HP LASERJET PROFESSIONAL P1560, LASERJET PROFESSIONAL P1600 Service Manual
LASERJET PROFESSIONAL P1560 and P1600
SERIES PRINTER
Service Manual
www.hp.com/support/ljp1560series
www.hp.com/support/ljp1600series
HP LaserJet Professional P1560 and
P1600 Series Printer
Service Manual
Copyright and License
Trademark Credits
© 2010 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: 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.
ENWW iii
Table of contents
1 Theory of operation ........................................................................................................................................ 1
Basic operation ..................................................................................................................................... 2
Major product systems ......................................................................................................... 2
Product block diagram ......................................................................................................... 2
Sequence of operation ......................................................................................................... 3
Normal sequence of operation ............................................................................ 3
Formatter-control system ..................................................................................................................... 4
Sleep mode .......................................................................................................................... 4
Input/output .......................................................................................................................... 4
CPU ..................................................................................................................................... 4
Memory ................................................................................................................................ 4
Firmware ............................................................................................................. 5
Memory use ........................................................................................................ 5
PJL overview ....................................................................................................................... 5
LEDM overview .................................................................................................................... 5
ACL overview ....................................................................................................................... 5
Control panel ....................................................................................................................... 6
Engine-control system .......................................................................................................................... 7
Motors, fans, clutches, solenoids, switches, and sensors ................................................... 8
DC controller operations .................................................................................................... 13
Fuser-control circuit ........................................................................................................... 15
Fuser failure detection ....................................................................................... 16
Fuser temperature control ................................................................................. 17
Fuser protective function ................................................................................... 18
Pressure roller cleaning .................................................................................... 18
Low-voltage power supply ................................................................................................. 19
Overcurrent/overvoltage protection ................................................................... 20
High-voltage power supply ................................................................................................ 21
Laser/scanner system ........................................................................................................ 22
Laser failure detection ....................................................................................... 23
Image-formation system ..................................................................................................................... 24
Electrophotographic process ............................................................................................. 24
Image formation process ................................................................................................... 26
Latent-image formation stage ........................................................................... 27
ENWW v
Primary charging .............................................................................. 27
Laser beam exposure ....................................................................... 27
Developing stage .............................................................................................. 28
Print cartridge ................................................................................... 28
Transfer stage ................................................................................................... 29
Fusing stage ..................................................................................... 29
Cleaning stage .................................................................................. 30
Pickup, feed, and delivery system ...................................................................................................... 31
Photo sensors and switches .............................................................................................. 32
Main-input tray or priority input slot .................................................................................................... 34
Jam detection .................................................................................................................... 34
2 Removal and replacement ........................................................................................................................... 35
Introduction ......................................................................................................................................... 36
Removal and replacement strategy ................................................................................................... 36
Electrostatic discharge ....................................................................................................................... 37
Required tools ................................................................................................................................... 37
Before performing service .................................................................................................................. 37
After performing service ..................................................................................................................... 38
Post-service test ................................................................................................................................. 38
Print-quality test ................................................................................................................. 38
Parts removal order ............................................................................................................................ 39
Pickup roller ........................................................................................................................................ 40
Separation pad ................................................................................................................................... 41
Transfer roller ..................................................................................................................................... 42
Covers ................................................................................................................................................ 43
Main-input tray ................................................................................................................... 43
Output bin tray extension ................................................................................................... 44
Left cover, simplex product ................................................................................................ 45
Remove the left cover, simplex product ............................................................ 45
Left cover, duplex product ................................................................................................. 47
Remove the left cover, duplex product .............................................................. 47
Right cover, simplex product ............................................................................................. 50
Remove the right cover, simplex product .......................................................... 50
Right cover, duplex product ............................................................................................... 52
Remove the right cover, duplex product ........................................................... 52
Duplex door, duplex product .............................................................................................. 55
Duplex frame, duplex product ............................................................................................ 56
Remove the duplex frame ................................................................................. 56
Cartridge door .................................................................................................................... 57
Control panel ..................................................................................................................... 59
Front cover ......................................................................................................................... 61
Remove the front cover ..................................................................................... 61
vi ENWW
Rear cover, simplex product .............................................................................................. 63
Remove the rear cover, simplex product .......................................................... 63
Face-down cover ............................................................................................................... 65
Remove the face-down cover ........................................................................... 65
Main assemblies ................................................................................................................................. 67
Formatter PCA ................................................................................................................... 67
Laser/scanner assembly .................................................................................................... 68
Remove the laser/scanner assembly ................................................................ 68
Reinstall the laser/scanner assembly ................................................................ 71
Pickup assembly ................................................................................................................ 72
Remove the pickup assembly ........................................................................... 72
Reinstall the pickup assembly ........................................................................... 78
Fuser .................................................................................................................................. 80
Remove the fuser .............................................................................................. 80
Reinstall the fuser ............................................................................................. 86
Main motor ......................................................................................................................... 87
Remove the main motor .................................................................................... 87
Reinstall the main-motor drive belt .................................................................... 92
Pickup solenoid .................................................................................................................. 93
Remove the pickup solenoid ............................................................................. 93
Engine controller PCA ....................................................................................................... 97
Remove the engine controller PCA ................................................................... 97
Reinstall the engine controller PCA ................................................................ 102
Duplex-reverse solenoid, duplex product ........................................................................ 104
Remove the duplex-reverse solenoid .............................................................. 104
Main fan, duplex product ................................................................................................. 107
Remove the main fan ...................................................................................... 107
Reinstall the main fan ...................................................................................... 109
Duplex-connector PCA, duplex product ........................................................................... 110
Remove the duplex-connector PCA ................................................................ 110
3 Solve problems ........................................................................................................................................... 113
Solve problems checklist .................................................................................................................. 114
Troubleshooting process .................................................................................................................. 116
Determine the problem source ....................................................................................... 116
Power subsystem ............................................................................................................ 117
Power-on checks ............................................................................................. 117
Tools for troubleshooting .................................................................................................................. 118
Individual component diagnostics .................................................................................... 118
Engine diagnostics .......................................................................................... 118
Engine-test button .......................................................................... 118
Components tests ........................................................................................... 119
Drum rotation functional check ...................................................... 119
ENWW vii
Half self-test functional check ......................................................... 119
Diagrams ......................................................................................................................... 120
Plug/jack locations .......................................................................................... 120
Location of connectors .................................................................................... 121
Locations of major components ...................................................................... 122
General timing charts ...................................................................................... 125
General circuit diagram ................................................................................... 126
Internal print-quality test pages ........................................................................................ 127
Cleaning page ................................................................................................. 127
Configuration page .......................................................................................... 127
Print-quality troubleshooting tools .................................................................................... 128
Repetitive defect ruler ..................................................................................... 128
Interpret control-panel light patterns ................................................................................ 128
Clear jams ........................................................................................................................................ 133
Common causes of jams ................................................................................................. 133
Jam locations ................................................................................................................... 133
Clear jams from the input trays ........................................................................................ 134
Clear jams from the duplexer ........................................................................................... 136
Clear jams from the output areas .................................................................................... 138
Clear jams from inside the product .................................................................................. 139
Solve repeated jams ........................................................................................................ 141
Change jam recovery ...................................................................................................... 142
Solve paper-handling problems ........................................................................................................ 143
Solve image-quality problems .......................................................................................................... 144
Image defect table ........................................................................................................... 144
Light print or faded .......................................................................................... 144
Toner specks ................................................................................................... 144
Dropouts .......................................................................................................... 145
Vertical lines .................................................................................................... 145
Gray background ............................................................................................. 145
Toner smear .................................................................................................... 146
Loose toner ..................................................................................................... 146
Vertical repetitive defects ................................................................................ 146
Misformed characters ...................................................................................... 146
Page skew ....................................................................................................... 147
Curl or wave .................................................................................................... 147
Wrinkles or creases ......................................................................................... 147
Toner scatter outline ....................................................................................... 148
Moisture .......................................................................................................... 148
Change print density ........................................................................................................ 149
Clean the product ............................................................................................................................. 150
Clean the pickup roller ..................................................................................................... 150
Clean the paper path ....................................................................................................... 151
Clean the print-cartridge area .......................................................................................... 153
viii ENWW
Clean the exterior ............................................................................................................ 154
Solve performance problems ........................................................................................................... 155
Solve connectivity problems ............................................................................................................. 156
Solve direct-connect problems ........................................................................................ 156
Solve network problems .................................................................................................. 156
Service mode functions .................................................................................................................... 158
Product resets .................................................................................................................. 158
Product updates ............................................................................................................................... 158
Firmware updates ............................................................................................................ 158
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
Assembly locations ........................................................................................................................... 163
Base product (no optional trays or accessories) .............................................................. 163
Covers .............................................................................................................................................. 164
Simplex model ................................................................................................................. 164
Duplex model ................................................................................................................... 16 6
Internal assemblies .......................................................................................................................... 168
Internal assemblies (1 of 3) ............................................................................................. 168
Internal assemblies (2 of 3) ............................................................................................. 170
Internal assemblies (3 of 3) ............................................................................................. 172
PCAs ................................................................................................................................................ 174
Alphabetical parts list ....................................................................................................................... 176
Numerical parts list ........................................................................................................................... 179
Appendix A Service and support ................................................................................................................. 183
Hewlett-Packard limited warranty statement .................................................................................... 184
HP's Premium Protection Warranty: LaserJet print cartridge limited warranty statement ................ 185
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
Physical specifications ..................................................................................................................... 192
ENWW ix
Power consumption .......................................................................................................................... 192
Acoustic specifications ..................................................................................................................... 192
Environmental specifications ............................................................................................................ 193
Appendix C Regulatory information ............................................................................................................ 195
FCC regulations ............................................................................................................................... 196
Declaration of conformity .................................................................................................................. 197
Certificate of Volatility ....................................................................................................................... 198
Safety statements ............................................................................................................................. 200
Laser safety ..................................................................................................................... 200
Canadian DOC regulations .............................................................................................. 200
VCCI statement (Japan) .................................................................................................. 200
Power cord instructions ................................................................................................... 200
Power cord statement (Japan) ......................................................................................... 200
EMC statement (Korea) ................................................................................................... 200
Laser statement for Finland ............................................................................................. 201
GS statement (Germany) ................................................................................................. 201
Substances Table (China) ............................................................................................... 202
Restriction on Hazardous Substances statement (Turkey) ............................................. 202
Index ................................................................................................................................................................. 203
x ENWW
List of tables
Table 1-1 Sequence of operation ....................................................................................................................... 3
Table 1-2 Motors ................................................................................................................................................ 8
Table 1-3 Fans ................................................................................................................................................... 9
Table 1-4 Solenoids and clutches .................................................................................................................... 10
Table 1-5 Switches ........................................................................................................................................... 11
Table 1-6 Sensors ............................................................................................................................................ 11
Table 1-7 DC controller controlled components ............................................................................................... 13
Table 1-8 Photo sensors, motor, and solenoid ................................................................................................ 32
Table 3-1 Basic problem solving .................................................................................................................... 114
Table 3-2 Status-light legend ......................................................................................................................... 128
Table 3-3 Control-panel lights ........................................................................................................................ 129
Table 4-1 Order parts, accessories, and supplies .......................................................................................... 160
Table 4-2 Related documentation and software ............................................................................................ 160
Table 4-3 Supplies part numbers ................................................................................................................... 160
Table 4-4 Customer replaceable units (CRU) kit part numbers ..................................................................... 161
Table 4-5 Whole-unit replacement part numbers ........................................................................................... 161
Table 4-6 Base product .................................................................................................................................. 163
Table 4-7 Simplex model ................................................................................................................................ 165
Table 4-8 Duplex model ................................................................................................................................. 167
Table 4-9 Internal assemblies (1 of 3) ............................................................................................................ 169
Table 4-10 Internal assemblies (2 of 3) .......................................................................................................... 171
Table 4-11 Internal assemblies (3 of 3) .......................................................................................................... 173
Table 4-12 PCAs ............................................................................................................................................ 175
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
Table B-4 Environmental specifications ......................................................................................................... 193
1
.................................................................................................................. 192
123
......................... 192
12
........................................................ 192
ENWW xi
List of figures
Figure 1-1 Product block diagram ...................................................................................................................... 2
Figure 1-2 Engine-control system ...................................................................................................................... 7
Figure 1-3 Motors ............................................................................................................................................... 8
Figure 1-4 Fans .................................................................................................................................................. 9
Figure 1-5 Solenoids and clutches ................................................................................................................... 10
Figure 1-6 Switches .......................................................................................................................................... 11
Figure 1-7 Sensors ........................................................................................................................................... 11
Figure 1-8 DC controller block diagram ............................................................................................................ 13
Figure 1-9 Fuser control circuit ......................................................................................................................... 15
Figure 1-10 Fuser-heater control circuit ........................................................................................................... 17
Figure 1-11 Low-voltage power supply (LVPS) ................................................................................................ 19
Figure 1-12 High-voltage power supply ............................................................................................................ 21
Figure 1-13 Laser/scanner system ................................................................................................................... 22
Figure 1-14 Electrophotographic process block diagram (1 of 2) .................................................................... 24
Figure 1-15 Electrophotographic process block diagram (2 of 2) .................................................................... 25
Figure 1-16 Image formation process .............................................................................................................. 26
Figure 1-17 Primary charging ........................................................................................................................... 27
Figure 1-18 Laser beam exposure ................................................................................................................... 27
Figure 1-19 Print cartridge ................................................................................................................................ 28
Figure 1-20 Transfer ......................................................................................................................................... 29
Figure 1-21 Separation ..................................................................................................................................... 29
Figure 1-22 Fusing ........................................................................................................................................... 30
Figure 1-23 Drum cleaning ............................................................................................................................... 30
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
ENWW xiii
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
xiv ENWW
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 2-75 Reinstall the fuser; correct wire harness installation ..................................................................... 86
Figure 2-76 Reinstall the fuser; incorrect wire harness installation .................................................................. 86
Figure 2-77 Remove the main motor (1 of 9) ................................................................................................... 87
Figure 2-78 Remove the main motor (2 of 9) ................................................................................................... 88
Figure 2-79 Remove the main motor (3 of 9) ................................................................................................... 88
Figure 2-80 Remove the main motor (4 of 9) ................................................................................................... 89
Figure 2-81 Remove the main motor (5 of 9) ................................................................................................... 89
Figure 2-82 Remove the main motor (6 of 9) ................................................................................................... 90
Figure 2-83 Remove the main motor (7 of 9) ................................................................................................... 90
Figure 2-84 Remove the main motor (8 of 9) ................................................................................................... 91
Figure 2-85 Remove the main motor (9 of 9) ................................................................................................... 91
Figure 2-86 Main-motor drive belt: correctly installed ...................................................................................... 92
Figure 2-87 Main-motor drive belt: incorrectly installed .................................................................................... 92
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
ENWW xv
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
Figure 3-2 Plug/jack locations ........................................................................................................................ 120
Figure 3-3 Engine controller PCA connectors ................................................................................................ 121
Figure 3-4 External view ................................................................................................................................. 122
Figure 3-5 Cross section view ........................................................................................................................ 123
Figure 3-6 General timing diagram ................................................................................................................. 125
Figure 3-7 Circuit diagram .............................................................................................................................. 126
Figure 4-1 Base product (no optional trays or accessories) ........................................................................... 163
Figure 4-2 Simplex model .............................................................................................................................. 164
Figure 4-3 Duplex model ................................................................................................................................ 166
Figure 4-4 Internal assemblies (1 of 3) ........................................................................................................... 168
Figure 4-5 Internal assemblies (2 of 3) ........................................................................................................... 170
Figure 4-6 Internal assemblies (3 of 3) ........................................................................................................... 172
Figure 4-7 PCAs ............................................................................................................................................. 174
xvi ENWW
1 Theory of operation
Basic operation
●
Formatter-control system
●
Engine-control system
●
Image-formation system
●
Pickup, feed, and delivery system
●
Main-input tray or priority input slot
●
ENWW 1
Basic operation
Major product systems
The product contains the following major systems:
Engine-control system
●
Laser/scanner system
●
Image-formation system
●
Pickup-and-feed system
●
Product block diagram
Figure 1-1 Product block diagram
LASER/SCANNER SYSTEM
ENGINE CONTROL
SYSTEM
IMAGE-FORMATION SYSTEM
PICKUP-AND-FEED SYSTEM
2 Chapter 1 Theory of operation ENWW
Sequence of operation
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
Name Timing Purpose
WAIT From 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)
PRINT From 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.
ENWW Basic operation 3
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:
Hi-Speed USB 2.0 port
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802.11b/g wireless networking (wireless models only)
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CPU
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.
4 Chapter 1 Theory of operation ENWW
Firmware
HP LaserJet Professional P1560 Printer series
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◦
HP LaserJet Professional P1600 Printer series
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◦
Memory use
HP LaserJet Professional P1560 Printer series
●
◦
HP LaserJet Professional P1600 Printer series
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◦
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
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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.
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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)
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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
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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
ENWW Formatter-control system 5
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.
6 Chapter 1 Theory of operation ENWW
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)
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DC controller
◦
Low-voltage power supply
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High-voltage power supply
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Fuser control
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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
ENWW Engine-control system 7
Motors, fans, clutches, solenoids, switches, and sensors
Figure 1-3 Motors
M1
M2
Table 1-2 Motors
Item Description Components driven
M1 Main motor
M2 Scanner motor
Pickup roller
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Feed roller
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Photosensitive drum
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Developing roller
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Pressure roller
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Delivery roller
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Duplex feed roller
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Scanner mirror
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8 Chapter 1 Theory of operation ENWW
Figure 1-4 Fans
Table 1-3 Fans
Item Description
FM1 Main fan
FM1
ENWW Engine-control system 9
Figure 1-5 Solenoids and clutches
SL1
Table 1-4 Solenoids and clutches
SL2
Item Description
SL1 Pickup solenoid
SL2 Duplex reverse solenoid
NOTE: Duplex models only.
10 Chapter 1 Theory of operation ENWW
Figure 1-6 Switches
Table 1-5 Switches
Item Description
SW501 Cartridge-door switch
SW502 Power switch; not shown
Figure 1-7 Sensors
Table 1-6 Sensors
PS702
PS701
PS751
Item Description
PS701 Fuser delivery sensor
ENWW Engine-control system 11
Table 1-6 Sensors (continued)
Item Description
PS702 Media-width sensor
PS751 Top-of-Page (TOP) sensor
PS901 Main-motor rotation-number sensor; not shown
12 Chapter 1 Theory of operation ENWW
DC controller operations
The DC controller controls the operational sequences of the product systems.
Figure 1-8 DC controller block diagram
AC input
Engine controller
Fuser unit
Transfer roller
Cartridge
Formatter
Low-voltage
power supply
High-voltage
power supply
Motor
Solenoid
Photointerrupter
DC controller
Switch
Laser scanner
Operation panel
Solenoid
Duplex model only
Fan
Duplex connector PCA
Table 1-7 DC controller controlled components
Component Designator Description
Motor M1 Main motor
M2 Scanner motor
ENWW Engine-control system 13
Table 1-7 DC controller controlled components (continued)
Component Designator Description
Solenoid SL1 Pickup solenoid
SL2 Duplex reverse solenoid
NOTE: Duplex models only.
Photointerrupter PS701 Fuser delivery sensor
PS702 Media-width sensor
PS751 Top-of-Page (TOP) sensor
PS901 Main-motor rotation-number sensor
Switch SW501 Cartridge-door switch
SW502 Power switch
Fan FM1 Main Fan
14 Chapter 1 Theory of operation ENWW
Fuser-control circuit
The fuser-control circuit monitors and controls the temperature in the fuser. The product uses ondemand fusing. The fuser-control circuit consists of the following major components:
Fuser heater (H1); heats the fusing film
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Thermistor (TH1); detects the fuser temperature (contact type)
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Thermoswitch (TP1); prevents abnormal temperature rise in the fuser (contact type)
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Figure 1-9 Fuser control circuit
Fuser film
TH1
TP1
H1
FUSER HEATER CONTROL signal
Fuser heater control
circuit
Fuser control
Pressure roller
FUSER TEMPERATURE signal
Fuser heater safety
circuit
DC controller
Engine controller
ENWW Engine-control system 15
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