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: CE663-90939
Edition 1, 4/2010
Microsoft®, Windows®, Windows® XP, and
Windows Vista® are U.S. registered
trademarks of Microsoft Corporation.
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.
ENWWiii
iv Conventions used in this guideENWW
Table of contents
1 Theory of operation ........................................................................................................................................ 1
Separation pad ................................................................................................................................... 41
Transfer roller ..................................................................................................................................... 42
4 Parts and diagrams ..................................................................................................................................... 159
Order parts by authorized service providers .................................................................................... 160
Order replacement parts .................................................................................................. 160
Related documentation and software .............................................................................. 160
Supplies part numbers ..................................................................................................... 160
Customer self repair parts ............................................................................................... 161
Service parts .................................................................................................................... 161
Whole-unit replacement part numbers ............................................................................. 161
How to use the parts lists and diagrams .......................................................................................... 162
End User License Agreement .......................................................................................................... 186
Customer self-repair warranty service .............................................................................................. 188
Customer support ............................................................................................................................. 188
Repack the product .......................................................................................................................... 189
Service information form .................................................................................................................. 190
Appendix B Specifications ............................................................................................................................ 191
Restriction on Hazardous Substances statement (Turkey) ............................................. 202
Index ................................................................................................................................................................. 203
xENWW
List of tables
Table 1-1 Sequence of operation ....................................................................................................................... 3
Table 4-13 Alphabetical parts list ................................................................................................................... 176
Table 4-14 Numerical parts list ....................................................................................................................... 179
Table B-1 Physical specifications
Table B-2 HP LaserJet Professional P1560 and P1600 Printer series (average in watts)
Table B-3 HP LaserJet Professional P1560 and P1600 Printer series
Figure 1-20 Transfer ......................................................................................................................................... 29
Figure 1-24 Pickup, feed, and delivery system block diagram ......................................................................... 31
Figure 1-25 Photo sensors, motor, and solenoid ............................................................................................. 32
Figure 2-1 Phillips and pozidrive screwdriver comparison ............................................................................... 37
Figure 2-2 Parts removal order ........................................................................................................................ 39
Figure 2-3 Remove the pickup roller (1 of 2) .................................................................................................... 40
Figure 2-4 Remove the pickup roller (2 of 2) .................................................................................................... 40
Figure 2-5 Remove the separation pad assembly ........................................................................................... 41
Figure 2-6 Remove the transfer roller .............................................................................................................. 42
Figure 2-7 Remove the tray .............................................................................................................................. 43
Figure 2-8 Remove the output bin tray extension ............................................................................................ 44
Figure 2-9 Remove the left cover, simplex product (1 of 4) ............................................................................. 45
ENWWxiii
Figure 2-10 Remove the left cover, simplex product (2 of 4) ........................................................................... 45
Figure 2-11 Remove the left cover, simplex product (3 of 4) ........................................................................... 46
Figure 2-12 Remove the left cover, simplex product (4 of 4) ........................................................................... 46
Figure 2-13 Remove the left cover, duplex product (1 of 5) ............................................................................. 47
Figure 2-14 Remove the left cover, duplex product (2 of 5) ............................................................................. 47
Figure 2-15 Remove the left cover, duplex product (3 of 5) ............................................................................. 48
Figure 2-16 Remove the left cover, duplex product (4 of 5) ............................................................................. 48
Figure 2-17 Remove the left cover, duplex product (5 of 5) ............................................................................. 49
Figure 2-18 Remove the right cover, simplex product (1 of 4) ......................................................................... 50
Figure 2-19 Remove the right cover, simplex product (2 of 4) ......................................................................... 50
Figure 2-20 Remove the right cover, simplex product (4 of 4) ......................................................................... 51
Figure 2-21 Remove the right cover, duplex product (1 of 5) ........................................................................... 52
Figure 2-22 Remove the right cover, duplex product (2 of 5) ........................................................................... 52
Figure 2-23 Remove the right cover, duplex product (3 of 5) ........................................................................... 53
Figure 2-24 Remove the right cover, duplex product (4 of 5) ........................................................................... 53
Figure 2-25 Remove the right cover, duplex product (5 of 5) ........................................................................... 54
Figure 2-26 Remove the duplex door, duplex product ..................................................................................... 55
Figure 2-27 Remove the duplex frame (1 of 2) ................................................................................................ 56
Figure 2-28 Remove the duplex frame (2 of 2) ................................................................................................ 56
Figure 2-29 Remove the cartridge door (1 of 3) ............................................................................................... 57
Figure 2-30 Remove the cartridge door (2 of 3) ............................................................................................... 57
Figure 2-31 Remove the cartridge door (3 of 3) ............................................................................................... 58
Figure 2-32 Remove the control panel (1 of 3) ................................................................................................ 59
Figure 2-33 Remove the control panel (2 of 3) ................................................................................................ 59
Figure 2-34 Remove the control panel (3 of 3) ................................................................................................ 60
Figure 2-35 Remove the front cover (1 of 3) .................................................................................................... 61
Figure 2-36 Remove the front cover (2 of 3) .................................................................................................... 62
Figure 2-37 Remove the front cover (3 of 3) .................................................................................................... 62
Figure 2-38 Remove the rear cover, simplex product (1 of 3) .......................................................................... 63
Figure 2-39 Remove the rear cover, simplex product (2 of 3) .......................................................................... 64
Figure 2-40 Remove the rear cover, simplex product (2 of 3) .......................................................................... 64
Figure 2-41 Remove the face-down cover (1 of 2) ........................................................................................... 65
Figure 2-42 Remove the face-down cover (2 of 2) ........................................................................................... 66
Figure 2-43 Remove the formatter PCA (1 of 2) .............................................................................................. 67
Figure 2-44 Remove the formatter PCA (2 of 2) .............................................................................................. 67
Figure 2-45 Remove the laser/scanner assembly (1 of 5) ............................................................................... 68
Figure 2-46 Remove the laser/scanner assembly (2 of 5) ............................................................................... 69
Figure 2-47 Remove the laser/scanner assembly (3 of 5) ............................................................................... 69
Figure 2-48 Remove the laser/scanner assembly (4 of 5) ............................................................................... 70
Figure 2-49 Remove the laser/scanner assembly (5 of 5) ............................................................................... 70
Figure 2-50 Reinstall the laser/scanner assembly ........................................................................................... 71
Figure 2-51 Remove the pickup assembly (1 of 10) ........................................................................................ 72
Figure 2-52 Remove the pickup assembly (2 of 10) ........................................................................................ 73
Figure 2-53 Remove the pickup assembly (3 of 10) ........................................................................................ 73
xivENWW
Figure 2-54 Remove the pickup assembly (4 of 10) ........................................................................................ 74
Figure 2-55 Remove the pickup assembly (5 of 10) ........................................................................................ 74
Figure 2-56 Remove the pickup assembly (6 of 10) ........................................................................................ 75
Figure 2-57 Remove the pickup assembly (7 of 10) ........................................................................................ 75
Figure 2-58 Remove the pickup assembly (8 of 10) ........................................................................................ 76
Figure 2-59 Remove the pickup assembly (9 of 10) ........................................................................................ 76
Figure 2-60 Remove the pickup assembly (10 of 10) ...................................................................................... 77
Figure 2-61 Reinstall the pickup assembly (1 of 4; correct ground spring position) ......................................... 78
Figure 2-62 Reinstall the pickup assembly (2 of 4; incorrect ground spring position) ...................................... 78
Figure 2-63 Reinstall the pickup assembly (3 of 4; lift plate in raised position) ................................................ 79
Figure 2-64 Reinstall the pickup assembly (4 of 4; lift plate in lowered position) ............................................. 79
Figure 2-65 Remove the fuser (1 of 10) ........................................................................................................... 80
Figure 2-66 Remove the fuser (2 of 10) ........................................................................................................... 81
Figure 2-67 Remove the fuser (3 of 10) ........................................................................................................... 81
Figure 2-68 Remove the fuser (4 of 10) ........................................................................................................... 82
Figure 2-69 Remove the fuser (5 of 10) ........................................................................................................... 82
Figure 2-70 Remove the fuser (6 of 10) ........................................................................................................... 83
Figure 2-71 Remove the fuser (7 of 10) ........................................................................................................... 83
Figure 2-72 Remove the fuser (8 of 10) ........................................................................................................... 84
Figure 2-73 Remove the fuser (9 of 10) ........................................................................................................... 84
Figure 2-74 Remove the fuser (10 of 10) ......................................................................................................... 85
Figure 2-88 Remove the pickup solenoid (1 of 7) ............................................................................................ 93
Figure 2-89 Remove the pickup solenoid (2 of 7) ............................................................................................ 94
Figure 2-90 Remove the pickup solenoid (3 of 7) ............................................................................................ 94
Figure 2-91 Remove the pickup solenoid (4 of 7) ............................................................................................ 95
Figure 2-92 Remove the solenoid (5 of 7) ........................................................................................................ 95
Figure 2-93 Remove the pickup solenoid (6 of 7) ............................................................................................ 96
Figure 2-94 Remove the pickup solenoid (7 of 7) ............................................................................................ 96
Figure 2-95 Remove the engine controller PCA (1 of 9) .................................................................................. 97
Figure 2-96 Remove the engine controller PCA (2 of 9) .................................................................................. 98
Figure 2-97 Remove the engine controller PCA (3 of 9) .................................................................................. 98
ENWWxv
Figure 2-98 Remove the engine controller PCA (4 of 9) .................................................................................. 99
Figure 2-99 Remove the engine controller PCA (5 of 9) .................................................................................. 99
Figure 2-100 Remove the engine controller PCA (6 of 9) .............................................................................. 100
Figure 2-101 Remove the engine controller PCA (7 of 9) .............................................................................. 100
Figure 2-102 Remove the engine controller PCA (8 of 9) .............................................................................. 101
Figure 2-103 Remove the engine controller PCA (10 of 9) ............................................................................ 101
Figure 2-104 Reinstall the engine controller PCA (1 of 4) .............................................................................. 102
Figure 2-105 Reinstall the engine controller PCA (2 of 4) .............................................................................. 102
Figure 2-106 Reinstall the engine controller PCA (3 of 4) .............................................................................. 103
Figure 2-107 Reinstall the engine controller PCA (4 of 4) .............................................................................. 103
Figure 2-108 Remove the duplex-reverse solenoid (1 of 5) ........................................................................... 104
Figure 2-109 Remove the duplex-reverse solenoid (2 of 5) ........................................................................... 105
Figure 2-110 Remove the duplex-reverse solenoid (3 of 5) ........................................................................... 105
Figure 2-111 Remove the duplex-reverse solenoid (4 of 5) ........................................................................... 106
Figure 2-112 Remove the duplex-reverse solenoid (5 of 5) ........................................................................... 106
Figure 2-113 Remove the main fan (1 of 4) ................................................................................................... 107
Figure 2-114 Remove the main fan (2 of 4) ................................................................................................... 108
Figure 2-115 Remove the main fan (3 of 4) ................................................................................................... 108
Figure 2-116 Remove the main fan (4 of 4) ................................................................................................... 109
Figure 2-117 Reinstall the main fan ............................................................................................................... 109
Figure 2-118 Remove the duplex-connector PCA (1 of 5) ............................................................................. 110
Figure 2-119 Remove the duplex-connector PCA (2 of 5) ............................................................................. 111
Figure 2-120 Remove the duplex-connector PCA (3 of 5) ............................................................................. 111
Figure 2-121 Remove the duplex-connector PCA (4 of 5) ............................................................................. 112
Figure 2-122 Remove the duplex-connector PCA (5 of 5) ............................................................................. 112
Figure 3-1 Sample engine test page .............................................................................................................. 118
The DC controller in the engine-control system controls the operational sequences of the product. The
table below describes durations and operations for each period of a print operation from when the
product is turned on until the motor stops rotating.
Normal sequence of operation
Table 1-1 Sequence of operation
NameTimingPurpose
WAITFrom the time the power switch is turned on, the door
STBY (standby) From the end of the WAIT or LSTR period until either
INTR (initial
rotation)
PRINTFrom the end of the INTR period until the last sheet
LSTR (last
rotation)
is closed or the product exits Sleep mode until the
product gets ready for a print operation.
a print command is sent or the power switch is turned
off.
From the time a print command is received until the
paper is picked up.
completes the fuser operation.
From the end of the PRINT period until the main motor
stops rotating.
Brings the product to ready state. The product
performs the following during the operations:
Detects the print cartridge
●
Heats the fuser film in the fuser
●
Rotates, and the stops, the main motor
●
Maintains the product in printable condition. The
product performs the following during the operation:
Enters Auto-Off mode if Auto-Off command is
●
received
The product performs the following during the
operations:
Drives the main motor
●
Activates the high-voltage power supply
●
Activates the laser/scanner
●
Warms the fuser heater
●
Forms the image on the photosensitive drum based
on the VIDEO signals from the formatter. Transfers
and fuses the toner image to the paper.
Moves the last printed sheet out of the product. The
product performs the following during the operations:
Stops the main motor
●
Deactivates the high-voltage power supply
●
Deactivates the laser/scanner
●
Deactivates the fuser heater
●
The product enters the INTR period as the LSTR
period is completed, if the formatter sends another
print command.
ENWWBasic operation3
Formatter-control system
The formatter is responsible for the following procedures:
Controlling sleep mode
●
Receiving and processing print data from the various product interfaces
●
Monitoring control-panel functions and relaying product-status information (through the control
●
panel and the network or bidirectional interface)
Developing and coordinating data placement and timing with the DC controller PCA
●
Storing font information
●
Communicating with the host computer through the network or the bidirectional interface
●
The formatter receives a print job from the network or bidirectional interface and separates it into image
information and instructions that control the printing process. The DC controller PCA synchronizes the
image-formation system with the paper-input and -output systems, and then signals the formatter to
send the print-image data.
Sleep mode
NOTE: This product uses an Auto-Off feature for sleep mode.
After a user-specified time, the Auto-Off feature automatically conserves electricity by substantially
reducing power consumption when the product is not printing. After a user-specified time, the product
automatically reduces its power consumption (Auto-Off). The product returns to the ready state when a
button is pressed, a print job is received, or a door is opened. When the product is in Auto-Off mode,
all of the control-panel LEDs and the power button backlight LED are off.
NOTE: Although the product lights are off in Auto-Off mode, the product functions normally when it
receives a print job.
Input/output
The product receives print data primarily from the following:
The formatter incorporates a 400 MHz Helium processor.
Memory
The random access memory (RAM) on the formatter PCA contains the page, I/O buffers, and the font
storage area. RAM stores printing and font information received from the host system, and can also
serve to temporarily store a full page of print-image data before the data is sent to the print engine.
4Chapter 1 Theory of operationENWW
Firmware
HP LaserJet Professional P1560 Printer series
●
◦
HP LaserJet Professional P1600 Printer series
●
◦
Memory use
HP LaserJet Professional P1560 Printer series
●
◦
HP LaserJet Professional P1600 Printer series
●
◦
PJL overview
The product has 8 MB of Synchronous DRAM, which is used for run-time firmware imaging
and specific print job information for the print job.
The product has 32 MB of Synchronous DRAM, which is used for run-time firmware imaging
and specific print job information for the print job.
The product has a 2 KB EEPROM and 64 MB of NAND Flash Memory, which is used for
product configuration information and printer driver firmware.
The product has a 8 KB EEPROM and 64 MB of NAND Flash Memory, which is used for
product configuration information and printer driver firmware.
The printer job language (PJL) is an integral part of configuration, in addition to the standard printer
command language (PCL). With standard cabling, the product can use PJL to perform a variety of
functions such as these:
Two-way communication with the host computer through a network connection or a USB
●
connection. The product can inform the host about such things as the control-panel settings, and
the control-panel settings can be changed from the host.
Dynamic I/O switching. The product uses this switching to be configured with a host on each I/O.
●
The product can receive data from more than one I/O simultaneously, until the I/O buffer is full.
This can occur even when the product is offline.
Context-sensitive switching. The product can automatically recognize the personality (PS or PCL)
●
of each job and configure itself to serve that personality.
Isolation of print environment settings from one print job to the next. For example, if a print job is
●
sent to the product in landscape mode, the subsequent print jobs print in landscape mode only if
they are formatted for landscape printing.
LEDM overview
NOTE: HP LaserJet Professional P1600 Printer series
The low-end data model (LEDM) provides one consistent data representation method and defines the
dynamic and capabilities tickets shared between clients and devices, as well as the access protocol,
event, security, and discovery methods.
ACL overview
The advanced control language (ACL) is a language that supports product control and firmware
downloads in printers that support both PJL/PCL and host-based printing. Each sequence of ACL
ENWWFormatter-control system5
commands must be preceded by a unified exit command (UEL) and an @PJL ENTER LANGUAGE=ACL
command. The ACL sequence is always followed by a UEL. Any number of commands can be placed
between the UELs. The only exception to these rules is the download command. If a firmware download
is done, the download command must be the last command in the sequence. It will not be followed by
a UEL.
The firmware searches for the UEL sequence when parsing commands. However, while downloading
binary data such as host-based code or NVRAM data the firmware suspends UEL parsing. To handle
hosts that “disappear” during binary sequences, the firmware times out all ACL command sessions. If
a timeout occurs during a non-download command sequence, it is treated as the receipt of a UEL. If a
timeout occurs during firmware download the product resets.
Control panel
The formatter sends and receives product status and command data to and from the control-panel PCA.
6Chapter 1 Theory of operationENWW
Engine-control system
The engine-control system coordinates all product functions, according to commands that the formatter
sends. The engine-control system drives the laser/scanner system, the image-formation system, and
the pickup/feed/delivery system.
The engine control system contains the following major components:
Engine-control unit (ECU)
●
DC controller
◦
Low-voltage power supply
◦
High-voltage power supply
●
Fuser control
●
Figure 1-2 Engine-control system
ENGINE CONTROL SYSTEM
DC controller
LASER/SCANNER SYSTEM
Formatter
Low-voltage power supply
IMAGE-FORMATION SYSTEM
High-voltage power supply
MEDIA-FEED SYSTEM
Fuser control
ENWWEngine-control system7
Motors, fans, clutches, solenoids, switches, and sensors
Figure 1-3 Motors
M1
M2
Table 1-2 Motors
ItemDescriptionComponents driven
M1Main motor
M2Scanner motor
Pickup roller
●
Feed roller
●
Photosensitive drum
●
Developing roller
●
Pressure roller
●
Delivery roller
●
Duplex feed roller
●
Scanner mirror
●
8Chapter 1 Theory of operationENWW
Figure 1-4 Fans
Table 1-3 Fans
ItemDescription
FM1Main fan
FM1
ENWWEngine-control system9
Figure 1-5 Solenoids and clutches
SL1
Table 1-4 Solenoids and clutches
SL2
ItemDescription
SL1Pickup solenoid
SL2Duplex reverse solenoid
NOTE: Duplex models only.
10Chapter 1 Theory of operationENWW
Figure 1-6 Switches
Table 1-5 Switches
ItemDescription
SW501Cartridge-door switch
SW502Power switch; not shown
Figure 1-7 Sensors
Table 1-6 Sensors
PS702
PS701
PS751
ItemDescription
PS701Fuser delivery sensor
ENWWEngine-control system11
Table 1-6 Sensors (continued)
ItemDescription
PS702Media-width sensor
PS751Top-of-Page (TOP) sensor
PS901Main-motor rotation-number sensor; not shown
12Chapter 1 Theory of operationENWW
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