CM6040 MFP CM6040f MFPCM6030 MFP CM6030f MFP

HP Color LaserJet CM6030 and CM6040 MFP Series Service Manual

HP Color LaserJet CM6040 MFP SeriesService Manual

Copyright and License

2008 Copyright Hewlett-PackardDevelopment Company, L.P.

Reproduction, adaptation, or translationwithout prior written permission is prohibited,except as allowed under the copyright laws.

The information contained herein is subjectto change without notice.

The only warranties for HP products andservices are set forth in the express warrantystatements accompanying such productsand services. Nothing herein should beconstrued as constituting an additionalwarranty. HP shall not be liable for technicalor editorial errors or omissions containedherein.

Part number: Q3938-90953

Edition 1, 04/2008

Trademark Credits

Adobe, Acrobat, and PostScript aretrademarks of Adobe Systems Incorporated.

Corel is a trademark or registeredtrademark of Corel Corporation or CorelCorporation Limited.

Microsoft, Windows, and Windows NTare U.S. registered trademarks of MicrosoftCorporation.

Windows Vista is either a registeredtrademark or trademark of MicrosoftCorporation in the United States and/or othercountries.

PANTONE is Pantone, Inc's check-standard trademark for color.

UNIX is a registered trademark of The OpenGroup.

ENERGY STAR and the ENERGY STARlogo are U.S. registered marks of the UnitedStates Environmental Protection Agency.

Table of contents

1 Product basicsProduct comparison ............................................................................................................................. 2Product features ................................................................................................................................... 4Product walkaround .............................................................................................................................. 7

Front view ............................................................................................................................ 7HP Color LaserJet CM6040 MFP Series ............................................................ 7

Back view ............................................................................................................................. 8Interface ports ...................................................................................................................... 9Serial number and model number location .......................................................................... 9

Supported operating systems ............................................................................................................. 11

2 Control panelUse the control panel ......................................................................................................................... 14

Control-panel layout ........................................................................................................... 14Home screen ..................................................................................................................... 15Buttons on the touchscreen ............................................................................................... 16Control-panel help system ................................................................................................. 16

Navigate the Administration menu ..................................................................................................... 17Information menu ............................................................................................................................... 18Default Job Options menu .................................................................................................................. 20

Default Options for Originals .............................................................................................. 20Image adjustment .............................................................................................................. 21Default Copy Options ......................................................................................................... 22Default Fax Options ........................................................................................................... 23Default E-mail Options ....................................................................................................... 24Default Send to Folder Options ......................................................................................... 25Default Print Options .......................................................................................................... 26

Time/Scheduling menu ....................................................................................................................... 27Management menu ............................................................................................................................ 29Initial Setup menu ............................................................................................................................... 31

Networking and I/O ............................................................................................................ 31Fax Setup .......................................................................................................................... 38E-mail Setup ...................................................................................................................... 41Send Setup menu .............................................................................................................. 41

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Device Behavior menu ....................................................................................................................... 42Print Quality menu .............................................................................................................................. 49Troubleshooting menu ........................................................................................................................ 53Resets menu ...................................................................................................................................... 59Service menu ..................................................................................................................................... 60

3 Paper and print mediaUnderstand paper and print media use .............................................................................................. 62Supported paper and print media sizes .............................................................................................. 63Supported paper types ....................................................................................................................... 66Special paper or print media guidelines ............................................................................................. 68Load paper and print media ............................................................................................................... 69

Load Tray 1 ........................................................................................................................ 69Print envelopes ................................................................................................. 70

Load trays 2, 3, 4, or 5 ....................................................................................................... 70Load standard-sized media into trays 2, 3, 4, or 5 ............................................ 70Load undetectable standard-sized media into Tray 2, 3, 4, and 5 .................... 72Load custom-size media into tray 2, 3, 4, or 5 .................................................. 73Load large size paper into Tray 3, 4, or 5 ......................................................... 74

Load letterhead, pre-printed, or pre-punched paper .......................................................... 74Change the Image Rotation setting ................................................................... 75Choose the correct orientation for loading letterhead, pre-printed, or pre-punched paper .................................................................................................. 75

Configure trays ................................................................................................................................... 79Configure a tray when loading paper ................................................................................. 79Configure a tray to match print job settings ....................................................................... 79Automatic media type sensing (auto sense mode) ............................................................ 79

Auto sense settings ........................................................................................... 80Select the paper by source, type, or size ........................................................................... 80

Source ............................................................................................................... 80Type and Size ................................................................................................... 81

Choose an output location .................................................................................................................. 82Standard output bins .......................................................................................................... 82Optional output accessories .............................................................................................. 82

3-bin stapler/stacker features ............................................................................ 82Booklet maker finisher features ......................................................................... 83Accessory walkaround ...................................................................................... 83

Use the booklet-making feature ......................................................................................... 84Create a booklet from the print driver ................................................................ 85Create a booklet from a copy ............................................................................ 85

Configure the accessory operation mode .......................................................................... 86Select the operating mode at the control panel ................................................. 86Select the operating mode in the printer driver ................................................. 86Select the operating mode in the printer driver (Mac OS X) ............................. 86

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4 Manage and maintain the productInformation pages ............................................................................................................................... 90HP Easy Printer Care ......................................................................................................................... 92

Open the HP Easy Printer Care software .......................................................................... 92HP Easy Printer Care software sections ............................................................................ 92

Embedded Web server ....................................................................................................................... 95Open the embedded Web server by using a network connection ..................................... 95Embedded Web server sections ........................................................................................ 96

Use HP Web Jetadmin software ........................................................................................................ 99Security features .............................................................................................................................. 100

Secure the embedded Web server .................................................................................. 100Foreign Interface Harness (FIH) ...................................................................................... 100

Requirements .................................................................................................. 100Use the FIH ..................................................................................................... 100

Enable the FIH portal ...................................................................... 100Disable the FIH portal ..................................................................... 101

Secure Disk Erase ........................................................................................................... 101Data affected ................................................................................................... 101Gain access to Secure Disk Erase .................................................................. 102Additional Information ..................................................................................... 102

DSS authentication .......................................................................................................... 102Lock the control-panel menus .......................................................................................... 102

Manage supplies .............................................................................................................................. 103Print-cartridge storage ..................................................................................................... 103HP policy on non-HP print cartridges ............................................................................... 103HP fraud hotline and Web site ......................................................................................... 103

Replace supplies .............................................................................................................................. 104Locate supplies ................................................................................................................ 104Supply replacement guidelines ........................................................................................ 104Approximate replacement intervals for supplies .............................................................. 105Change print cartridges ................................................................................................... 105Change image drums ...................................................................................................... 108Install memory ................................................................................................................. 111

Install DDR memory DIMMs ............................................................................ 111Enable memory ............................................................................................... 114

Enable memory for Windows 2000 and XP .................................... 114Install an HP Jetdirect or EIO print server card or EIO hard disk .................... 115

Replace the staple cartridge ............................................................................................ 117Replace saddle stitch staple cartridges in the booklet maker .......................................... 119

Clean the product ............................................................................................................................. 122Clean the outside of the product ...................................................................................... 122Clean the product interior ................................................................................................ 122

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Clean the 3X500 sheet input tray .................................................................................... 124Clean the IPTU ................................................................................................................ 125Clean the touchscreen ..................................................................................................... 125Clean the scanner glass .................................................................................................. 125Cleaning the ADF delivery system ................................................................................... 126

Clean the ADF delivery system ....................................................................... 126Clean the ADF rollers ...................................................................................... 127

ADF maintenance kit ........................................................................................................................ 129Calibrate the scanner ....................................................................................................................... 130Upgrade the firmware ....................................................................................................................... 131

Determine the current firmware version ........................................................................... 131Download new firmware from the HP Web site ............................................................... 131Transfer the new firmware to the product ........................................................................ 131

Use FTP to upload the firmware through a browser ....................................... 131Use FTP to upgrade the firmware on a network connection ........................... 132Use HP Web Jetadmin to upgrade the firmware ............................................. 133Use MS-DOS commands to upgrade the firmware ......................................... 133

Use the HP Jetdirect firmware ......................................................................................... 133Set the real-time clock ...................................................................................................................... 135

Set the date format .......................................................................................................... 135Set the date ..................................................................................................................... 135Set the time format .......................................................................................................... 135Set the time ...................................................................................................................... 135

5 Theory of operationBasic operation ................................................................................................................................. 138

Sequence of operation ..................................................................................................... 138Formatter system ............................................................................................................................. 140

Sleep mode ...................................................................................................................... 140Resolution Enhancement technology (REt) ..................................................................... 140Input/output ...................................................................................................................... 141CPU ................................................................................................................................. 141Memory ............................................................................................................................ 141

Hard disk ......................................................................................................... 141Random-access memory ................................................................................ 141DIMM slot ........................................................................................................ 141Nonvolatile memory ........................................................................................ 141

PJL overview ................................................................................................................... 141PML ................................................................................................................................. 142Control panel ................................................................................................................... 142

Engine-control system ...................................................................................................................... 143DC controller .................................................................................................................... 144

Solenoids ........................................................................................................ 144

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Switches .......................................................................................................... 145Sensors ........................................................................................................... 146Motors and fans .............................................................................................. 147

Fuser control .................................................................................................................... 149Fuser temperature-control circuit .................................................................... 151Fuser over-temperature protection .................................................................. 152Fuser-failure detection .................................................................................... 153Fuser identification .......................................................................................... 153Fuser-life detection .......................................................................................... 154

Relay-failure detection ..................................................................................................... 154Low-voltage power supply ............................................................................................... 154

Overcurrent/overvoltage protection ................................................................. 155Safety .............................................................................................................. 155Voltage detection ............................................................................................ 155Sleep (powersave) mode ................................................................................ 155

High-voltage power supply .............................................................................................. 155Laser/scanner system ...................................................................................................................... 158Image-formation system ................................................................................................................... 160

Image-formation process ................................................................................................. 161Step 1: Pre-exposure ...................................................................................... 162Step 2: Primary charging ................................................................................. 162Step 3: Laser-beam exposure ......................................................................... 163Step 4: Development ....................................................................................... 163Step 5: Primary transfer .................................................................................. 164Step 6: Secondary transfer ............................................................................. 164Step 7: Separation .......................................................................................... 165Step 8: Fusing ................................................................................................. 165Step 9: ITB cleaning ........................................................................................ 166Step 10: Drum cleaning ................................................................................... 166

Print cartridge .................................................................................................................. 167Imaging drum ................................................................................................................... 168

Developing roller engagement and disengagement ........................................ 170Intermediate transfer belt (ITB) unit ................................................................................. 171

Primary-transfer-roller engagement and disengagement ................................ 171ITB unit detection ............................................................................................ 173

Secondary-transfer-roller unit .......................................................................................... 175Calibration ........................................................................................................................ 175

Color-misregistration contol ............................................................................ 176Image stabilization control ............................................................................... 177

Pickup, feed, and delivery system .................................................................................................... 178Pickup-and-feed unit ........................................................................................................ 181

Cassette pickup ............................................................................................... 183Cassette paper-size and cassette-presence detection ................... 183Cassette lift operation ..................................................................... 185

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Cassette paper-level and paper-presence detection ...................... 186Multifeed prevention ....................................................................... 187

Multipurpose tray pickup ................................................................................. 188Multipurpose tray last-paper detection ........................................... 189

Paper feed ....................................................................................................... 190Skew-feed prevention ..................................................................... 191Paper-type detection ...................................................................... 192Feed-speed control ......................................................................... 193

Fusing and delivery unit ................................................................................................... 195Loop control .................................................................................................... 195Pressure-roller pressurization control ............................................................. 196

Duplexing unit .................................................................................................................. 197Duplexing reverse and feed control ................................................................ 198

Jam detection ................................................................................................................................... 199Optional input trays .......................................................................................................................... 201

Paper-feeder pickup and feed operation ......................................................................... 204Scanner component ......................................................................................................................... 206

Product boards ................................................................................................................ 207Scanner system block diagram ........................................................................................ 208Scanner image-data path ................................................................................................ 209Scanner power topology .................................................................................................. 210Scanner power states ...................................................................................................... 211Sensor topology ............................................................................................................... 212Boards I/Os ...................................................................................................................... 215Scanner operation flow .................................................................................................... 217

ADF .................................................................................................................................................. 221Input tray .......................................................................................................................... 221ADF simplex-printing operation sequence ....................................................................... 221ADF duplex-printing operation sequence ........................................................................ 222Multifeed operation .......................................................................................................... 223End of a scan job operation ............................................................................................. 224Paper pick and separation operation ............................................................................... 224Deskew ............................................................................................................................ 225

6 Removal and replacementRemoval and replacement strategy .................................................................................................. 228

Introduction ...................................................................................................................... 228Required tools .................................................................................................................. 229Types of screws ............................................................................................................... 229Service approach ............................................................................................................. 230Before performing service ................................................................................................ 230After performing service ................................................................................................... 230Parts removal order ......................................................................................................... 231

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User-replaceable parts ..................................................................................................................... 232Fuser ................................................................................................................................ 233Transfer roller .................................................................................................................. 236Intermediate transfer belt (ITB) ........................................................................................ 238Tray 1 pickup and separation rollers ................................................................................ 241Tray 2, 3, 4, and 5 pickup rollers .................................................................................... 243Formatter ......................................................................................................................... 245Tray 2 ............................................................................................................................... 248Trays 3, 4, and 5 .............................................................................................................. 248

Service-replaceable parts ................................................................................................................. 249Secondary transfer unit .................................................................................................... 249Multipurpose drive unit ..................................................................................................... 254Multipurpose-tray guide (Tray 1) unit ............................................................................... 258Cassette (Tray 2) pickup unit ........................................................................................... 259Rear-left cover ................................................................................................................. 260Rear-right cover ............................................................................................................... 261Rear cover ....................................................................................................................... 262Low-voltage power-supply unit ........................................................................................ 263High-voltage power supply PCA (A) ................................................................................ 264Lifter-drive unit ................................................................................................................. 266Fuser motor ..................................................................................................................... 269Intermediate-transfer belt (ITB) motor ............................................................................. 270Face-down output bin ...................................................................................................... 271Left cover ......................................................................................................................... 272Laser/scanner fan duct .................................................................................................... 273Print-cartridge driver PCA ................................................................................................ 275High-voltage power supply PCA (B) ................................................................................ 277Formatter case ................................................................................................................. 279DC controller PCA ........................................................................................................... 281Environmental sensor ...................................................................................................... 283Image-drum motor ........................................................................................................... 284Fuser fan .......................................................................................................................... 286Print-cartridge feed motor (black) .................................................................................... 287Print-cartridge feed motor (yellow, magenta, and cyan) .................................................. 288Cartridge fan unit ............................................................................................................. 289Laser/scanner fan unit ..................................................................................................... 290Fuser power-supply unit .................................................................................................. 291Primary transfer-roller disengagement motor .................................................................. 292Print-cartridge drive unit (yellow and magenta) ............................................................... 293Print-cartridge drive unit (cyan and black) ....................................................................... 298Print-cartridge interface PCA (cyan and black) ................................................................ 299Print-cartridge interface PCA (yellow and magenta) ........................................................ 300Main drive unit ................................................................................................................. 301Cartridge fan duct ............................................................................................................ 303

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Duplex switchback tray .................................................................................................... 304Front lower cover ............................................................................................................. 305Inner cover ....................................................................................................................... 306Rear scanner cover ......................................................................................................... 308Right upper cover ............................................................................................................ 309Front door ........................................................................................................................ 310Front door assembly ........................................................................................................ 311Color-misregistration and image-density sensor unit ....................................................... 312Pressure-release sensor unit ........................................................................................... 313Scanner cover .................................................................................................................. 315Laser/scanner assembly (yellow and magenta) .............................................................. 316Laser/scanner assembly (cyan and black) ...................................................................... 319VOC fan ........................................................................................................................... 322Duplexing reverse unit ..................................................................................................... 323Face-down delivery unit ................................................................................................... 324Face-down cover ............................................................................................................. 326Right-door assembly ........................................................................................................ 327Duplexing feed unit .......................................................................................................... 329Multipurpose-tray (Tray 1) pickup unit ............................................................................. 331Thermopile unit ................................................................................................................ 334Front-lower cover ............................................................................................................. 335ITB duct ........................................................................................................................... 336

Optional input trays .......................................................................................................................... 3371x500-sheet input tray ..................................................................................................... 337

Right door ........................................................................................................ 337Lower-rear cover ............................................................................................. 339Front-right cover .............................................................................................. 340Right cover ...................................................................................................... 341Front-upper cover ............................................................................................ 342Lower-left cover ............................................................................................... 343Front-lower door .............................................................................................. 344Box .................................................................................................................. 345Pickup unit ....................................................................................................... 346

Input tray is attached ...................................................................... 346Paper feeder is not attached .......................................................... 347

Auto-close unit ................................................................................................ 349Pickup motor ................................................................................................... 350Paper-feeder driver PCA ................................................................................. 351

3x500-sheet input tray ..................................................................................................... 352Right door ........................................................................................................ 352Lower-rear cover ............................................................................................. 352Front-right cover .............................................................................................. 352Right cover ...................................................................................................... 352Front-upper cover ............................................................................................ 352

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Left cover ........................................................................................................ 352Pickup unit (middle cassette) .......................................................................... 353Pickup unit (lower cassette) ............................................................................ 354Pickup unit (upper cassette) ............................................................................ 354

Paper feeder is attached ................................................................ 354Paper feeder is not attached .......................................................... 355

Auto-close unit ................................................................................................ 357Pickup motor ................................................................................................... 357Paper-feeder driver PCA ................................................................................. 357

Scanner ............................................................................................................................................ 358Optical scanner ................................................................................................................ 358Upper-left scanner cover ................................................................................................. 362Upper-right scanner cover ............................................................................................... 363Control panel ................................................................................................................... 364Front scanner cover ......................................................................................................... 366Lower-left scanner cover ................................................................................................. 368Lower-right scanner cover ............................................................................................... 370Top scanner cover ........................................................................................................... 371Glass assembly ............................................................................................................... 372Carriage unit .................................................................................................................... 373Configure the SCB when replacing the carriage unit, inverter, SCB, or opticalscanner ............................................................................................................................ 378Pulley assembly and motor unit ....................................................................................... 380Rail ................................................................................................................................... 383Inverter ............................................................................................................................. 384

Inverter unit ..................................................................................................... 384Lid sensor ........................................................................................................................ 386SCB, CPB, and SCUID .................................................................................................... 388Power-supply unit ............................................................................................................ 391Scanner fan ..................................................................................................................... 393SCB fan ........................................................................................................................... 394Control panel fan ............................................................................................................. 395Fan filter ........................................................................................................................... 396

ADF .................................................................................................................................................. 397ADF assembly ................................................................................................................. 397ADF input tray sensors .................................................................................................... 399Separation floor assembly ............................................................................................... 401Diverter ............................................................................................................................ 403Jam cover ........................................................................................................................ 404Hinge assemblies ............................................................................................................ 406Float assembly ................................................................................................................. 407White backing .................................................................................................................. 410Front end cover (cap) ...................................................................................................... 412Rear end cover (cap) ....................................................................................................... 414

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ADF PCA and wire harness ............................................................................................. 417Input tray .......................................................................................................................... 419

7 Solve problemsIntroduction ....................................................................................................................................... 422Troubleshooting process .................................................................................................................. 423

Determine the problem source ........................................................................................ 423Pre-troubleshooting checklist .......................................................................... 423Troubleshooting checklist ................................................................................ 424Troubleshooting flowchart ............................................................................... 426

Power subsystem ............................................................................................................ 427Power-on checks ............................................................................................. 427

Power-on troubleshooting overview ............................................... 427Tools for troubleshooting .................................................................................................................. 429

Internal print-quality test pages ........................................................................................ 429Print-quality-troubleshooting pages ................................................................. 429Diagnostics page ............................................................................................. 429Cleaning page ................................................................................................. 430Configuration pages ........................................................................................ 431

Configuration page ......................................................................... 431HP embedded Jetdirect page ......................................................... 433Embedded protocol page ............................................................... 434Finding important information on the configuration pages .............. 435

Solve performance problems ........................................................................................................... 436Solve connectivity problems ............................................................................................................. 437

Solve direct-connect problems ........................................................................................ 437Solve network connectivity problems ............................................................................... 437

Solve network printing problems ..................................................................... 437Verify communication over the network .......................................................... 438

Control-panel message types ........................................................................................................... 439Control-panel messages .................................................................................................................. 440Event log messages ......................................................................................................................... 511

Print an event log ............................................................................................................. 511Show an event log ........................................................................................................... 511Clear the event log ........................................................................................................... 511Event log message .......................................................................................................... 512

Paper-handling problems ................................................................................................................. 519Jams ................................................................................................................................ 519

Common causes of jams ................................................................................. 519Jam locations .................................................................................................. 520Clear jams ....................................................................................................... 520

Jam sensors ................................................................................... 521AREA 1: Jams in the output bin ...................................................... 522

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AREA 2 and 3: Jams in the fuser and transfer area ....................... 524AREA 4: Jams in the duplex area ................................................... 531AREA 5: Jams in Tray 2 and the internal paper path ..................... 535AREA 6:Jams in Tray 1 .................................................................. 539AREA 7: Jams in optional Trays 3, 4, and 5 ................................... 543AREA 8: Jams in the optional finishing devices ............................. 547AREA 9: Jams in the ADF .............................................................. 552Clear staple jams ............................................................................ 553

Jam recovery ................................................................................................... 557Product feeds multiple sheets .......................................................................................... 558Product pulls from incorrect tray ...................................................................................... 558Product feeds incorrect page size ................................................................................... 558Paper does not feed automatically .................................................................................. 559Paper does not feed from Tray 2, 3, 4, or 5 ..................................................................... 559Transparencies or glossy paper will not feed .................................................................. 560Envelopes jam or will not feed in the product .................................................................. 561Output is curled or wrinkled ............................................................................................. 561Product will not duplex or duplexes incorrectly ................................................................ 562

Solve image quality problems .......................................................................................................... 563Example print quality problems ........................................................................................ 563Repetitive defects ruler .................................................................................................... 563Overhead transparency defects ....................................................................................... 565Print quality problems associated with the environment .................................................. 565Print quality problems associated with jams .................................................................... 565Optimize and improve image quality ................................................................................ 565

Use supported paper ....................................................................................... 566Calibrate the product ....................................................................................... 566Specify the correct paper type ........................................................................ 566Clean the fuser ................................................................................................ 567Respond to control-panel error messages ...................................................... 568

Clean the registration second transfer assembly ........................... 568Use manual print modes ................................................................................. 570Print-quality-troubleshooting pages ................................................................. 571

Image-quality issues ........................................................................................................ 574Interface troubleshooting .................................................................................................................. 579

Communication checks .................................................................................................... 579EIO troubleshooting ......................................................................................................... 579

Engine diagnostics ........................................................................................................................... 580LED diagnostics ............................................................................................................... 580

Understand lights on the formatter .................................................................. 580HP Jetdirect LEDs .......................................................................... 580Heartbeat LED ................................................................................ 581

Understand lights on the SCB ......................................................................... 581Understand lights on the copy-process board (CPB) ...................................... 583

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Engine-test button ............................................................................................................ 583Troubleshooting menu ..................................................................................................... 584Diagnostics mode ............................................................................................................ 585Diagnostics that put the engine into the special diagnostics mode ................................. 585Diagnostic tests ............................................................................................................... 586Disable cartridge check ................................................................................................... 587Paper-path sensors test ................................................................................................... 587Paper-path test ................................................................................................................ 589Manual sensor test (special-mode test) ........................................................................... 590Component tests .............................................................................................................. 592

Component test (special-mode test) ............................................................... 592Transfer-motors test ........................................................................................ 592Belt-only test ................................................................................................... 592Image-drum motors test .................................................................................. 592CMYK-laser test .............................................................................................. 593Fuser-motor test .............................................................................................. 593Fuser pressure-release motor test .................................................................. 593Color-alienation motor test .............................................................................. 593ITB-contact/alienation test ............................................................................... 593Paper-transport motor test .............................................................................. 594Tray-1 pickup-solenoid test ............................................................................. 594Tray-2 pickup-motor test ................................................................................. 594Duplexer reverse-motor test ............................................................................ 594Duplexer refeed-motor test ............................................................................. 594

Print/stop test ................................................................................................................... 596Color-band test ................................................................................................................ 597Scanner tests ................................................................................................................... 597

Service-mode functions .................................................................................................................... 598Service menu ................................................................................................................... 598Product resets .................................................................................................................. 600

NVRAM initialization ........................................................................................ 600Solve scanner problems ................................................................................................................... 601Solve fax problems ........................................................................................................................... 602Solve e-mail problems ...................................................................................................................... 603

Validate the SMTP gateway address ............................................................................... 603Validate the LDAP gateway address ............................................................................... 603

Diagrams .......................................................................................................................................... 604Connectors ...................................................................................................................... 604

DC controller PCA ........................................................................................... 604PCAs ............................................................................................................... 604Product base ................................................................................................... 6061 x 500 input tray ............................................................................................. 6093 x 500 input tray ............................................................................................. 610IPTU ................................................................................................................ 611

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Fans ................................................................................................................................. 611Product base ................................................................................................... 611

Sensors ............................................................................................................................ 612Product base ................................................................................................... 6121 x 500 input tray ............................................................................................. 6143 x 500 input tray ............................................................................................. 615IPTU ................................................................................................................ 616

Motors .............................................................................................................................. 617Product base ................................................................................................... 6171 x 500 input tray ............................................................................................. 6183 x 500 input tray ............................................................................................. 619IPTU ................................................................................................................ 620

Solenoids ......................................................................................................................... 620Product base ................................................................................................... 6201 x 500 input tray ............................................................................................. 6213 x 500 input tray ............................................................................................. 621

Switches .......................................................................................................................... 622Product base ................................................................................................... 6221 x 500 input tray ............................................................................................. 6233 x 500 input tray ............................................................................................. 623

Block diagrams ................................................................................................................ 625Main assemblies ............................................................................................. 625Main parts ....................................................................................................... 628PCAs ............................................................................................................... 6291 x 500 input tray ............................................................................................. 6303 x 500 input tray ............................................................................................. 631Intermediate paper-transfer unit (IPTU) .......................................................... 632Scanner ........................................................................................................... 632

Components (scanner) ................................................................... 632ADF ................................................................................................................. 633

Sensors (ADF) ................................................................................ 633General timing chart ........................................................................................................ 634General circuit diagrams .................................................................................................. 634

Signals .............................................................................................................................................. 639

8 Output accessories and intermediate paper transfer unit (IPTU)Theory of operation .......................................................................................................................... 668

Intermediate paper transfer unit (IPTU) ........................................................................... 668Basic operation ............................................................................................... 668Feed operation ................................................................................................ 670Jam detection .................................................................................................. 670

3-bin stapler/stacker ........................................................................................................ 671Basic operation ............................................................................................... 671

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Electrical circuitry ............................................................................ 672Feed drive system ........................................................................................... 672

Construction of the control system ................................................. 673Paper delivery path (stapler/stacker and booklet maker) ............... 675

Intermediate-process output-bin assembly (stapler/stacker and bookletmaker) ............................................................................................................. 679

Stack job offset ............................................................................... 679Process output bin paper-stacking operation .................................................. 681Offset operation ............................................................................................... 681Stack trailing-edge assist operation ................................................................ 682Stack delivery operation .................................................................................. 682Staple operation (stapler/stacker and booklet maker) ..................................... 683

Staple unit ....................................................................................... 686Shift the staple unit .......................................................................................... 687Stack operation (stapler/stacker and booklet maker) ...................................... 689

Output bin operation ....................................................................... 689Shutter operation ............................................................................ 691

Jam detection .................................................................................................. 692Power supply ................................................................................................... 693

Power-supply route ......................................................................... 693Protection function .......................................................................... 693

HP Booklet Maker/Finisher accessory ............................................................................. 694Basic operation ............................................................................................... 694

Basic operation of the stacker unit ................................................. 694Electrical circuitry of the stacker unit .............................................. 694Basic operation of the booklet maker unit ...................................... 695Electrical circuitry for the booklet maker unit .................................. 696Feed drive system .......................................................................... 696Paper-delivery path (booklet maker only) ....................................... 701

Basic operation for the booklet maker ............................................................. 702Control of the inlet flappers ............................................................................. 706Control of paper movement ............................................................................. 709Alignment of paper .......................................................................................... 711Control the phase of the crescent roller .......................................................... 713Overview of folding .......................................................................................... 715Control of stack movement ............................................................................. 716Fold the stack .................................................................................................. 716Double folding a stack ..................................................................................... 719Intermediate-process-tray assembly ............................................................... 720Staple operation .............................................................................................. 721

Stapler unit ..................................................................................... 721Stapling operation ........................................................................... 722Stitcher (stapler) unit ...................................................................... 722

Stack operation ............................................................................................... 723

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Jam detection .................................................................................................. 723Detect jams in the stacker unit ....................................................... 724Detect jams in the booklet maker unit ............................................ 724

Power supply ................................................................................................... 725Power-supply route for the stacker unit .......................................... 725Protective function for the stacker unit ........................................... 726Power-supply route for the booklet maker unit ............................... 726Protective function for the booklet maker unit ................................ 726

Specifications ................................................................................................................................... 727Accessory specifications .................................................................................................. 727Stapler/stacker output-bin capacities ............................................................................... 732Booklet-maker output-bin capacities ................................................................................ 733

Removal and replacement ............................................................................................................... 734Intermediate paper transfer unit (IPTU) ........................................................................... 734

IPTU ................................................................................................................ 734Upper guide assembly .................................................................................... 736Rear cover ....................................................................................................... 738Fan unit ........................................................................................................... 742Right belt-drive unit ......................................................................................... 743Left belt-drive unit ............................................................................................ 746Finisher lock-assembly .................................................................................... 748IPTU paper-feed motor 1 ................................................................................ 750IPTU paper-feed motor 2 ................................................................................ 751IPTU driver PCA .............................................................................................. 752

Stapler/stacker and Booklet maker .................................................................................. 753Identify the booklet maker and stapler/stacker ............................................... 753Remove the booklet maker and stapler/stacker from the printer .................... 754External covers ............................................................................................... 757

Entrance lower-guide assembly ..................................................... 757Front door ....................................................................................... 758Rear cover ...................................................................................... 759Front-foot cover .............................................................................. 760Rear-foot cover ............................................................................... 760Front inside-upper cover ................................................................. 761Front inside-lower cover (booklet maker only) ................................ 762Left-upper cover ............................................................................. 763Top door ......................................................................................... 765Grate-shaped upper guide .............................................................. 767Move output bins 1 and 2 ............................................................... 768Grate-shaped lower guide .............................................................. 770PCA cover ...................................................................................... 771

Drive system ................................................................................................... 772Stapler ............................................................................................ 772Stapler assembly ............................................................................ 774

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Swing unit ....................................................................................... 777Upper crossmember unit ................................................................ 781Saddle unit (booklet maker only) .................................................... 784Saddle-stapler assembly (booklet maker only) ............................... 788Positioning plate unit (inner side-plate assembly) (booklet makeronly) ................................................................................................ 789

Document feed system ................................................................................... 792Operation-tray assembly ................................................................ 792Output-bin 1 .................................................................................... 797Output-bin 2 .................................................................................... 799Upper output bin (stapler-stacker only) .......................................... 801Buffer rollers ................................................................................... 802Booklet-delivery output bin (booklet maker only) ............................ 803Booklet-delivery output bin unit (booklet maker only) ..................... 804Return roller unit ............................................................................. 805Pressure roller unit ......................................................................... 807Entrance upper guide unit .............................................................. 812Upper-delivery guide (booklet maker only) ..................................... 814Inlet feed unit (stapler-stacker only) ............................................... 815Inlet feed unit (booklet maker only) ................................................ 818Paper-folding roller (booklet maker only) ........................................ 821

Electrical system ............................................................................................. 826Stacker controller PCA ................................................................... 826Saddle-stitcher controller PCA (booklet maker only) ...................... 827

Solve problems ................................................................................................................................. 828Intermediate paper-transfer unit (IPTU) ........................................................................... 828

......................................................................................................................... 828Stapler/stacker and booklet maker .................................................................................. 828

Individual component diagnostics ................................................................... 828Manual sensor test ......................................................................... 828Component test .............................................................................. 829LED diagnostics .............................................................................. 830

Diagrams ......................................................................................................... 832Cross sections ................................................................................ 832Sensors ......................................................................................... 835Microswitches ................................................................................. 839Solenoids ........................................................................................ 841Motors ............................................................................................. 843Clutches .......................................................................................... 845PCA ................................................................................................ 846Variable resistors, LED, and check pins ........................................ 849Circuit diagrams .............................................................................. 852

Adjustments ................................................................................................... 857Adjust the alignment position .......................................................... 857

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Adjust the staple position ................................................................ 857Adjust the folding position to the stitch position (Booklet makeronly) ................................................................................................ 859Adjust the stitcher unit .................................................................... 862

9 Parts and diagramsOrder parts, accessories, and supplies ............................................................................................ 866

Order directly from HP ..................................................................................................... 866Order directly through the software ................................................................................. 866Orderable and non-orderable parts ................................................................................. 866

Replacement kits .............................................................................................................................. 868Printer supplies and accessories ..................................................................................... 868

Printer ............................................................................................................................................... 872Printer parts ..................................................................................................................... 872

Input-accessory devices ................................................................................................................... 916Input trays ........................................................................................................................ 916

Output-accessory devices ................................................................................................................ 934Intermediate paper-transfer unit (IPTU) ........................................................................... 934Stapler/stacker and booklet-maker .................................................................................. 945

Automatic document-feeder (ADF) ................................................................................................. 1016Automatic document feeder (ADF) assemblies ............................................................. 1016

Scanner .......................................................................................................................................... 1032Scanner assemblies ...................................................................................................... 1032

Alphabetical parts list ..................................................................................................................... 1066Numerical parts list ......................................................................................................................... 1094

Appendix A Service and supportHewlett-Packard limited warranty statement .................................................................................. 1124Print cartridge limited warranty statement ...................................................................................... 1126Color LaserJet Fuser Kit, Transfer Kit, and Roller Kit Limited Warranty Statement ....................... 1127Customer self repair warranty service ............................................................................................ 1128Customer support ........................................................................................................................... 1129Availability of support and service .................................................................................................. 1130HP maintenance agreements ......................................................................................................... 1131

On-site service agreements ........................................................................................... 1131Priority onsite service ..................................................................................................... 1131Next-day onsite service ................................................................................................. 1131Weekly (volume) on-site service .................................................................................... 1131

Appendix B Product specificationsPhysical specifications ................................................................................................................... 1134Electrical specifications .................................................................................................................. 1135Acoustic specifications ................................................................................................................... 1136

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Environmental specifications .......................................................................................................... 1137

Appendix C Regulatory informationCompliance with FCC regulations .................................................................................................. 1140Declaration of Conformity ............................................................................................................... 1141Declaration of Conformity ............................................................................................................... 1142Environmental product stewardship program ................................................................................. 1143

Protecting the environment ............................................................................................ 1143Ozone production .......................................................................................................... 1143Power consumption ....................................................................................................... 1143Toner consumption ........................................................................................................ 1143Paper use ...................................................................................................................... 1143Plastics .......................................................................................................................... 1143HP LaserJet print supplies ............................................................................................. 1143Return and recycling instructions ................................................................................... 1144

United States and Puerto Rico ...................................................................... 1144Multiple returns (more than one cartridge) ................................... 1144Single returns ............................................................................... 1144Shipping ........................................................................................ 1144

Non-U.S. returns ............................................................................