HP m604, m605, m606 Troubleshooting Manual

Troubleshooting Manual

LaserJet Enterprise M604, M605, M606

www.hp.com/support/lj604 www.hp.com/support/lj605 www.hp.com/support/lj606

For printer part removal and part numbers information, see the Repair Manual.

M604n M605n

M604dn M605dn M606dn

M605x M606x

HP LaserJet Enterprise M604, M605, M606

Troubleshooting Manual

Trademark Credits

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.

Edition 1, 4/2015

Microsoft®, Windows®, Windows® XP, and Windows Vista® are U.S. registered trademarks of Microsoft Corporation.

Conventions used in this guide

TIP: Helpful hints or shortcuts.

Reinstallation tip: Reinstallation helpful hints, shortcuts, or considerations.

NOTE: Information that explains a concept or how to complete a task.

IMPORTANT: Information that help the user to avoid potential printer error conditions.

CAUTION: Procedures that the user must follow to avoid losing data or damaging the printer.

WARNING! Procedures that the user must follow to avoid personal injury, catastrophic loss of data, or

extensive damage to the printer.

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iv Conventions used in this guide ENWW

For additional service and support information

HP service personnel, go to the Service Access Work Bench (SAW) at http://h41302.www4.hp.com/km/saw/

home.do.

Channel partners, go to HP Channel Services Network (CNS) at https://h30125.www3.hp.com/hpcsn.

●

To access HP PartSurfer information from any mobile device, go to http://partsurfermobile.hp.com/ or scan the Quick Response (QR) code below.

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Install and congure

●

Printer specications

●

Up-to-date control-panel message (CPMD) troubleshooting

●

Solutions for printer issues and emerging issues

●

Remove and replace part instructions and videos

●

Service advisories

●

Warranty & regulatory information

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vi For additional service and support information ENWW

Table of contents

1 Theory of operation ....................................................................................................................................... 1

Related documentation and software ................................................................................................................... 2

Basic operation ...................................................................................................................................................... 3

Sequence of operation ........................................................................................................................ 4

Formatter-control system ..................................................................................................................................... 5

Sleep mode .......................................................................................................................................... 5

Printer job language (PJL) ................................................................................................................... 6

Printer management language (PML) ................................................................................................. 6

Control panel ....................................................................................................................................... 6

Easy-access USB port .......................................................................................................................... 7

Wireless ............................................................................................................................................... 7

Near eld communication (NFC) .......................................................................................................... 7

CPU ....................................................................................................................................................... 7

Input/output ........................................................................................................................................ 7

Memory ................................................................................................................................................ 7

Firmware ........................................................................................................................... 8

Nonvolatile random access memory (NVRAM) ................................................................. 8

Random access memory (RAM) ........................................................................................ 8

HP Memory Enhancement technology (MEt) .................................................................... 8

Engine-control system .......................................................................................................................................... 9

DC controller ...................................................................................................................................... 10

Motors ............................................................................................................................. 11

Fans ................................................................................................................................. 11

Solenoids ......................................................................................................................... 12

Switches .......................................................................................................................... 12

Sensors ........................................................................................................................... 13

Low-voltage power supply ................................................................................................................ 14

Low-voltage power supply voltages description ........................................................... 14

Over-current/over-voltage protection ........................................................................... 15

Sleep mode operation ..................................................................................................... 15

Low-voltage power supply failure detection ................................................................. 15

High-voltage power supply ............................................................................................................... 16

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Fuser bias ........................................................................................................................ 17

Engine power supply ......................................................................................................................... 17

Fuser-control circuit ........................................................................................................ 17

Fuser temperature control ............................................................................................. 17

Fuser unit life detection .................................................................................................. 18

Fuser unit identication .................................................................................................. 18

Engine laser/scanner system .............................................................................................................................. 19

Laser failure detection ...................................................................................................................... 21

Image formation process .................................................................................................................. 22

Step 1: Primary charging ................................................................................................ 23

Step 2: Laser-beam exposure ......................................................................................... 24

Step 3: Development ...................................................................................................... 24

Step 4: Transfer ............................................................................................................... 25

Step 5: Separation ........................................................................................................... 25

Step 6: Fusing .................................................................................................................. 26

Step 7: Drum cleaning ..................................................................................................... 26

Step 8: Drum charge elimination .................................................................................... 27

Pickup, feed, and delivery system ....................................................................................................................... 28

Photo sensors and switches ............................................................................................................. 28

Motors, clutches, and solenoids ........................................................................................................ 28

Tray 1 (multipurpose)/Tray 2 (base printer) ..................................................................................... 29

Tray 1 paper pickup and feed ......................................................................................... 29

Tray 2 paper presence detection .................................................................................... 29

Tray 2 paper pickup and feed ......................................................................................... 30

Tray 2 multiple-feed prevention ..................................................................................... 30

Tray 2 tray presence detection ....................................................................................... 31

Tray 2 skew feed prevention ........................................................................................... 31

Duplexer ............................................................................................................................................ 32

Duplexing reverse and duplex feed control ................................................................... 32

Side registration adjustment operation (DP) ................................................................. 34

Jam detection/prevention ................................................................................................................. 35

Fuser wrapping jam detection ........................................................................................ 39

Pressure roller pressurization and depressurization control ...................... 39

Input accessories ................................................................................................................................................. 41

Trays 3-6 ........................................................................................................................................... 42

Trays 3-6 driver PCA ....................................................................................................... 42

Trays 3-6 motor control .................................................................................................. 43

Trays 3-6 electrical components .................................................................................... 43

Trays 3-6 media size detection ...................................................................................... 44

Trays 3-6 paper pickup ................................................................................................... 44

Trays 3-6 multiple feed prevention ................................................................................ 45

viii ENWW

Trays 3-6 tray presence detection .................................................................................. 45

Trays 3-6 tray lift operation ........................................................................................... 45

Trays 3-6 jam detection .................................................................................................. 45

High-capacity input (HCI) feeder ....................................................................................................... 46

HCI driver PCA .................................................................................................................. 46

HCI motor control ............................................................................................................ 47

HCI electrical components .............................................................................................. 48

HCI media size detection ................................................................................................. 48

HCI paper pickup ............................................................................................................. 48

HCI multiple feed prevention .......................................................................................... 49

HCI tray lift operation ..................................................................................................... 50

HCI jam detection ............................................................................................................ 51

Envelope feeder ................................................................................................................................ 52

Envelope feeder driver PCA ............................................................................................ 52

Envelope feeder motor control ....................................................................................... 52

Envelope feeder electrical components ......................................................................... 53

Envelope feeder paper pickup ........................................................................................ 54

Envelope feeder multiple feed prevention ..................................................................... 54

Envelope feeder multiple feed detection ....................................................................... 54

Envelope feeder jam detection ....................................................................................... 56

Duplexer ............................................................................................................................................ 57

Duplexer driver PCA ........................................................................................................ 57

Duplexer motor control .................................................................................................. 57

Duplexer electrical components ..................................................................................... 58

Duplexer paper pickup .................................................................................................... 59

Side registration adjustment operation (DP) ............................................... 60

Duplexer jam detection ................................................................................................... 62

2 Solve problems ............................................................................................................................................ 63

For additional service and support ..................................................................................................................... 64

Solve problems checklist ..................................................................................................................................... 65

Solve problems checklist ................................................................................................................... 65

Print the conguration page ............................................................................................................. 68

Print menu map ................................................................................................................................. 69

Print current settings pages ............................................................................................................. 70

Print event log ................................................................................................................................... 70

Pre-boot menu options ..................................................................................................................... 73

Remote Admin ................................................................................................................. 82

Required software and network connection ................................................ 82

Connect a remote connection ....................................................................... 84

Disconnect a remote connection .................................................................. 88

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Troubleshooting process ..................................................................................................................................... 91

Determine the problem source ......................................................................................................... 91

Troubleshooting owchart ............................................................................................. 91

Power subsystem .............................................................................................................................. 92

Power-on checks ............................................................................................................. 92

Power-on troubleshooting overview ........................................................... 92

Control panel checks ......................................................................................................................... 95

Control-panel diagnostics .............................................................................................. 96

Touchscreen diagnostic mode (M605x and M606x only) ............................ 96

Control-panel system diagnostics (touchscreen control panel) ............... 100

Control panel diagnostic owcharts (M605x and M606x only) ................................... 115

Touchscreen black, white, or dim (no image) ............................................ 116

Touchscreen is slow to respond or requires multiple presses to

respond ....................................................................................................... 117

Touchscreen has an unresponsive zone .................................................... 118

No control panel sound .............................................................................. 119

Home button is unresponsive .................................................................... 120

Hardware integration pocket (HIP) is not functioning (control panel

functional) .................................................................................................. 121

Tools for troubleshooting .................................................................................................................................. 122

Individual component diagnostics .................................................................................................. 122

Tools for troubleshooting: LED diagnostics ................................................................. 122

Understand lights on the formatter ........................................................... 122

Tools for troubleshooting: Engine diagnostics ............................................................ 123

Engine test button ...................................................................................... 123

Defeating interlocks ................................................................................... 124

Disable cartridge check .............................................................................. 125

Tools for troubleshooting: Paper path and sensor diagnostic tests ........................... 126

Paper path test ........................................................................................... 126

Paper path sensors test ............................................................................. 127

Manual sensor tests ................................................................................... 129

Tray/bin manual sensor test ...................................................................... 131

Tools for troubleshooting: Print/stop test ................................................................... 133

Tools for troubleshooting: Component tests ............................................................... 134

Individual component diagnostics (special-mode test) ............................ 134

Diagrams ......................................................................................................................................... 136

Diagrams: Block diagrams ............................................................................................ 136

Sensors and switches ................................................................................. 136

Cross section diagrams .............................................................................. 141

Diagrams: Printed circuit assembly (PCA) connector locations ................................... 146

DC controller connections .......................................................................... 146

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Formatter PCA ............................................................................................ 148

Printer base connectors ............................................................................. 149

1x500-sheet feeder connectors ................................................................ 150

1,500-sheet high-capacity feeder connectors .......................................... 150

Duplexer connectors .................................................................................. 151

Envelope feeder connectors ...................................................................... 151

Diagrams: External plug and port locations ................................................................. 151

Diagrams: Locations of major assemblies ................................................................... 153

Main assemblies (printer base) .................................................................. 153

Motors and fans (printer base) ................................................................... 155

Printed circuit assemblies (PCAs; printer base) ......................................... 156

1x500-sheet paper feeder ......................................................................... 157

1x1500-sheet paper feeder ....................................................................... 158

Diagrams: General timing chart ................................................................................... 160

Diagrams: General circuit diagrams ............................................................................. 161

Internal print-quality test pages .................................................................................................... 168

Print a conguration page ............................................................................................ 168

HP embedded Jetdirect page ..................................................................... 170

Wireless page ............................................................................................. 171

Finding important information on the conguration pages ..................... 173

Print a fuser test page .................................................................................................. 174

Print a cleaning page .................................................................................................... 176

Enable and congure auto cleaning ........................................................... 176

Control-panel menus ...................................................................................................................... 177

Administration menu .................................................................................................... 177

Reports menu ............................................................................................. 177

General Settings menu ............................................................................... 179

General Print Settings menu ...................................................................... 184

Default Print Options menu ....................................................................... 187

Display Settings menu ............................................................................... 189

Manage Supplies menu .............................................................................. 191

Manage Trays menu ................................................................................... 193

Stapler/Stacker Settings menu .................................................................. 195

Network Settings menu ............................................................................. 196

Troubleshooting menu ............................................................................... 207

Device Maintenance menu ............................................................................................ 210

Backup/Restore menu ................................................................................ 210

Calibration/Cleaning menu ......................................................................... 210

USB Firmware Upgrade menu .................................................................... 212

Service menu .............................................................................................. 212

Control panel message document (CPMD) ..................................................................................... 213

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Control-panel message types ...................................................................................... 213

Control-panel messages and event log entries ........................................................... 213

10.XX.YZ Error Messages ........................................................................... 213

11.XX.YZ Error Messages ........................................................................... 219

13.XX.YZ Error Messages ........................................................................... 219

20.XX.YZ Error Messages ........................................................................... 237

32.XX.YX and 33.XX.YZ Error Messages .................................................... 238

40.XX.YZ Error Messages ........................................................................... 245

41.XX.YZ Error Messages ........................................................................... 246

42.XX.YZ Error Messages ........................................................................... 254

47.XX.XX Error Messages ........................................................................... 254

48.XX.YY Error Messages ........................................................................... 256

49.XX.YY Error Messages ........................................................................... 256

50.WX.YZ Error Messages .......................................................................... 257

51.XX.YZ, 52.XX.YZ Error Messages .......................................................... 261

54.XX.YZ Error Messages ........................................................................... 261

55.XX.YZ, 56.XX.YZ Error Messages .......................................................... 262

57.XX.YZ Error Messages ........................................................................... 263

58.XX.YZ Error Messages ........................................................................... 265

59.XX.YZ Error Messages ........................................................................... 266

60.00.0Y, 62.00.00 Error Messages ........................................................... 268

65.X0.AZ Error Messages ........................................................................... 269

66.WX.YZ Error Messages .......................................................................... 269

70.XX.YY Error Messages ........................................................................... 271

80.XX.YY, 82.XX.YY Error Messages ........................................................... 271

98.0X.0Y Error Messages ........................................................................... 273

99.XX.YY Error Messages ........................................................................... 274

Alpha Error Messages ................................................................................. 281

Tools for troubleshooting: Event log messages .......................................................... 311

Print or view an event log ........................................................................... 312

Clear the event log ..................................................................................... 313

Solve image-quality problems .......................................................................................................................... 314

Improve print quality ...................................................................................................................... 314

Repetitive image defect ruler ....................................................................................... 314

Use a ruler to measure between repetitive defects .................................. 315

Print-quality troubleshooting pages ............................................................................ 318

Print from a dierent software program ..................................................................... 322

Check the paper-type setting for the print job ............................................................ 322

Check toner-cartridge status ....................................................................................... 322

Clean the printer ........................................................................................................... 323

Print a cleaning page .................................................................................. 323

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Visually inspect the toner cartridge or cartridges ....................................................... 324

Check paper and the printing environment ................................................................. 324

Use manual print modes ............................................................................................... 324

Image defects table ...................................................................................................... 327

Clean the printer ................................................................................................................................................ 335

Clean the paper path ....................................................................................................................... 335

Print a cleaning page ....................................................................................................................... 335

Clean the Tray 1 rollers ................................................................................................................... 336

Step 1: Remove the Tray 1 rollers ................................................................................ 336

Step 2: Clean the Tray 1 rollers ..................................................................................... 339

Step 3: Install the Tray 1 rollers .................................................................................... 340

Clean the Tray 2-X rollers ................................................................................................................ 345

Step 1: Remove the tray ............................................................................................... 345

Step 2: Remove the pickup, feed, and separation rollers ............................................ 345

Step 3: Clean the Tray 2-X rollers ................................................................................. 347

Step 4: Install the pickup, feed, and separation rollers ............................................... 347

Step 5: Install the tray .................................................................................................. 350

Clean the 1,500-sheet high capacity input (HCI) feeder rollers ..................................................... 351

Step 1: Remove the pickup, feed, and separation rollers ............................................ 351

Step 2: Clean the HCI rollers ......................................................................................... 353

Step 3: Install the pickup, feed, and separation rollers ............................................... 353

Solve paper handling problems ........................................................................................................................ 357

Product feeds incorrect page size ................................................................................................... 357

Product pulls from incorrect tray .................................................................................................... 357

Product will not duplex or duplexes incorrectly ............................................................................. 357

Paper does not feed from Tray 2-X ................................................................................................. 358

Output is curled or wrinkled ............................................................................................................ 358

Product does not pick up paper or misfeeds .................................................................................. 359

The product does not pick up paper ............................................................................. 359

The product picks up multiple sheets of paper ............................................................ 360

Paper does not feed automatically .............................................................................. 360

Clear paper jams ................................................................................................................................................ 361

Paper path jam sensor locations .................................................................................................... 362

Auto-navigation for clearing jams .................................................................................................. 365

Experiencing frequent or recurring paper jams? ............................................................................ 365

Clear paper jams in Tray 1 ............................................................................................................... 367

Clear paper jams in Tray 2 and the 500-sheet trays ...................................................................... 368

Clear paper jams in the optional 1,500-sheet high-capacity tray ................................................. 370

Clear paper jams in the toner-cartridge area ................................................................................. 372

Clear paper jams in the rear output bin .......................................................................................... 375

Clear paper jams in the fuser area .................................................................................................. 376

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Clear paper jams in the output bin .................................................................................................. 381

Clear paper jams in the duplexer .................................................................................................... 382

Clear paper jams in the envelope feeder ........................................................................................ 384

Clear paper jams in the 5-bin mailbox ............................................................................................ 386

Clear jams in the stacker or stapler/stacker ................................................................................... 388

Clear paper jams in the stacker or stapler/stacker ...................................................... 388

Clear staple jams in the stapler/stacker ....................................................................... 389

Change jam recovery ....................................................................................................................... 391

Solve performance problems ............................................................................................................................ 392

Factors aecting print performance ............................................................................................... 392

Print speeds ..................................................................................................................................... 393

The product does not print or it prints slowly ................................................................................ 393

The product prints slowly ............................................................................................................... 394

Solve connectivity problems ............................................................................................................................. 395

Solve USB connection problems ..................................................................................................... 395

Solve wired network problems ....................................................................................................... 395

Poor physical connection .............................................................................................. 395

The computer is using the incorrect IP address for the product .................................. 395

The computer is unable to communicate with the product ......................................... 396

The product is using incorrect link and duplex settings for the network .................... 396

New software programs might be causing compatibility problems ........................... 396

The computer or workstation might be set up incorrectly .......................................... 396

The product is disabled, or other network settings are incorrect ............................... 396

Service mode functions ..................................................................................................................................... 397

Service menu ................................................................................................................................... 397

Product resets ................................................................................................................................. 398

Restore factory-set defaults ........................................................................................ 398

Restore the service ID ................................................................................................... 399

Product cold reset ......................................................................................................... 400

Format Disk and Partial Clean functions ........................................................................................ 401

Active and repository rmware locations .................................................................... 401

Partial Clean .................................................................................................................. 401

Execute a Partial Clean ............................................................................... 402

Format Disk ................................................................................................................... 402

Execute a Format Disk ................................................................................ 403

Firmware upgrades ............................................................................................................................................ 405

Determine the installed revision of rmware ................................................................................. 406

Perform a rmware upgrade .......................................................................................................... 407

HP Embedded Web Server ............................................................................................ 407

USB ash drive (Pre-boot menu) .................................................................................. 408

USB ash drive (control-panel menu) .......................................................................... 410

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Appendix A Printer specications .................................................................................................................. 411

Printer dimensions ............................................................................................................................................ 412

Dimensions for the products, as sold ............................................................................................. 412

Dimensions for the input and output accessories .......................................................................... 414

Dimensions for sample combinations of the products and optional accessories ......................... 418

Combination one ........................................................................................................... 418

Combination two ........................................................................................................... 419

Combination three ........................................................................................................ 419

Printer space requirements ............................................................................................................................... 421

Power consumption, electrical specications, and acoustic emissions ........................................................... 422

Operating-environment range .......................................................................................................................... 423

Certicate of Volatility ....................................................................................................................................... 424

Index ........................................................................................................................................................... 427

ENWW xv

xvi ENWW

List of tables

Table 1-1 Sequence of operation .......................................................................................................................................... 4

Table 1-2 Motors ................................................................................................................................................................. 11

Table 1-3 Fans ..................................................................................................................................................................... 11

Table 1-4 Solenoids ............................................................................................................................................................ 12

Table 1-5 Switches .............................................................................................................................................................. 12

Table 1-6 Sensors ............................................................................................................................................................... 13

Table 1-7 Converted DC voltages ....................................................................................................................................... 14

Table 1-8 Image formation process ................................................................................................................................... 23

Table 1-9 Media presence and size detection (Tray 2 and 1x500- sheet feeder) .............................................................. 29

Table 1-10 Jam detection sensors ..................................................................................................................................... 36

Table 1-11 Jams that the printer detects ........................................................................................................................... 36

Table 2-1 Pre-boot menu options (1 of 7) .......................................................................................................................... 76

Table 2-2 Pre-boot menu options (2 of 7) .......................................................................................................................... 77

Table 2-3 Pre-boot menu options (3 of 7) .......................................................................................................................... 78

Table 2-4 Pre-boot menu options (4 of 7) .......................................................................................................................... 78

Table 2-5 Pre-boot menu options (5 of 7) .......................................................................................................................... 79

Table 2-6 Pre-boot menu options (6 of 7) .......................................................................................................................... 80

Table 2-7 Pre-boot menu options (7 of 7) .......................................................................................................................... 81

Table 2-8 Troubleshooting owchart ................................................................................................................................. 91

Table 2-9 Paper-path sensors diagnostic tests ............................................................................................................... 127

Table 2-10 Manual sensor diagnostic tests ..................................................................................................................... 130

Table 2-11 Tray/bin manual sensors ................................................................................................................................ 132

Table 2-12 Component test details .................................................................................................................................. 135

Table 2-13 Product base, sensors and switches block diagram ...................................................................................... 136

Table 2-14 1x500-sheet paper feeder, sensors and switches block diagram ................................................................ 137

Table 2-15 1,500-sheet high capacity input feeder, sensors and switches block diagram ............................................ 138

Table 2-16 Envelope feeder, sensors and switches block diagram ................................................................................. 139

Table 2-17 Duplexer, sensors and switches block diagram ............................................................................................. 140

Table 2-18 Product base, cross section diagram ............................................................................................................. 141

Table 2-19 1x500-sheet paper feeder, cross section diagram ........................................................................................ 142

Table 2-20 1,500-sheet high capacity input (HCI) feeder, cross section diagram ........................................................... 143

Table 2-21 Envelope feeder, cross section diagram ........................................................................................................ 144

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Table 2-22 Duplexer, cross section diagram .................................................................................................................... 145

Table 2-23 Tray, cross section diagram ............................................................................................................................ 145

Table 2-24 DC controller connectors ................................................................................................................................ 146

Table 2-25 Formatter PCA ................................................................................................................................................ 148

Table 2-26 External plug and port locations .................................................................................................................... 152

Table 2-27 Main assemblies (1 of 2; printer base) ........................................................................................................... 153

Table 2-28 Main assemblies (2 of 2; printer base) ........................................................................................................... 154

Table 2-29 Motors and fans (printer base) ....................................................................................................................... 155

Table 2-30 PCAs (printer base) ......................................................................................................................................... 156

Table 2-31 Main assemblies (1x500-sheet paper feeder) ............................................................................................... 157

Table 2-32 Printed circuit assembly and solenoid (1x500-sheet paper feeder) ............................................................. 157

Table 2-33 Main assemblies (1x1500-sheet paper feeder) ............................................................................................. 158

Table 2-34 Printed circuit assembly (PCA) and motor (1x1500-sheet paper feeder) ..................................................... 158

Table 2-35 Printed circuit assembly (PCA) and motor (1x1500-sheet paper feeder) ..................................................... 159

Table 2-36 Conguration page ......................................................................................................................................... 169

Table 2-37 HP embedded Jetdirect page ......................................................................................................................... 170

Table 2-38 Wireless page ................................................................................................................................................. 171

Table 2-39 Important information on the conguration pages ...................................................................................... 173

Table 2-40 Reports menu ................................................................................................................................................. 177

Table 2-41 General Settings menu ................................................................................................................................... 179

Table 2-42 General Print Settings menu .......................................................................................................................... 184

Table 2-43 Default Print Options menu ........................................................................................................................... 187

Table 2-44 Display Settings menu ................................................................................................................................... 189

Table 2-45 Manage Supplies menu .................................................................................................................................. 191

Table 2-46 Manage Trays menu ....................................................................................................................................... 193

Table 2-47 Default Print Options menu ........................................................................................................................... 195

Table 2-48 Network Settings menu ................................................................................................................................. 196

Table 2-49 Embedded Jetdirect Menu .............................................................................................................................. 196

Table 2-50 Troubleshooting menu ................................................................................................................................... 207

Table 2-51 Backup/Restore menu .................................................................................................................................... 210

Table 2-52 Sample event log page ................................................................................................................................... 311

Table 2-53 Repetitive defects .......................................................................................................................................... 314

Table 2-54 Print modes under the Adjust Paper Types submenu ................................................................................... 326

Table 2-55 Print modes under the Optimize submenu .................................................................................................... 326

Table 2-56 Image defects table ........................................................................................................................................ 327

Table 2-57 Product feeds incorrect page size .................................................................................................................. 357

Table 2-58 Product pulls from incorrect tray ................................................................................................................... 357

Table 2-59 Product will not duplex (print 2-sided jobs) or duplexes incorrectly ............................................................ 357

Table 2-60 Paper does not feed from Tray 2-X ................................................................................................................ 358

Table 2-61 Output is curled or wrinkled ........................................................................................................................... 358

Table 2-62 Paper does not feed automatically ................................................................................................................ 360

xviii ENWW

Table 2-63 Product base jam sensors .............................................................................................................................. 362

Table 2-64 1x500-sheet paper-feeder jam sensors ........................................................................................................ 363

Table 2-65 1,500-sheet high-capacity input (HCI) feeder jam sensors .......................................................................... 364

Table 2-66 Duplexer jam sensors ..................................................................................................................................... 365

Table 2-67 Solve performance problems ......................................................................................................................... 392

Table A-1 Operating-environment specications ............................................................................................................ 423

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xx ENWW

List of gures

Figure 1-1 Relationship between the main printer systems ............................................................................................... 3

Figure 1-2 Engine-control system ........................................................................................................................................ 9

Figure 1-3 DC controller block diagram .............................................................................................................................. 10

Figure 1-4 Low-voltage power-supply circuit .................................................................................................................... 14

Figure 1-5 High-voltage power supply circuits .................................................................................................................. 16

Figure 1-6 Fuser control ..................................................................................................................................................... 17

Figure 1-7 Fuser temperature-control circuit .................................................................................................................... 18

Figure 1-8 Laser/scanner system ....................................................................................................................................... 20

Figure 1-9 Image-formation system .................................................................................................................................. 22

Figure 1-10 Image-formation process ............................................................................................................................... 23

Figure 1-11 Primary charging ............................................................................................................................................. 24

Figure 1-12 Laser-beam exposure ..................................................................................................................................... 24

Figure 1-13 Development ................................................................................................................................................... 25

Figure 1-14 Primary transfer .............................................................................................................................................. 25

Figure 1-15 Separation ....................................................................................................................................................... 26

Figure 1-16 Fusing .............................................................................................................................................................. 26

Figure 1-17 Drum cleaning ................................................................................................................................................. 27

Figure 1-18 Drum charge elimination ................................................................................................................................ 27

Figure 1-19 Photo sensors ................................................................................................................................................. 28

Figure 1-20 Tray 2 multiple-feed prevention ..................................................................................................................... 31

Figure 1-21 Skew-feed prevention ..................................................................................................................................... 32

Figure 1-22 Duplex block diagram ..................................................................................................................................... 34

Figure 1-23 Side registration adjustment operation (DP) ................................................................................................. 35

Figure 1-24 Jam detection sensors .................................................................................................................................... 36

Figure 1-25 Pressure roller pressure release control ........................................................................................................ 40

Figure 1-26 1 x 500-sheet paper feeder ............................................................................................................................ 42

Figure 1-27 1 x 500-sheet paper feeder block diagram .................................................................................................... 43

Figure 1-28 1 x 500-sheet paper feeder circuit diagram ................................................................................................... 44

Figure 1-29 HCI ................................................................................................................................................................... 46

Figure 1-30 HCI block diagram ........................................................................................................................................... 47

Figure 1-31 HCI circuit diagram .......................................................................................................................................... 48

Figure 1-32 HCI lift .............................................................................................................................................................. 50

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Figure 1-33 Envelope feeder .............................................................................................................................................. 52

Figure 1-34 Envelope feeder block diagram ...................................................................................................................... 53

Figure 1-35 Envelope feeder circuit diagram ..................................................................................................................... 53

Figure 1-36 Envelope feeder multiple feed detection ....................................................................................................... 55

Figure 1-37 Envelope feeder jam detection ....................................................................................................................... 56

Figure 1-38 Duplexer .......................................................................................................................................................... 57

Figure 1-39 Envelope feeder block diagram ...................................................................................................................... 58

Figure 1-40 Duplexer circuit diagram ................................................................................................................................. 59

Figure 1-41 Side registration adjustment operation (DP) ................................................................................................. 61

Figure 1-42 Envelope feeder jam detection ....................................................................................................................... 62

Figure 2-1 Open the Pre-boot menu .................................................................................................................................. 73

Figure 2-2 Pre-boot menu .................................................................................................................................................. 74

Figure 2-3 Open the Pre-boot menu .................................................................................................................................. 75

Figure 2-4 Open the Control Panel ..................................................................................................................................... 83

Figure 2-5 Turn Windows features on or o ...................................................................................................................... 83

Figure 2-6 Enable the telnet client feature ........................................................................................................................ 84

Figure 2-7 Select the +3:Administrator item ..................................................................................................................... 85

Figure 2-8 Select the +A:Remote Admin item .................................................................................................................... 85

Figure 2-9 Select the 1:Start Telnet item ........................................................................................................................... 85

Figure 2-10 Telnet connecting message ............................................................................................................................ 85

Figure 2-11 Telnet error message ...................................................................................................................................... 86

Figure 2-12 Telnet server function initialized .................................................................................................................... 86

Figure 2-13 Open a command window ............................................................................................................................... 87

Figure 2-14 Start a telnet session ...................................................................................................................................... 87

Figure 2-15 Establish a telnet connection ......................................................................................................................... 87

Figure 2-16 Enter the PIN ................................................................................................................................................... 88

Figure 2-17 Remote Admin window ................................................................................................................................... 88

Figure 2-18 Access the administrator menu ...................................................................................................................... 89

Figure 2-19 Access the remote admin menu ...................................................................................................................... 89

Figure 2-20 Terminate the telnet connection .................................................................................................................... 90

Figure 2-21 Diagnostic-tests access button ...................................................................................................................... 96

Figure 2-22 Press the diagnostics-access button .............................................................................................................. 97

Figure 2-23 Control-panel version A yellow screen ........................................................................................................... 97

Figure 2-24 Touch the screen to advance colored screens ................................................................................................ 98

Figure 2-25 Exit the diagnostic mode ................................................................................................................................ 99

Figure 2-26 Open the Pre-boot menu .............................................................................................................................. 100

Figure 2-27 Pre-boot menu .............................................................................................................................................. 101

Figure 2-28 Access the administration menu .................................................................................................................. 102

Figure 2-29 Access the diagnostics menu ........................................................................................................................ 102

Figure 2-30 Open the screen test ..................................................................................................................................... 103

Figure 2-31 Blue vertical gradient screen ........................................................................................................................ 103

xxii ENWW

Figure 2-32 Open the touch test ...................................................................................................................................... 107

Figure 2-33 Touch the white grid ..................................................................................................................................... 107

Figure 2-34 Verify the mark ............................................................................................................................................. 108

Figure 2-35 Open the softkey test ................................................................................................................................... 109

Figure 2-36 Touch the Home button ................................................................................................................................ 109

Figure 2-37 Successful test .............................................................................................................................................. 110

Figure 2-38 Open the backlight test ................................................................................................................................. 111

Figure 2-39 Open the sound test ...................................................................................................................................... 112

Figure 2-40 Do not open the keyboard test ..................................................................................................................... 113

Figure 2-41 Open the sound test ...................................................................................................................................... 114

Figure 2-42 Touchscreen blank, white, or dim (no image) .............................................................................................. 116

Figure 2-43 Touchscreen is slow to respond or requires multiple presses to respond ................................................... 117

Figure 2-44 Touchscreen has an unresponsive zone ....................................................................................................... 118

Figure 2-45 No control panel sound ................................................................................................................................. 119

Figure 2-46 Home button is unresponsive ....................................................................................................................... 120

Figure 2-47 Hardware integration pocket (HIP) is not functioning (control panel functional) ....................................... 121

Figure 2-48 Engine test button ........................................................................................................................................ 123

Figure 2-49 Defeating interlocks ...................................................................................................................................... 124

Figure 2-50 Printer base, sensors and switches block diagram ...................................................................................... 136

Figure 2-51 1x500-sheet paper feeder, sensors and switches block diagram ............................................................... 137

Figure 2-52 1,500-sheet high capacity input feeder, sensors and switches block diagram .......................................... 138

Figure 2-53 Envelope feeder, sensors and switches block diagram ............................................................................... 139

Figure 2-54 Duplexer, sensors and switches block diagram ........................................................................................... 140

Figure 2-55 Printer base, cross section diagram ............................................................................................................. 141

Figure 2-56 1x500-sheet paper feeder, cross section diagram ...................................................................................... 142

Figure 2-57 1,500-sheet high capacity input (HCI) feeder, cross section diagram ......................................................... 143

Figure 2-58 Envelope feeder, cross section diagram ....................................................................................................... 144

Figure 2-59 Duplexer, cross section diagram ................................................................................................................... 145

Figure 2-60 Tray, cross section diagram .......................................................................................................................... 145

Figure 2-61 DC controller PCA connectors ....................................................................................................................... 146

Figure 2-62 Formatter PCA ............................................................................................................................................... 148

Figure 2-63 Printer base connectors ................................................................................................................................ 149

Figure 2-64 1x500-sheet feeder connectors ................................................................................................................... 150

Figure 2-65 1,500-sheet high-capacity feeder connectors ............................................................................................ 150

Figure 2-66 Stapling mailbox connectors ........................................................................................................................ 151

Figure 2-67 Envelope feeder connectors ......................................................................................................................... 151

Figure 2-68 External plug and port locations .................................................................................................................. 152

Figure 2-69 Main assemblies (1 of 2; printer base) ......................................................................................................... 153

Figure 2-70 Main assemblies (2 of 2; printer base) ......................................................................................................... 154

Figure 2-71 Motors and fans (printer base) ..................................................................................................................... 155

Figure 2-72 PCAs (printer base) ....................................................................................................................................... 156

ENWW xxiii

Figure 2-73 Main assemblies (1x500-sheet paper feeder) ............................................................................................. 157

Figure 2-74 Printed circuit assembly and solenoid (1x500-sheet paper feeder) ........................................................... 157

Figure 2-75 Main assemblies (1x1500-sheet paper feeder) ........................................................................................... 158

Figure 2-76 Printed circuit assembly (PCA) and motor (1x1500-sheet paper feeder) ................................................... 158

Figure 2-77 Printed circuit assembly (PCA) and motor (1x1500-sheet paper feeder) ................................................... 159

Figure 2-78 General timing chart ..................................................................................................................................... 160

Figure 2-79 General circuit diagram for the printer base (1 of 3) ................................................................................... 161

Figure 2-80 General circuit diagram for the printer base (2 of 3) ................................................................................... 162

Figure 2-81 General circuit diagram for the printer base (3 of 3) ................................................................................... 163

Figure 2-82 General circuit diagram for the 1x500-sheet feeder ................................................................................... 164

Figure 2-83 General circuit diagram for the 1,500-sheet high-capacity feeder (HCI) .................................................... 165

Figure 2-84 General circuit diagram for the envelope feeder ......................................................................................... 166

Figure 2-85 General circuit diagram for the duplexer ..................................................................................................... 167

Figure 2-86 Conguration page ....................................................................................................................................... 169

Figure 2-87 Conguration page ....................................................................................................................................... 170

Figure 2-88 Wireless page ................................................................................................................................................ 171

Figure 2-89 Print a fuser test page .................................................................................................................................. 175

Figure 2-90 Paper Tray guides ......................................................................................................................................... 220

Figure 2-91 Paper Tray overll guide ............................................................................................................................... 220

Figure 2-92 Paper Tray guides ......................................................................................................................................... 222

Figure 2-93 Paper Tray overll guide ............................................................................................................................... 222

Figure 2-94 Paper Tray guides ......................................................................................................................................... 224

Figure 2-95 Paper Tray overll guide ............................................................................................................................... 224

Figure 2-96 Paper Tray guides ......................................................................................................................................... 226

Figure 2-97 Paper Tray overll guide ............................................................................................................................... 226

Figure 2-98 Sample event log .......................................................................................................................................... 311

Figure 2-99 Examples of repetitive defects ..................................................................................................................... 316

Figure 2-100 Place the ruler on the page ......................................................................................................................... 317

Figure 2-101 Locate the next repetitive defect ............................................................................................................... 317

Figure 2-102 Determine the defective assembly ............................................................................................................ 318

Figure 2-103 Print-quality troubleshooting procedure page .......................................................................................... 320

Figure 2-104 Black print-quality troubleshooting page .................................................................................................. 321

Figure 2-105 Open the front cover ................................................................................................................................... 336

Figure 2-106 Open the separation roller cover ................................................................................................................ 336

Figure 2-107 Slide the separation roller .......................................................................................................................... 337

Figure 2-108 Remove the separation roller ..................................................................................................................... 337

Figure 2-109 Remove one screw ...................................................................................................................................... 338

Figure 2-110 Remove the bushing ................................................................................................................................... 338

Figure 2-111 Remove the cover ....................................................................................................................................... 339

Figure 2-112 Remove the Tray 1 pickup and feed rollers ................................................................................................ 339

Figure 2-113 Clean the rollers .......................................................................................................................................... 340

xxiv ENWW

Figure 2-114 Install the Tray 1 pickup and feed rollers ................................................................................................... 340

Figure 2-115 Remove the cover ....................................................................................................................................... 341

Figure 2-116 Install the bushing ...................................................................................................................................... 342

Figure 2-117 Install one screw ......................................................................................................................................... 342

Figure 2-118 Open the separation roller cover ................................................................................................................ 343

Figure 2-119 Position the separation roller ..................................................................................................................... 343

Figure 2-120 Install the separation roller ........................................................................................................................ 344

Figure 2-121 Close the front cover ................................................................................................................................... 344

Figure 2-122 Remove the tray ......................................................................................................................................... 345

Figure 2-123 Open the cover ............................................................................................................................................ 345

Figure 2-124 Remove the feed roller ............................................................................................................................... 346

Figure 2-125 Remove the feed roller ............................................................................................................................... 346

Figure 2-126 Remove the pick roller ................................................................................................................................ 347

Figure 2-127 Clean the rollers .......................................................................................................................................... 347

Figure 2-128 Install the pick roller ................................................................................................................................... 348

Figure 2-129 Install the feed roller .................................................................................................................................. 348

Figure 2-130 Open the cover ............................................................................................................................................ 349

Figure 2-131 Align the torque limiter ............................................................................................................................... 349

Figure 2-132 Install the feed roller .................................................................................................................................. 350

Figure 2-133 Install the tray ............................................................................................................................................. 350

Figure 2-134 Open the feeder door .................................................................................................................................. 351

Figure 2-135 Open the separation-roller cover ............................................................................................................... 351

Figure 2-136 Remove the separation roller ..................................................................................................................... 352

Figure 2-137 Remove the feed roller ............................................................................................................................... 352

Figure 2-138 Remove the pick roller ................................................................................................................................ 353

Figure 2-139 Clean the rollers .......................................................................................................................................... 353

Figure 2-140 Install the pick roller ................................................................................................................................... 354

Figure 2-141 Install the feed roller .................................................................................................................................. 354

Figure 2-142 Open the separation-roller cover ............................................................................................................... 355

Figure 2-143 Check the torque limiter ............................................................................................................................. 355

Figure 2-144 Install the feed roller .................................................................................................................................. 356

Figure 2-145 Close the feeder door ................................................................................................................................. 356

Figure 2-146 Product base jam sensors .......................................................................................................................... 362

Figure 2-147 1x500-sheet paper-feeder jam sensors .................................................................................................... 363

Figure 2-148 1,500-sheet high-capacity input (HCI) feeder jam sensors ....................................................................... 364

Figure 2-149 Duplexer jam sensors ................................................................................................................................. 365

Figure 2-150 Open the Pre-boot menu ............................................................................................................................ 400

Figure 2-151 Open the Pre-boot menu ............................................................................................................................ 402

Figure 2-152 Open the Pre-boot menu ............................................................................................................................ 403

Figure 2-153 Open the Pre-boot menu ............................................................................................................................ 408

Figure A-1 Dimensions for the n models .......................................................................................................................... 412

ENWW xxv

Figure A-2 Dimensions for the dn models ........................................................................................................................ 413

Figure A-3 Dimensions for the x models .......................................................................................................................... 414

Figure A-4 Dimensions for the 1 x 500-sheet paper feeder ............................................................................................ 414

Figure A-5 Dimensions for the 1,500-sheet high-capacity input tray ............................................................................ 415

Figure A-6 Dimensions for the stacker ............................................................................................................................. 416

Figure A-7 Dimensions for the stapler/stacker ................................................................................................................ 416

Figure A-8 Dimensions for the 5-bin mailbox .................................................................................................................. 417

Figure A-9 Dimensions for the printer stand ................................................................................................................... 417

Figure A-10 Dimensions for Combination one ................................................................................................................. 418

Figure A-11 Dimensions for Combination two ................................................................................................................. 419

Figure A-12 Dimensions for Combination three .............................................................................................................. 420

Figure A-13 Certicate of Volatility 1 of 2) ...................................................................................................................... 424

Figure A-14 Certicate of Volatility (2 of 2) ..................................................................................................................... 425

xxvi ENWW

1 Theory of operation

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