HP Laserjet 1010 Printer

service hp LaserJet 1010 1012 1015 series printer

hp LaserJet 1010 series printer Service Manual

Copyright Information © 2003 Copyright Hewlett-Packard Development Company, LP Reproduction, adaptations, or translation without prior written permission is prohibited except as allowed under copyright laws. The information contained in this document is subject to change without notice. The only warranties for HP products and services are set forth in the express warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty. HP shall not be liable for technical or editorial errors or omissions contained herein. Part number Q2460-90928 Edition 1, 8/2003 Information regarding FCC Class B, Parts 15 and 68 requirements can be found in the user guide.

Notice To U.S. Government Users:

Restricted Rights Commercial

Warning!

Table of contents 1 Product Information HP LaserJet 1010 series has three product configurations......................................................2 The HP LaserJet 1010, 1012, and 1015.............................................................................2 Introduction............................................................................................................................... 3 Overview of product..................................................................................................................4 Model and serial numbers..................................................................................................4 Hardware description..........................................................................................................5 Firmware description .........................................................................................................6 Product Specifications..............................................................................................................7 HEWLETT-PACKARD LIMITED WARRANTY STATEMENT ..................................................9 Extended warranty..................................................................................................................10 Print cartridge information ......................................................................................................11 Refilled print cartridges ...................................................................................................11 Recycling print cartridges ................................................................................................11 Declaration of Conformity.......................................................................................................12 For Regulatory Topics ONLY, contact:...................................................................................13 Laser safety statement.....................................................................................................13 Canadian DOC regulations...............................................................................................13 Korean EMI statement......................................................................................................13 Laser statement for Finland..............................................................................................14 2 Installation and Operation Operating environment ..........................................................................................................16 Identifying the control panel components...............................................................................17 Product media specifications..................................................................................................18 Supported media sizes (printer).......................................................................................18 Guidelines for using media.....................................................................................................19 Paper and Transparencies ..............................................................................................19 Common media problems table .......................................................................................19 Labels ..............................................................................................................................19 Envelopes ........................................................................................................................20 Card stock and heavy media ...........................................................................................20 Loading media .......................................................................................................................22 Loading media to print......................................................................................................22 3 Maintenance Life expectancies of parts that wear ......................................................................................24 Cleaning the product...............................................................................................................25 Cleaning the print path.....................................................................................................25 Cleaning the print cartridge area......................................................................................26 Cleaning the printer pickup roller .....................................................................................27 User-replaceable parts ...........................................................................................................29 Replacing the printer pickup roller ...................................................................................29 Replacing the printer separation pad................................................................................31

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Replacing the main input tray (paper pickup tray assembly)............................................33 Replacing the output tray extension (delivery tray assembly)..........................................34 4 Operational overview Basic functions........................................................................................................................36 Formatter system....................................................................................................................37 Central processing unit ....................................................................................................37 RAM.................................................................................................................................. 37 Universal Serial Bus interface..........................................................................................37 Parallel interface (HP LaserJet 1015 only).......................................................................37 Control panel....................................................................................................................37 Draft mode .......................................................................................................................38 MEt................................................................................................................................... 38 Enhanced I/O ...................................................................................................................38 PJL overview ...................................................................................................................38 Printer functions......................................................................................................................39 Engine control system (engine control unit and power assembly)...................................39 Image formation system...................................................................................................43 Printer paper feed system................................................................................................44 Jam detection ..................................................................................................................46 Solenoid, sensors, and switches......................................................................................46 Basic sequence of operation (formatter-to-printer)...........................................................47 5 Removal and replacement Removal and replacement strategy........................................................................................52 Required tools .................................................................................................................52 Before performing service................................................................................................52 Print cartridge ..................................................................................................................52 Differences between the series models............................................................................53 Part removal order ...........................................................................................................53 User-replaceable parts ...........................................................................................................55 Replacing the printer pickup roller ...................................................................................55 Replacing the printer separation pad................................................................................57 Replacing the main input tray (paper pick-up tray assembly)...........................................59 Replacing the output tray extension (delivery tray assembly)..........................................60 Covers..................................................................................................................................... 61 Right side cover................................................................................................................62 Left side cover..................................................................................................................65 Print cartridge access door, fuser cover, and rear panel..................................................65 Front cover.......................................................................................................................68 Internal assemblies.................................................................................................................70 Transfer roller assembly...................................................................................................70 Engine power assembly...................................................................................................72 Fuser (fixing) assembly....................................................................................................73 Paper pickup assembly....................................................................................................75 Engine control unit assembly............................................................................................76 Laser scanner assembly...................................................................................................78 6 Troubleshooting Basic troubleshooting..............................................................................................................82 Control panel power-on functions...........................................................................................84 Power-on Functions: Time Ranges..................................................................................84 Control Panel Pages...............................................................................................................86 Control Panel Pages: Time Ranges.................................................................................86 iv

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Control Panel Lights................................................................................................................87 Control Panel Light Patterns.............................................................................................87 Fatal Errors.......................................................................................................................91 Image troubleshooting............................................................................................................92 Print cartridge problems...................................................................................................92 Solving image-quality problems .......................................................................................92 Solving paper-feed problems..................................................................................................99 Solving print paper-feed problems....................................................................................99 Functional checks.................................................................................................................103 Half self-test functional check.........................................................................................103 Drum rotation functional check ......................................................................................105 High-voltage contacts check...........................................................................................105 Troubleshooting tools ...........................................................................................................107 Repetitive image defect ruler..........................................................................................107 Circuit diagram ..............................................................................................................108 Solenoid, sensors, and switches...........................................................................................109 7 Parts and diagrams Ordering parts and supplies .................................................................................................112 Parts .............................................................................................................................. 112 Related documentation and software ............................................................................112 Parts that wear .............................................................................................................112 Accessories and consumables ............................................................................................113 Common hardware ........................................................................................................114 How to use the parts lists and diagrams ........................................................................114 Field-replaceable units .........................................................................................................115 Alphabetical parts list............................................................................................................118 Numerical parts list...............................................................................................................119 Index

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List of tables Table 1-1. Physical specifications.............................................................................................7 Table 1-2. Environmental specifications ..................................................................................7 Table 1-3. Performance of HP LaserJet 1010..........................................................................7 Table 1-4. Performance of HP LaserJet 1012 and 1015..........................................................7 Table 1-5. Electrical specifications............................................................................................7 Table 2-1. Media types...........................................................................................................18 Table 3-1. Life expectancies of parts that wear......................................................................24 Table 4-1. Basic sequence of operation.................................................................................47 Table 6-1. Basic troubleshooting ..........................................................................................82 Table 6-2. Solving print image-quality problems.....................................................................93 Table 6-3. Solving print paper-feed problems.........................................................................99 Table 7-1. Technical support websites ................................................................................112 Table 7-2. Accessories ........................................................................................................113 Table 7-3. Replaceable Assemblies ....................................................................................116 Table 7-4. Alphabetical parts list...........................................................................................118 Table 7-5. Numerical parts list..............................................................................................119

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List of figures Figure 1-1. Model and serial number labels..............................................................................4 Figure 1-2. Front and side view................................................................................................4 Figure 1-3. Back and side view.................................................................................................5 Figure 2-1. Dimensions of product..........................................................................................16 Figure 2-2. Control panel lights and buttons...........................................................................17 Figure 4-1. Basic configuration...............................................................................................36 Figure 4-2. Printer functional block diagram...........................................................................39 Figure 4-3. Laser/scanner operation.......................................................................................41 Figure 4-4. High-voltage power supply circuit.........................................................................42 Figure 4-5. Image formation block diagram............................................................................43 Figure 4-6. Printer paper path ................................................................................................45 Figure 4-7. Solenoid, photosensors, and switches.................................................................47 Figure 4-8. Printer timing diagram ........................................................................................49 Figure 5-1. Removing the print cartridge................................................................................53 Figure 5-2. HP LaserJet 1015 parallel port.............................................................................53 Figure 5-3. Product teardown tree..........................................................................................54 Figure 5-4. Removing the right side cover (1 of 5)..................................................................62 Figure 5-5. Removing the right side cover (2 of 5)..................................................................62 Figure 5-6. Removing the right side cover (3 of 5)..................................................................63 Figure 5-7. Removing the right side cover (4 of 5)..................................................................64 Figure 5-8. Removing the right side cover (5 of 5)..................................................................64 Figure 5-9. Removing the rear panel (1 of 5)..........................................................................65 Figure 5-10. Removing the rear panel (2 of 5)........................................................................66 Figure 5-11. Removing the rear panel (3 of 5)........................................................................66 Figure 5-12. Removing the rear panel (4 of 5)........................................................................67 Figure 5-13. Removing the rear panel (5 of 5)........................................................................67 Figure 5-14. Removing the front cover (1 of 3).......................................................................68 Figure 5-15. Removing the front cover (2 of 3).......................................................................68 Figure 5-16. Removing the front cover (3 of 3).......................................................................69 Figure 5-17. Removing the transfer roller (1 of 3)...................................................................70 Figure 5-18. Removing the transfer roller (2 of 3)...................................................................71 Figure 5-19. Removing the transfer roller (3 of 3)...................................................................72 Figure 5-20. Removing the engine power assembly (1 of 2)..................................................73 Figure 5-21. Removing the engine power assembly (2 of 2)..................................................73 Figure 5-22. Removing the fuser (fixing) assembly................................................................74 Figure 5-23. Fragile tab on fuser assembly............................................................................75 Figure 5-24. Removing the paper pickup assembly................................................................75 Figure 5-25. Removing the ECU assembly (1 of 5)................................................................76 Figure 5-26. Removing the ECU assembly (2 of 5)................................................................76 Figure 5-27. Removing the ECU assembly (3 of 5)................................................................77 Figure 5-28. Removing the ECU assembly (4 of 5)................................................................77 Figure 5-29. Removing the ECU assembly (5 of 5)................................................................78 Figure 5-30. Removing the laser scanner assembly...............................................................79 Figure 6-1. Control panel lights legend...................................................................................87 Figure 6-2. Check the fuser connections..............................................................................104 Figure 6-3. Check the fuser connections..............................................................................104

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Figure 6-4. Print cartridge high-voltage contacts..................................................................106 Figure 6-5. Printer high-voltage contacts..............................................................................106 Figure 6-6. Repetitive image defect ruler..............................................................................107 Figure 6-7. Circuit diagram...................................................................................................108 Figure 6-8. Solenoid, photosensors, and switches...............................................................109 Figure 7-1. All Models ..........................................................................................................115 Figure 7-2. Exploded View: Field Replaceable Units ...........................................................116 x

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Product Information This chapter provides general product information for HP LaserJet 1010 series printers. HP LaserJet 1010 series has three product configurations......................................................2 The HP LaserJet 1010, 1012, and 1015.............................................................................2 Introduction............................................................................................................................... 3 Overview of product..................................................................................................................4 Model and serial numbers..................................................................................................4 Hardware description..........................................................................................................5 Firmware description .........................................................................................................6 Product Specifications..............................................................................................................7 HEWLETT-PACKARD LIMITED WARRANTY STATEMENT ..................................................9 Extended warranty..................................................................................................................10 Print cartridge information ......................................................................................................11 Refilled print cartridges ...................................................................................................11 Recycling print cartridges ................................................................................................11 Declaration of Conformity.......................................................................................................12 For Regulatory Topics ONLY, contact:...................................................................................13 Laser safety statement.....................................................................................................13 Canadian DOC regulations...............................................................................................13 Korean EMI statement......................................................................................................13 Laser statement for Finland..............................................................................................14

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HP LaserJet 1010 series has three product configurations The HP LaserJet 1010, 1012, and 1015 The HP LaserJet 1010 is the base model of the series. It offers the following: ● Prints up to 12 pages per minute. ● 8 seconds to first page out. ● 600 x 600 dpi. ● 150 sheet paper capacity (20 lb). ● A priority input tray. ● A horizontal paper feed path. ● 8 MB of RAM (not expandable). ● A host-based driver. ● A USB port The HP LaserJet 1012 is the mid-range model of the series. It offers all the features of the HP LaserJet 1010, plus the following: ● Prints up to 14 pages per minute A4 (15 letter). ● 1200 x 1200 dpi effective output quality [600 x 600 x 2 dpi with HP Resolution Enhancement (REt) technology. ● Networking support through HP Jetdirect devices The HP LaserJet 1015 is the top model of the series. It offers all the features of the HP LaserJet 1012, plus the following: ● 16 MB of RAM (not expandable). ● A host-based driver and HP's PCL 5e driver. ● A USB port and a parallel port 2 Chapter 1 Product Information

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Introduction The HP LaserJet 1010 series is designed to print documents easily with the laser quality you have come to expect from an HP LaserJet product.

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Overview of product Model and serial numbers The model number and serial number are listed on an identification label located on the back of the product. The serial number contains information about the country/region of origin, revision level, production code, and production number of the product. The label also contains power rating and regulatory information. Figure 1-1. Model and serial number labels 1 10 9 8 7 6 2 3 5 4 Figure 1-2. Front and side view 1 Attention light 2 Ready light 3 Go light 4 Go button 5 Cancel job button 6 Print cartridge door 7 Priority feed slot 8 Main input tray 9 Tray cover (only with HP LaserJet 1012 printer and HP LaserJet 1015 printer in some countries/ regions) 10 Output bin 4 Chapter 1 Product Information

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11 12 13 14 15 Figure 1-3. Back and side view 11 USB port 12 Parallel port (HP LaserJet 1015 printer only) 13 On/off switch 14 Power receptacle 15 Separation pad Hardware description The HP LaserJet 1010 product provides 600 x 600 dpi printing. The HP LaserJet 1012, and 1015 offer 600 x 600 x 2 dpi printing (effectively 1200 dot per inch (dpi) using HP REt technology). The product prints at 12 pages per minute (HP LaserJet 1010) or 15 ppm for letter-size paper and 14 ppm for A4-size paper (HP LaserJet 1012 and HP LaserJet 1015). With 600 dpi printing for the HP LaserJet 1010 printer and an effective 1200 dpi printing resolution for the other models, the product has exceptional text and graphics print quality. The simple control panel and improved paper handling make this product very easy to use. The main input tray has a 150-sheet (20 lb paper) capacity for continuous, multiple-page printing. The priority input tray is used for manual feeding single sheets of most recommended media and will hold up to ten sheets of 20 lb paper. Both trays are center- justified for all supported paper sizes. The output bin holds up to 125 sheets of 20 lb paper. The product has a very fast first-page-out, at less than eight seconds. The base memory contains 8 MB of RAM, and an embedded 133 MHz processor. The print engine has an average duty cycle of 1,000 pages per month (7,000 peak). The standard toner life is 2,000 pages with 5 percent toner coverage.

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Firmware description The firmware in the product includes: ● Host based printing ● PCL Level 5e (HP LaserJet 1015 printer) ● EconoMode functionality The 1012 and 1015 firmware has Resolution Enhancement technology (REt). 6 Chapter 1 Product Information

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Product Specifications Table 1-1. Physical specifications Product Height Depth Width Weight physical dimensions 208 mm (8.2 in) 230 mm (9.1 in) 370 mm (14.6 in) 5.9 kg (13 lbs) Table 1-2. Environmental specifications Category Specification Operating environment (unit plugged into an AC outlet) ● Temperature: 10° to 32.5° C (50° to 90.5° F) ● Humidity: 20 to 80 percent relative humidity (no condensation) Storage environment (unit not plugged into an AC outlet) ● Temperature: 0° to 40° C (32° to 104° F) ● Humidity: 10 to 80 percent relative humidity (no condensation) Table 1-3. Performance of HP LaserJet 1010 Item Value Print resolution Normal black and white 600 by 600 dpi Print speed A4, black and white 12 ppm Table 1-4. Performance of HP LaserJet 1012 and 1015 Item Value Print resolution Normal black and white 600 by 600 x 2 (effective 1200 dpi resolution using HP REt technology) dpi Print speed A4, black and white 14 ppm Table 1-5. Electrical specifications Item 110-volt models 220-volt models Power supply 110 to 127 V (+/- 10 %) 220 to 240 V (+/- 10 %) 50 to 60 Hz (+/- 2 Hz) 50 to 60 Hz (+/- 2 Hz)

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Item 110-volt models 220-volt models Power consumption (typical) During printing 250 W (average) 250 W (average) During standby 2 W (average) 2 W (average) Power Save mode 2 W (average) 2 W (average) Off mode 0 W (average) 0 W (average) Heat output During printing X BTU/hr X BTU/hr Minimum recommended circuit capacity

4.5 A

2.3 A

Warning!

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Hewlett-Packard Limited Warranty Statement

Hp Product

Duration Of Limited Warranty

Warranty Or Condition, Whether Written Or Oral, Is Expressed Or Implied And Hp

Specifically Disclaims Any Implied Warranties Or Conditions Of Merchantability,

The Warranty Terms Contained In This Statement, Except To The Extent Lawfully

Statutory Rights Applicable To The Sale Of This Product To You.

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Hewlett-Packard Limited Warranty Statement

Extended warranty In most countries/regions, HP Care Pack provides additional coverage, beyond standard warranty for the HP device and for all HP-supplied internal components. This hardware maintenance can uplift the standard warranty, for example, from next-day to same-day service, and/or extend it up to 5 years. The HP Care Pack can provide Express Exchange or onsite service. For more information, see the support flyer that came with your device for the appropriate phone numbers and information. 10 Chapter 1 Product Information

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Print cartridge information The print cartridge is designed to simplify replacement of the major consumable parts. The print cartridge contains the printing mechanism and a supply of toner. At 5 percent page coverage, a standard print cartridge will print approximately 2,000 pages. However, a cartridge should print more pages if it regularly prints pages with less coverage, such as short memos. The cartridge might print fewer pages if heavy or bold print is used. For best results, always use a print cartridge before the expiration date stamped on the cartridge box. Refilled print cartridges While Hewlett-Packard does not prohibit the use of refilled print cartridges during the warranty period or while the product is under a maintenance contract, it is not recommended for the following reasons: ● Repairs resulting from the use of refilled cartridges are not covered under Hewlett- Packard warranty or maintenance contracts. ● Hewlett-Packard has no control or process to ensure that a refilled cartridge functions at the high level of reliability of a new HP LaserJet toner cartridge. Hewlett-Packard also cannot predict the long-term reliability effect on the product from using different toner formulations found in refilled cartridges. ● The print quality of HP LaserJet print cartridges influences the customer’s perception of the product. Hewlett-Packard has no control over the actual print quality of a refilled cartridge. ● Parts that are critical to print quality may not be replaced when the cartridge is refilled with toner. Recycling print cartridges In order to reduce waste, Hewlett-Packard offers a recycling program. Cartridge components that do not wear out are recycled. Plastics and other materials are recycled. Hewlett-Packard pays the shipping costs from the user to the recycling plant (within the United States). To join this recycling effort, follow the instructions inside the print cartridge box. Refer to http://www.hp.com/recycle for more information.

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Declaration of Conformity Declaration of Conformity according to ISO/IEC Guide 22 and EN 45014 Manufacturer Name: Hewlett-Packard Company Manufacturer Address: 11311 Chinden Boulevard Boise, , Idaho 83714-1021, USA declares that the product Product Name: HP LaserJet 1010 Series Printer Product Number: Q2460A, Q2461A, Q2462A, (Regulatory Model Number: BOISB-0207-00) Product Options:

All

Iec 60950:1999 / En 60950:2000

Gb4943:1995

Emc:

En 61000-3-2:1995/A14

En 61000-3-3:1995

En 55024:1998

As / Nzs 3548:1995 +A1 +A2 / Gb9254:1998

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For Regulatory Topics ONLY, contact: Laser safety statement The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration has implemented regulations for laser products manufactured since August 1,

Warning!

«Cem».»

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Laser statement for Finland

Laserturvallisuus

Luokan 1 Laserlaite

Laserlaite Klass 1 Laser Apparat

Varoitus!

Varning!

Huolto

Varo!

Varning!

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Installation and Operation This chapter provides an overview of the appropriate operating environment, describes the control panel, and describes media requirements and loading media to print. Operating environment ..........................................................................................................16 Identifying the control panel components...............................................................................17 Product media specifications..................................................................................................18 Supported media sizes (printer).......................................................................................18 Guidelines for using media.....................................................................................................19 Paper and Transparencies ..............................................................................................19 Common media problems table .......................................................................................19 Labels ..............................................................................................................................19 Envelopes ........................................................................................................................20 Card stock and heavy media ...........................................................................................20 Loading media .......................................................................................................................22 Loading media to print......................................................................................................22

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Operating environment Place the product on a sturdy, level surface in a well-ventilated area that meets the following environmental requirements: ● Temperature: 10° to 32.5° C (50° to 90.5° F) ● Humidity: 20 to 80 percent relative humidity (no condensation) ● Away from direct sunlight, open flames, and ammonia fumes ● Sufficient space around the product to allow for proper access and ventilation 208mm (8.2 inches) 370mm (14.6 inches) 230mm (9.1 inches) Figure 2-1. Dimensions of product 16 Chapter 2 Installation and Operation

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Identifying the control panel components The printer control panel has three lights and two buttons. These lights produce patterns that identify your printer’ s status. 1 2 3 4 Figure 2-2. Control panel lights and buttons 1 Attention light: Indicates printer media input tray is empty, print cartridge door is open, print cartridge is missing, and other errors. 2 Ready light: Indicates that the printer is ready to print. 3 Go button and light: To print a demo page, or to continue printing while in manual feed mode, press and release the Go button. To print a configuration page, press and hold the Go button between 5 and 10 seconds until the attention and ready lights flash. To run a cycle to clean the paper path (using a transparency), press and hold the Go button for at least 10 seconds until the attention and ready lights stay on. 4 Cancel Job button: When the printer is processing data, press the Cancel Job button to cancel the print job. Note The two printer buttons, Go and Cancel are mechanically linked and activate the same switch on the formatter. The formatter switch performs the correct function, based on the state of the printer when either button is pressed. Ease-of-use studies during product design resulted in offering the user a Go and a Cancel button rather than just a single button.

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Product media specifications The product accepts a variety of media. Properties such as weight, grain, and moisture content are important factors affecting printer performance and output quality. Media should conform to the guidelines in the User Guide located on the product CD. Media that does not meet HP guidelines might cause poor print quality, increased media jams, or premature wear on the product. This may require repair.

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Guidelines for using media HP LaserJet printers produce excellent print quality documents. You can print on a variety of media, such as paper (including up to 100 percent recycled fiber content paper), envelopes, labels, transparencies, and custom-sized media. Paper and Transparencies Paper must be of good quality and free of cuts, nicks, tears, spots, loose particles, dust, wrinkles, holes, and curled or bent edges. Check the label on the paper package for details about the type of paper (such as bond or recycled). Some paper causes print quality problems, jamming, or damage to the printer. Note Do not use letterhead that is printed with low-temperature inks, such as those used in some types of thermography, raised letterhead, or colored paper or preprinted forms that use inks incompatible with the printer temperature [200° C (392° F) for 0.1 second]. Transparencies must be able to withstand 200° C (392° F), the printer’s maximum temperature. Common media problems table Symptom Problem with paper Solution Poor print quality or toner adhesion, or problems with feeding. Too moist, too rough, too smooth, or embossed. Faulty paper lot. Try another kind of paper between 100 and 250 Sheffield and 4 to 6 percent moisture content. Dropouts, jamming, or curl. Stored improperly. Store paper flat in its moisture- proof wrapping. Increased gray background shading. Might be too heavy. Use lighter paper. Excessive curl, or problems with feeding. Too moist, wrong grain direction, or short-grain construction. Use long-grain paper. Print using the straight-through output path. Jamming, or damage to printer. Cutouts or perforations. Do not use paper with cutouts or perforations. Problems with feeding. Ragged edges. Use good quality paper. Labels When selecting labels, consider the following factors: ● Adhesives: The adhesive material should be stable at 200° C (392° F), the printer’s maximum temperature. ● Arrangement: Only use labels with no exposed backing between them. Labels can peel off sheets that have spaces between the labels, causing serious jams.

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● Curl: Prior to printing, labels must lie flat with no more than 13 mm (0.5 in) of curl in any direction. ● Condition: Do not use labels with wrinkles, bubbles, or other indications of separation. Never use a sheet of labels that has already been run through the printer. Envelopes Envelope construction is critical. Envelope fold lines can vary considerably, not only between manufacturers, but also within a box from the same manufacturer. Successful printing on envelopes depends on the quality of the envelopes. When selecting envelopes, consider the following factors: ● Weight: The weight of the envelope paper should not exceed 105 g/m2 (28 lb), or jamming might result. ● Construction: Prior to printing, envelopes should lie flat with less than 6 mm (0.25 in) curl and should not contain air. Envelopes that trap air may cause problems. ● Condition: Make sure that the envelopes are not wrinkled, nicked, or otherwise damaged. ● Sizes: From 90 x 160 mm (3.5 x 6.3 in) to 178 x 254 mm (7 x 10 in). Store envelopes flat. If air is trapped in an envelope, creating an air bubble, the envelope might wrinkle during printing. Envelopes with double-side seams An envelope with double-side-seam construction (vertical seams at both ends of the envelope rather than diagonal seams) is more likely to wrinkle. Make sure the seam extends all the way to the corner of the envelope as shown in top figure of the following illustration: Should print well. May jam or wrinkle. Envelopes with adhesive strips or flaps Envelopes with a peel-off adhesive strip or with more than one flap that folds over to seal must use adhesives compatible with the heat and pressure in the printer: 200°C (392° F). The extra flaps and strips might cause wrinkling, creasing, or jams. Card stock and heavy media For optimum performance, do not use paper heavier than 157 g/m 2 (42-lb). Paper that is too heavy might cause misfeeds, stacking problems, paper jams, poor toner fusing, poor print quality, or excessive mechanical wear. 20 Chapter 2 Installation and Operation

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Note You might be able to print on heavier paper if you do not fill the input tray to capacity and if you use paper with a smoothness rating of 100 to 180 Sheffield. Card stock construction ● Smoothness: 135-157 g/m 2 (36-to 42-lb) card stock should have a smoothness rating of 100 to 180 Sheffield. 60-135 g/m 2 (16- to 36-lb) card stock should have a smoothness rating of 100 to 250 Sheffield. ● Construction : Card stock should lie flat with less than 5 mm (0.2 in) of curl. ● Condition: Make sure that the card stock is not wrinkled, nicked, or otherwise damaged. ● Sizes: Only use card stock within the following size ranges: ● Minimum: 76 x 127 mm (3 x 5 in) ● Maximum: 216 x 356 mm (8.5 x 14 in) Card stock guidelines ● Set margins at least 2 mm (0.08 in) away from the edges.

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Loading media Loading media in the HP LaserJet 1010 series printers is simple and straightforward. Loading media to print This section describes loading bulk media to print. Main input tray The main input tray holds up to 150 sheets of 75 g/m2 (20 lb) paper or a 25 mm (0.98 in) stack of heavier media. Load media with the top forward and the side to be printed facing up. To prevent jams and skew, always adjust the side media guides. Priority input tray The priority input tray can be used to feed one page at a time of a recommended media for manual feeding and special operations. It can hold up to ten pages of 75 g/m2 (20 lb) paper, but is best used for feeding one page at a time of paper, heavier paper, envelope, transparency, or card stock. Load media with the top forward and the side to be printed facing up. To prevent jams and skew, always adjust the side media guides. If you try to print on media that is wrinkled, folded, or damaged in any way, a jam might occur. See the User Guide located on the product CD for more information. Note When you add new media, make sure that you remove all of the media from the input tray and straighten the stack of new media. This helps prevent multiple sheets of media from feeding through the printer at one time, reducing paper jams. Specific types of media ● Transparencies and labels: Load transparencies and labels with the top forward and the side to be printed facing up. See the User Guide located on the product CD for more information. ● Envelopes: Load envelopes with the narrow, stamp side forward and the side to be printed facing up. See the User Guide located on the product CD for more information. ● Letterhead or preprinted forms: Load with the top forward and the side to be printed facing up. See the User Guide for more information. ● Cards and custom-sized media: Load with the narrow side forward and the side to be printed facing up. See the User Guide located on the product CD for more information. 22 Chapter 2 Installation and Operation

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Maintenance This chapter describes the life expectancy of parts that wear, printer cleaning, printer maintenance, and the replacement of user-replaceable parts. Life expectancies of parts that wear ......................................................................................24 Cleaning the product...............................................................................................................25 Cleaning the print path.....................................................................................................25 Cleaning the print cartridge area......................................................................................26 Cleaning the printer pickup roller .....................................................................................27 User-replaceable parts ...........................................................................................................29 Replacing the printer pickup roller ...................................................................................29 Replacing the printer separation pad................................................................................31 Replacing the main input tray (paper pickup tray assembly)............................................33 Replacing the output tray extension (delivery tray assembly)..........................................34

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Life expectancies of parts that wear Inspect any parts that wear when servicing the product. Replace them as needed, based on failure or wear, rather than on usage. The following table lists approximate schedules for replacing consumables. Table 3-1. Life expectancies of parts that wear Description Part number Life (estimated) Remarks Print cartridge (user- replaceable)

Q2612A

Rl1-0266-000Cn

Rc1-2095-000Cn

Rm1-0650-000Cn

240 V)

Rg9-1494-030Cn

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Cleaning the product

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Caution

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Cleaning the print cartridge area You do not need to clean the print cartridge area often. However, cleaning this area can improve the quality of your printed sheets.

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Remove the pickup roller as described in steps 1 through 5 of Replacing the printer pickup roller.

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User-replaceable parts To order a new pickup roller or separation pad, go to http://partsdirect.hp.com. Replacing the printer pickup roller If the printer regularly misfeeds (no media feeds through) and cleaning the pickup roller does not fix it, replace the pickup roller.

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Note The following procedure requires a #2 Phillips-head screwdriver.

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Replacing the output tray extension (delivery tray assembly) If you break or damage the output tray extension (also called the delivery tray assembly), you can replace it. To order parts, go to http://partsdirect.hp.com.

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Operational overview This chapter describes the general components of the HP LaserJet 1010 series and their theory of operation. Basic functions........................................................................................................................36 Formatter system....................................................................................................................37 Central processing unit ....................................................................................................37 RAM.................................................................................................................................. 37 Universal Serial Bus interface..........................................................................................37 Parallel interface (HP LaserJet 1015 only).......................................................................37 Control panel....................................................................................................................37 Draft mode .......................................................................................................................38 MEt................................................................................................................................... 38 Enhanced I/O ...................................................................................................................38 PJL overview ...................................................................................................................38 Printer functions......................................................................................................................39 Engine control system (engine control unit and power assembly)...................................39 Image formation system...................................................................................................43 Printer paper feed system................................................................................................44 Jam detection ..................................................................................................................46 Solenoid, sensors, and switches......................................................................................46 Basic sequence of operation (formatter-to-printer)...........................................................47

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Basic functions The major functions of the printer and the corresponding systems providing them are: ● Formatter and I/O functions ● Formatter system ● Printer functions and operation ● Engine control system (engine control unit--ECU--and engine power assembly) ● Image formation system ● Paper feed system

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Formatter system The formatter coordinates the major systems. It is responsible for the following: ● Receiving and processing print data from the printer interface (from the computer) ● Monitoring the control panel and relaying printer status information ● Developing and coordinating data placement and timing with the print engine ● Communicating with the host computer through the bidirectional interface The formatter receives print data from the parallel interface or the Universal Serial Bus (USB) interface and converts it into a dot image. The ECU synchronizes the image formation system with the paper feed system and signals the formatter to send the print image data to the laser system. The formatter sends the print image data (dots) in the form of a video signal, and the printing process begins. Central processing unit The formatter uses an embedded Coldfire V4 microprocessor operating at 133 MHz.

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Draft mode Depending on which driver is used, selecting draft or EconoMode from the driver allows the product to use approximately 50 percent less toner, extending the life of the print cartridge. MEt HP MEt effectively doubles the standard memory through a variety of font and data- compression methods. Enhanced I/O The Enhanced I/O feature allows product memory to be used for storing data received from the host computer. When Enhanced I/O is enabled, you can send more data to the product in shorter amounts of time, which allows you to return to your application sooner. Enhanced I/O has the following options: ● Auto —allows the product to use Enhanced I/O memory allocation to increase the speed of data transfer from the host computer to the product, if necessary. The default setting is Auto. ● Off —uses the minimum amount of product memory for storing data sent from the host computer. ● Page protect—allows the formatter to create the entire page image in page buffer memory before physically moving the media through the printer. This process ensures that the entire page will be printed. Page complexity (ruling lines, complex graphics, or dense text) can exceed the printer’s ability to create the page image fast enough to keep pace with the image formation process. If Page Protect is disabled and a page is too complex, the page might print in parts (for example, the top half on one page and the bottom half on the next page). Some print-data loss is likely in these instances, and the product will display an error message. PJL overview When using the parallel port on the HP LaserJet 1015, Printer Job Language (PJL) is an integral part of configuration (in addition to the standard Printer Command Language--PCL). With IEEE 1284-compliant parallel cable (standard ECP cabling), PJL allows the product to perform functions such as: ● Two-way communication with the host computer through a bidirectional parallel connection. The product can communicate information to the host (such as the control panel status). ● 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. Note PJL commands can be sent to the printer only from a DOS command prompt and through a parallel cable, and thus apply only to the HP LaserJet 1015. DOS applications are not supported over a USB interface. 38 Chapter 4 Operational overview

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Printer functions Printer functions are divided into five groups: ● Engine control ● Formatter ● Image formation ● Laser/scanner ● Pickup and feed The following figure is a block diagram of the printer: Output tray Priority input tray Main input tray To external device (host computer, etc.) Scanning mirror Laser diode Cleaning unit Fuser unit Primary charging roller Photo sensitive drum Engine power assembly

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The ECU controls the following systems and functions: ● Printer engine control ● Paper motion monitoring and control (printing) ● Motor ● Printer laser/scanner unit The engine power assembly provides the power system: ● AC power distribution ● DC power distribution ● Overcurrent/overvoltage protection ● High-voltage power distribution Printer engine control system Paper motion monitoring and control The ECU controls paper motion in the printer by continuously monitoring the two paper sensors and coordinating the timing with the other print processes. For a detailed explanation of paper movement and the interaction of the sensors and pickup solenoid with the paper movement process, see Printer paper feed system. Motor The ECU controls the motor. The motor drives all of the printer paper movement. Printer laser/scanner unit The ECU sends signals to the laser/scanner assembly to modulate the laser diode's on and off modes and to drive the laser/scanner motor. 40 Chapter 4 Operational overview

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There are two overvoltage devices in this product: ● Fuse F101 provides overcurrent protection for the fusing system circuitry. ● Fuse F102 (110V products only) provides overcurrent protection to the printer DC power supply circuitry. You can check or replace the fuses by removing the left cover. If either of these fuses fail, replace the engine power assembly. High-voltage power distribution The high-voltage power supply applies an overlap of DC and AC voltage to the primary charging roller and to the developing roller. This circuit also applies a positive or negative DC voltage to the transfer roller according to the instructions from the engine control unit. This circuit also controls the image density by changing the primary AC voltage and the developing AC bias according to the print density setting (which is set using HP Toolbox). High voltage is disabled when the print cartridge door is open.

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Image formation system Laser printing requires the interaction of several different technologies including electronics, optics, and electrophotographics to provide a printed page. Each process functions independently and must be coordinated with the other printer processes. Image formation consists of seven processes: Electrostatic latent image formation stage Paper direction Direction of drum rotation

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Step 6 After the image is transferred, the media enters the fuser assembly where heat from the fuser and pressure from the pressure roller permanently bond the toner image to media. The paper delivery sensor (PS803) determines that the media has successfully moved out of the fusing area. Step 7 The fuser assembly exit rollers deliver media to the paper output bin face down. Pick-up roller Transfer roller Delivery roller Priority input tray Main input tray Pressure roller Fuser

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Jam detection The top-of-page sensor (PS801) and the paper delivery sensor (PS803) detect media moving through the printer. If a jam is detected, the ECU immediately stops the printing process and displays the a jam light on the control panel. Conditions of jam detection ● Pickup delay jam—Paper does not reach the top-of-page sensor (PS801) within 1.4 seconds after the pickup solenoid (SL1) has been turned on, a second pickup operation is attempted, and paper again does not reach the top-of-page sensor within 1.4 seconds.. ● Pickup stationary jam—The top-of-page sensor (PS801) does not detect the trailing edge of media within 4.6 seconds of detecting the leading edge. ● Delivery-delay jam—The paper delivery sensor (PS803) does not detect the leading edge of media within 2.1 seconds after the top-of-page sensor (PS801) detects the leading edge. ● Wrapping jam—The paper delivery sensor (PS803) does not detect the trailing edge of the media within 1.5 seconds after the top-of-page sensor (PS801) detects the leading edge and within ten seconds after the paper delivery sensor (PS803) detects the leading edge. ● Delivery-stationary jam—The paper delivery sensor (PS803) does not detect the leading edge of media within 2.2 seconds after the top-of-page sensor (PS801) detects the trailing edge. ● Residual paper jam—The top-of-page sensor (PS801) or the paper delivery sensor (PS803) detect media in the initial rotation period. ● Door open jam—The top-of-page sensor (PS801) or the paper delivery sensor (PS803) detect media while the print cartridge door is open. Solenoid, sensors, and switches The following figure shows the locations of the solenoid, sensors, and switches. 46 Chapter 4 Operational overview

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➁ ➂ ➃ ➀ ➄ ➅ ➆ Figure 4-7. Solenoid, photosensors, and switches 1 Door switch detects whether or not the print cartridge door is closed. Printing cannot continue until the print cartridge door is closed. 2 Power switch. 3 Paper-width sensor senses the width of the paper. 4 Paper delivery sensor senses when paper has successfully moved out of the fusing area. 5 Top-of-page sensor detects the leading and trailing edges of the paper. It synchronizes the photosensitive drum and the top of the paper. 6 Solenoid. 7 Motor. Basic sequence of operation (formatter-to-printer) The operation sequence of the printer is controlled by the microprocessor (CPU) on the ECU. The following events take place during normal printer operation: Table 4-1. Basic sequence of operation Period Purpose Remarks WAIT After the product is turned on until the end of the initial rotation of the main motor. To clear the drum surface of potential and to clean the primary charging roller. Detects whether or not the cartridge is installed. STBY (Standby) From the end of the WAIT period or the LSTR period until the pickup command is sent from the formatter. Or, from the end of the LSTR period until the product is turned off. To pause until the product is ready to print.

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Period Purpose Remarks INTR (Initial Rotation Period) After the pickup command has been sent from the formatter until the media reaches the top- of-page sensor (PS801). To stabilize the photosensitive drum sensitivity in preparation for printing. Also to clean the primary charging roller. PRINT (Print) From the end of the initial rotation until the primary voltage goes OFF. To form images on the photosensitive drum based on the VIDEO signals (/VDO, VDO) sent from the formatter and to transfer the toner image onto the media. LSTR (Last Rotation Period) After the primary voltage goes OFF until the main motor stops rotating. To deliver the last page. Also to clean the primary charging roller. When the pickup command is sent from the video controller, the printer enters the INTR period immediately after the end of the LSTR period. 48 Chapter 4 Operational overview

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Removal and replacement This chapter describes the removal and replacement of field-replaceable units (FRUs) only. Removal and replacement strategy........................................................................................52 Required tools .................................................................................................................52 Before performing service................................................................................................52 Print cartridge ..................................................................................................................52 Differences between the series models............................................................................53 Part removal order ...........................................................................................................53 User-replaceable parts ...........................................................................................................55 Replacing the printer pickup roller ...................................................................................55 Replacing the printer separation pad................................................................................57 Replacing the main input tray (paper pick-up tray assembly)...........................................59 Replacing the output tray extension (delivery tray assembly)..........................................60 Covers..................................................................................................................................... 61 Right side cover................................................................................................................62 Left side cover..................................................................................................................65 Print cartridge access door, fuser cover, and rear panel..................................................65 Front cover.......................................................................................................................68 Internal assemblies.................................................................................................................70 Transfer roller assembly...................................................................................................70 Engine power assembly...................................................................................................72 Fuser (fixing) assembly....................................................................................................73 Paper pickup assembly....................................................................................................75 Engine control unit assembly............................................................................................76 Laser scanner assembly...................................................................................................78

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Removal and replacement strategy Detailed steps and images showing part removal are included here. Replacement is generally the reverse of removal. Occasionally, notes are included to provide directions for difficult or critical replacement procedures.

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Figure 5-1. Removing the print cartridge Differences between the series models With the exception of the nameplate, there is no physical difference between the HP LaserJet 1010 and HP LaserJet 1012 printers. The differences between these models are in firmware functionality. The HP LaserJet 1015 printer has a parallel port (callout 1, figure 5-2) in addition to the USB port. 1 Figure 5-2. HP LaserJet 1015 parallel port Part removal order Use the following illustration to determine which parts must be removed before removing other parts.

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Product teardown tree Right Side Cover Transfer Roller Front Cover Assembly Rear Panel Assembly

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User-replaceable parts To order a new pickup roller or separation pad, go to http://partsdirect.hp.com. Replacing the printer pickup roller If the printer regularly misfeeds (no media feeds through) and cleaning the pickup roller does not fix it, replace the pickup roller.

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Note The following procedure requires a #2 Phillips-head screwdriver.

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Replacing the output tray extension (delivery tray assembly) If you break or damage the output tray extension (also called the delivery tray assembly), you can replace it.

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Covers Remove the covers to access the internal replaceable parts.

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Internal assemblies This section describes the removal of internal assemblies. Replacement is accomplished by following the removal steps in reverse. Reassembly notes are included where reversal of removal steps requires additional information. Note When replacing internal assemblies, ensure that any component parts that are not provided with the new assembly get transferred from the failed assembly to the new assembly. For example, sensor PCBs are not included with the fuser assembly or the paper pickup assembly. The sensor PCB from the failed assembly must be transferred to the new assembly. Transfer roller assembly Before proceeding, make sure it is absolutely necessary to remove the transfer roller.

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Figure 5-23. Fragile tab on fuser assembly Paper pickup assembly

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Note When replacing the paper pickup assembly, be sure to transfer the sensor PCB and, if necessary, the separation pad assembly to the new paper pickup assembly. Engine control unit assembly

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Troubleshooting This chapter describes how to isolate and resolve printer problems, image problems, and media problems. Troubleshooting details are provided to resolve problems or to isolate replaceable parts. Basic troubleshooting..............................................................................................................82 Control panel power-on functions...........................................................................................84 Power-on Functions: Time Ranges..................................................................................84 Control Panel Pages...............................................................................................................86 Control Panel Pages: Time Ranges.................................................................................86 Control Panel Lights................................................................................................................87 Control Panel Light Patterns.............................................................................................87 Fatal Errors.......................................................................................................................91 Image troubleshooting............................................................................................................92 Print cartridge problems...................................................................................................92 Solving image-quality problems .......................................................................................92 Solving paper-feed problems..................................................................................................99 Solving print paper-feed problems....................................................................................99 Functional checks.................................................................................................................103 Half self-test functional check.........................................................................................103 Drum rotation functional check ......................................................................................105 High-voltage contacts check...........................................................................................105 Troubleshooting tools ...........................................................................................................107 Repetitive image defect ruler..........................................................................................107 Circuit diagram ..............................................................................................................108 Solenoid, sensors, and switches...........................................................................................109

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Basic troubleshooting Table 6-1. Basic troubleshooting Issue Cause Solution Did the printer turn on? No power due to failed power source, cable, or switch.

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Issue Cause Solution Is the software installed correctly? Software is not installed correctly, or an error occurred during software installation. Uninstall and then reload the product software. Make sure you use the correct installation procedure and the correct port setting. Does the product print from the computer? Connect the USB cable (or parallel if preferred with the HP LaserJet 1015) to the printer and the computer. Print a test page from the printer properties box or print from an application like Notepad. The cable is not connected correctly. Reconnect the cable. An incorrect driver is selected. Select the proper driver. Other devices are connected to the parallel port. Disconnect the other devices and try again to print. There is an LPT port driver problem in Microsoft Windows. Correct or reset the computer’s port settings.

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Control panel power-on functions Powering on the printer while pressing the Go button for varying amounts of time accesses important printer functionality for resetting the printer, resetting NVRAM, and performing self- tests. The general procedure for initiating a power-on function is as follows (refer to the table for specific time ranges for the desired function):

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NVMEM super initialization Release Go more than 50 seconds after power-up. Ready: ON Note After releasing Go, all lights will blink in unison for three seconds. Press and hold Go again. All lights will turn off. In the next 3 seconds, the lights will turn on one at a time. When all are lit, release Go. The initialization will run to completion and the printer will return to the ready state.

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Control Panel Pages When the printer is in the ready state, pressing the Go button for varying amounts of time accesses important printer reports. The general procedure for initiating the power on actions is as follows (refer to the table for specific time ranges for each action):

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Control Panel Lights The printer displays status and errors through patterns of the Go, Ready, and Attention lights. If any lights are blinking, the error is usually resolvable. In all cases:

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Printer Status Lights Description Processing data - Device is processing or receiving data Go Ready Attention In the Data Processing state, the Ready light is blinking and the Go and Attention lights are off. Pressing Go cancels the current job without printing another non-picked page. The printer returns to the Ready state after the job has been canceled. Job Cancel Ready Attention Go In the Job Cancel state, all the lights cycle. Pressing Go has no effect. Once the job cancel process is complete, the printer goes to the Ready state. 88 Chapter 6 Troubleshooting

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Printer Status Lights Description Continuable error Go Ready Attention In the continuable error state, the Go light is on, the Ready light is off, and the Attention light is blinking. Press Go to attempt to recover from the error and continue printing. If the printer recovers from the error, it will move to the Processing data state and complete the job. If the recovery fails, the device will return to the continuable error state. This state can be reached in the following circumstances: ● Manual Feed ● Out of paper for the specified tray ● General continuable error ● Memory overflow (error 20) / memory full. Note: PCL only. ● Temporary engine error (41.x errors) ● I/O error (22 error) / Buffer flow error Note: Parallel only. ● I/O data error (40 error) (Bad Connection) Note: Parallel only. ● Memory configuration error ● Personality/Job related error ● Fuser high temperature (50.011 error) Note The LJ1010 product series does not have paper out sensors. When the printer goes to a continuable error state because its out of paper, the user the will need to reload paper and press Go to continue. No secondary error information is provided to the user from the lights.

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Printer Status Lights Description Attention State Go Ready Attention In the Attention state, the Attention light is blinking and the Go and Ready lights are off. This state can be reached in the following circumstances: ● Paper tray is empty ● Door open ● Toner Cartridge Missing ● Paper jam/ Tray Misfeed Pressing Go attempts to reset after a jam is cleared or is ignored in the other error cases. It may be necessary to clear the error manually and press Go or close the top cover. If the error still persists, the device will return to the Attention state. Note The LJ1010 product series does not have paper out sensors. When the printer is in an Attention state because the paper tray is empty, the user must reload paper and press Go. Fatal Error Go Ready Attention While in the fatal error state, all three LED's are on continuously. Pressing Go displays the secondary error information for the fatal error, and releasing the button(s) will cause the device to return to the initial "fatal error" state. (See.) Cleaning Page Ready Attention Go The cleaning page is activated using the Toolbox application. Button presses are ignored during cleaning mode. Sleep Mode Go Ready Attention From the customer's perspective Sleep mode is the same as Ready mode. 90 Chapter 6 Troubleshooting

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Fatal Errors If the printer displays all lights on solid and the error is not resolved by cycling the power, then a fatal error has occurred. The two identifiable errors are failed communication between the formatter and the engine and a failed fuser. If neither of these are identified using the following procedure, replace the printer.

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Image troubleshooting Print cartridge problems Checking the print cartridge Image formation defects are frequently the result of problems in the print cartridge. If there is any doubt, always replace the print cartridge before troubleshooting image defects. Use the following checklist to make sure that the print cartridge is still operable. □ Make sure that the print cartridge is installed properly and the shipping tape is removed. □ Inspect the print cartridge for toner level. □ Check the expiration date stamped on the print cartridge box. □ Check the print cartridge to see if it has been disassembled or refilled. □ Inspect the print cartridge to see if toner is leaking through worn seals. □ Check the surface of the photosensitive drum in the cartridge to see if it has been damaged or scratched. Touching the drum contaminates the photosensitive surface and can cause spotting and image defects. □ Blurred areas on printed pages indicate that the photosensitive drum in the cartridge has been overexposed to light. Because overexposure to light causes permanent damage to the photosensitive drum, the cartridge should be replaced. Note A print cartridge weighs approximately 675 gm. (approx. 23.8 oz.) when it is full, approximately 600 gm. (approx. 21.2 oz.) when it first fades, and approximately 585 gm. (approx. 20.6 oz.) when it is empty. To redistribute toner in the print cartridge Before installing a new print cartridge or when toner begins to run low, redistribute the toner by rotating the cartridge back and forth five or six times. Solving image-quality problems Use the following tables to help solve problems with printed pages. If the problem occurs when printing, see Table 6-2. Solving print image-quality problems. Also, see Table 6-3. Solving print paper-feed problems. 92 Chapter 6 Troubleshooting

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Solving print image-quality problems Table 6-2. Solving print image-quality problems Issue Cause Solution Page is not produced. The product is not plugged in or power switch is off. Make sure that the product is plugged into a live wall outlet or power strip. The printer is registering a jam. Check the lights. If the Attention light is flashing, the printer may have a paper jam. Clear the jam and press the Go button to clear the jam. The computer cable is loose. Check that the cable between the product and the computer is securely connected. Output pages are blank. The tape was not removed from the print cartridge. Remove the print cartridge, remove the tape, and return the print cartridge. The print cartridge is out of toner. Replace the print cartridge. The high-voltage connection between the printer and the print cartridge is interrupted. Perform a High-voltage contacts check. Parts of the page around the edges are not printing. The printer cannot print all the way to the edge of the paper. The printer has minimum margins on each edge of approximately 6 mm (0.25 in). To get the image to fit into this printable area, slightly reduce the size of the image. Reduction settings are on the Effects tab of the printer properties dialog. The reduction setting is incorrect. Reduction settings are on the Effects tab of the printer properties dialog. Also may be in a Page Setup setting in the application. The paper size setting is incorrect. Paper size settings are on the Paper tab of the printer properties dialog. Also may be controlled under a Page Setup selection in the application.

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Issue Cause Solution Random toner specks appear on the printed page. . The media you are using does not meet HP’s specifications (for example, it is too moist or too rough). Make sure that the media meets specifications detailed in the HP LaserJet Printer Family Print Media Guide. The print path needs to be cleaned. Clean the print path. (See chapter 4.) Characters are only partially printed (also referred to as dropouts). A single sheet of paper is defective. Try reprinting the job. The print density needs to be adjusted. Adjust the print density from the toolbox utility (Settings tab). The moisture content of the paper is inconsistent, or the paper has moist or wet spots on the surface. Make sure that the media meets HP’s specifications. The paper was damaged by inconsistent manufacturing processes. Make sure that the media meets specifications detailed in the HP LaserJet Printer Family Print Media Guide. EconoMode is selected in the software. Deselect EconoMode. The wrong type of paper is selected in the printer properties dialog. Select the correct media type under "Type is" (in the printer properties dialog, on the Paper tab). The print cartridge is depleted or damaged. Replace the print cartridge. Vertical black lines appear on the printed page. The print cartridge is depleted or damaged. Replace the print cartridge. Rarely, the fuser is defective. Replace the fuser. 94 Chapter 6 Troubleshooting

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Issue Cause Solution The printed page has a gray background. The wrong type of paper is selected in the printer properties dialog. Select the correct media type under "Type is" (in the printer properties dialog, on the Paper tab). The print density setting is too high. Decrease the print density using the toolbox utility (Settings tab). The media basis weight is too high. Change the media to a lower basis weight. The print path needs to be cleaned. Clean the print path. (See chapter 4.) The printer is operating in humidity or temperature conditions that are not within the recommended ranges. Move the product to a different location. The print cartridge is worn or damaged. Replace the print cartridge. Toner smears appear on the printed page. The print path needs to be cleaned. Clean the print path. (See chapter 4.) The media you are using does not meet HP’s specifications (for example, it is too moist or too rough). Make sure that the media meets specifications detailed in the HP LaserJet Printer Family Print Media Guide. The print cartridge is worn or damaged. Replace the print cartridge. The wrong type of paper is selected in the printer properties dialog. Select the correct media type under "Type is" (in the printer properties dialog, on the Paper tab). The fuser damaged. Perform the Half self-test functional check. If the error persists, replace the fuser. If, after replacing the fuser, the error persists, replace the ECU.

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Issue Cause Solution The toner is loose, and it does not stay attached to the printed page. The media you are using does not meet HP’s specifications. (For example, it is too moist or too rough.) Make sure that the media meets specifications detailed in the HP LaserJet Printer Family Print Media Guide. The wrong type of paper is selected in the printer properties dialog. Select the correct media type under "Type is" (in the printer properties dialog, on the Paper tab). The power strip is not working correctly or the AC power is not meeting the specified requirements. Plug the product directly into an AC outlet. Ensure that the power source is clean. The printer is operating in humidity or temperature conditions that are not within the recommended ranges. Move the product to a different location. The fuser is damaged. Perform a Half self-test functional check. If the error persists, replace the fuser. If, after replacing the fuser, the error persists, replace the engine power assembly. Repetitive vertical defects appear on the printed page. The internal parts have toner on them. If the defects occur on the back of the page, the problem will probably correct itself after a few more printed pages. Otherwise, clean the printer. (See chapter 4.) The wrong type of paper is selected in the printer properties dialog. Select the correct media type under "Type is" (in the printer properties dialog, on the Paper tab). If the repetitive mark occurs at equal distance between marks, either the print cartridge, transfer roller, paper pickup assembly, or fuser is damaged. Use the defect ruler to identify the spacing. Check the appropriate assembly and replace if necessary. (Repetitive image defect ruler) Characters are poorly formed and are producing hollow images. The wrong type of paper is selected in the printer properties dialog. Select the correct media type under "Type is" (in the printer properties dialog, on the Paper tab). The media is too slick or too thick. Try a different media. Make sure that the media meets specifications detailed in the HP LaserJet Printer Family Print Media Guide. 96 Chapter 6 Troubleshooting

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Issue Cause Solution Pages are skewed. The media is loaded incorrectly. Reload the media, and make sure that the media guides are not too tight or too loose against the media stack. The input tray is too full. Remove some of the sheets. The main input tray can hold up to 150 sheets of 20-lb. (75 g/m2 ) bond weight paper (or fewer pages of heavier media, a stack no higher than 25 mm). The priority input tray can hold up to ten sheets of 20- lb. (75 g/m2) bond weight paper, one sheet of heavier media, or one envelope or card. The media you are using does not meet HP’s specifications (for example, it is too moist or too rough). Make sure that the media meets specifications detailed in the HP LaserJet Printer Family Print Media Guide. The printed page has curls or waves. The printer is operating in humidity or temperature conditions that are not within the recommended ranges. Move the product to a different location. The wrong type of paper is selected in the printer properties dialog. Select the correct media type under "Type is" (in the printer properties dialog, on the Paper tab). The media you are using does not meet HP’s specifications (for example, it is too moist or too rough). Make sure that the media meets specifications detailed in the HP LaserJet Printer Family Print Media Guide. The media was in the input tray for too long. Turn the stack of media over and put it back in the tray. Rotate the media 180° and put it back in the tray.

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Issue Cause Solution Large amounts of toner are scattered around the characters. The media resistivity is too high (most often happens when transparencies acquire a static charge).

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Solving paper-feed problems Use the following table to solve problems related to moving paper or documents through the product. Solving print paper-feed problems Table 6-3. Solving print paper-feed problems Issue Cause Solution Pages are coming out curled or wrinkled. Paper curl is inherent to the laser printing processes, and occurs when paper is subjected to heat. Paper curl tends to relax as the paper cools while resting on a flat surface. Make sure that the media meets specifications detailed in the Print Media Guide for the HP LaserJet family. Reset the fuser mode to the default. Paper is not stored properly. Whenever possible, store paper in its sealed ream at room temperature. The media is too long for the printer output bin. Use the long media extension. The printer is operating in humidity or temperature conditions that are not within the recommended ranges. Move the product to a different location. The wrong type of paper is selected in the printer properties dialog. Select the correct media type under "Type is" (in the printer properties dialog, on the Paper tab). The media you are using does not meet HP’s specifications (for example, it is too moist or too rough). Make sure that the media meets specifications detailed in the HP LaserJet Printer Family Print Media Guide. The media was in the input tray for too long. Turn the stack of media over and put it back in the tray. Rotate the media 180° and put it back in the tray.

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Issue Cause Solution Print is misaligned on the page (skewed pages). The media is loaded incorrectly. Reload the media, and make sure that the media guides are not too tight or too loose against the media stack. The input tray is too full. Remove some of the sheets. The main input tray can hold up to 150 sheets of 20-lb. (75 g/m2 ) bond weight paper (or fewer pages of heavier media, a stack no higher than 25 mm). The priority input tray can hold up to ten sheets of 20- lb. (75 g/m2) bond weight paper, one sheet of heavier media, or one envelope or card. The media you are using does not meet HP’s specifications (for example, it is too moist or too rough). Make sure that the media meets specifications detailed in the HP LaserJet Printer Family Print Media Guide. 100 Chapter 6 Troubleshooting

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Issue Cause Solution The printer feeds multiple sheets or jams frequently from the main input tray or priority input tray. Paper guides are not adjusted properly or paper is not far enough forward. Slide the guides against the sides of the stack in the main input tray or the priority input tray to center the paper. Make sure the guides are not adjusted too tightly. Stack is not neat and aligned well on all sides. Remove paper, align stack, and replace. The main input tray is overfilled. Remove some of the sheets. The main input tray can hold up to 250 sheets of 20-lb. (75 g/m2 ) bond weight paper (less for heavier paper) or from 20 to 30 envelopes. The priority input tray is overfilled. Remove media or feed single sheets. The priority input tray is designed for optimal feeding of single sheets, especially when heavier media is used. It can hold up to ten sheets of 20-lb. (75 g/m2 ) bond weight paper (one sheet of heavier paper) or one envelope. The paper was poorly cut by the manufacturer and is sticking together. “Break” the ream of paper by curving it into an upside-down u-shape; this can effectively decrease multifeeds. Also try turning the paper around to feed the opposite end first, or use a different type of paper. The paper does not meet HP’s specifications for print media. Make sure that the media meets specifications detailed in the Print Media Guide for the HP LaserJet family. The output capacity was exceeded in the paper output bin. Do not allow more than 125 sheets of 20-lb. (75 g/m2) bond weight paper (less for heavier paper) to fill the paper output bin. The pickup roller is dirty. Clean the pickup roller. The pickup roller is damaged. Replace the pickup roller. The separation pad is damaged. Replace the separation pad.

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Issue Cause Solution The printer feeds multiple sheets or jams frequently from the main input tray or priority input tray (continued). A sensor is not operating properly. The chances of a sensor failing are very small. However, debris around the sensor arms may cause them to register a jam. There are only three sensors in the printer (top of page, paper width, and delivery). Check them to ensure that the sensor arms can move freely. On the rare occasion of a failed sensor, replace the printer. 102 Chapter 6 Troubleshooting

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Functional checks This section includes five functional checks for troubleshooting. Half self-test functional check The print process can be subdivided into the following stages: ● image formation stage (charges the drum and writes a latent image to the drum with the laser) ● development stage (forms a toner image on the drum) ● transfer stage (transfers the image to paper) ● cleaning stage (removes excess toner from the drum) ● fusing stage (applies heat and pressure to make the image on paper permanent) To perform a half self-test check The purpose of the half self-test check is to begin the printing process and then interrupt it right in the middle. Examining the printer components at that point allows you to determine which stage in the print process is malfunctioning.

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Figure 6-2. Check the fuser connections 1 Figure 6-3. Check the fuser connections 104 Chapter 6 Troubleshooting

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Drum rotation functional check The photosensitive drum, located in the print cartridge, must rotate for the print process to work. The photosensitive drum receives its drive from the main motor through a system of gears on the right side of the printer. Note This test is especially important if refilled print cartridges have been used.

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1 Figure 6-4. Print cartridge high-voltage contacts To check the printer high-voltage contacts The printer has three spring-loaded pins that make contact with the high-voltage points on the print cartridge. Verify that the pins are not dirty or corroded and that the spring-loading action is functional. If the pins are dirty or obstructed, clean them. If they are damaged, replace the printer. 1 Figure 6-5. Printer high-voltage contacts 106 Chapter 6 Troubleshooting

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Troubleshooting tools If the printer output has a consistent, repetitive defect, then use the following ruler to predict which part needs to be replaced based on the measured distance between the repetitions of the defect. Repetitive image defect ruler First occurrence of print defect (0.00 inches) Transfer roller 46.3 mm (1.82 inches) Print cartridge 37.7 mm (1.48 inches) Print cartridge 30.8 mm (1.21 inches) Paper pick-up assembly 55.2 mm (2.17 inches) Fuser (Fixing assembly) 56.5 mm (2.22 inches) Fuser (Fixing assembly) 41.0 mm (1.61 inches) Print cartridge 76.3 mm (3.00 inches) Figure 6-6. Repetitive image defect ruler

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Circuit diagram 1 3 2 4 6 5 4 3 2 1

D

C

B

A

Sw101

M

Pcb

Bd

Sw301

M

Inl101

Fu101

Fu102

Tp1

H701

Th1

J1102

Fsrth

Gnd

J102

J204

Ps803

J203

J802

Sl001

Cpud

+24V

+3.3V

Posns

Gnd

Gnd

/Vdo

Vdo

Gnd

Cnt1

Cnt0

Gnd

+5V

/Bdi

J002

J801

Gnd

/Dec

/Acc

+24Vr

J904

J905

Fwd

/Si

/So

/Clk

/Strb

Gnd

J901

J201

J2

J902

Ach

Acn

Ps802

Ps801

J801

+3.3V

Pisns

Pwsns

Gnd

J202

+24Vr

Gnd

+24Vr

Gnd

+24Vr

Gnd

+3.3V

+24V

/Posns

Gnd

/Pisns

Pwsv

/Pwsns

Prpwm

Prac

Dvac

Trndc

Trpdc

Fsrd

Fsrth

Rlyd

Trcrnt

Dosns

J001

/Mb

Mb

/Ma

Ma

J909

+24Vr

Cpud

+5V

Gnd

Gnd

+3.3V

/Reseto

/Sclk

/Sc

/Bdo

Gnd

/Vdo

Vdo

Gnd

J910

Acn

Ach

P5

J5

J6

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Solenoid, sensors, and switches The following figure shows the locations of the solenoid, sensors, and switches. ➁ ➂ ➃ ➀ ➄ ➅ ➆ Figure 6-8. Solenoid, photosensors, and switches 1 Door switch detects whether or not the print cartridge door is closed. Printing cannot continue until the print cartridge door is closed. 2 Power switch. 3 Paper-width sensor senses the width of the paper. 4 Paper delivery sensor senses when paper has successfully moved out of the fusing area. 5 Top-of-page sensor detects the leading and trailing edges of the paper. It synchronizes the photosensitive drum and the top of the paper. 6 Solenoid. 7 Motor.

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110 Chapter 6 Troubleshooting

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Parts and diagrams This chapter provides an exploded view showing the replaceable parts of the printer, tables of replaceable parts, and links to other resources. Ordering parts and supplies .................................................................................................112 Parts .............................................................................................................................. 112 Related documentation and software ............................................................................112 Parts that wear .............................................................................................................112 Accessories and consumables ............................................................................................113 Common hardware ........................................................................................................114 How to use the parts lists and diagrams ........................................................................114 Field-replaceable units .........................................................................................................115

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Ordering parts and supplies This section describes web resources for ordering parts and technical support as well as resources for ordering related documentation and software. Parts Order replacement parts from the following website: http://www.hp.com/ssg/parts/ direct_order.html Related documentation and software Order documentation and software from the websites listed in Table 7-1. Technical support websites: Table 7-1. Technical support websites HP Customer Care Online Software drivers, support documentation, and answers to frequently asked questions http://www.hp.com/go/support HP Technical Training (North America) Classes and schedules http://www.hp.com/go/resellertraining Parts Parts information http://outfield.external.hp.com/spi/welcome.htm Parts that wear The parts that wear on the product are listed in chapter 3 of this manual. Parts are available directly from Hewlett-Packard at the following numbers: ●

Us: (800) 538-8787

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Accessories and consumables Table 7-2. Accessories Product name Description Product number Part number Exchange number Print cartridges, cables, and HP Jetdirect Print Servers Print cartridge 2,000 page cartridge

N/A

Q2612A

Ieee-1284

N/A

C2950A

N/A

C2951A

Q2460A

Q2460A

Q2460A

N/A

N/A

N/A

N/A

N/A

N/A

J3265A

J3265-61001

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Product name Description Product number Part number Exchange number HP Jetdirect Print Server Model 500x Token Ring

J3264A

J3264-61001

J3263A

J3263-61001

T)

J3258B

J3258-61001

J6038A

J6038-60001

N/A

J6038-60001

J6061A

J6061-61001

J6062A

J6062-61001

N/A

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Field-replaceable units 1 2 Figure 7-1. All Models Ref Description Part number Qty 1 Exchange-LJ1010-110V Printer

Q2460-69001

Q2460-69002

Q2461-69001

Q2461-69002

Q2462-69001

Q2462-69002

Q2463-69001

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5 6 1 11 2 3 4 7 8 9 10 12 Figure 7-2. Exploded View: Field Replaceable Units Table 7-3. Replaceable Assemblies Ref Description Part number Qty 1

Paper Pickup Tray Ass'Y

Rm1-0629-000

Delivery Tray Ass'Y

Rm1-0659-000

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Ref Description Part number Qty 3

Separation Pad Ass'Y

Rm1-0648-000

Roller, Pickup

Rl1-0266-000

Fuser (Fixing Ass'Y) 110-127V

Rm1-0650-000

Fuser (Fixing Ass'Y) 220-240V

Rm1-0656-000

Engine Power Ass'Y 110-127V

Rm1-0807-000

Engine Power Ass'Y 220-240V

Rm1-0808-000

Laser Scanner Ass'Y

Rm1-0171-000

Engine Control Ass'Y

Rm1-0806-000

Transfer Roller Ass'Y

Rm1-0658-000

Paper Pickup Ass'Y

Rm1-0641-000

Q2460-67914

Q2460-67915

Rc1-1957-000

N/A

Q2460-60101

N/A

Q2460-60102

N/A

Q2460-60103

N/A

Q2460-60104

N/A

Q2460-60105

N/A

Q2460-60106

N/A

Q2460-90928

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Alphabetical parts list Table 7-4. Alphabetical parts list Description Part number Table and page CD Rom-Asia

Q2460-60104

Q2460-60105

Q2460-60103

Q2460-60102

Q2460-60101

Q2460-60106

Delivery Tray Ass'Y

Rm1-0659-000

Rc1-1957-000

Q2460-67914

Q2460-67915

Engine Control Ass'Y

Rm1-0806-000

Engine Power Ass'Y 110-127V

Rm1-0807-000

Engine Power Ass'Y 220-240V

Rm1-0808-000

Q2460-69001

Q2463-69001

Q2460-69002

Q2461-69001

Q2461-69002

Q2462-69001

Q2462-69002

Fuser (Fixing Ass'Y) 110-127V

Rm1-0650-000

Fuser (Fixing Ass'Y) 220-240V

Rm1-0656-000

Laser Scanner Ass'Y

Rm1-0171-000

Paper Pickup Ass'Y

Rm1-0641-000

Paper Pickup Tray Ass'Y

Rm1-0629-000

Roller, Pickup

Rl1-0266-000

Separation Pad Ass'Y

Rm1-0648-000

Q2460-90928

Transfer Roller Ass'Y

Rm1-0658-000

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Numerical parts list Table 7-5. Numerical parts list Part number Description Table and page

Q2462-69002

Q2463-69001

Q2460-60101

Q2460-60102

Q2460-60103

Q2460-60104

Q2460-60105

Q2460-60106

Q2460-67914

Q2460-67915

Q2460-69001

Q2460-69002

Q2460-90928

Q2461-69001

Q2461-69002

Q2462-69001

Rc1-1957-000

Rl1-0266-000

Roller, Pickup

Rm1-0171-000

Laser Scanner Ass'Y

Rm1-0629-000

Paper Pickup Tray Ass'Y

Rm1-0641-000

Paper Pickup Ass'Y

Rm1-0648-000

Separation Pad Ass'Y

Rm1-0650-000

Fuser (Fixing Ass'Y) 110-127V

Rm1-0656-000

Fuser (Fixing Ass'Y) 220-240V

Rm1-0658-000

Transfer Roller Ass'Y

Rm1-0659-000

Delivery Tray Ass'Y

Rm1-0806-000

Engine Control Ass'Y

Rm1-0807-000

Engine Power Ass'Y 110-127V

Rm1-0808-000

Engine Power Ass'Y 220-240V

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120 Chapter 7 Parts and diagrams

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Index

A

B

C

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country of origin, identifying 4 coverage, printer 11 covers, removing front 68 left side 65 rear 65 right side 62 CPU, formatter 37 crooked pages, troubleshooting 97, 100 curl, troubleshooting 97, 99 custom-sized media, loading 22 Customer Care Online 112 cut-off edges 93

D

E

Ecu

F

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features 5 operations 37 front cover, removing 68 FRUs (field replaceable units) procedures for replacing 51 fuser (fixing) assembly removing 73 fuser assembly exit rollers 45 life expectancy 24 operations 44 temperature, adjusting 95, 96 troubleshooting 94 fuser cover, removing 65 fuses, overcurrent protection (F101, F102) 42 fusing stage, image formation process 44

G

H

I

J

K

L

M

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manuals ordering 112 margins, minimum 93 media common problems 19 guidelines 19 loading 22 sizes 18 specifications 18 memory base 5 buffer 38 formatter 37 Memory Enhancement technology (MEt) 6, 38 mirror operations 43 misalignment troubleshooting 97, 100 misfeeds, frequent.. See feeding problems, troubleshooting\ model number 4 models differences 53 motor operations 40 multifeeds printer input trays 31, 57, 101, 102 See also feeding problems, troubleshooting\

N

Nvram

O

P

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pickup roller cleaning 27 operations 44 replacing 29, 55 pickup solenoid (SL001) locating 46, 109 operations 44, 46 pickup stationary jam 46 pins high-voltage power supply 106 PJL (Printer Job Language) features 38 pliers, required 52 ports, troubleshooting

Lpt

Q

R

Ram

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rear panel 65 right side cover 62 transfer roller assembly 70 removing parts 52, 53 repetitive defects, troubleshooting 96, 107 replacement intervals consumables 24 print cartridges 5 recycling used print cartridges 11 replacement parts.. See parts replacing parts 29, 52, 53, 55 report, troubleshooting control panel 84 reports, troubleshooting control panel 86 residual paper jams 46 Resolution Enhancement technology (REt) 6 resolution, maximum 5 revision level 4 right side cover, removing 62

Rom

S

T

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text, troubleshooting misprinted 94, 96 timing diagram, general 49 toner cloth, ordering 114 image formation operations 44 loose, troubleshooting 96 redistributing 92 scattered, troubleshooting 98 smears, troubleshooting 95 specks, troubleshooting 94, 98 waste cleaning operations 44 toner cartridge extending life of 38 part number 113 removing 52 toner cartridges checking 92, 105 drum rotation check 105 operations 44 toner cartridges.. See print cartridges tools, required 52 trailing edge, detection 46 Training, HP Technical 112 transfer roller cleaning around 25 operations 44 power supply 42 removing 70 transfer stage, image formation process 44 transparencies cleaning print path with 25 loading 22 specifications for 19 trays.. See main input tray\ troubleshooting control panel 82 control panel error report 84 control panel lights 87 control panel pages 86 loose toner 96, 97, 99, 100 LPT ports 83 printing 82, 83 smears 95 software installation 83 spots 95 vertical white lines 98 troubleshooting steps 82 two-way communications 37, 38

U

Usb

V

W

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128 Index

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Appendix A: Status, Warnings & Errors Reference

Header A = Auto-Continuable C = Continuable

LED Pattern Headers

G = Go LED

R = Ready LED

A = Attention LED

Button Headers

G = Go button

LED Pattern Values

C = Cycling

B = Blinking

S = Solid

Button Values

P = Single Press

H = Hold

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Cp

A

C

Led

Description

Status Messages

G R

A G

Manual Feed w/Pause

Manually Feed

[Type] [Size]

X

S

B P

62 No System

S

S

B

S

B

P

Scan Buffer Error (64) *

64 Printer Error

S

B

S

S

P

79.Xxxx Printer

Error

S

B

S

S

B

P

New

Functionality

Initiate Continuous Self-Test

C

S

C

S

S

B

C

S

S

S

H

Appendix B: Quick Card Reference

Led Legend

Initialize/Boot All LED’s initially on, then cycle

Continuable Error

Ready Fatal Error

Processing Data

Accessory Error

Job Cancel LED’s cycle until reset is complet Cleaning Page- LED’s cycle until process is complete

Attention (Door, Paper, Toner)

Button Feature Descriptions

On Off Blink Cycle Go Ready Attention Go Ready Attention Go Ready Attention Go Ready Attention Go Ready Attention Go Ready Attention Go Ready Attention Go Ready Attention Go Ready Attention

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134 Appendix B

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*Q2460-90928*

*Q2460-90928*

Q2460-90928

www.s-manuals.com