HP m652, m653, mfp, m681, m682 Troubleshooting Manual

Service manual: Troubleshooting

HP Color LaserJet Enterprise M652, M653 HP Color LaserJet Managed E65050, E65060 HP Color LaserJet Managed E65150, E65160 HP Color LaserJet Enterprise MFP M681, M682 HP Color LaserJet Managed MFP E67550, E67560 HP Color LaserJet Managed MFP E67650, E67660

www.hp.com/videos/LaserJet www.hp.com/support/colorlj652 www.hp.com/support/colorlj653 www.hp.com/support/ljE65050 www.hp.com/support/ljE65060 www.hp.com/support/colorljE65150 www.hp.com/support/colorljE65160

www.hp.com/support/colorljM681MFP www.hp.com/support/colorljM682MFP www.hp.com/support/ljE67550MFP www.hp.com/support/ljE67560MFP www.hp.com/support/colorljE67650MFP www.hp.com/support/colorljE67660MFP

Service manual: Troubleshooting

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 3, 5/2019

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.

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

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

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

HP service and support

Learn about HP access to additional service and support information.

Additional service and support for channel partners

Channel partners, go to partner.hp.com, and then use the steps below to access the HP Web-based Interactive Search Engine (WISE).

Access WISE for Channel partners

1. Select Services & Support, and then select Services Delivery.

2. Select Technical Support, and then select Technical Documentation.

Find information about the following topics

● Service manuals

● Service advisories

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

● Install and congure

● Printer specications

● Solutions for printer issues and emerging issues

● Remove and replace part instructions and videos

● Warranty and regulatory information

Additional service and support for HP internal personnel

HP internal personnel, go to one of the following Web-based Interactive Search Engine (WISE) sites:

Americas (AMS)

– https://support.hp.com/wise/home/ams-enWISE - English

– https://support.hp.com/wise/home/ams-esWISE - Spanish

– https://support.hp.com/wise/home/ams-ptWISE - Portuguese

– https://support.hp.com/wise/home/ams-frWISE - French

Asia Pacic / Japan (APJ)

○ https://support.hp.com/wise/home/apj-enWISE - English

○ https://support.hp.com/wise/home/apj-jaWISE - Japanese

○ https://support.hp.com/wise/home/apj-koWISE - Korean

○ https://support.hp.com/wise/home/apj-zh-HansWISE - Chinese (simplied)

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○ https://support.hp.com/wise/home/apj-zh-HantWISE - Chinese (traditional)

○ https://support.hp.com/wise/home/apj-thWISE - Thai

Europe / Middle East / Africa (EMEA)

– https://support.hp.com/wise/home/emea-enWISE - English

vi HP service and support ENWW

Table of contents

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

HP service and support ........................................................................................................................................................... 2

Additional service and support for channel partners .................................................................................... 2

Additional service and support for HP internal personnel ............................................................................ 2

Basic operation ......................................................................................................................................................................... 4

Sequence of operation ........................................................................................................................................ 5

Formatter-control system ...................................................................................................................................................... 7

Sleep mode ........................................................................................................................................................... 7

Printer job language (PJL) ................................................................................................................................... 8

Printer management language (PML) .............................................................................................................. 8

Control panel ........................................................................................................................................................ 8

Easy-access USB port ......................................................................................................................................... 9

Wireless ................................................................................................................................................................. 9

CPU ......................................................................................................................................................................... 9

Input/output (I/O) ................................................................................................................................................. 9

Memory ................................................................................................................................................................. 9

embedded MultiMedia Card (eMMC) ............................................................................................. 9

Hard disk drive (HDD) ................................................................................................................... 10

Fax PCA ........................................................................................................................................... 10

Nonvolatile random access memory (NVRAM) ........................................................................ 10

Random access memory (RAM) ................................................................................................. 10

HP Memory Enhancement technology (MEt) ........................................................................... 10

Engine-control system .......................................................................................................................................................... 11

DC controller ....................................................................................................................................................... 12

Motors ............................................................................................................................................. 13

Fans ................................................................................................................................................. 14

Solenoids ........................................................................................................................................ 14

Clutches .......................................................................................................................................... 15

Switches ......................................................................................................................................... 15

Sensors ........................................................................................................................................... 16

Front door lock function .............................................................................................................. 16

Low-voltage power supply .............................................................................................................................. 17

ENWW vii

Low-voltage power supply voltages description ..................................................................... 18

Over-current/over-voltage protection ....................................................................................... 19

Sleep mode operation .................................................................................................................. 19

Low-voltage power supply failure detection ........................................................................... 19

Low-voltage power supply functions ........................................................................................ 20

High-voltage power supplies ........................................................................................................................... 20

High-voltage power supply circuits ........................................................................................... 21

Fuser bias ....................................................................................................................................... 22

Fuser control ...................................................................................................................................................... 23

Fuser circuits .................................................................................................................................. 23

Fuser control functions ................................................................................................................ 24

Fuser temperature control .......................................................................................................... 24

Fuser heater protection ............................................................................................................... 25

Fuser unit life detection ............................................................................................................... 26

Fuser identication ....................................................................................................................... 26

Engine laser scanner system ............................................................................................................................................... 27

Laser scanner failure detection ....................................................................................................................... 28

Safety .................................................................................................................................................................. 28

Image-formation process ................................................................................................................................ 29

Step 1: Pre-exposure ................................................................................................................... 34

Step 2: Primary charging ............................................................................................................. 34

Step 3: Laser-beam exposure .................................................................................................... 35

Step 4: Development .................................................................................................................... 35

Step 5: Primary transfer .............................................................................................................. 36

Step 6: Secondary transfer .......................................................................................................... 36

Step 7: Separation ........................................................................................................................ 37

Step 8: Fusing ................................................................................................................................ 37

Step 9: ITB cleaning ...................................................................................................................... 38

Step 10: Drum cleaning ............................................................................................................... 38

Toner cartridges ................................................................................................................................................. 39

Design ............................................................................................................................................. 39

Memory chip .................................................................................................................................. 41

Dynamic security ........................................................................................................................... 41

JetIntelligence ............................................................................................................................... 41

Authentication .......................................................................................................... 41

Anti-theft ................................................................................................................... 41

Toner seal ....................................................................................................................................... 42

Toner level and cartridge life detection ..................................................................................... 42

Developing unit engagement and disengagement control ................................................... 42

Intermediate transfer belt (ITB) unit ............................................................................................................... 44

Primary-transfer roller engagement and disengagement control ....................................... 45

viii ENWW

ITB unit detection .......................................................................................................................... 47

ITB cleaning mechanism .............................................................................................................. 48

Secondary transfer roller functions ........................................................................................... 48

Calibration ...................................................................................................................................... 49

Pickup, feed, and delivery system ....................................................................................................................................... 50

Photo sensors and switches ............................................................................................................................ 51

Motors, clutches, and solenoids ...................................................................................................................... 53

Paper trays ......................................................................................................................................................... 54

Tray 2 media type detection ....................................................................................................... 54

Feed speed control ....................................................................................................................... 55

Duplexing unit .................................................................................................................................................... 57

Duplexing reverse and duplex feed control ............................................................................. 57

Jam detection/prevention ................................................................................................................................ 57

Fuser wrapping jam detection .................................................................................................... 61

Loop control .............................................................................................................. 61

Pressure roller pressurization and depressurization control ........................... 61

Input accessories .................................................................................................................................................................... 63

550-sheet paper feeder ................................................................................................................................... 63

550-sheet paper feeder controller ............................................................................................ 63

550-sheet paper feeder motor control ..................................................................................... 64

550-sheet paper feeder electrical components ...................................................................... 64

550-sheet paper feeder paper pickup ...................................................................................... 65

550-sheet paper feeder multiple feed prevention ................................................................. 65

550-sheet paper feeder tray presence detection ................................................................... 65

550-sheet paper feeder tray lift operation .............................................................................. 66

550-sheet paper feeder jam detection ..................................................................................... 67

550-sheet paper-feeder .................................................................................................................................. 68

Motor control ................................................................................................................................. 72

Pickup-and-feed Operation ......................................................................................................... 72

Staple stacker multi bin mailbox ..................................................................................................................... 76

Motor Control ................................................................................................................................. 79

Fan Control ..................................................................................................................................... 80

Delivery Operation ........................................................................................................................ 80

Scanning and image capture system (M681/M682/E67550/E67560/E67650/E67660) ......................................... 83

Document feeder system (M681/M682/E67550/E67560/E67650/E67660) ............................................................ 84

Document feed system .................................................................................................................................... 84

Sensors in the document feeder .................................................................................................................... 84

Document feeder paper path .......................................................................................................................... 85

Document feeder simplex operation ............................................................................................................. 86

Document feeder e-duplex operation ........................................................................................................... 87

Deskew operation ............................................................................................................................................. 87

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Document feeder hinges .................................................................................................................................. 88

2 Solve problems ....................................................................................................................................................................................... 91

HP service and support ......................................................................................................................................................... 92

Additional service and support for channel partners .................................................................................. 92

Additional service and support for HP internal personnel .......................................................................... 92

Manually unlock the front door ............................................................................................................................................ 94

Solve problems checklist ...................................................................................................................................................... 97

Solve problems checklist .................................................................................................................................. 97

Print conguration report .............................................................................................................................. 101

Print settings menu map ............................................................................................................................... 102

Print current settings pages .......................................................................................................................... 102

Print event log ................................................................................................................................................. 103

Pre-boot menu options .................................................................................................................................. 105

Remote Admin ................................................................................................................................................. 115

Required software and network connection .......................................................................... 115

Telnet client ............................................................................................................ 116

Network connection .............................................................................................. 117

Connect a remote connection .................................................................................................. 117

Disconnect a remote connection ............................................................................................. 121

Troubleshooting process .................................................................................................................................................... 124

Determine the problem source .................................................................................................................... 124

Troubleshooting owchart ....................................................................................................... 125

Power subsystem ........................................................................................................................................... 126

Power-on checks ........................................................................................................................ 126

Power-on troubleshooting overview .................................................................. 126

Troubleshooting a blank display, black display, no display, or no power

situation ................................................................................................................... 126

Control panel checks ...................................................................................................................................... 129

Control panel diagnostics .......................................................................................................... 129

Touchscreen diagnostic mode ............................................................................. 129

Control panel system diagnostics ....................................................................... 132

Control panel diagnostic owcharts ........................................................................................ 147

Touchscreen black, white, or dim (no image) .................................................... 148

Touchscreen has an unresponsive zone ............................................................ 149

No control panel sound ......................................................................................... 150

Home button is unresponsive .............................................................................. 151

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

functional) ............................................................................................................... 152

Scanning subsystem (MFP) ........................................................................................................................... 152

Tools for troubleshooting ................................................................................................................................................... 153

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Individual component diagnostics ................................................................................................................ 153

Tools for troubleshooting: LED diagnostics ........................................................................... 153

Understand lights on the formatter ................................................................... 153

Tools for troubleshooting: Engine diagnostics ...................................................................... 156

Engine test button ................................................................................................. 156

Defeating interlocks .............................................................................................. 158

Disable cartridge check ......................................................................................... 160

Tools for troubleshooting: Paper path and sensor diagnostic tests .................................. 161

Paper path test ....................................................................................................... 161

Paper path sensors test ........................................................................................ 162

Manual sensor tests .............................................................................................. 164

Tray/bin manual sensor test ................................................................................ 166

Tools for troubleshooting: Print/stop test .............................................................................. 167

Tools for troubleshooting: Component tests ......................................................................... 169

Individual component diagnostics (special-mode test) ................................... 169

Scanner tests (MFP only) ........................................................................................................... 171

Scanner tests .......................................................................................................... 171

Diagrams .......................................................................................................................................................... 173

Diagrams: Block diagrams ........................................................................................................ 173

Sensors and switches ........................................................................................... 173

Cross section diagrams ......................................................................................... 177

Printed circuit assembly (PCA) connector locations ......................................... 183

Diagrams: External plug and port locations ........................................................................... 196

Diagrams: Locations of major assemblies ............................................................................. 198

Main assemblies (printer base) ............................................................................ 198

Motor and fans ....................................................................................................... 200

Rollers and toner collection unit ......................................................................... 202

Printed circuit assemblies (PCAs; printer base) ................................................ 203

Switches—E65150/E65160/E67650/E67660 models .................................. 204

Diagrams: General timing chart ............................................................................................... 205

Diagrams: General circuit diagrams ........................................................................................ 206

Internal test and information pages ............................................................................................................ 214

Print the conguration page ..................................................................................................... 214

Print a conguration page from a touchscreen control panel ........................ 214

Print a conguration page from an LCD control panel .................................... 214

HP embedded Jetdirect page ............................................................................... 216

Finding important information on the conguration pages ........................... 217

Control panel menus ...................................................................................................................................... 218

Reports menu ............................................................................................................................. 218

Settings menu ............................................................................................................................. 221

Copy menu (MFP only) ............................................................................................................... 256

ENWW xi

Scan menu (MFP only) ............................................................................................................... 261

Fax menu (fax models only) ..................................................................................................... 276

Print menu ................................................................................................................................... 279

Supplies menu ............................................................................................................................ 280

Trays menu .................................................................................................................................. 281

Support Tools menu ................................................................................................................... 281

Maintenance menu ................................................................................................ 281

Troubleshooting menu ......................................................................................... 285

Service menu .......................................................................................................... 289

Resolve print-quality problems ......................................................................................................................................... 290

Introduction ...................................................................................................................................................... 290

Troubleshoot print quality ............................................................................................................................. 290

Update the printer rmware ..................................................................................................... 290

Print from a dierent software program ................................................................................ 290

Check the paper-type setting for the print job ...................................................................... 290

Check the paper type setting on the printer ..................................................... 290

Check the paper type setting (Windows) ........................................................... 291

Check the paper type setting (macOS) ............................................................... 291

Check toner-cartridge status .................................................................................................... 291

Print a cleaning page ................................................................................................................. 292

Visually inspect the toner cartridge or cartridges ................................................................. 292

Check paper and the printing environment ............................................................................ 293

Step one: Use paper that meets HP specications .......................................... 293

Step two: Check the environment ....................................................................... 293

Step three: Set the individual tray alignment .................................................... 293

Try a dierent print driver ......................................................................................................... 294

Troubleshoot image defects ......................................................................................................................... 295

Clean the printer .................................................................................................................................................................. 304

Clean the paper path ...................................................................................................................................... 304

Print a cleaning page ...................................................................................................................................... 304

Enable and congure auto cleaning (touchscreen control panels only) ................................................ 305

Check the scanner glass for dirt and smudges .......................................................................................... 305

Clean the pickup rollers and separation pad in the document feeder (MFP only) ................................ 307

Solve paper handling problems ........................................................................................................................................ 309

Printer feeds incorrect page size .................................................................................................................. 309

Printer pulls from incorrect tray ................................................................................................................... 309

Printer will not duplex or duplexes incorrectly .......................................................................................... 309

Paper does not feed from Tray 2-X ............................................................................................................. 310

Output is curled or wrinkled .......................................................................................................................... 310

Printer does not pick up paper or misfeeds ................................................................................................ 311

The printer does not pick up paper ......................................................................................... 311

xii ENWW

The printer picks up multiple sheets of paper ....................................................................... 312

Paper does not feed automatically ......................................................................................... 312

Clear paper jams ............................................................................................................................................. 313

Paper path jam sensor locations ............................................................................................. 314

Auto-navigation for clearing paper jams ................................................................................ 317

Experiencing frequent or recurring paper jams? ................................................................... 317

Clear paper jams in the document feeder .............................................................................. 318

13.A1 tray 1 paper jam .............................................................................................................. 320

13.A2 tray 2 paper jam .............................................................................................................. 322

13.A3, 13.A4, 13.A5 tray 3, tray 4, tray 5 paper jam ............................................................ 326

13.A 2000-sheet tray paper jam ............................................................................................. 331

13.B9, 13.B2, 13.FF fuser paper jam ...................................................................................... 335

Clear jams in the output bin ...................................................................................................... 338

13.70.stapler/stacker paper jam ............................................................................................. 339

Clear staple jams in the 3-bin stapler/stacker ....................................................................... 341

Change jam recovery ................................................................................................................. 343

Solve performance problems ............................................................................................................................................ 344

Factors aecting print performance ............................................................................................................ 344

Print speeds ..................................................................................................................................................... 345

The printer does not print or it prints slowly .............................................................................................. 345

The printer prints slowly ........................................................................................................... 345

The printer does not print ......................................................................................................... 346

Solve wired network problems .......................................................................................................................................... 347

Introduction ...................................................................................................................................................... 347

Poor physical connection ............................................................................................................................... 347

The computer is using the incorrect IP address for the printer ............................................................... 347

The computer is unable to communicate with the printer ....................................................................... 348

The printer is using incorrect link and duplex settings for the network ................................................ 348

New software programs might be causing compatibility problems ...................................................... 348

The computer or workstation might be set up incorrectly ...................................................................... 348

The printer is disabled, or other network settings are incorrect ............................................................. 348

Solve wireless network problems ..................................................................................................................................... 349

Introduction ...................................................................................................................................................... 349

Wireless connectivity checklist ..................................................................................................................... 349

The printer does not print after the wireless conguration completes ................................................. 350

The printer does not print, and the computer has a third-party rewall installed .............................. 350

The wireless connection does not work after moving the wireless router or printer .......................... 350

Cannot connect more computers to the wireless printer ........................................................................ 350

The wireless printer loses communication when connected to a VPN .................................................. 351

The network does not appear in the wireless networks list .................................................................... 351

The wireless network is not functioning ..................................................................................................... 351

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Reduce interference on a wireless network ............................................................................................... 351

Service mode functions ...................................................................................................................................................... 352

Service menu ................................................................................................................................................... 352

Printer resets ................................................................................................................................................... 354

Restore factory-set defaults .................................................................................................... 354

Restore the service ID ................................................................................................................ 355

Printer cold reset ........................................................................................................................ 355

Format Disk and Partial Clean functions ..................................................................................................... 357

Active and repository rmware locations ............................................................................... 357

Partial Clean ................................................................................................................................ 357

Execute a Partial Clean ......................................................................................... 358

Format Disk ................................................................................................................................. 358

Execute a Format Disk .......................................................................................... 359

Firmware upgrades ............................................................................................................................................................. 361

Determine the installed revision of rmware ............................................................................................. 362

Perform a rmware upgrade ........................................................................................................................ 364

HP Embedded Web Server ........................................................................................................ 364

USB ash drive (control-panel menu) ..................................................................................... 365

USB ash drive (Pre-boot menu) ............................................................................................. 366

Solve fax problems or email .............................................................................................................................................. 368

Appendix A Printer specications ......................................................................................................................................................... 369

Printer dimensions .............................................................................................................................................................. 370

Printer dimensions (M652/M653/E65050/E65060/E65150/E65160) ................................................. 370

Printer dimensions (M681/M682/E67550/E67560/E67650/E67660) ................................................. 373

Printer space requirements ............................................................................................................................................... 376

Power consumption, electrical specications, and acoustic emissions ...................................................................... 376

Operating-environment range .......................................................................................................................................... 377

Operating-environment range (M652/M653/E65050/E65060/E65150/E65160) ............................. 377

Operating-environment range (M681/M682/E67550/E67560/E67650/E67660) ............................. 378

Certicates of Volatility ....................................................................................................................................................... 379

Appendix B Revision history .................................................................................................................................................................. 383

Revision history .................................................................................................................................................................... 384

Index ........................................................................................................................................................................................................... 385

xiv ENWW

List of tables

Table 1-1 Sequence of operation ........................................................................................................................................................... 5

Table 1-2 Motors ..................................................................................................................................................................................... 13

Table 1-3 Fans ......................................................................................................................................................................................... 14

Table 1-4 Solenoids ................................................................................................................................................................................ 14

Table 1-5 Clutches .................................................................................................................................................................................. 15

Table 1-6 Switches .................................................................................................................................................................................. 15

Table 1-7 Sensors ................................................................................................................................................................................... 16

Table 1-8 Converted DC voltages ......................................................................................................................................................... 18

Table 1-9 Low-voltage power supply functions ................................................................................................................................ 20

Table 1-10 High-voltage power supply circuits ................................................................................................................................. 21

Table 1-11 Fuser components .............................................................................................................................................................. 23

Table 1-12 Low-voltage power supply functions .............................................................................................................................. 24

Table 1-15 Toner cartridge functions .................................................................................................................................................. 39

Table 1-17 Primary-transfer roller engagement states ................................................................................................................... 45

Table 1-18 Secondary transfer roller functions ................................................................................................................................. 48

Table 1-19 Calibration functions .......................................................................................................................................................... 49

Table 1-20 Photo sensors and switches ............................................................................................................................................. 52

Table 1-21 Motors, clutches, and solenoids ....................................................................................................................................... 53

Table 1-22 Print mode and feed speed ............................................................................................................................................... 55

Table 1-23 Pickup, feed and delivery system functions ................................................................................................................... 56

Table 1-25 550-sheet paper feeder motor control .......................................................................................................................... 64

Table 1-26 550-sheet paper feeder electrical components ........................................................................................................... 64

Table 1-27 Pickup feed components (1x550-sheet paper feeder) ................................................................................................ 65

Table 1-29 Electrical component list (1x550-sheet paper-feeder/3x550-sheet paper-feeder) .............................................. 73

Table 1-30 Electrical component list (2,550-sheet paper-feeder) ................................................................................................. 74

Table 1-31 Paper-feeder functions ...................................................................................................................................................... 75

Table 1-32 Motor list .............................................................................................................................................................................. 79

Table 1-33 Electrical component list ................................................................................................................................................... 80

Table 1-34 Stapler/stacker functions .................................................................................................................................................. 82

Table 1-35 Document feeder sensors ................................................................................................................................................. 85

Table 1-36 Document feeder paper path ........................................................................................................................................... 85

Table 2-1 Pre-boot menu options (1 of 7) ....................................................................................................................................... 108

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Table 2-2 Pre-boot menu options (2 of 7) ....................................................................................................................................... 109

Table 2-3 Pre-boot menu options (3 of 7) ....................................................................................................................................... 110

Table 2-4 Pre-boot menu options (4 of 7) ....................................................................................................................................... 111

Table 2-5 Pre-boot menu options (5 of 7) ....................................................................................................................................... 111

Table 2-6 Pre-boot menu options (6 of 7) ....................................................................................................................................... 112

Table 2-7 Pre-boot menu options (7 of 7) ....................................................................................................................................... 113

Table 2-8 Troubleshooting owchart ................................................................................................................................................ 125

Table 2-9 Heartbeat LED, product initialization ............................................................................................................................... 154

Table 2-10 Heartbeat LED, product operational ............................................................................................................................. 155

Table 2-11 Paper-path sensors diagnostic tests ............................................................................................................................ 162

Table 2-12 Manual sensor diagnostic tests ..................................................................................................................................... 165

Table 2-13 Tray/bin manual sensors ................................................................................................................................................ 167

Table 2-14 Component test details ................................................................................................................................................... 170

Table 2-15 Product base, sensors and switches block diagram ................................................................................................... 173

Table 2-16 1x500-sheet paper feeder, sensors and switches block diagram ........................................................................... 174

Table 2-17 Paper deck, sensors and switches block diagram ...................................................................................................... 174

Table 2-18 HCI, sensors and switches block diagram .................................................................................................................... 175

Table 2-19 HP Stapling Mailbox, sensors and switches block diagram ....................................................................................... 176

Table 2-20 Product base, cross section diagram ............................................................................................................................ 177

Table 2-21 1x550-sheet paper feeder, cross section diagram .................................................................................................... 178

Table 2-22 Paper deck, 1x550, cross section diagram .................................................................................................................. 179

Table 2-23 Paper deck, 3x550, cross section diagram .................................................................................................................. 180

Table 2-24 HCI, cross section diagram .............................................................................................................................................. 181

Table 2-25 HP Stapling Mailbox, cross section diagram ................................................................................................................ 182

Table 2-26 DC controller connectors—M652/M653/M681/M682 ............................................................................................... 183

Table 2-27 DC controller connectors—E65150/E65160/E67650/E67660 .............................................................................. 185

Table 2-28 Formatter PCA connectors—M652/M653/E65050/E65060/E65150/E65160 .................................................... 187

Table 2-29 Formatter PCA connectors—M681/M682/E67550/E67560/E67650/E67660 .................................................... 188

Table 2-30 1x550-sheet paper feeder controller PCA connectors .............................................................................................. 190

Table 2-31 Paper deck controller PCA connectors, 1x550 ............................................................................................................ 191

Table 2-32 Paper deck controller PCA connectors, 3x550 and 2,550 ......................................................................................... 192

Table 2-33 HP Stapling Mailbox controller PCA connectors .......................................................................................................... 194

Table 2-34 Scanner controller PCA connectors ............................................................................................................................... 195

Table 2-35 Main assemblies (printer base) ...................................................................................................................................... 198

Table 2-36 Main assemblies (printer base) ...................................................................................................................................... 199

Table 2-37 Motors ................................................................................................................................................................................ 200

Table 2-38 Fans .................................................................................................................................................................................... 201

Table 2-39 Rollers ................................................................................................................................................................................ 202

Table 2-40 PCAs (printer base) ........................................................................................................................................................... 203

Table 2-41 Switches—E65150/E65160/E67650/E67660 models ............................................................................................ 204

Table 2-42 Important information on the conguration pages .................................................................................................... 217

xvi ENWW

Table 2-43 Reports menu ................................................................................................................................................................... 218

Table 2-44 Settings menu ................................................................................................................................................................... 221

Table 2-45 Copy menu (MFP only) ..................................................................................................................................................... 256

Table 2-46 Scan menu (MFP) .............................................................................................................................................................. 261

Table 2-47 Fax menu (fax models only) ........................................................................................................................................... 276

Table 2-48 Print Options menu .......................................................................................................................................................... 279

Table 2-49 Supplies menu .................................................................................................................................................................. 280

Table 2-50 Trays menu ........................................................................................................................................................................ 281

Table 2-51 Backup/Restore menu ..................................................................................................................................................... 281

Table 2-52 Calibrate/Cleaning menu ................................................................................................................................................. 282

Table 2-53 Troubleshooting menu .................................................................................................................................................... 285

Table 2-54 Image defects table quick reference ............................................................................................................................. 295

Table 2-55 Banding defects ................................................................................................................................................................ 297

Table 2-56 Black page ......................................................................................................................................................................... 297

Table 2-57 Blank page — No print .................................................................................................................................................... 298

Table 2-58 Color plane registrations defects (color models only) ............................................................................................... 298

Table 2-59 Fixing/fuser defects ......................................................................................................................................................... 299

Table 2-60 Gray background or dark print ....................................................................................................................................... 300

Table 2-61 Image placement defects ............................................................................................................................................... 300

Table 2-62 Light print .......................................................................................................................................................................... 301

Table 2-63 Output defects .................................................................................................................................................................. 302

Table 2-64 Streak defects ................................................................................................................................................................... 303

Table 2-65 Printer feeds incorrect page size ................................................................................................................................... 309

Table 2-66 Printer pulls from incorrect tray ..................................................................................................................................... 309

Table 2-67 Printer will not duplex (print 2-sided jobs) or duplexes incorrectly ......................................................................... 309

Table 2-68 Paper does not feed from Tray 2-X ............................................................................................................................... 310

Table 2-69 Output is curled or wrinkled ........................................................................................................................................... 310

Table 2-70 Paper does not feed automatically ............................................................................................................................... 312

Table 2-71 Printer base jam sensors ................................................................................................................................................ 314

Table 2-72 1x550-sheet and 3x550-sheet paper-deck jam sensors ......................................................................................... 314

Table 2-73 1x550-sheet and 3x550-sheet paper-deck jam sensors ......................................................................................... 315

Table 2-74 2,550-sheet paper deck jam sensors ........................................................................................................................... 316

Table 2-75 Document feeder, sensors block diagram ................................................................................................................... 316

Table 2-76 Solve performance problems ......................................................................................................................................... 344

Table A-1 Dimensions for the n and dn models .............................................................................................................................. 370

Table A-2 Dimensions for the x model .............................................................................................................................................. 370

Table A-3 Dimensions for the 1 x 550-sheet paper feeder ........................................................................................................... 370

Table A-4 Dimensions for the printer with one 1 x 550-sheet paper feeder ............................................................................. 370

Table A-5 Dimensions for the 1 x 550-sheet paper feeder with stand ....................................................................................... 371

Table A-6 Dimensions for the printer and the 1 x 550-sheet paper feeder with stand ........................................................... 371

Table A-7 Dimensions for the 3 x 550-sheet paper feeder with stand ....................................................................................... 371

ENWW xvii

Table A-8 Dimensions for the printer and the 3 x 550-sheet paper feeder with stand ........................................................... 371

Table A-9 Dimensions for the High-capacity input feeder (HCI) with stand ................................................................................ 372

Table A-10 Dimensions for the printer and the High-capacity input feeder (HCI) with stand .................................................. 372

Table A-11 Dimensions for the M681dh/Flow M681f/E67650/E67660 models ...................................................................... 373

Table A-12 Dimensions for the M681f models ................................................................................................................................ 373

Table A-13 Dimensions for the Flow M681z models ...................................................................................................................... 373

Table A-14 Dimensions for the Flow M682z models ...................................................................................................................... 373

Table A-15 Dimensions for the 1 x 550-sheet paper feeder ........................................................................................................ 373

Table A-16 Dimensions for the printer with one 1 x 550-sheet paper feeder ........................................................................... 374

Table A-17 Dimensions for the 1 x 550-sheet paper feeder with stand ..................................................................................... 374

Table A-18 Dimensions for the printer and the 1 x 550-sheet paper feeder with stand ......................................................... 374

Table A-19 Dimensions for the 3 x 550-sheet paper feeder with stand ..................................................................................... 375

Table A-20 Dimensions for the printer and the 3 x 550-sheet paper feeder with stand ......................................................... 375

Table A-21 Dimensions for the High-capacity input tray with stand ........................................................................................... 375

Table A-22 Dimensions for the printer and the high-capacity input tray with stand ................................................................ 375

Table A-23 Operating-environment specications ......................................................................................................................... 377

Table A-24 Operating-environment specications ......................................................................................................................... 378

Table B-1 Revision history ................................................................................................................................................................... 384

xviii ENWW

List of gures

Figure 1-6 High-voltage power supply circuits .................................................................................................................................. 21

Figure 1-7 Fuser temperature-control circuit .................................................................................................................................... 25

Figure 1-13 Pre-exposure ..................................................................................................................................................................... 34

Figure 1-14 Primary charging ............................................................................................................................................................... 34

Figure 1-15 Laser-beam exposure ...................................................................................................................................................... 35

Figure 1-16 Development ..................................................................................................................................................................... 35

Figure 1-17 Primary transfer ................................................................................................................................................................ 36

Figure 1-18 Secondary transfer ........................................................................................................................................................... 36

Figure 1-19 Separation .......................................................................................................................................................................... 37

Figure 1-20 Fusing .................................................................................................................................................................................. 37

Figure 1-21 ITB Cleaning ....................................................................................................................................................................... 38

Figure 1-22 Drum cleaning .................................................................................................................................................................... 38

Figure 1-23 Toner cartridge system .................................................................................................................................................... 39

Figure 1-24 Developer roller engagement and alienation control ................................................................................................. 43

Figure 1-26 Three states of primary-transfer roller engagement and disengagement ............................................................. 46

Figure 1-27 ITB cleaning process ......................................................................................................................................................... 48

Figure 1-29 Pickup, feed, and delivery system photo sensors and switches ............................................................................... 52

Figure 1-30 Pickup, feed, and delivery system motors, clutches, and solenoids ........................................................................ 53

Figure 1-31 Media sensors .................................................................................................................................................................... 55

Figure 1-35 550-sheet paper feeder driver PCA ............................................................................................................................... 64

Figure 1-36 Paper pickup and feed operation (550-sheet paper feeder) ..................................................................................... 65

Figure 1-41 1x550-sheet paper-feeder/3x550-sheet paper-feeder electrical components .................................................... 73

Figure 1-42 Outline of electrical component (2,550-sheet paper-feeder) ................................................................................... 74

Figure 1-45 Motors and solenoids ....................................................................................................................................................... 80

Figure 1-46 Stapler/stacker sensors and switches ........................................................................................................................... 81

Figure 1-47 Document feeder sensors ............................................................................................................................................... 85

Figure 1-48 Document feeder paper path .......................................................................................................................................... 85

Figure 1-49 Deskew operation ............................................................................................................................................................. 88

Figure 1-50 Document feeder open (book mode) ............................................................................................................................ 89

Figure 1-51 Document feeder open (60º to 80º) .............................................................................................................................. 89

Figure 2-1 Open the Pre-boot menu ................................................................................................................................................. 105

Figure 2-2 Pre-boot menu .................................................................................................................................................................. 106

ENWW xix

Figure 2-3 Open the Pre-boot menu ................................................................................................................................................. 107

Figure 2-4 Open the Control Panel .................................................................................................................................................... 116

Figure 2-5 Turn Windows features on or o .................................................................................................................................... 116

Figure 2-6 Enable the telnet client feature ...................................................................................................................................... 117

Figure 2-7 Select the +3:Administrator item ................................................................................................................................... 118

Figure 2-8 Select the +A:Remote Admin item ................................................................................................................................. 118

Figure 2-9 Select the 1:Start Telnet item ......................................................................................................................................... 118

Figure 2-10 Telnet connecting message .......................................................................................................................................... 118

Figure 2-11 Telnet error message ..................................................................................................................................................... 119

Figure 2-12 Telnet server function initialized .................................................................................................................................. 119

Figure 2-13 Open a command window ............................................................................................................................................. 120

Figure 2-14 Start a telnet session ..................................................................................................................................................... 120

Figure 2-15 Establish a telnet connection ....................................................................................................................................... 120

Figure 2-16 Enter the PIN ................................................................................................................................................................... 121

Figure 2-17 Remote Admin window .................................................................................................................................................. 121

Figure 2-18 Access the administrator menu .................................................................................................................................... 122

Figure 2-19 Access the remote admin menu .................................................................................................................................. 122

Figure 2-20 Terminate the telnet connection ................................................................................................................................. 123

Figure 2-21 Diagnostic-tests access button .................................................................................................................................... 129

Figure 2-22 Diagnostic-tests access button .................................................................................................................................... 130

Figure 2-23 Press the diagnostics-access button .......................................................................................................................... 130

Figure 2-24 Exit the diagnostic mode ............................................................................................................................................... 131

Figure 2-25 Open the Pre-boot menu .............................................................................................................................................. 132

Figure 2-26 Pre-boot menu ................................................................................................................................................................ 133

Figure 2-27 Access the administration menu .................................................................................................................................. 134

Figure 2-28 Access the diagnostics menu ........................................................................................................................................ 134

Figure 2-29 Open the screen test ...................................................................................................................................................... 135

Figure 2-30 Blue vertical gradient screen ........................................................................................................................................ 135

Figure 2-31 Open the touch test ........................................................................................................................................................ 139

Figure 2-32 Touch the white grid ....................................................................................................................................................... 139

Figure 2-33 Verify the mark ............................................................................................................................................................... 140

Figure 2-34 Open the softkey test .................................................................................................................................................... 141

Figure 2-35 Touch the Home button ................................................................................................................................................. 141

Figure 2-36 Successful test ................................................................................................................................................................ 142

Figure 2-37 Open the backlight test .................................................................................................................................................. 143

Figure 2-38 Open the sound test ....................................................................................................................................................... 144

Figure 2-39 Open the keyboard test ................................................................................................................................................. 145

Figure 2-40 Open the sound test ....................................................................................................................................................... 146

Figure 2-41 Touchscreen blank, white, or dim (no image) ............................................................................................................ 148

Figure 2-42 Touchscreen has an unresponsive zone ..................................................................................................................... 149

Figure 2-43 No control panel sound .................................................................................................................................................. 150

xx ENWW

Figure 2-44 Home button is unresponsive ...................................................................................................................................... 151

Figure 2-45 Hardware integration pocket (HIP) is not functioning (control panel functional) ................................................ 152

Figure 2-46 Engine test button .......................................................................................................................................................... 157

Figure 2-47 Defeating interlocks (front door) .................................................................................................................................. 158

Figure 2-48 Defeating interlocks (right door) .................................................................................................................................. 159

Figure 2-49 Printer base, sensors and switches block diagram ................................................................................................... 173

Figure 2-50 1x550-sheet paper feeder, sensors and switches block diagram ......................................................................... 174

Figure 2-51 Paper deck, sensors and switches block diagram ..................................................................................................... 174

Figure 2-52 HCI, sensors and switches block diagram ................................................................................................................... 175

Figure 2-53 HP Stapling Mailbox, sensors and switches block diagram ..................................................................................... 176

Figure 2-54 Printer base, cross section diagram ............................................................................................................................ 177

Figure 2-55 1x550-sheet paper feeder, cross section diagram .................................................................................................. 178

Figure 2-56 Paper deck, 1x550, cross section diagram ................................................................................................................. 179

Figure 2-57 Paper deck, 3x550, cross section diagram ................................................................................................................. 180

Figure 2-58 HCI, cross section diagram ............................................................................................................................................ 181

Figure 2-59 HP Stapling Mailbox, cross section diagram ............................................................................................................... 182

Figure 2-60 DC controller PCA connectors—M652/M653/M681/M682 ..................................................................................... 183

Figure 2-61 DC controller PCA connectors—E65150/E65160/E67650/E67660 ..................................................................... 185

Figure 2-62 Formatter PCA connectors—M652/M653/E65050/E65060/E65150/E65160 .................................................. 187

Figure 2-63 Formatter PCA connectors—M681/M682/E67550/E67560/E67650/E67660 .................................................. 188

Figure 2-64 1x550-sheet paper feeder controller PCA connectors ............................................................................................ 190

Figure 2-65 Paper deck controller PCA connectors, 1x550 .......................................................................................................... 191

Figure 2-66 Paper deck controller PCA connectors, 3x550 and 2,550 ....................................................................................... 192

Figure 2-67 HP Stapling Mailbox controller PCA connectors ......................................................................................................... 194

Figure 2-68 Scanner controller PCA connectors ............................................................................................................................. 195

Figure 2-69 External plug and port locations (M652/M653/E65050/E65060/E65150/E65160) ......................................... 196

Figure 2-70 External plug and port locations (M681/M682/E67550/E67560/E67650/E67660) ......................................... 197

Figure 2-71 Main assemblies .............................................................................................................................................................. 198

Figure 2-72 Main assemblies .............................................................................................................................................................. 199

Figure 2-73 Motors ............................................................................................................................................................................... 200

Figure 2-74 Fans ................................................................................................................................................................................... 201

Figure 2-75 Rollers ............................................................................................................................................................................... 202

Figure 2-76 PCAs (printer base) ......................................................................................................................................................... 203

Figure 2-77 Switches—E65150/E65160/E67650/E67660 models .......................................................................................... 204

Figure 2-78 General timing chart ....................................................................................................................................................... 205

Figure 2-79 General circuit diagram for the M652/M653/M681/M682 printer base (1 of 3) .................................................. 206

Figure 2-80 General circuit diagram for the M652/M653/M681/M682 printer base (2 of 3) .................................................. 206

Figure 2-81 General circuit diagram for the M652/M653/M681/M682 printer base (3 of 3) .................................................. 207

Figure 2-82 General circuit diagram for the E65150/E65160/E67650/E67660 printer base (1 of 4) .................................. 208

Figure 2-83 General circuit diagram for the E65150/E65160/E67650/E67660 printer base (2 of 4) .................................. 209

Figure 2-84 General circuit diagram for the E65150/E65160/E67650/E67660 printer base (3 of 4) .................................. 210

ENWW xxi

Figure 2-85 General circuit diagram for the E65150/E65160/E67650/E67660 printer base (4 of 4) .................................. 211

Figure 2-86 General circuit diagram for the 550-sheet feeder .................................................................................................... 212

Figure 2-87 General circuit diagram for the 1x550-sheet and 3x550-sheet paper decks ...................................................... 212

Figure 2-88 General circuit diagram for the 2,550-sheet paper deck ......................................................................................... 213

Figure 2-89 General circuit diagram for the stapling mailbox ...................................................................................................... 213

Figure 2-90 Conguration page ......................................................................................................................................................... 215

Figure 2-91 HP embedded Jetdirect page ....................................................................................................................................... 216

Figure 2-92 Printer jam sensors ........................................................................................................................................................ 314

Figure 2-93 1x550-sheet paper-feeder jam sensors .................................................................................................................... 314

Figure 2-94 1x550-sheet and 3x550-sheet paper-deck jam sensors ........................................................................................ 315

Figure 2-95 2,550-sheet paper deck jam sensors ......................................................................................................................... 316

Figure 2-96 Document feeder jam sensors ..................................................................................................................................... 316

Figure 2-97 Open the Pre-boot menu .............................................................................................................................................. 356

Figure 2-98 Open the Pre-boot menu .............................................................................................................................................. 358

Figure 2-99 Open the Pre-boot menu .............................................................................................................................................. 359

Figure 2-100 Conguration report .................................................................................................................................................... 363

Figure 2-101 Open the Pre-boot menu ............................................................................................................................................ 366

Figure A-1 Certicate of Volatility (1 of 2; M652/M653/E65050/E65060/E65150/E65160) ................................................. 379

Figure A-2 Certicate of Volatility (2 of 2; M652/M653/E65050/E65060/E65150/E65160) ................................................. 380

Figure A-3 Certicate of Volatility (1 of 2; M681/M682/E67550/E67560/E67650/E67660) ................................................. 381

Figure A-4 Certicate of Volatility (2 of 2; M681/M682/E67550/E67560/E67650/E67660) ................................................. 382

xxii ENWW

1 Theory of operation

●

HP service and support

●

Basic operation

●

Formatter-control system

●

Engine-control system

●

Engine laser scanner system

●

Pickup, feed, and delivery system

●

Input accessories

●

Scanning and image capture system (M681/M682/E67550/E67560/E67650/E67660)

●

Document feeder system (M681/M682/E67550/E67560/E67650/E67660)

ENWW 1

HP service and support

Learn about HP access to additional service and support information.

Additional service and support for channel partners

Channel partners, go to partner.hp.com, and then use the steps below to access the HP Web-based Interactive Search Engine (WISE).

Access WISE for Channel partners

1. Select Services & Support, and then select Services Delivery.

2. Select Technical Support, and then select Technical Documentation.

Find information about the following topics

● Service manuals

● Service advisories

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

● Install and congure

● Printer specications

● Solutions for printer issues and emerging issues

● Remove and replace part instructions and videos

● Warranty and regulatory information

Additional service and support for HP internal personnel

HP internal personnel, go to one of the following Web-based Interactive Search Engine (WISE) sites:

Americas (AMS)

– https://support.hp.com/wise/home/ams-enWISE - English

– https://support.hp.com/wise/home/ams-esWISE - Spanish

– https://support.hp.com/wise/home/ams-ptWISE - Portuguese

– https://support.hp.com/wise/home/ams-frWISE - French

Asia Pacic / Japan (APJ)

– https://support.hp.com/wise/home/apj-enWISE - English

– https://support.hp.com/wise/home/apj-jaWISE - Japanese

– https://support.hp.com/wise/home/apj-koWISE - Korean

– https://support.hp.com/wise/home/apj-zh-HansWISE - Chinese (simplied)

2 Chapter 1 Theory of operation ENWW

– https://support.hp.com/wise/home/apj-zh-HantWISE - Chinese (traditional)

– https://support.hp.com/wise/home/apj-thWISE - Thai

Europe / Middle East / Africa (EMEA)

– https://support.hp.com/wise/home/emea-enWISE - English

ENWW HP service and support 3

Basic operation

Engine-control system

Laser scanner system

Image-formation system

Pickup, feed and delivery system

Accessory

The printer routes all high-level processes through the formatter, which stores font information, processes the print image, and communicates with the host computer.

The basic printer operation comprises the following systems:

● The engine-control system, which includes the power supply and the DC controller printed circuit assembly

(PCA)

● The laser scanner system, which forms the latent image on the photosensitive drum

● The image-formation system, which transfers a toner image onto the paper

● The pickup, feed, and delivery system, which uses a system of rollers and belts to transport the paper

through the printer

● Accessory (optional paper feeder)

Figure 1-1 Relationship among the main printer systems

4 Chapter 1 Theory of operation ENWW

Sequence of operation

The DC controller PCA controls the operating sequence, as described in the following table.

Table 1-1 Sequence of operation

Period Duration Description

Waiting From the time the power is turned on, the door is

closed, or when the printer exits Sleep mode until the printer is ready for printing.

Standby From the end of the waiting sequence, the last rotation

until the formatter receives a print command, or until the printer is turned o.

● Detects the fuser

● Heats the fuser sleeve in the fuser

● Pressurizes the pressure roller in the fuser

● Detects the toner cartridges

● Alienates all of the developing rollers from the

photosensitive drums in the toner cartridges

● Alienates all of the transfer rollers from the

photosensitive drums in the toner cartridges

● Rotates and stops each motor

● Rotates and stops each fan

● Detects the ITB

● Cleans the ITB and secondary transfer roller

● Is in the Ready state

● Enters Sleep mode if the formatter sends the

sleep command

● Rotates and stops each fan

● Calibrates if the formatter sends the calibration

command

Initial rotation From the time the formatter receives a print command

until the paper enters the paper path.

● Rotates each motor

● Rotates each fan

● Activates the high-voltage power supply

● Prepares the laser scanner unit

● Warms the fuser to the correct temperature

ENWW Basic operation 5

Table 1-1 Sequence of operation (continued)

Period Duration Description

Printing From the time the rst sheet of paper enters the paper

path until the last sheet has passed through the fuser.

Last rotation From the time the last sheet of paper exits the fuser

until the motors stop rotating.

● Forms the image on the photosensitive drums

● Transfers the toner to the paper

● Fuses the toner image onto the paper

● Moves the last printed sheet into the output bin

● Stops each motor

● Stops each fan

● Stops the high-voltage power supply

● Stops the laser scanner unit

● Turns the fuser heater o

● If another print command is received, the printer

enters the initial rotation period when the last rotation is complete.

6 Chapter 1 Theory of operation ENWW

Formatter-control system

The formatter performs the following functions:

● Controls sleep mode

● Receives and processes print data from the various printer interfaces

● Monitors control panel functions and relays printer status information through the control panel and the

network or bi-directional interface

● Develops and coordinates data placement and timing with the DC controller PCA

● Stores font information

● Communicates with the host computer through the network or the bidirectional interface

The formatter receives a print job from the network or bidirectional interface and separates it into image information and instructions that control the printing process. The DC controller PCA synchronizes the image formation system with the paper input and output systems, and then signals the formatter to send the print image data.

Sleep mode

NOTE: To modify sleep settings: At the control panel, select the Settingsmenu, select the General menu, select

the Energy Settings menu, and then select Sleep Settings.

This feature conserves power after the printer has been idle for an adjustable period of time. When the printer is in Sleep mode, the printer retains all settings, downloaded fonts, and macros. The default setting is for Sleep mode to be enabled, and the printer enters Sleep mode after a 30-second idle time.

The printer rmware uses a combination of timers and Sleep settings to control when the printer enters a dierent state as well as what states the printer will enter. The available states are listed below, in descending order, from using the most power to using the least power:

● Active: The printer control panel is fully illuminated. The power button light is illuminated.

● Shallow sleep: The printer control panel is dim and the content is grayed out, but is still readable. The

power button light is illuminated.

● Sleep: The printer control panel is o (blacked out). The power button light blinks once every three

seconds.

● Deep sleep: The printer control panel is o (blacked out). The power button light blinks once every three

seconds. The control panel and power button appearance is the same in this state as the sleep state. However, the printer is drawing less than 1 watt of power in the deep sleep state (as opposed to 6 watts of power in the sleep state).

● O: This state is entered by pressing the power button or removing power from the printer. The power

button light is not illuminated.

NOTE: In some countries/regions, Sleep mode cannot be turned o.

The printer exits Sleep mode and enters the warm-up cycle when any of the following events occur:

● The printer receives a print job, valid data, or a PML or PJL command.

● A control-panel button is pressed or the touchscreen is touched.

ENWW Formatter-control system 7

● A cover or door is opened.

● The engine self-test switch is pressed.

● A paper tray, other than Tray 1, is opened.

NOTE: If the printer is in the deep sleep state, opening a paper tray will not cause the printer to exit Sleep

mode.

NOTE: Printer error messages override the Sleep message. Some messages, such as 49 errors, do not allow

the printer to enter Sleep mode. Other messages allow the printer to enter Sleep mode at the appropriate time, but the error message continues to appear.

Printer job language (PJL)

PJL is an integral part of printer conguration, in addition to the standard printer command language (PCL) and PostScript (PS). With standard cabling, the printer can use PJL to perform a variety of functions, such as these:

● Two-way communication with the host computer through a network connection or a USB device port: The

printer can inform the host about the control-panel settings, and the control-panel settings can be changed from the host.

● Dynamic I/O switching: The printer uses this switching to be congured with a host on each I/O. The printer

can receive data from more than one I/O simultaneously, until the I/O buer is full. This can occur even when the printer is oine.

● Context-sensitive switching: The printer can automatically recognize the personality (PS or PCL) of each job

and congure itself to serve that personality.

● Isolation of print environment settings from one print job to the next: For example, if a print job is sent to

the printer in landscape mode, the subsequent print jobs print in landscape only if they are formatted for landscape printing.

Printer management language (PML)

PML allows remote conguration of the printer and status read-back from the printer through the I/O ports.

Control panel

The M652n/M652dn control panel is a 6.85 cm (2.7 in) four-line color display with numeric keypad and additional buttons for navigating control panel menus. The M653dn/M653x/M653dh/E65150/E65160 control panel is a

10.9 cm (4.3 in) full-color SVGA with infrared touchscreen and adjustable viewing angle. The M681/M682/ E67550/E67560/E67650/E67660 control panel is a 20.3 cm (8 in) full-color SVGA with infrared touchscreen and adjustable viewing angle.

The M681/M682/E67550/E67560/E67650/E67660 control panel has a diagnostic mode to allow testing of the touchscreen, Home button, and speaker. The control panels do not require calibration.

The M653dn, M653x, and M653dh control panel has a diagnostic button on the back with some diagnostic capabilities.

See the Control-panel checks section of this manual for more information on accessing control panel diagnostics.

8 Chapter 1 Theory of operation ENWW

Easy-access USB port

This printer features easy-access USB printing, for quickly printing les without sending them from a computer. The printer accepts standard USB ash drives in the USB port near the control panel. It supports the following types of les:

● .pdf: A portable document format le used to present and exchange documents reliably, independent of

software, hardware, or operating system.

● .prn: A generic le created by choosing “Print to File” within the Print dialog box.

● .pcl: A le created in the Printer Command Language (PCL) which describes the layout of text and graphics

for the document.

● .ps: A le created in the Adobe PostScript language. These les can contain images, text or a combination

thereof.

● .cht: A vector graphics format le supported by a variety of charting and graphics software.

The USB port is disabled by default. Follow the instructions in the printer user guide to enable the USB port and print USB documents.

Wireless

The M653x and Flow M682z models contain a wireless card to enable wireless direct printing over a 802.11b/g/n wireless connection.

NOTE: This card does not enable the printer to connect to the network.

CPU

The formatter incorporates a 1.2 GHz processor.

Input/output (I/O)

The printer has three I/O interfaces:

● Hi-Speed USB 2.0

● 10/100/1000 Ethernet LAN connection with IPv4 and IPv6

● Easy-access USB printing (no computer required)

Memory

The formatter incorporates dierent types of memory and storage to store the printer rmware as well as printjob data and user settings.

embedded MultiMedia Card (eMMC)

The embedded MultiMedia Card (eMMC) on the formatter stores the rmware for the M652/M653/E65050/ E65060/E65150/E65160 models. A remote rmware upgrade process is used to overwrite and upgrade the rmware. If a hard disk drive (HDD) is installed on the M652/M653/E65050/E65060/E65150/E65160 models, the rmware will automatically transfer to the HDD. Print jobs may also be stored on the eMMC for printing privately or at a later time.

ENWW Formatter-control system 9

Hard disk drive (HDD)

The hard disk drive (HDD) on the formatter stores the rmware for the M681/M682/E67550/E67560/E67650/ E67660 models. A remote rmware upgrade process is used to overwrite and upgrade the rmware. Print jobs may also be stored on the HDD for printing privately or at a later time.

Fax PCA

The fax PCA allows the transmission and receipt of faxes. Fax jobs are stored temporarily on the PCA.

Nonvolatile random access memory (NVRAM)

The printer uses NVRAM to store printer and user conguration settings. The contents of NVRAM are retained when the printer is turned o or disconnected.

Random access memory (RAM)

The RAM on the formatter serves as a temporary storage area for printing and system operation.

HP Memory Enhancement technology (MEt)

MEt eectively doubles the amount of standard memory through a variety of font- and data-compression methods.

NOTE: MEt is available only in when printing in printer command language (PCL) mode. It is not functional when

printing in PostScript (PS) mode.

10 Chapter 1 Theory of operation ENWW

Engine-control system

Output accessory

Formatter

Laser scanner system

Image-formation system

Pickup, feed and delivery

system

DC controller

High-voltage power supply

Fuser control

Low-voltage power supply

Input accessory

Engine-control system

The engine-control system receives commands from the formatter and interacts with the other main systems to coordinate all printer functions. The engine-control system consists of the following components:

● DC controller

● Low-voltage power supply

● High-voltage power supplies

●

Fuser power supply

Figure 1-2 Engine-control system

ENWW Engine-control system 11

DC controller

Formatter

Control panel

Input accessory

Laser scanner ass’y

Output accessory

T2 roller

LED

Sensor

Fan

Motor

Clutch

Solenoid

Switch

Photointerrupte

DC controller

Motor

Fan

Photointerrupter

LED

Fan

AC input

Low-voltage

power supply

Fuser

High-voltage

power supply

Transfer

High-voltage

power supply

Developer

ITB ass’y

Cartridge

(Y/M/C/K)

Switch

The DC controller controls the operation of the printer and its components. The DC controller starts the printer operation when the printer power is turned on and the power supply sends DC voltage to the DC controller. After the printer enters the standby period, the DC controller sends out various signals to operate motors, solenoids, and other printer components based on the print command and image data that the host computer sends.

Figure 1-3 DC controller block diagram

12 Chapter 1 Theory of operation ENWW

Motors

The printer has eight motors. The motors drive the components in the paper-feed and image-formation systems.

The DC controller monitors the fuser motor, the scanner motor, and drum motors 1, 2, and 3 to determine if a motor has failed. It noties the formatter when it encounters the following conditions:

● Startup failure: the motor does not reach a specied speed within a specied time from when the motor

starts.

● Rotational failure: the rotational speed of the motor is not in the specied range for a specied time after

the motor reaches a specied speed.

Table 1-2 Motors

Abbreviation Name Purpose Failure detection Replacement part number

M1 Drum motor 1 Drives the yellow photosensitive

drum and yellow developing roller

M2 Drum motor 2 Drives the magenta photosensitive

drum, magenta developing roller, cyan photosensitive drum, and cyan developing roller

M3 Drum motor 3 Drives the black photosensitive drum,

black developing roller, and ITB

M4 Fuser motor Drives the pressure roller and

delivery roller; the pressurization and release of the pressure roller; and the engagement and disengagement of the primary and secondary transfer rollers

M5 Pickup motor Drives the registration roller, Tray 1

pickup roller, Tray 2 pickup roller, and Tray 2 feed roller

M6 Developer disengagement

motor

M7 Scanner motor Drives the scanner mirror Yes Laser scanner assembly

M8 Duplex reverse motor Drives the duplex reverse roller No Right door

Drives the engagement and disengagement of the developing rollers

Yes Drum motor

(RM2-1956-000CN)

Yes Drum motor

(RM2-1956-000CN)

Yes Drum motor

(RM2-1956-000CN)

Yes Fuser drive assembly

(RM2-1934-000CN)

No Paper pickup drive

assembly (RM2-6556-000CN)

Yes Stepping motor

(RK2-7757-000CN)

(RM2-1237-000CN)

(RM2-6622-000CN)

ENWW Engine-control system 13

Fans

The printer has six fans for preventing the temperature from rising in the printer and for cooling the printed pages.

The DC controller determines if there is a fan failure and noties the formatter if the fan locks for a specied time from when the fan starts.

Table 1-3 Fans

Abbreviation Name Cooling area Type Speed Replacement part

number

Solenoids

FM1 Power supply fan Around the low-voltage

power supply unit

FM2 Cartridge fan Around the toner cartridges Intake Full Fan

FM3 Left upper front fan Around the fuser

Around the delivery assembly

FM4 Left upper rear fan Around the fuser

Around the delivery assembly

FM5 Front fan Fuser Intake Full/half Fan

FM6 Rear fan Around the low-voltage

power supply assembly

Around the formatter

Table

1-4 Solenoids

Abbreviation Component name Replacement part number

Intake Full/half Fan

(RK2-7953-000CN)

(RK2-6124-000CN)

(RK2-7951-000CN)

(RK2-7949-000CN)

(RK2-6124-000CN)

SL1 Primary transfer roller disengagement solenoid Right door assembly (RM2-6622-000CN)

SL2 Tray 1 pickup solenoid Right door assembly (RM2-6622-000CN)

SL3 Duplex reverse solenoid Right door assembly (RM2-6622-000CN)

SL4 Front door left lock solenoid (E65150/E65160/E67650/

E67660 models)

SL5 Front door right lock solenoid (E65150/E65160/E67650/

E67660 models)

Part not available

14 Chapter 1 Theory of operation ENWW

Clutches

Switches

Table 1-5 Clutches

Abbreviation Component name

CL1 Tray 2 pickup clutch

CL2 Duplex re-pickup clutch

Table 1-6 Switches

Abbreviation Component name Replacement part number

SW1 24V interlock switch Interlock switch cable assembly (RM2-8449-000CN; part not

available)

SW2 ITB toner collection near full switch Lever full ag (RC4-6528-000CN; part not available)

SW3 5V right door switch Right door assembly (RM2-6622-000CN)

SW4 Power supply switch Power supply switch assembly (RM2-1947-000CN)

SW5 Tray 2 media size switch Size detect switch assembly (RM2-1946-000CN; part not available)

SW6 24V front door microswitch Microswitch (RK2-0535-000CN)

SW9 5V interlock switch (E65150/E65160/E67650/

E67660 models)

SW101 Test print switch Part not available

Part not available

ENWW Engine-control system 15

Sensors

Table 1-7 Sensors

Abbreviation Component name Replacement part number

SR11 Registration sensor Registration assembly (RM2-1957-000CN)

SR12 Registration media width sensor 1 Registration assembly (RM2-1957-000CN)

SR13 Registration media width sensor 2 Registration assembly (RM2-1957-000CN)

SR14 Tray 2 media out sensor Paper pick-up roller assembly (RM2-1275-000CN)

SR51 Drum home position sensor Y Main drive assembly (RM2-1927-000CN)

SR52 Drum home position sensor MC Main drive assembly (RM2-1927-000CN)

SR53 Drum home position sensor K Main drive assembly (RM2-1927-000CN)

SR54 Developer alienation sensor Main drive assembly (RM2-1927-000CN)

SR62 FD1 media full sensor Paper delivery assembly (RM2-6621-000CN)

SR66 Duplex apper position sensor Paper delivery assembly (RM2-6621-000CN)

SR94 Duplex feed sensor Right door assembly (RM2-6622-000CN)

SR95 Tray 1 media out sensor Right door assembly (RM2-6622-000CN)

SR1901 ITB alienation sensor ITB maintenance kit (P1B93-67901)

SR8611 Fuser output sensor 1 Fuser kit (110V) (RM2-1928-000CN)

SR8612 Fuser pressure release sensor Fuser kit (110V) (RM2-1928-000CN)

SR8613 Fuser output sensor 2 Fuser kit (110V) (RM2-1928-000CN)

SR8615 Fuser loop sensor Fuser kit (110V) (RM2-1928-000CN)

Front door lock function

The E65150/E65160/E67650/E67660 models have a front-door locking mechanism. The lock mechanisms reside on the right and left ends of the front door, and the lock function works with two solenoids (SL4/SL5). The DC controller makes the solenoids function when it receives a formatter command to lock or unlock the front door. The solenoids maintain the front door lock/unlock status even after they function.

Fuser kit (220V) (RM2-1929-000CN)

16 Chapter 1 Theory of operation ENWW

Low-voltage power supply

+5VD

AC input

Low-voltage power supply

Rectifying

circuit

Protection

circuit

+24V

generation

circuit

Fuse

FU100

+3.3V

generation

circuit

Fuser

24V interlock

switch

SW1

+24VA

Power supply

switch

SW4

Zero crossing

detection circuit

5VB_OFF

DC controller

+24VB

+3.3VB2

+3.3VB

FET

+5VA

+5VB

+3.3VA

POWER_SW

+5VC

Formatter

Fuse

FU101

Rectifying

circuit

Protection

circuit

+5V

generation

circuit

24V_RMT

/ZEROX

+3.3VC

+5VA

5V_PWM

FET

5V interlock switch

SW3

PFC_RMT

The low-voltage power-supply (LVPS) circuit converts the AC power from the wall receptacle into the DC voltage that the printer components use.

IMPORTANT: Make sure to plug the printer into the correct power source (110/220V).

Figure 1-4 Low-voltage power-supply circuit—M652/M653/M681/M682

ENWW Engine-control system 17

+5VD

AC input

Low-voltage power supply

Rectifying

circuit

Protection

circuit

+24V

generation

circuit

Fuse

FU100

+3.3V

generation

circuit

Fuser

24V interlock

switch

SW1

+24VA

Power supply

switch

SW4

Zero crossing

detection circuit

5VB_OFF

DC controller

+24VB

+3.3VB2

+3.3VB

FET

+5VA

+5VB

+3.3VA

POWER_SW

+5VC

Formatter

Fuse

FU101

Rectifying

circuit

Protection

circuit

+5V

generation

circuit

24V_RMT

/ZEROX

+3.3VC

+5VA

5V_PWM

FET

5V right interlock switch

SW3

PFC_RMT

+5VA1+5VA1

5V left interlock switch

SW9

Figure 1-5 Low-voltage power-supply circuit—E65150/E65160/E67650/E67660

Low-voltage power supply voltages description

The low-voltage power supply converts the AC power into three DC voltages, which it then subdivides, as described in the following table.

Table

1-8 Converted DC voltages

Main DC voltage Sub-voltage Behavior

+24 V +24 VA Constantly supplied

+24 VB Interrupted when the right door is open (SW1/SW3)

+5 V +5 VA Constantly supplied

18 Chapter 1 Theory of operation ENWW

Stopped during active OFF or inactive OFF

Table 1-8 Converted DC voltages (continued)

Main DC voltage Sub-voltage Behavior

+5 VB Constantly supplied

Stopped during active OFF or inactive OFF

+5 VC Constantly supplied

Stopped during active OFF or inactive OFF

+5VD Constantly supplied

Stopped during active OFF or inactive OFF

Stopped when the front door or the right door is opened (SW1/SW3)

+3.3 V +3.3 VA Constantly supplied

+3.3 VB Constantly supplied

Stopped during inactive OFF

+3.3V B2 Constantly supplied

Stopped during inactive OFF

Intermittent supplied during active OFF

+3.3 VC Constantly supplied

Over-current/over-voltage protection

The low-voltage power supply automatically stops supplying the DC voltage to the printer components whenever it detects excessive current or abnormal voltage. The low-voltage power supply has a protective circuit against over-current and over-voltage to prevent failures in the power supply circuit.

CAUTION: If DC voltage is not being supplied from the low-voltage power supply, the protective function might

be running. In this case, turn the power switch o and unplug the power cord.

Do not turn the power switch on until the root cause is found and corrected.

If the protective function is active, the DC controller noties the formatter of a low-voltage power supply failure. In addition, the low-voltage power supply has two fuses to protect against over-current. If over-current ows into the AC line, the fuse stops the AC power.

Sleep mode operation

Sleep mode conserves energy by stopping the power to several components when the printer is idle. If the DC controller detects voltage that is too high when the printer is in Sleep mode, it determines that the low-voltage power supply has failed, and it noties the formatter.

Stopped during active OFF or inactive OFF

Low-voltage power supply failure detection

The DC controller determines a low-voltage power supply failure and noties the formatter when the lowvoltage power supply does not supply +24 V.

ENWW Engine-control system 19

Low-voltage power supply functions

The printer has the following low-voltage power supply functions.

Table 1-9 Low-voltage power supply functions

Function Supported feature

Sleep mode No

Power supply voltage detection No

Automatic power OFF No

Automatic power ON/OFF No

Active OFF Yes

Inactive OFF Yes

Network mode No

Power switch illumination No

Low-voltage power supply failure detection No

Power save mode No

High-voltage power supplies

The DC controller controls the high-voltage power supplies (HVPS) to generate biases. The high-voltage power supplies deliver the high-voltage biases to the following components used to transfer toner during the imageformation process:

● Primary charging roller (in the toner cartridges)

● Developing roller (in the toner cartridges)

● Primary transfer roller

● Secondary transfer roller

● Pressure roller

● ITB cleaning brush

20 Chapter 1 Theory of operation ENWW

High-voltage power supply circuits

T2 roller

Pressure roller

ITB cleaning brush

Primarycharging bias

circuit

Developing bias

circuit

T2 bias circuit

Fuser bias circuit

DC controller

High-voltage power supply D

High-voltage power supply T

ITB brush bias circuit

T1 roller

T1 bias circuit

The high-voltage power supplies contains the following separate circuits.

Figure 1-6 High-voltage power supply circuits

Table 1-10 High-voltage power supply circuits

Circuit Description

Primary-charging-bias generation The primary charging bias negatively charges the surface of the photosensitive drum to

Developing-bias generation The developing bias adheres toner to an electrostatic latent image formed on the

Primary-transfer-bias generation The primary transfer bias transfers the toner from each photosensitive drum onto the ITB.

Secondary-transfer-bias generation The positive secondary transfer bias transfers the toner image from the ITB onto the paper.

prepare for image formation.

photosensitive drums.

The negative bias transfers residual toner on the secondary transfer roller back to the ITB. The residual toner on the ITB is deposited in the toner collection unit.

ENWW Engine-control system 21

Fuser bias

The printer uses instant-on fusing, which allows faster increases in fuser temperature to print the rst page faster when a printer is coming out of low-power mode. The fuser bias is DC positive for improved print quality. The fuser bias circuit is located in the high-voltage power supply, HVPS (T).

22 Chapter 1 Theory of operation ENWW

Fuser control

FUSER TEMPERATURE signal

FUSER HEATER CONTROL signal

DC controller

Low-voltage power supply

TH1

TP1

H1, H2

Pressure roller

Fuser film

Fuser heater

control circuit

Fuser heater safety circuit

TH3

TH2

The DC controller and components in the fuser perform the following functions related to fuser operation:

● Control fuser temperature

● Detect fuser failures

● Prevent excessive temperature rise

● Detect remaining life in the fuser

● Determine if the correct fuser is installed

Fuser circuits

The fuser heater control circuit and the fuser heater safety circuit control the fuser temperature according to commands from the DC controller. The fuser consists of the following major components:

Table 1-11 Fuser components

Type of component Abbreviation Name Function

Heaters H1 Fuser main heater Heats the center of the fuser sleeve

H2 Fuser sub-heater Heats the edge of the fuser sleeve

ENWW Engine-control system 23

Table 1-11 Fuser components (continued)

Type of component Abbreviation Name Function

Thermistors

(Contact type)

Thermoswitch

(Non-contact type)

Fuser control functions

The printer has the following fuser control functions.

Table 1-12 Low-voltage power supply functions

Failure detection function Supported feature

Fuser temperature control Yes

Fuser failure detection Yes

Frequency detection circuit failure detection Yes

Fuser pressure release mechanism failure detection Yes

TH1 Main thermistor Detects the center temperature of

the fuser heater

TH2 Sub-thermistor 1 Detects the temperature at one end

of the fuser heater

TH3 Sub-thermistor 2 Detects the temperature at one end

of the fuser heater

TP1 Thermoswitch Prevents an abnormal temperature

rise in the fuser heater

Fuser type discrepancy detection Yes

Fuser type identication detection No

Fuser presence detection Yes

Fuser life detection Yes

Relay failure detection No

Pressure roller cleaning Yes

Fuser temperature control

The temperatures of the two rollers in the fuser uctuate according to the stage of the printing process. The DC controller sends commands to the fuser-control circuit to adjust temperatures.

24 Chapter 1 Theory of operation ENWW

H1, H2

TP1

Fuser film ass’y

Fuser

Pressure

roller

Low-voltage power supply

Fuser heater safety circuit

DC controller

Relay drive

circuit

TH1

RL201

RL211

AC input

Fuser heater

controlcircuit

Zero crossing

detection

circuit

TH3

TH2

+24VRL

+24VB

RLD

+24VRL

Relay drive

circuit

FSR_F_TH

FSR_C_TH

FSR_R_TH

FSAFE_RL_N

FSRD_M

FSRD_S

FSAFE_TRIAC

/ZEROX

Figure 1-7 Fuser temperature-control circuit

Fuser heater protection

Fuser heater protection is a feature that detects excessive temperatures in the fuser and interrupts the power supply to the fuser heater.

The following three protective components prevent the fuser heater from excessive rising temperature:

● DC controller: When a thermistor or sub-thermistor detects a temperature above a certain threshold, the

DC controller interrupts power to the specic heater.

● Fuser-heater safety circuit: The fuser heater safety circuit monitors the detected temperature of the sub-

thermistors.

● Thermoswitch: If the temperature in the heaters is abnormally high, and the temperature in the

thermoswitch exceeds a specied value, the contact to the thermoswitch breaks.

ENWW Engine-control system 25

Fuser unit life detection

The fuser life is tracked by fuser rotations, and not by the number of pages printed. This is a more accurate tracking method since the fuser rotates for every print job. There will be variations in fuser life depending on customer usage. Customers who are running one- and two-page intermittent jobs with long pauses between each job might reach the fuser low message sooner due to the fuser rotating more times per page than it would for larger print jobs.

Fuser identication

The printer detects the type and presence of the fuser. The DC controller noties the formatter when it fails to detect the type (110V or 220V) or presence of the fuser.

NOTE: This printer detects if a fuser of the correct voltage for the printer is installed. If a fuser of the incorrect

voltage is installed, the DC controller noties the formatter and an error message is displayed on the control panel.

26 Chapter 1 Theory of operation ENWW

Engine laser scanner system

DC controller

Scanner mirror

Scanner motor ass’y

Laser ass’y

Photosensitive drum

BD sensor

Photosensitive drum

The laser scanner system forms the latent electrostatic image on the photosensitive drums inside each of the toner cartridges.

The DC controller receives instructions from the formatter regarding the image of the page to be printed. The DC controller signals the lasers to emit light, and the laser beams pass through lenses and onto the scanner mirror, which rotates at a constant speed. The mirror reects the beam onto the photosensitive drum in the pattern required for the image, exposing the surface of the drum so it can receive toner.

The main components of the laser scanner system are the laser assembly and the scanner motor assembly, which are controlled by signals sent from the DC controller.

Figure 1-8 Laser scanner system

ENWW Engine laser scanner system 27

Laser scanner failure detection

The DC controller determines an optical unit failure and noties the formatter of the error status when any of the following occurs:

● BD sensor failure detection

● Laser scanner motor startup failure: The scanner motor does not reach a specied rotation frequency

within a specied period of time from when the laser scanner starts up.

● Laser scanner motor abnormal rotation: The laser scanner motor does not reach a specied rotational

frequency within a specied period of time during a print operation.

● Laser scanner failure detection

For example, the control panel will show a 51.00.XX error message when a laser scanner error occurs. The control panel messages document may then be consulted for appropriate troubleshooting steps.

Safety

The laser scanner assembly has a mechanical laser shutter. For the safety of users and service technicians, the laser shutter interrupts the optical path of the laser scanner assembly when the front door (SW1/SW3) or right door (SW1/SW3) are opened.

The E65150/E65160/E67650/E67660 models have interlock switches. In case that one of the following doors opens, the interlock switches set to OFF, which stops output to the laser for the user/service technician’s safety.

● Front door (SW1/SW3/SW9)

● Right door (SW1/SW3)

28 Chapter 1 Theory of operation ENWW

Image-formation process

The image-formation system creates the printed image on the paper. The system consists of the following components:

● Toner cartridges

● Intermediate transfer belt (ITB)

● Primary transfer roller

●

Secondary transfer roller

● Fuser

● Laser scanner

● High-voltage power supplies

The DC Controller controls the internal components of the image formation system (according to commands received from the formatter) to form the toner image on the photosensitive drum surface. The toner image is then transferred to the print media and fused.

ENWW Engine laser scanner system 29

Figure 1-9 Image-formation system

Laser scanner ass’y

ITB

Fuser

Cartridge

High-voltage power supplyD

DC controller

High-voltage power supplyT

T1 roller

T2 roller

30 Chapter 1 Theory of operation ENWW

Figure 1-10 Image-formation system motors

M4M3M6M1M2

DC controller

Abbreviation Component name

M1 Drum motor 1

M2 Drum motor 2

M3 Drum motor 3

M4 Fuser motor

M6 Developer alienation motor

ENWW Engine laser scanner system 31

Figure 1-11 Image formation system sensors

SR54

SW2

SR51

SR52

SR53

SR1901

DC controller

Registration density sensor 1 Registration density sensor 2

Environment

sensor

Media sensor

Table 1-13 Image formation system electrical component list

Abbreviation Component name

SW2 ITB Toner collection near full switch

SR51 Drum home position sensor Y

SR52 Drum home position sensor MC

SR53 Drum home position sensor K

SR54 Developer alienation sensor

SR1901 ITB alienation sensor

– Registration density sensor 1

– Registration density sensor 2

– Environment sensor

– Media sensor

The image-formation process consists of ten steps divided into six functional blocks.

32 Chapter 1 Theory of operation ENWW

Figure 1-12 Image-formation process

Latent image formation

Pickup

4. Developing

Fusing

Transfer

: Direction of drum rotation

: Paper path

: Functional block

: Step

Delivery

8. Fusing

7. Separation

6. Secondary transfer

Developing

5. Primary transfer

10. Drum cleaning

Drum cleaning

1. Pre-exposure2. Primary charging

3. Laser-beam exposure

9. ITB cleaning

ITB cleaning

YMC

Table 1-14 Image formation process

Functional block Steps Description

Latent image formation 1. Pre-exposure

Development 4. Development Toner adheres to the electrostatic latent image on the

Transfer 5. Primary transfer

Fusing 8. Fusing The toner fuses to the paper to make a permanent

ITB cleaning 9. ITB cleaning Residual toner is removed from the ITB.

Drum cleaning 10. Drum cleaning Residual toner is removed from the photosensitive

An invisible latent image forms on the surface of the photosensitive drums.

2. Primary charging

3. Laser-beam exposure

photosensitive drums.

The toner image transfers to the ITB and then to the paper.

6. Secondary transfer

7. Separation

image.

drums.

ENWW Engine laser scanner system 33

Step 1: Pre-exposure

LED

Photosensitive drum

Primary charging bias

Primary charging roller

Photosensitive drum

Light from the pre-exposure LED strikes the surface of the photosensitive drum to remove any residual electrical charges from the drum surface.

Figure 1-13 Pre-exposure

Step 2: Primary charging

The primary-charging roller contacts the photosensitive drum and charges the drum with negative potential.

Figure 1-14 Primary charging

34 Chapter 1 Theory of operation ENWW

Step 3: Laser-beam exposure

Photosensitive drum

Laser beam

Developer blade

Developer roller

Developing bias

Photosensitive drum

The laser beam strikes the surface of the photosensitive drum in the areas where the image will form. The negative charge neutralizes in those areas, which are then ready to accept toner.

Figure 1-15 Laser-beam exposure

Step 4: Development

Toner acquires a negative charge as the developing cylinder contacts the developing blade. Because the negatively-charged surface of the photosensitive drums have been neutralized where they have been struck by the laser beam, the toner adheres to those areas on the drums. The latent image becomes visible on the surface of each drum.

Figure 1-16 Development

ENWW Engine laser scanner system 35

Step 5: Primary transfer

T1 roller

T1 bias

ITB

Photosensitive

drum

ITB

Paper

T2 roller

T2 bias

The positively-charged primary-transfer rollers contact the ITB, giving the ITB a positive charge. The ITB attracts the negatively-charged toner from the surface of each photosensitive drum, and the complete toner image transfers onto the ITB.

Figure 1-17 Primary transfer

Step 6: Secondary transfer

The paper acquires a positive charge from the secondary-transfer roller, and attracts the negatively-charged toner from the surface of the ITB. The complete toner image transfers onto the paper.

Figure 1-18 Secondary transfer

36 Chapter 1 Theory of operation ENWW

Step 7: Separation

ITB

Paper

T2 roller

Static charge eliminator

Paper

Fuser heater

Fuser film

Pressure roller

Fusing bias

The stiness of the paper causes it to separate from the ITB as the ITB bends. The static-charge eliminator removes excess charge from the paper to make sure that the toner fuses correctly.

Figure 1-19 Separation

Step 8: Fusing

To create the permanent image, the paper passes through heated, pressurized rollers to melt the toner onto the page. Fusing bias is added to the pressure roller to improve the print quality.

Figure 1-20 Fusing

ENWW Engine laser scanner system 37

Step 9: ITB cleaning

Toner feed screw

Cleaning blade

ITB cleaning brush

ITB brush bias

Photosensitive

drum

T1 roller

ITB

T1 bias

Photosensitive

drum

Cleaning blade

Toner feed screw

The cleaning blade scrapes the residual toner o the surface of the ITB. The residual toner feed screw deposits residual toner in the toner collection unit. The residual toner which cannot be removed by the cleaning blade is charged by the ITB cleaning brush, and then transferred from the ITB surface to the photosensitive drum by the primary transfer (T1) roller.

Figure 1-21 ITB Cleaning

Step 10: Drum cleaning

The cleaning blade scrapes the residual toner o the surface of the photosensitive drum. The toner feed screw deposits the residual toner in the toner collection unit.

Figure 1-22 Drum cleaning

38 Chapter 1 Theory of operation ENWW

Toner cartridges

SR54

Developer

DC controller

E-label

Developer roller

Cartridge

Primary charging

roller

Photosensitive drum

M1/M2/M3

SR51/SR52/SR53

The printer has four toner cartridges, one for each color: cyan, magenta, yellow, and black.

Design

Each toner cartridge is lled with toner and consists of the following components:

● Photosensitive drum

● Developer roller

● Primary-charging roller

● Memory chip

The DC controller rotates the drum motor to drive the photosensitive drum, developer roller, and the primarycharging roller.

Figure 1-23 Toner cartridge system

Table 1-15 Toner cartridge functions

Function Applied

ENWW Engine laser scanner system 39

Table 1-15 Toner cartridge functions (continued)

Cartridge presence detection Yes

Toner level detection Yes

Cartridge life detection Yes

Cartridge mis-installation detection Yes

Developer alienation control Yes

Developer alienation motor failure detection Yes

Drum discharge mechanism No

40 Chapter 1 Theory of operation ENWW

Memory chip

The memory chip is non-volatile memory that stores information about the usage of the toner cartridge and helps protect the customer from counterfeit cartridges. This chip is also used to detect the presence of a cartridge within the printer or when a cartridge is installed in the wrong slot. The printer reads and writes the data in the memory chip.

Dynamic security

Certain HP printers use cartridges that have security chips or electronic circuitry. Cartridges using a non-HP chip or modied or non-HP circuitry* might not work. And, those that work today might not work in the future.

As is standard in the printing business, HP has a process for authenticating cartridges. HP continues to use security measures to protect the quality of our customer experience, maintain the integrity of our printing systems, and protect our intellectual property. These measures include authentication methods that change periodically and might prevent some third-party supplies from working now or in the future. HP printers and original HP cartridges deliver the best quality, security and reliability. When cartridges are cloned or counterfeited, the customer is exposed to quality and potential security risks, compromising the printing experience.

* Non-HP chips and modied or non-HP electronic circuitry are not produced or validated by HP. HP cannot guarantee that these chips or circuitry will work in your printer now or in the future. If you are using a nonoriginal HP cartridge, please check with your supplier to ensure your cartridge has an original HP security chip or unmodied HP electronic circuitry.

JetIntelligence

JetIntelligence supports two features for managing toner cartridges.

● The authentication feature allows customers to specify the use of only genuine HP toner cartridges in the

● The anti-theft feature enables locking a cartridge to a specic printer or eet of printers.

Authentication

The genuine HP authentication feature allows a customer to specify that only genuine HP supplies can be used in a printer. If a non-HP or used supply is installed, the printer will not print. This feature is disabled by default, and can be enabled or disabled from the control panel or the Embedded Web Server (EWS).

If a genuine HP toner cartridge from another printer is moved to a printer with this feature enabled, the toner cartridge will authenticate and print, unless the toner cartridge has passed the low state. If the toner cartridge has passed the low state, an Unauthorized Cartridge message displays on the control panel.

If a non-HP toner cartridge is used in a printer with this feature enabled, the message Unauthorized Cartridge appears on the control-panel display.

NOTE: If a customer suspects they have a counterfeit cartridge, they should report it by going to www.hp.com/go/anticounterfeit and selecting Report now.

Anti-theft

printer.

The toner cartridge anti-theft feature allows a customer to congure the printer to automatically lock genuine HP toner cartridges to a specic printer or eet of printers when they are installed. A locked toner cartridge will only work in the specied printer or eet of printers. This feature prevents toner cartridges from being stolen and used in another printer, or from being moved from an authorized printer to an unauthorized printer. This

ENWW Engine laser scanner system 41

feature is disabled by default, and can be enabled or disabled from the control panel, the Embedded Web Server (EWS), or Web Jetadmin.

When the anti-theft feature is enabled, the toner cartridge in a printer will only work in the specied printer or eet of printers. If a locked toner cartridge is moved to another printer, the cartridge will not print and the message Protected Cartridge appears on the control-panel display.

NOTE: When a toner cartridge is locked to a specic printer or eet of printers, it cannot be unlocked. This is a

permanent operation.

Toner seal

The toner cartridge seal is opened automatically when the toner cartridge is installed into the printer.

Toner level and cartridge life detection

Toner level detection: The DC controller detects the remaining toner in the cartridge by the optical detection method and then noties the formatter of the remaining toner level.

Cartridge life detection: Cartridge life detection is measured in two ways.

1. Toner level:

– For the rst 75% of cartridge life, toner level is measure through pixel counting by the DC controller.

Once the level reaches 25%, the toner level sensor utilizes electrical properties to determine the amount of toner remaining.

2. Rotations of internal components (OPC and developer roller):

– The DC controller monitors these two life parameters and reports them to the formatter as percent

life remaining. End of cartridge life is determined by the lower value of the two.

Developing unit engagement and disengagement control

The printer can print in full-color mode or in black-only mode. To print in black-only mode, the printer disengages the developing rollers in the cyan, magenta, and yellow toner cartridges, which maximizes the life of the cartridges.

42 Chapter 1 Theory of operation ENWW

Figure 1-24 Developer roller engagement and alienation control

Developing unit is disengaged

Developing disengagement motor

Photosensitive drum

Developing unit

Developing disengagement cam

SR4 Developing home position sensor

DC controller

Developing unit is engaged

The developer roller engagement and alienation control operates as follows: When the printer is turned on and when each print job is completed, all four of the developing units are disengaged from the photosensitive drums.

● The drive of the developer alienation motor rotates the developer alienation cam.

● As the cam rotates, the developing unit engages with or separates from the photosensitive drum.

When the print mode is full color, the developing units engage with the drums. When the print mode is blackonly, only the black developing unit engages with the drum.

The DC controller determines a developer alienation motor failure and noties the formatter when it does not detect a specied signal from the developer alienation sensor during the developing unit engagement and disengagement operation.

ENWW Engine laser scanner system 43

Intermediate transfer belt (ITB) unit

DC controller

ITB toner collection near full switch

ITB cleaner

Toner collection box

SR1901

T1 roller

ITB drive roller

Drum motor 3

ITB

M4 Fuser motor

T1 roller alienation solenoid

SL1

The ITB unit accepts the toner images from the photosensitive drums and transfers the completed image to the paper. The ITB unit has the following main components:

● Intermediate transfer belt (ITB)

● ITB-drive roller

● Primary-transfer roller

●

ITB cleaner

Drum motor 3 drives the ITB drive roller, which rotates the ITB. The motion of the ITB causes the primary transfer rollers to rotate. The ITB cleaner cleans the ITB surface.

Figure 1-25 ITB Unit

Table 1-16 ITB assembly functions

Function Applied

T1 roller alienation control Yes

T1 roller alienation mechanism failure detection Yes

ITB ass’y life detection Yes

ITB ass’y presence detection No

Blade cleaning mechanism Yes

Electrostatic cleaning mechanism Yes

ITB toner collection box full detection Yes

ITB toner collection box presence detection No

ITB perimeter detection Yes

ITB seal detection sensor failure detection No

44 Chapter 1 Theory of operation ENWW

Primary-transfer roller engagement and disengagement control

Depending on the requirements of the print job, the primary-transfer rollers engage with the ITB so it can receive toner from the photosensitive drums. The primary-transfer rollers have three engagement states.

Table 1-17 Primary-transfer roller engagement states

All rollers disengaged The ITB is disengaged from all the four photosensitive drums. This state is the home

position for the ITB unit.

All rollers engaged The ITB is engaged with all four photosensitive drums. This is the state for full-color

printing.

Black roller engaged The ITB is engaged with only the black photosensitive drum. This is the state for black-only

printing.

ENWW Engine laser scanner system 45

Figure 1-26 Three states of primary-transfer roller engagement and disengagement

Four colors are disengaged

Four colors are engaged

Only black is engaged

Fuser motor

Fuser motor control

SR5

Primary transfer roller

disengagement signal

Primary transfer roller

disengagement solenoid

control signal

The primary-transfer-roller disengagement motor rotates or reverses to place the primary-transfer-roller disengagement cam into one of three positions. The cam causes the transfer-roller slide plate to move to the right or left. This movement causes the primary-transfer rollers to move up to engage the ITB with the photosensitive drum or down to disengage it.

The DC controller expects to receive a signal from the ITB home-position sensor when the primary-transfer roller engages or disengages. If the DC controller does not receive this signal, but detects that the primarytransfer-roller disengagement motor is rotating, the DC controller determines that the primary-transferdisengagement mechanism has failed, and noties the formatter. The formatter will then display a 59.00.F0 message on the control panel.

46 Chapter 1 Theory of operation ENWW

ITB unit detection

The DC controller monitors several signals from the ITB unit to detect status.

ITB unit life detection The DC controller detects whether the ITB unit is new by monitoring the new ITB

ITB unit presence detection The DC controller detects the presence of an ITB unit by monitoring the primary-

unit sensor. The DC controller determines the ITB unit is at end of life and noties the formatter when a specied number of pages are printed after the ITB unit is replaced. If swapping ITB units between two printers for troubleshooting purposes, be sure to return the ITB units to their original printers to maintain the correct life count.

NOTE: When installing a new ITB, refer to the instructions for resetting the ITB life

counter in the installation guide provided with the replacement part.

transfer roller disengagement sensor. The DC controller turns on the primarytransfer disengagement solenoid for specied times during an initial rotation period when the following events occur:

● The printer is turned on

● The printer exits sleep mode

● The door is closed

The DC controller determines the absences of an ITB unit and noties the formatter when it does not detect a specied signal from the new primary-transfer roller disengagement sensor.

ENWW Engine laser scanner system 47

ITB cleaning mechanism

The cleaning blade in the ITB cleaner scrapes the residual toner o the ITB surface and deposits the residual toner into the toner collection unit. The residual toner feed screw deposits the residual toner to the residual toner feed unit. The ITB motor and the residual toner feed motor drive the screw. The residual toner that cannot be removed by the cleaning blade is charged by the ITB cleaning brush, and then transferred from the ITB surface to the photosensitive drum by the primary transfer (T1) roller. The DC controller detects whether the toner collection unit is full by using the toner collection unit full sensor, and then noties the formatter.

Figure 1-27 ITB cleaning process

Secondary transfer roller functions

The secondary transfer roller transfers the image from the ITB onto the paper.

The printer has the following secondary transfer roller functions.

Table

1-18 Secondary transfer roller functions

Function Supported feature

Secondary transfer roller cleaning mechanism Yes

Secondary transfer roller presence detection No

Secondary transfer roller life detection No

Secondary transfer roller alienation control Yes

48 Chapter 1 Theory of operation ENWW

Calibration

The printer calibrates itself to maintain proper print quality. The calibration corrects color-misregistration and color-density variation due to environmental changes or internal variation in the printer.

The printer has the following calibration functions.

Table 1-19 Calibration functions

Function Supported feature

Color-plane registration correction control Yes

Environment correction control Yes

Image density control (DMAX) Yes

Image halftone control (DHALF) Yes

Registration density sensor failure detection Yes

Color sensor control No

Gray axis control (GAS) No

Environment sensor failure detection Yes

ENWW Engine laser scanner system 49

Pickup, feed, and delivery system

The DC controller controls the pickup, feed, and delivery system according to commands from the formatter. The pickup, feed, and delivery system uses a series of rollers to move the paper through the printer.

The pickup, feed, and delivery system consists of the following three functional blocks. The DC controller controls each block to pick up, feed and deliver the paper.

● Pickup-and-feed-block: Controls the movement of the paper from each pickup source to the fuser inlet

● Fuser-and-delivery-block: Controls the movement of the paper from the fuser to the delivery destination

● Duplex block: Controls the movement of the paper from the duplex switchback unit to the duplex re-pickup

unit.

50 Chapter 1 Theory of operation ENWW

Simplex paper path

Duplex block

Pickup-and-feed block

Fuser-and-delivery block

Duplex paper path

Simplex paper path

Figure 1-28 Pickup, feed, and delivery system

Photo sensors and switches

The following gure shows the sensors and switches for the pickup, feed, and delivery system.

ENWW Pickup, feed, and delivery system 51

Figure 1-29 Pickup, feed, and delivery system photo sensors and switches

SW5

SR14

SR95

SR94

SR12/13

SR11

SR8615

SR8611/8613

SR62

Table 1-20 Photo sensors and switches

Abbreviation Component name

SR11 Registration sensor

SR12 Registration media width sensor 1

SR13 Registration media width sensor 2

SR14 Tray 2 media out sensor

SR62 FD1 media full sensor

SR94 Duplex feed sensor

SR95 Tray 1 media out sensor

SR8611 Fuser output sensor 1

SR8613 Fuser output sensor 2

SR8615 Fuser loop sensor

SW5 Tray 2 media size switch 1

MS Media sensor

52 Chapter 1 Theory of operation ENWW

Motors, clutches, and solenoids

SL3

CL1 CL2 SL2

The following gure shows the motors, clutches, and solenoids for the pickup, feed, and delivery system.

Figure 1-30 Pickup, feed, and delivery system motors, clutches, and solenoids

Table 1-21 Motors, clutches, and solenoids

Abbreviation Component Replacement part number

M3 Drum motor 3 Drum motor assembly (RM2-1956-000CN)

M4 Fuser motor Fuser motor assembly (RM2-1955-000CN)

M5 Pickup motor Paper pickup assembly (RM2-6556-000CN)

M8 Duplex reverse motor Right door assembly (RM2-6622-000CN)

SL2 Tray 1 pickup solenoid Right door assembly (RM2-6622-000CN)

SL3 Duplex reverse solenoid Right door assembly (RM2-6622-000CN)

CL1 Tray 2 pickup clutch Lifter drive assembly (RM2-6669-000CN)

CL2 Duplex re-pickup clutch Right door assembly (RM2-6622-000CN)

ENWW Pickup, feed, and delivery system 53

Paper trays

Tray 2 media type detection

The printer selects the optimal print mode based upon the media type detected by the media sensor. The media sensor consists of an optical sensor, which detects the surface texture of the paper, and an ultrasonic sensor, which measures the thickness of the paper. The formatter informs the DC controller that the printer is in autosense mode and the DC controller changes the fuser mode based on media type.

Following are the print modes detected by the printer:

● Normal

● Heavy media 1

● Heavy media 2

● Heavy media 3

● Light media 1

● Light media 2

● Light media 3

● Glossy media 1

● Glossy media 2

● Glossy media 3

● Glossy

● OHT

● Designated media 1

● Designated media 2

● Designated media 3

The DC controller determines a media sensor error and reports it to the formatter when the value detected by the media sensor is out of a specied range of values.

54 Chapter 1 Theory of operation ENWW

Figure 1-31 Media sensors

Ultrasonic sensor

Registration ass’y

Optical sensor

Feed speed control

The DC controller adjusts the feed speed to improve the print quality depending on the paper type. The paper is fed at a specied speed according to the print mode designated by the formatter.

Table 1-22 Print mode and feed speed

Print mode

Feed speed

Media sensor detection

Full color Monochrome

Auto - - Yes

Normal 1/1 1/1 Yes

Heavy media 1 3/4 3/4 No

Heavy media 2 1/2 1/2 Yes

Heavy media 3 1/3 1/3 Yes

Light media 1 1/1 1/1 Yes

Light media 2 1/1 1/1 Yes

Light media 3 1/2 1/2 Yes

Glossy media 1 1/3 1/3 Yes

Glossy media 2 1/3 1/3 Yes

Glossy media 3 1/3 1/3 Yes

Glossy lm 1/3 1/3 Yes

Photo media 1 - - No

Photo media 2 - - No

Photo media 3 - - No

Envelope 1 1/3 1/3 No

Envelope 2 - - No

Envelope 3 - - No

ENWW Pickup, feed, and delivery system 55

Table 1-22 Print mode and feed speed (continued)

Print mode

OHT 1/3 1/3 Yes

Label 1/2 1/2 No

Designated media 1 1/2 1/2 No

Designated media 2 1/3 1/3 No

Designated media 3 3/4 3/4 No

1/1 speed = 210 mm/s 1/2 speed = 105 mm/s 1/3 speed = 70 mm/s

Feed speed

Full color Monochrome

Media sensor detection

Table 1-23 Pickup, feed and delivery system functions

Function Supported

Tray 2 media size detection Yes

Tray 2 presence detection Yes

Tray 2 media surface detection No

Tray 2 media presence detection Yes

Tray 2 media level detection No

Tray 2 lift-up control Yes

Tray 2 lift-down control No

Tray 2 multiple-feed prevention mechanism Yes

Tray 1 media presence detection Yes

Tray 1 media width detection No

Tray 1 last-media detection No

Skew-feed prevention mechanism Yes

Feed speed control Yes

Loop control Yes

Media detection Yes

OHT detection Yes

Image leading edge positioning Yes

Media length detection Yes

Media width detection Yes

Pressure roller pressure release control Yes

Output bin media-full detection Yes

Automatic delivery Yes

56 Chapter 1 Theory of operation ENWW

Table 1-23 Pickup, feed and delivery system functions (continued)

Function Supported

Duplex switchback control Yes

Duplex feed control Yes

Duplexing unit

The duplexing unit reverses the paper and feeds it through the paper path to print the second side.

Duplexing reverse and duplex feed control

The duplex reverse control reverses the paper after the rst side is printed and feeds it to the duplex re-pickup position to print the second side of the page.

1. At a specied time after the rst side of a page is printed, the duplex reverse motor rotates, and the duplex

reverse solenoid is turned on.

2. The duplex apper moves, and the paper feeds to the duplex reverse unit.

3. After a specied period of time, the duplex reverse motor reverses, and the paper feeds to the duplex feed

unit.

4. The duplex reverse motor and the pickup motor move the paper to the duplex re-pickup position.

5. The duplex reverse motor and the duplex feed clutch stop, and the paper feed operation pauses.

6. After a specied period of time, the duplex reverse motor rotates, and the duplex feed clutch is turned on.

The paper is then picked up again.

Jam detection/prevention

The printer uses the following sensors to detect the paper as it moves through the paper path and to report to the DC controller if the paper has jammed.

● Registration sensor (SR11)

● Registration media width sensor 1 (SR12)

● Registration media width sensor 2 (SR13)

● FD1 (output bin) media full sensor (SR62)

● Duplex feed sensor (SR94)

● Fuser output sensor 1 (SR8611)

● Fuser output sensor 2 (SR8613)

● Fuser loop sensor (SR8615)

● PF (paper feeder) feed sensor (PS3602) — 550-sheet paper feeder only

● PD (paper deck) cassette 1 feed sensor (PS3401) — 1x550-sheet paper-feeder, 3x550-sheet paper-

feeder, and 2,550-sheet paper-feeder only

ENWW Pickup, feed, and delivery system 57

● PD (paper deck) cassette 2 feed sensor (PS4501) — 3x550-sheet paper-feeder and 2,550-sheet paper-

SR11

SR62

SR94

SR12/13

SR8615

SR8611/8613

SR3602

feeder only

● PD (paper deck) cassette 3 feed sensor (PS5601) — 3x550-sheet paper-feeder only

Figure 1-32 Paper-path jam detection sensors

The printer determines that a jam has occurred if one of these sensors detects paper at an inappropriate time. The DC controller stops the print operation and noties the formatter.

58 Chapter 1 Theory of operation ENWW

Figure 1-33 paper-feeder paper-path jam detection sensors

SR3602

SR11

SR94

SR12/13

SR8615

SR62

SR8611/8613

SR4501

SR5601

ENWW Pickup, feed, and delivery system 59

Table 1-24 Jams that the printer detects

Jam Supported feature

No pick jam 1 Yes

No pick jam 2 Yes

No pick jam 3 Yes

No pick jam 4 No

Pickup stay jam 1 Yes

Pickup stay jam 2 No

Pickup stay jam 3 No

Pickup stay jam 4 No

Fuser delivery delay jam 1 Yes

Fuser delivery delay jam 2 No

Fuser delivery delay jam 3 No

Fuser delivery delay jam 4 No

Fuser delivery stay jam 1 Yes

Fuser delivery stay jam 2 No

Fuser delivery stay jam 3 No

Fuser delivery stay jam 4 No

Residual paper jam 1 Yes

Residual paper jam 2 No

Residual paper jam 3 No

Residual paper jam 4 No

Door open jam 1 Yes

Door open jam 2 No

Door open jam 3 No

Door open jam 4 No

Fuser wrap jam1 Yes

Fuser wrap jam2 No

Fuser wrap jam3 No

Fuser wrap jam4 No

Duplex switchback jam1 No

Duplex switchback jam2 No

Duplex switchback jam3 No

Duplex switchback jam4 No

Duplex re-pickup jam 1 Yes

60 Chapter 1 Theory of operation ENWW

Table 1-24 Jams that the printer detects (continued)

Jam Supported feature

Duplex re-pickup jam 2 No

Duplex re-pickup jam 3 No

Duplex re-pickup jam 4 No

Delivery delay jam 1 Yes

Delivery delay jam 2 No

Delivery delay jam 3 No

Delivery delay jam 4 No

Delivery stay jam 1 No

Delivery stay jam 2 No

Delivery stay jam 3 No

Delivery stay jam 4 No

Multiple feed jam 1 No

Multiple feed jam 2 No

Multiple feed jam 3 No

Multiple feed jam 4 No

Duplex feed delay jam 1 Yes

Inappropriate to the delivery path Jam 1 No

Inappropriate to the delivery path Jam 2 No

Fuser wrapping jam detection

The printer includes controls for detecting when a jam occurs causing the paper to wrap around the fuser roller.

Loop control

The loop control stabilizes the paper feed operation before the paper enters the fuser. If the pressure roller rotates slower than the secondary transfer roller, the paper loop increases and an image defect or paper crease occurs. If the pressure roller rotates faster than the secondary transfer roller, the paper loop decreases and a vertical scanning magnication failure occurs because the pressure roller pulls the paper.

To prevent these problems, the loop sensor detects the paper loop before the paper enters the fuser. The DC controller adjusts the rotational speed of the fuser motor according to the output signals from the loop sensor and maintains the paper loop. The DC controller slows the fuser motor when the sensor is o and speeds up the motor when the sensor is on.

Pressure roller pressurization and depressurization control

To prevent excessive wear on the pressure roller and help with jam-clearing procedures, the pressure roller pressurizes only during printing and standby. The DC controller reverses the fuser motor. The fuser motor rotates the fuser pressure-release cam.

The pressure roller depressurizes under the following conditions:

ENWW Pickup, feed, and delivery system 61

● The printer is turned o

● Any failure occurs

● During power-save mode

A paper jam is detected

●

If the DC controller does not sense the fuser pressure-release sensor for a specied period after it reverses the fuser motor, it noties the formatter that a fuser pressure-release mechanism failure has occurred.

62 Chapter 1 Theory of operation ENWW

Input accessories

NOTE: Optional 1x550-sheet, 3x550 sheet, and 2,550 paper feeders are available for this printer. The printer

supports up to three of these paper feeders at a time.

550-sheet paper feeder

The 550-sheet paper feeder is installed under the printer. It picks up paper and feeds it into the printer.

Figure 1-34 550-sheet paper feeder

550-sheet paper feeder controller

The paper feeder controller controls the operational sequence of the paper feeder.

ENWW Input accessories 63

Figure 1-35 550-sheet paper feeder driver PCA

Clutch

Switch

Photointerruptor

DC controller Paper feeder controller

+3.3VB

+24VA

Motor

550-sheet paper feeder

550-sheet paper feeder motor control

The 550-sheet paper feeder has one motor for lifting the tray and feeding paper.

Table

1-25 550-sheet paper feeder motor control

Component Drives Failure detection

M3602 Feed motor (550-sheet paper feeder) Tray pickup roller (B5L24-67904)

550-sheet paper feeder electrical components

The paper feeder contains several motors, solenoids, sensors, and switches, as described in the following table.

Table

1-26 550-sheet paper feeder electrical components

Component type Abbreviation Component name Replacement part number

Motor M3602 Feed motor (550-sheet paper feeder) Paper feed assembly

Clutch CL3602 Tray pick up clutch (550-sheet paper

feeder)

Switches SW3601 Right door switch (550-sheet paper

SW3602 Tray detection switch (550-sheet paper

Sensors PS3601 Tray media-out sensor (550-sheet

feeder)

paper feeder)

Tray feed roller (RM2-6684-000CN)

Paper feed assembly (RM2-5145-000CN)

Lifter drive assembly (RM2-6669-000CN)

(RM2-5145-000CN)

Lifter drive assembly (RM2-5149-000CN)

Right door (RM2-5146-000CN)

Switch button (WC2-5806-000CN)

Paper pick up assembly (RM2-5154-000CN)

64 Chapter 1 Theory of operation ENWW

Table 1-26 550-sheet paper feeder electrical components (continued)

M3602

PS3601

PS3602

SW3602

CL3602

SW3601

Component type Abbreviation Component name Replacement part number

PS3602 Feed sensor (550-sheet paper feeder) Paper feed assembly

550-sheet paper feeder paper pickup

The 550-sheet paper feeder picks up one sheet from the paper-feeder tray and feeds it to the printer.

Figure 1-36 Paper pickup and feed operation (550-sheet paper feeder)

(RM2-5145-000CN)

Table 1-27 Pickup feed components (1x550-sheet paper feeder)

Abbreviation Component Replacement part number

M3602 Feed motor (550-sheet paper feeder) Paper feed assembly (RM2-5145-000CN)

CL3602 Tray pickup clutch (550-sheet paper feeder) Part not available

SW3601 Media size switch

SW3602 Door switch

PS3601 Tray media-out sensor (550-sheet paper feeder) Paper pick up assembly (RM2-5154-000CN)

PS3602 Feed sensor (550-sheet paper feeder) Paper feed assembly (RM2-5145-000CN)

550-sheet paper feeder multiple feed prevention

The multiple-feed prevention for the 550-sheet paper feeder is operated in the same way as that of the printer base.

550-sheet paper feeder tray presence detection

The presence detection for the 550-sheet paper feeder is the same way as that of the printer base.

ENWW Input accessories 65

550-sheet paper feeder tray lift operation

The 550-sheet paper feeder keeps the paper stack surface at the correct pickup position. The tray lift operation occurs under the following conditions:

● The printer is turned on.

● The tray is inserted.

● The paper stack surface of the tray lowers.

The sequence occurs as follows:

1. The feeder tray-lifting motor rotates and the lifter moves up.

2. When the paper-feeder media-stack-surface sensor detects the stack surface of the paper, the lifting

motor stops.

3. The lifting motor rotates again to lift the lifter when the paper-feeder media-stack-surface sensor detects

the stack surface, and then lowers during printing.

If a tray media-stack-surface sensor does not detect a stack surface within a specied period after the lifting motor starts rotating, the paper feeder driver determines that the lifting motor has failed and noties the formatter through the DC controller.

The paper-feeder driver noties the formatter if either of the paper-feeder media-stack-surface sensors fails to detect the stack surface within a specied period from when a lift-up operation starts.

66 Chapter 1 Theory of operation ENWW

550-sheet paper feeder jam detection

The 550-sheet paper feeder uses the feed sensor (SR21) and right door switch (SW20) to detect the presence of paper and to check whether paper has jammed.

The 550-sheet paper feeder detects the following jams:

● Media input delay jam 1 (550-sheet paper feeder): Paper did not reach the registration sensor in time.

● Media input delay jam 2 (550-sheet paper feeder): Paper did not reach the source tray feed sensor in time.

● Media input delay jam 3 (550-sheet paper feeder): Paper did not reach the tray 3 feed sensor in time.

● Pickup stationary jam (550-sheet paper feeder): The feed sensor does not detect the trailing edge of paper

within a specied time after the sensor detects the leading edge.

● Residual paper jam (550-sheet paper feeder): The feed sensor detects the presence of paper for a

specied time during an automatic delivery operation.

● Right door open jam (550-sheet paper feeder): The right door open is detected during a paper feed

operation.

ENWW Input accessories 67

550-sheet paper-feeder

Figure 1-37 Paper path (1x550-sheet paper-feeder)

68 Chapter 1 Theory of operation ENWW

Figure 1-38 Paper path (3x550-sheet paper-feeder)

ENWW Input accessories 69

Figure 1-39 Paper path (2,550-sheet paper-feeder)

70 Chapter 1 Theory of operation ENWW

Figure 1-40 paper-feeder controller

Clutch

Switch

Photointerruptor

DC controller Paper deck controller

+3.3VB

+24VA

Motor

1x550-sheet paper deck/3x550-sheet paper deck/2550-sheet paper deck

Table 1-28 Paper-feeder electrical component list

Component type Abbreviation Component name 1x550 PD 3x550 PD2,550 PD

Motor M3401 PD cassette 1 lifter motor Yes Yes Yes

M3402 PD feed motor 1 Yes Yes Yes

M4501 PD cassette 2 lifter motor No Yes Yes

M4502 PD feed motor 2 No Yes Yes

M5601 PD cassette 3 lifter motor No Yes No

M5602 PD feed motor 3 No Yes No

Clutch CL3401 PD cassette 1 pickup clutch Yes Yes Yes

CL4501 PD cassette 2 pickup clutch No Yes Yes

CL5601 PD cassette 3 pickup clutch No Yes No

Switch SW3401 PD Cassette 1 media size switch 1 Yes Yes Yes

SW3402 PD Cassette 1 media size switch 2 Yes Yes Yes

SW4501 PD Cassette 2 media size switch 1 No Yes Yes

SW4502 PD Cassette 2 media size switch 2 No Yes No

SW5601 PD Cassette 3 media size switch 1 No Yes No

SW5602 PD Cassette 3 media size switch 2 No Yes No

SW3403 PD door switch Yes Yes Yes

Photointerrupter PS3401 PD cassette 1 feed sensor Yes Yes Yes

PS3402 PD cassette 1 media out sensor Yes Yes Yes

PS3403 PD cassette 1 media surface sensor Yes Yes Yes

PS3413 PD pickup roller alienation sensor Yes Yes Yes

ENWW Input accessories 71

Table 1-28 Paper-feeder electrical component list (continued)

Component type Abbreviation Component name 1x550 PD 3x550 PD2,550 PD

Motor control

Component name Components driven

M3401 PD Cassette 1 lifter motor Lift up the cassette 1

M3402 PD feed motor 1 Cassette pickup roller, cassette feed roller, and feed roller

M4501 PD Cassette 2 lifter motor

PS4501 PD cassette 2 feed sensor No Yes Yes

PS4502 PD cassette 2 media out sensor No Yes Yes

PS4503 PD cassette 2 media surface sensor No Yes Yes

PS5601 PD cassette 3 feed sensor No Yes No

PS5602 PD cassette 3 media out sensor No Yes No

PS5603 PD cassette 3 media surface sensor No Yes No

Lift up the cassette 2 or tray

M4502 PD feed motor 2 Cassette pickup roller, cassette feed roller, tray pickup roller, tray feed roller, and

M5601 PD Cassette 3 lifter motor

M5602 PD feed motor 3

Only for 3x550-sheet paper-feeder and 2,550-sheet paper-feeder

Only for 3x550-sheet paper-feeder

Pickup-and-feed Operation

The paper-feeder picks up the sheet of paper one by one in the paper-feeder cassette and feeds it to the printer.

feed roller

Lift up the cassette 3

Cassette pickup roller, cassette feed roller and feed roller

72 Chapter 1 Theory of operation ENWW

Figure 1-41 1x550-sheet paper-feeder/3x550-sheet paper-feeder electrical components

M4502

M3401

PS5603

PS5602

PS5601

CL5601

M5602

M3402

SW5601

SW5602

M5601

SW4501

SW4502

M4501

PS3402

SW3403

PS3401

PS4501

PS4502

PS3413

PS4503

PS3403

SW3401

SW3402

CL3401

CL4501

Table 1-29 Electrical component list (1x550-sheet paper-feeder/3x550-sheet paper-feeder)

Abbreviation Component name 1x550 PD 3x550 PD

M3401 PD cassette 1 lifter motor Yes Yes

M3402 PD feed motor 1 Yes Yes

M4501 PD cassette 2 lifter motor No Yes

M4502 PD feed motor 2 No Yes

M5601 PD cassette 3 lifter motor No Yes

M5602 PD feed motor 3 No Yes

CL3401 PD cassette 1 pickup clutch Yes Yes

CL4501 PD cassette 2 pickup clutch No Yes

CL5601 PD cassette 3 pickup clutch No Yes

SW3401 PD Cassette 1 media size switch 1 Yes Yes

SW3402 PD Cassette 1 media size switch 2 Yes Yes

SW4501 PD Cassette 2 media size switch 1 No Yes

SW4502 PD Cassette 2 media size switch 2 No Yes

SW5601 PD Cassette 3 media size switch 1 No Yes

SW5602 PD Cassette 3 media size switch 2 No Yes

SW3403 PD door switch Yes Yes

PS3401 PD cassette 1 feed sensor Yes Yes

PS3402 PD cassette 1 media out sensor Yes Yes

ENWW Input accessories 73

Table 1-29 Electrical component list (1x550-sheet paper-feeder/3x550-sheet paper-feeder) (continued)

M3402

M4501

PS3402

SW3403

PS3401

PS4501

PS4502

PS3413

PS4503

PS3403

SW4501

SW3401

SW3402

CL3401

CL4501

M3401

M4502

Abbreviation Component name 1x550 PD 3x550 PD

PS3403 PD cassette 1 media surface sensor Yes Yes

PS3413 PD pickup roller alienation sensor Yes Yes

PS4501 PD cassette 2 feed sensor No Yes

PS4502 PD cassette 2 media out sensor No Yes

PS4503 PD cassette 2 media surface sensor No Yes

PS5601 PD cassette 3 feed sensor No Yes

PS5602 PD cassette 3 media out sensor No Yes

PS5603 PD cassette 3 media surface sensor No Yes

Figure 1-42 Outline of electrical component (2,550-sheet paper-feeder)

Table 1-30 Electrical component list (2,550-sheet paper-feeder)

Abbreviation Component name

M3401 PD cassette 1 lifter motor

M3402 PD feed motor 1

M4501 PD cassette 2 lifter motor

M4502 PD feed motor 2

CL3401 PD cassette 1 pickup clutch

CL4501 PD cassette 2 pickup clutch

SW3401 PD Cassette 1 media size switch 1

74 Chapter 1 Theory of operation ENWW

Table 1-30 Electrical component list (2,550-sheet paper-feeder) (continued)

Abbreviation Component name

SW3402 PD Cassette 1 media size switch 2

SW4501 PD Cassette 2 media size switch 1

SW3403 PD door switch

PS3401 PD cassette 1 feed sensor

PS3402 PD cassette 1 media out sensor

PS3403 PD cassette 1 media surface sensor

PS3413 PD pickup roller alienation sensor

PS4501 PD cassette 2 feed sensor

PS4502 PD cassette 2 media out sensor

PS4503 PD cassette 2 media surface sensor

Table 1-31 Paper-feeder functions

Function Supported

Cassette lift-up control Yes

Cassette presence detection Yes

Cassette media size detection Yes

Cassette media stack surface detection Yes

Cassette media out detection Yes

Cassette media level detection No

Multiple-feed prevention Yes

Automatic delivery Yes

ENWW Input accessories 75

Staple stacker multi bin mailbox

The staple stacker multi bin mailbox (SSMBM) is installed on the upper side of the printer, and it delivers the print media to output tray after the staple process. The SSMBM controller controls the operation sequence of the SSMBM.

Figure 1-43 Staple stacker multi bin mailbox paper path

76 Chapter 1 Theory of operation ENWW

HP m652, m653, mfp, m681, m682 Troubleshooting Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Theory of operation

HP service and support

Additional service and support for channel partners

Additional service and support for HP internal personnel

Basic operation

Sequence of operation

Formatter-control system

Sleep mode

Printer job language (PJL)

Printer management language (PML)

Control panel

Easy-access USB port

Wireless

Input/output (I/O)

Memory

embedded MultiMedia Card (eMMC)

Hard disk drive (HDD)

Fax PCA

Nonvolatile random access memory (NVRAM)

Random access memory (RAM)

HP Memory Enhancement technology (MEt)

Engine-control system

DC controller

Motors

Fans

Solenoids

Clutches

Switches

Sensors

Front door lock function

Low-voltage power supply

Low-voltage power supply voltages description

Over-current/over-voltage protection

Sleep mode operation

Low-voltage power supply failure detection

Low-voltage power supply functions

High-voltage power supplies

High-voltage power supply circuits

Fuser bias

Fuser control

Fuser circuits

Fuser control functions

Fuser temperature control

Fuser heater protection

Fuser unit life detection

Engine laser scanner system

Laser scanner failure detection

Safety

Image-formation process

Step 1: Pre-exposure

Step 2: Primary charging

Step 3: Laser-beam exposure

Step 4: Development

Step 5: Primary transfer

Step 6: Secondary transfer

Step 7: Separation

Step 8: Fusing

Step 9: ITB cleaning

Step 10: Drum cleaning

Toner cartridges

Design

Memory chip

Dynamic security

JetIntelligence

Authentication

Anti-theft

Toner seal

Toner level and cartridge life detection

Developing unit engagement and disengagement control

Intermediate transfer belt (ITB) unit

Primary-transfer roller engagement and disengagement control

ITB unit detection

ITB cleaning mechanism

Secondary transfer roller functions

Calibration

Pickup, feed, and delivery system