	16	Pressure roller
7	Pre-transfer roller	17	Fuser
8	Tray 1 pickup roller	18	Fuser delivery roller
9	Tray 1 feed roller	19	Intermediate delivery roller
10	Tray 1 separation roller

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Basic operation

3

Figure 1-3 Internal components, 1x500-sheet feeder
	1	2	3	4
1	Pickup roller
2	Feed roller
3	Separation roller
4	Feed roller

Figure 1-4 Internal components, 1,500-sheet paper deck
	1	2	3	4
1	Pickup roller
2	Feed roller

4

Chapter 1 Theory of operation

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3Separation roller

4Feed roller

Figure 1-5 Internal components, envelope feeder

1

2

3

4

5

6

1Feed roller

2Upper separation roller

3Lower separation roller

4Separation guide

5Weight

6Pickup roller

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Basic operation

5

Figure 1-6 Internal components, duplexer

1

2

1Oblique rollers

2Re-pickup rollers

Figure 1-7 Internal components, custom media cassette

1

1	Separation roller

6

Chapter 1 Theory of operation

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