Service Manual HP LaserJet 5L (C3941A)
© Copyright Hewlett-Packard Company 1995 All Rights Reserved. Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws. Publication number C3941-90987 First edition, September 1995 Hewlett-Packard Company 11311 Chinden Boulevard Boise, Idaho 83714 Warranty The information contained in this document is subject to change without notice.
Conventions This manual uses the following conventions: Color is used to emphasize items which are important to the material under discussion. The names of major printer parts and assemblies are CAPITALIZED. Bold is used for emphasis, particularly in situations where italic type would be confusing. Italic type is used to indicate related documents or emphasis. Note Notes contain important information set off from the text.
Chapter Descriptions 1 Product Information Orientation to the printer, as well as the service and repair philosophy, is discussed. Information on obtaining assistance and warranty is also here. 2 Site Requirements Here are recommendations pertaining to installation requirements. 3 Operating Overview This chapter has detailed information about the Control Panel. Sample self tests and printer reset information are also included.
List of Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 2-1 Figure 2-2 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5 Figure 3-6 Figure 4-1 Figure 4-2 Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 6-1 Figure 6-2 Figure 6-3 Figure 6-4 Figure 6-5 Figure 6-6 Figure 6-7 Figure 6-8 Figure 6-9 Figure 6-10 Figure 6-11 Figure 6-12 Figure 6-13 Figure 6-14 Figure 6-15 Figure 6-16 Figure 6-17 Figure 6-18 Figure 6-19 Figure 6-20 Figure 6-21 Figure 6-22 HP LaserJ
Figure 6-23 Figure 6-24 Figure 6-25 Figure 6-26 Figure 6-27 Figure 6-28 Figure 6-29 Figure 6-30 Figure 6-31 Figure 6-32 Figure 6-33 Figure 6-34 Figure 6-35 Figure 6-36 Figure 6-37 Figure 6-38 Figure 6-39 Figure 6-40 Figure 6-41 Figure 6-42 Figure 7-1 Figure 7-2 Figure 7-3 Figure 7-4 Figure 7-5 Figure 7-6 Figure 7-7 Figure 7-8 Figure 7-9 Figure 8-1 Figure 8-2 Figure 8-3 Figure 8-4 Figure 8-5 Figure 8-6 Figure 8-7 Figure 8-8 Figure 8-9 Figure 8-10 Figure B-1 vi Pickup Roller Assembly Removal (1 of 2) . . .
List of Tables Table 1-1 Table 1-2 Table 1-3 Table 1-4 Table 1-5 Table 1-6 Table 2-1 Table 2-2 Table 3-1 Table 3-1 Table 3-2 Table 4-1 Table 4-2 Table 5-1 Table 5-2 Table 7-1 Table 7-2 Table 7-3 Table 7-4 Table 7-4 Table 7-4 Table 7-5 Table 7-6 Table 7-7 Table 7-8 Table 8-1 Table 8-2 Table 8-3 Table 8-4 Table 8-5 Table 8-5 Table 8-6 Table A-1 Table A-2 Printer Features . . . . . . . . . . . . . . . . . . Paper Capacities and Sizes . . . . . . . . . . . . Performance Specifications . . . . . . . . . . .
viii
1 Product Information Contents Printer Features . . . . . . . . . . . . . . . . . . . . . . Paper Capacities and Sizes . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . Model and Serial . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Product Overview . . . . . . . . . . . . . . . . . . . . Front/Side Views of the Printer . . . . . . . . . . . . Front Door Assemblies . . . . . . . . . . . . . . . .
1-2 Product Information
Printer Features Table 1-1 Printer Features Features HP LaserJet 5L (C3941A) Print Speed 4 ppm Text & Graphics Resolution 300 or 600 dpi Printer Language Enhanced PCL 5 Monthly Usage (pages) 4,000 pages Memory: Standard1 Maximum Memory Capacity 1 Mbyte RAM (70nsec) 9 Mbyte total (available in increments of 1, 2, 4, and 8 Mbytes) 5 V JEDIA card2 Internal Typefaces 26 Scalable Typefaces Standard Interfaces Parallel (Bi-tronics) Power Control SleepMode Control Panel 3 LEDs 1 Front Panel But
Identification Model and Serial The model number and serial numbers are listed on identification labels located on the bottom of the printer. The model number is alphanumeric, such as C3941A for the HP LaserJet 5L printer. The serial number contains information about the Country of Origin, the Revision Level, the Production Code, and production number of the printer. The rear labels also contain power rating and regulatory information as shown in Figure 1-1.
Specifications Table 1-3 Performance Specifications Category Specification Print Speed* 4 ppm Monthly Usage (Duty Cycle) 4,000 pages Life Expectancy of Toner Cartridge (pages)** 2,500 pages @ 5% coverage First Print A4 <23 seconds Letter <23 seconds * Actual speed depends on data complexity and software handling efficiency. ** Toner cartridge life can be extended by using EconoMode.
Product Overview Figure 1-2 Front/Side Views of the Printer 1. Paper Input Support 7. Front Panel Button 2. Paper Output Support 8. Paper Output Bin 3. Paper Guides 9. Paper Path Lever 4. Error (top) Light 10. Serial and Model Number (under printer) 5. Data (middle) Light 11. Paper Input Bin 6. Ready (bottom) Light 12. Single Sheet Input Slot 1-6 Product Information 13.
Figure 1-3 Front Door Assemblies 14. Paper Release Lever 16. Transfer Roller 15. Toner Cartridge Compartment 17.
Figure 1-4 I Back View of the Printer 18. Power Cable Connector 19. Parallel Cable Connector 1-8 Product Information 20.
Service Approach Repair of the printer normally begins with the use of the printer’s internal diagnostics in conjunction with the troubleshooting procedures in Chapter 7. Once a faulty part is located, repair is generally accomplished by assembly level replacement of Field Replaceable Units (FRUs). Some mechanical assemblies may be repaired at the subassembly level. PCA component replacement is not supported by Hewlett-Packard. Part numbers for all FRUs are located in Chapter 8 of this manual.
Table 1-6 Related Documentation Description Part Number SMO 5010-3991 X C3941-90901 X HP PCL5 Printer Language Technical Reference Information Package 5010-3994 X X HP LaserJet Printer Family Paper Specifications Guide 5010-3990 X X LaserJet Basic Hardware Training Course 5961-0880 X X C3941+49A-60001 (NTSC) C3941+49A-60002 (PAL) X HP LaserJet Family Quick Reference Service Guide HP LaserJet 5L Printer User’s Manual HPLJ 5L Hardware Training Kit Specific Application Drivers X SME H
Technical Assistance HP ASAP HP ASAP (Automated Support Access Program) provides free user technical support information 24 hours a day, 7 days a week. The ASAP system includes HP AUDIO-TIPS and HP FIRST, both explained below. The ASAP service requires a touchtone phone. HP AUDIO-TIPS HP AUDIO-TIPS is an interactive voice response system providing prerecorded answers to the most frequently asked questions by HP LaserJet printer users.
Customer Information Centers (North America Only) For presales information, contact the nearest Hewlett-Packard Customer Information Center, 1-800-752-0900 in North America. Customer Support Center (Assist Line) The HP Customer Support Center, (208-323-2551) is available to answer technical questions regarding setup, configuration, installation, and operation of HP printers in the PC and Macintosh environments.
Warranty This warranty gives you specific legal rights. You may also have other rights, which may vary from area to area. Hewlett-Packard warrants the 5L LaserJet printer against defects in materials and workmanship for a period of one year from the date of purchase by the end user and is not transferable. During the warranty period, Hewlett-Packard will, at its option, either repair or replace hardware products that prove to be defective.
If you are using a mechanical switchbox, ensure that it is equipped with a surge protector. Damage to your printer could occur from the use of unprotected mechanical switchboxes. The warranty period begins either on the date of delivery or, where the purchase price includes installation by Hewlett-Packard, on the date of installation. Warranty Limitations The warranty set forth above is exclusive and no other warranty, whether written or oral, is expressed or implied.
2 Site Requirements Contents Site Requirements . . . . . . . . . . . . Operating Environment . . . . . . . . Printer Space Requirements . . . . . . . The HP C3906A Toner Cartridge . . . . Storage Conditions . . . . . . . . . . Storing Opened Toner Cartridges . . . Toner Cartridge Handling Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 -2 Site Requirements
Site Requirements Operating Environment The environmental requirements listed in the table below must be maintained to ensure the proper operation of this printer. Table 2-1 Environmental Requirements LaserJet 5L & Cartridge Temperature Humidity Operating Storage 50 to 90.5° F (10 to 32.5° C) 32 to 104° F (0 to 40° C) 20 to 80% RH (with no condensation) 10 to 80% RH (with no condensation) Consider the following points before installing the printer: • Install in a well-ventilated, dust-free area.
Printer Space Requirements Figure 2-1 Printer Space Requirements Table 2-2 Printer Dimensions Description Dimension Width 13.2 in. (335.5 mm) Depth 12.3 in. (311.2 mm) Height (storage) (operational) 8.9 in. (227.5 mm) 14.6 in. (372.7 mm)* Weight (with toner cartridge) 15.9 lbs. (7.2 kg) Toner cartridge weight** 1.5 lbs. (.7 kg) * With letter input assembly extended. ** Some quantity of toner will reside in the waste toner area of a toner cartridge when the toner supply is exhausted.
The HP C3906A Toner Cartridge Toner cartridges contain components that are sensitive to light, temperature, and humidity. Follow the recommendations in this section to ensure the highest quality and longest life of HP toner cartridges. Keep the printer within the following environmental conditions for optimum performance. Storage Conditions The toner cartridge is affected by its environment. Packaging protects the toner cartridge from light and increases its storage life.
Toner Cartridge Handling Suggestions • Before installing a cartridge, distribute the toner evenly by rotating the cartridge back and forth five to six times. (See Figure 2-2.) Repeat this action when toner begins to run low. Figure 2-2 Ton erC artri dge C39 06A Toner Cartridge Distribution • Do not touch the surface of the photosensitive drum in the cartridge. Protect the drum from light and contamination. • Do not expose the cartridge to unnecessary vibrations or shock.
3 Installation and Configuration Contents Unpacking and Installation . . . . . . . . . . . . Step 1: Choose the best location . . . . . . . Step 2: Unpack the printer . . . . . . . . . . Step 3: Check package contents . . . . . . . Step 4: Install the toner cartridge . . . . . . . Step 5: Load paper . . . . . . . . . . . . . . Step 6: Attach the power cord . . . . . . . . Step 7: Install printing software . . . . . . . Host-Based Printer Driver . . . . . . . . . . . Host-Based Printer Settings . . . . . . .
3-2 Installation and Configuration
Unpacking and Installation Before unpacking the printer, inspect the shipping container for signs of physical damage. Since a damaged shipping box is an indication of improper handling during shipping, the printer may also be damaged. If the shipping container has any sign of damage, unpack the printer and plug it in with the carrier’s agent present. If the printer appears damaged or fails a self test, do not accept it. (See “Printing a Self-Test Page” later in this chapter.
Step 4: Install the toner cartridge 1 Open the EP Cartridge door. 2 Remove toner cartridge from its box and cut it open. Save the packing materials for possible cartridge storage. 3 Shake the cartridge vigorously to distribute the toner evenly inside the cartridge. (See Figure 2-2.) 4 Grasp the toner sealing tab on the right side of the cartridge. Pull firmly to remove the strip of sealing tape. 5 Grasp the plastic cartridge body and slide the cartridge into the printer, pushing it firmly into place.
If your system does not meet these minimum requirements, only the PCL driver software will be installed. Note Minimum System Requirements • 486 or above PC with 8 Mbytes DRAM (minimum) • Fully functional bi-directional cable (IEEE 1284-compliant cable recommended) • HP LaserJet 5L printer connected and powered on To install the printing software 1 2 3 4 5 6 7 Turn on your computer. Start Microsoft Windows and install Disk 1 into your disk drive A. From Program Manager, select File.
If you would like to connect another device to the LPT port you have configured to use with the HP LaserJet 5L, select the other device from the Microsoft Windows Control Panel and restart windows. The HP LaserJet printer is capable of receiving and processing both PCL commands and host-based generated data. Host-Based Printer Settings To select printer settings, open the HP LaserJet 5L Printer group within Program Manager and select HP 5L Driver Settings. The Printer Settings window will appear.
Host-Based Printing Status To view your printer’s status, open the HP LaserJet 5L Printer group within Program Manager and select Status Window. As shown in Figure 3-2 below, the status window reports your printer’s current status. In this case, the printer is Ready. Figure 3-2 Host-Based Printing Status This host-based status window is only compatible with the HP LaserJet 5L.
PCL Printer Settings To change printer settings, select Control Panel, Printers, HP LaserJet 5L (PCL), Setup. The printer settings window will appear. (See Figure 3-3.) Select from the following options: • Paper—Select Paper Size, Paper Source (manual feed), Copies, Orientation (portrait or landscape), and Set Custom Paper Size. • Print Quality—Select Print Optimization Settings and Economode. • Fonts—Choose to run the HP Font Installer and to add True Type Fonts.
PCL Printing Status To view your printer’s status, open the HP LaserJet 5L PCL Printer group within Program Manager and select Status Window. As shown in Figure 3-4 below, the status window reports your printer’s current status. In this case, the printer is Ready. Figure 3-4 PCL Printing Status As with the host-based software, the PCL software has its own, unique status window, but both windows cannot be active at the same time. To use both drivers, see “Using Host-Based and PCL Drivers Together” below.
Using the Control Panel Control Panel Layout The Control Panel consists of three status lights and a Front Panel Button located at the front of the printer. The Control Panel consists of one button and three status lights.
LED Lights The LED lights provide a quick way to check the printer’s status. Table 3-1 When this Indicator: Indicator Lights (1 of 2) Looks like this: It means this: Do this: On Ready Ready to print. Blinking Print job in progress. Let job finish printing. On Form Feed There is unprinted data in the buffer. Briefly press the Front Panel Button to print the remaining data. Blinking Manual Feed The printer is in manual feed mode.
Table 3-1 When this indicator: Indicator Lights (Continued 2 of 2) Looks like this: Blinking It means this: Error (light blinking) Page Too Complex Do this: Briefly press and release the Front Panel Button to continue printing. There may be some data loss on the page. The page may be too complex for the printer’s memory capacity Hint: To avoid this in the future: or the printer may not be able to create the image fast enough to 1.
The Front Panel Button Depending on what state the printer is in, pressing the Front Panel Button allows you to control printing tasks by either starting or resuming a printer function. Use the Front Panel Button to accomplish the following tasks: Table 3-2 Front Panel Button Usage Function Action Lights Result Wake Up Briefly push and release the button. All lights are off while plugged into power source. The printer will wake up to a ready state. Self Test Briefly push and release the button.
Printing a Self-Test Page A self-test page can be useful in troubleshooting printer problems and determining which fonts have been downloaded to the printer. Figure 3-5 Self-test Page The self-test page includes an internal font listing showing all 26 provided fonts (1) and a listing of the current printer configuration (2). (If any fonts have been downloaded to the printer a second page will print.) To print a self-test page: 1 Make sure the Ready (bottom) Light is on, and all other lights are off.
Continuous Self Test A continuous self test can be useful for troubleshooting paper path and other problems. To print a continuous self test: 1 Disconnect the printer from the power source. 2 Press and hold down the Front Panel Button while connecting power. 3 Continue holding the button for about five seconds. All lights will illuminate at once, then each will light in sequence. 4 Release the button.
Printing an Engine Test The engine test print can be used to verify that the print engine is functioning correctly. The Formatter PCA is completely bypassed during an engine test. Consequently, this test is useful for isolating engine printer problems. The engine test prints a full page of vertical lines down the entire printable area. This page is useful for checking and adjusting registration. Note Perform the engine test with the printer covers in place, as shown in Figure 3-6.
Resetting the Printer Resetting the printer accomplishes the following: • Clears all data from the printer’s memory (including unprinted data, downloaded fonts, and macros). • Stops any printing that is taking place and ejects the page. • Removes some error conditions. • Resets the printer to its factory default settings. To Reset the Printer Press and hold the Front Panel Button until the three control panel lights blink quickly in succession (about 5 seconds), then let go of the button.
3-18 Installation and Configuration
4 Printer Maintenance Contents Life Expectancy of Consumables . Toner Cartridge Life . . . . . . . . Saving Toner with EconoMode Refilled Toner Cartridges . . . . Recycling Toner Cartridges . . . Cleaning the Printer . . . . . . . . Cleaning Printer Components . . Cleaning Spilled Toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 Printer Maintenance
Life Expectancy of Consumables Always inspect the components listed in Table 4-1 for wear when servicing the printer. Replace these components as needed, based on printer failures or wear, not strictly on usage. Table 4-1 Life Expectancy of Consumables Description Part No. Est Life (pgs) Remarks Toner Cartridge (user replaceable) C3906A 2,500* When print becomes faint, shake cartridge to distribute remaining toner.
Toner Cartridge Life The toner cartridge has been designed to simplify the replacement of the printer’s major “consumable” parts. The toner cartridge contains the printing mechanism and a supply of toner. When using a typical word-processing application, a toner cartridge will print approximately 2500 pages where the text covers about 5% of the page. Figure 4-1 Five Percent Text Coverage When regularly printing pages with less coverage, such as short memos, a toner cartridge should print over 2500 pages.
proofs. EconoMode can be set through your printer driver. See Chapter 3 for information. Notes Some software applications may refer to this as “draft mode." Refilled Toner Cartridges While Hewlett-Packard does not prohibit the use of refilled toner cartridges during the warranty period or while under a maintenance contract, we do not recommend their use.
Cleaning the Printer To maintain the print quality, thoroughly clean the printer: • Every time you change the toner cartridge. • After printing approximately 2,500 pages. • Whenever print quality problems occur. Clean the outside of the printer with a lightly water-dampened cloth. Clean the inside with only a dry, lint-free cloth. Observe the warnings and cautions below. WARNING! Before you begin these steps, unplug the printer to avoid shock hazard.
Cleaning Printer Components CAUTION To avoid permanent damage to the toner cartridge, do not use ammonia-based cleaners on or around the printer. Do not touch the transfer roller with your fingers. Contaminants on the roller can cause print quality problems. Table 4-2 Cleaning Printer Components COMPONENT CLEANING METHOD/NOTES Outside Covers Use a water-dampened cloth. Do not use solvents or ammonia-based cleaners. Inside General Use a dry, lint free cloth.
Figure 4-2 Static Eliminator Teeth (located in front of the transfer roller) Cleaning Spilled Toner Defective toner cartridges can develop leaks. In addition, after a paper jam has occurred, there may be some toner remaining on the rollers and guides inside the printer. The pages that print immediately after the jam may pick up this toner. Clean spilled toner with a cloth slightly dampened in cold water. Do not touch the Transfer Roller with the damp cloth or with your fingers.
5 Functional Overview Contents Basic Printer Functions . . . . . . . . . . . . DC Controller/Power System . . . . . . . . Print Engine Control System . . . . . . . Power System (on DC Controller PCA) . Formatter System . . . . . . . . . . . . . . . CPU . . . . . . . . . . . . . . . . . . . . Read Only Memory (ROM) . . . . . . . . Random Access Memory (RAM) . . . . . Parallel Interface . . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . . Resolution Enhancement (REt) . . . . . . EconoMode .
5-2 Functional Overview
Basic Printer Functions This chapter presents a generalized functional overview of the printer and the printing processes.
DC Controller/Power System The DC Controller PCA coordinates all print engine activities, drives the laser, and coordinates print data from the Formatter PCA with the image formation process. The DC Controller also includes both AC and dc power supply and distribution circuitry.
Print Engine Control System Laser and Scanner Drive Based on information received from the Formatter, the DC Controller sends signals to the Laser/Scanner Assembly to modulate the laser diode ON and OFF and to drive the Laser/Scanner motor. Refer to “Image Formation System,” later in this chapter for more information.
Power System (on DC Controller PCA) The AC, dc, and high voltage power supply circuits are all contained within the DC Controller PCA. AC Power Distribution The AC power circuitry supplies AC voltage whenever the power cord is connected to the AC power source. AC voltage is distributed to the dc power supply circuitry and to the AC driver circuitry, which controls AC voltage to the fusing assembly’s heating element.
• A job is received. • The Front Panel Button is pressed. • The printer front door is opened. Note The printer will not enter SleepMode if there is a printer error. High Voltage Power Distribution The High Voltage Power Supply PCA applies an overlap of dc and AC voltage to the primary charging roller and the developing roller. This circuit also applies a positive or negative dc voltage to the transfer charging roller according to the instructions from the CPU on the DC Controller PCA.
Formatter System The Formatter PCA is responsible for the following: • • • • • Receiving and processing print data from the printer interface. Monitoring Front Panel Button and relaying printer status information. Developing and coordinating data placement and timing with the print engine. Storing font information. Communicating with the host computer through the Bi-Directional Interface. The Formatter PCA receives print data from the Bi-Tronics Interface and converts it into a dot image.
Control Panel Status LED Lights The Formatter uses three LEDs mounted under the printer cover to communicate printer status to the user. Refer to “Using the Control Panel” in Chapter 3 and “Printer Error Troubleshooting” in Chapter 7 for more information on the lights. Front Panel Button The Formatter PCA is connected to a microswitch located on the control panel PCA. The single button is used for such functions as self test, reset, and to display error codes.
EconoMode The EconoMode setting uses approximately 50% less toner than standard mode printing by reducing the dot density. However, EconoMode does not extend toner cartridge component life. EconoMode, which can also be thought of as “draft mode,” is user-selectable through some software applications. The default setting is Off. Figure 5-3 EconoMode vs Normal Mode Note EconoMode does not affect print speed or memory usage.
Enhanced I/O The Enhanced I/O feature allows printer memory to be used for storing data received from the host computer. When Enhanced I/O is enabled, you can send more data to your printer in shorter amounts of time, which allows you to return to your application sooner. Enhanced I/O has the following options: • Auto—allows the printer to use Enhanced I/O memory allocation to increase the speed of data transfer from the host computer to the printer, if necessary.
Image Formation System Laser printing requires the interaction of several different technologies (such as 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 six processes: • • • • • • Step 1. Drum Cleaning Step 2. Drum Conditioning Step 3. Image Writing Step 4. Image Developing Step 5. Image Transferring Step 6.
Toner Cartridge As the “heart” of the Image Formation System, the toner cartridge houses the cleaning, conditioning, and developing steps of the process. The toner cartridge contains the photosensitive drum, primary charging roller, developing station, toner cavity, and cleaning station. Including these components, which wear, degrade, or are consumed in the replaceable toner cartridge, eliminates the need for a service call when replacement is required.
Step 4: Image Developing At this stage of the process, the latent electrostatic image is present on the drum. The toner particles obtain a negative surface charge by rubbing against the developing cylinder which is connected to a negative dc supply. The negatively charged toner is attracted to the discharged (exposed, grounded) areas of the drum, and repelled from the negatively charged (non-exposed) areas.
Paper Feed System Both the Paper Input Bin and the Single Sheet Input Slot merge into one, main input area. Paper placed in either of these areas enables the Paper Out Sensor (sensor 202), which informs the DC Controller that paper is present. When the printer receives a print job and is ready to print, the DC Controller enables the Laser/Scanner Assembly and the Motor. Paper motion begins when the DC Controller energizes solenoid SL1. This causes the paper pick up roller to rotate once.
Figure 5-5 shows a simplified paper path and the locations of the photosensors and rollers.
Figure 5-6 shows the locations of the photosensors, switches, solenoid, and other important printer elements. Table 5-1 describes the function of each photosensor and the solenoid. Figure 5-6 Solenoid and Sensors Table 5-1 Solenoid and Photosensors No. Name Description SL1 Paper Pick-up Solenoid Enables the Paper Pickup Roller. PS201 Paper Exit Sensor Senses when paper has successfully moved out of the fusing area and the next sheet of paper can be fed.
Paper Jam Detection The Paper Out Sensor (PS202), Paper Registration Sensor (PS203), and the Paper Exit Sensor (PS201) detect when paper is moving through the printer. (See Figure 5-5 for roller and sensor locations.) If a paper jam is detected, the DC Controller immediately stops the printing process and causes a paper jam indication on the front panel. A paper jam can be detected under any of the following conditions: • Power-On Jams. Paper is present under either PS201 or PS203 at power-on.
Basic Sequence of Operation The Formatter PCA and the DC Controller PCA share information during printer operation. The DC Controller-to-Formatter Connector (J201) forms a link which operates as a serial data bus. This allows printer status, command information, and dot-image data to be passed between the two PCAs. Figure 5-7 shows the general timing of the printer events.
Figure 5-7 General Timing Diagram 5 - 20 Functional Overview
6 Removal and Replacement Contents Removal and Replacement Strategy . . . . Required Tools . . . . . . . . . . . . . . . Installing Memory Cards (DRAM) . . . . Covers and Doors . . . . . . . . . . . . . . Back Cover . . . . . . . . . . . . . . . EP Door Assembly . . . . . . . . . . . Memory Door . . . . . . . . . . . . . . Main Cover and Paper Input Assembly . Internal Assemblies . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . Exit Roller Assembly . . . . . . . . . . Delivery Assembly .
6-2 Removal and Replacement
Removal and Replacement Strategy This chapter documents removal and replacement of Field Replaceable Units (FRUs) only. Exchange assemblies should be sent to SMO for repair. Replacement is generally the reverse of removal. Occasionally, notes are included to provide direction for difficult or critical replacement procedures. WARNING! Unplug the power cord from the power outlet before attempting to service the printer. If this warning is not followed, severe injury may result.
Required Tools • • • • Caution #2 Phillips Screwdriver 5.5 mm Hexhead Screwdriver Small Flathead Screwdriver Needlenose Pliers. A Posidriv screwdriver will damage the printer’s screw heads. Use Phillips only. Figure 6-1 shows the difference between a Phillips and a Posidriv screwdriver. Note that a Phillips tip has more beveled surfaces.
Installing Memory Cards (DRAM) 1 Unplug the power cord from the printer. You 2 3 4 5 should not install a memory card while the printer is in SleepMode. Open the Printer Door, remove the toner cartridge, and close the Printer Door. Protect the toner cartridge from light while you are working on the printer. Remove any paper in the paper tray. Gently tip the printer onto its side so that the memory cover is on top as shown in Figure 3.
Covers and Doors Back Cover 1 Unplug the power cord and remove the parallel cable from the back of the printer. 2 Remove the toner cartridge. 3 Lift the Input Extender assembly. Caution You must lift the Input Extender when the covers are removed or it will break. 4 Remove the (3) screws (Figure 6-2, callout 1).
5 Separate the rear panel from the main cover, pulling the lower corners away from the printer first, then using a flathead screwdriver to pry the two upper corners apart (Figure 6-3, callout 1). 6 To remove the cover, pull it downward (Figure 6-3, callout 2). Figure 6-3 Back Cover Removal (2 of 2) To reinstall Make certain the Input Extender is up.
EP Door Assembly 1 2 3 4 Unplug the power cord and remove the parallel cable from the back of the printer. Open the EP door. Remove the toner cartridge. Along the door hinge, there is a flex point. Press the left tab inward to release it. The right tab will fall out easily (Figure 6-4).
Memory Door 1 2 3 4 Unplug the power cord and remove the parallel cable from the back of the printer. Remove the toner cartridge. Gently tip the printer onto its side so that the Control Panel is on top. Carefully pull the door tab out (Figure 6-5, callout 1) and away from the printer in a gentle rocking motion (Figure 6-5, callout 2).
Main Cover and Paper Input Assembly 1 Remove the toner cartridge. 2 Remove memory door. Remove the memory door first. The door will break if you remove the Main Cover without removing the memory door. Caution Remove the EP Door Assembly. Remove the Back Cover. Remove the (2) screws from the top of the printer (Figure 6-6, callout 1). Grasp the two lower, front corners of the printer and pull gently outward to release the front of the Main Cover. 7 Lift the cover straight off.
Internal Assemblies Control Panel 1 Remove the Printer Covers. 2 Release the Control Panel connector (Figure 6-7, callout 1). 3 Press the tab on the top of the Control Panel downward (Figure 6-7, callout 2). The Control Panel will pop out of the printer chassis. 4 Lift the Control Panel out.
Exit Roller Assembly 1 Remove Printer Covers. 2 Grasp the tabs at the lower ends of the Exit Roller bushings and pull inward. This will release the tabs from the printer chassis (Figure 6-8, callout 1). 3 Rotate the tabs 90 degrees, clear of the printer chassis (Figure 6-8, callout 2). 4 Lift the roller out.
Delivery Assembly 1 Remove the Printer Covers and Exit Roller Assembly. 2 Remove the EP Right-Hand assembly by pressing the tab in (Figure 6-9, callout 1) and sliding the assembly toward the front of the printer (Figure 6-9, callout 2). Note The EP Right-Hand assembly must be removed to access any fuser components.
3 Remove the (2) screws (Figure 6-10, callout 1). Once the screws have been removed, rotate the rear of the assembly up and lift it out of the printer. Figure 6-10 Delivery Assembly Removal (2 of 2) Caution Upon replacement, make certain that the positioning pins on the bottom of the assembly are properly positioned before tightening the screws. Note The tabs on the front end of the Delivery Assembly must fit under the sheet metal fuser plate below.
Fuser Pressure Plate 1 Remove Printer Covers and Delivery Assembly (Figures 6-9 and 6-10). 2 Remove the (2) screws (Figure 6-11, callout 1). 3 Press the Fuser Plate retainer clips out to release the Pressure Plate (Figure 6-11, callout 2). 4 Rotate the plate around and lift up to remove it (Figure 6-11, callout 3).
To reinstall: The Fuser Pressure Plate is kept in place by four locking mechanisms in each corner. Place the rear slits in the plate over the rear brackets that hold the Fusing Assembly (Figure 6-12, callout 1). Lower the plate over the retaining clips, pressing on both sides of the Fuser Pressure Plate (Figure 6-12, callout, 2). It is important that the spring is placed over the positioning pin (callout 3) or the toner cartridge will not glide into place. Replace the screws.
Heating Element 1 Remove Printer Covers, Delivery Assembly (Figures 6-9 and 6-10), and Fuser Pressure Plate (Figure 6-11). 2 Remove the wire cover (on the right side of the printer) for the Heating Element wires by pressing in on the tab and pulling outward (Figure 6-13, callout 1).
3 Disconnect the AC voltage to the Heating Element by releasing the connector located on the DC Controller. Press down on the connector release with a small, flathead screwdriver (Figure 6-14, callout 1). (Since this is a small space, it is much easier to reach the connector with a screwdriver.) Pull straight out (Figure 6-14, callout 2).
4 Remove the wire from the wire guides along the right-side of the printer. 5 Disconnect the thermistor feedback connector in the left front side of the Fusing Assembly (Figure 6-15). Figure 6-15 Heating Element Removal (3 of 3) 6 Lift the Heating Element out.
Pressure Roller 1 Remove Printer Covers, Delivery Assembly (Figures 6-9 and 6-10), Fuser Pressure Plate (Figure 6-11), and Heating Element (Figures 6-13 through 6-15). 2 Remove the Pressure Roller guide by lifting the edge (Figure 6-16, callout 1) and then rolling it gently backward (Figure 6-16, callout 2). Figure 6-16 Pressure Roller Removal 3 Lift the right end of the Pressure Roller up and out of the printer chassis. The left side will follow easily with the Pressure Roller gear still attached.
Face-Up/Face-Down Lever 1 Remove Printer Covers, Delivery Assembly (Figures 6-9 and 6-10), Fuser Pressure Plate (Figure 6-11), and Heating Element (Figures 6-13 through 6-15), and Pressure Roller (Figure 6-16). 2 Rotate the lever forward 90 degrees (past the spring) and pull it straight out the front of the printer. To reinstall 1 Make sure the lever arm is on the left and is initially pointing downward. 2 Pull the spring forward using needlenose pliers.
Fuser Exit Roller Assembly 1 Remove Printer Covers, Delivery Assembly (Figures 6-9 and 6-10), Fuser Pressure Plate (Figure 6-11), and Heating Element (Figures 6-13 through 6-15), Pressure Roller (Figure 6-16), and Face-Up/Face-Down Lever (Figure 6-17). 2 Remove the gear from the left end of the roller shaft. 3 Remove the Exit Roller Assembly by pressing the small, white tab upward (Figure 6-18, callout 1) and rotating it around (Figure 6-18, callout 2).
Paper Exit Sensor Flag 1 Remove the Printer Covers, Delivery Assembly (Figures 6-9 and 6-10), and Fuser Pressure Plate (Figure 6-11). 2 Remove the Paper Exit Sensor flag by pressing down on the left side and pulling up on the right side. To reinstall Note It is important that you reinstall the flag correctly, since installing it incorrectly will cause the Control Panel to display an error with the Paper Exit Sensor (PS201).
Top Assemblies Laser/Scanner Assembly 1 Remove the Printer Covers. 2 Remove both Laser/Scanner connectors (Figure 6-20, callout 1). 3 Remove all (4) screws and lift the assembly straight off (Figure 6-20, callout 2).
Solenoid 1 Remove the Printer Covers. 2 On the left side of the printer, remove the paper pickup gear (Figure 6-21, callout 1) by pressing the tabs in the center of the gear outward and pulling the gear off (Figure 6-21).
3 Remove the Solenoid connector (J204) from the DC Controller (Figure 6-22, callout 1). 4 Remove the self-tapping screw that holds the Solenoid in place (Figure 6-22, callout 2). 5 Unthread the wires from the printer chassis. 6 Lift the Solenoid off. Figure 6-22 Solenoid Removal (2 of 2) Note 6 - 26 When reinstalling this part, the Paper Pickup Gear is keyed to go on the shaft in only one way.
Pickup Roller Assembly 1 Remove the Printer Covers. 2 Remove the paper pickup gear (Figure 6-21). Note This gear is keyed to go on the shaft in only one way. 3 Remove the pickup roller grounding clip on the right of the printer by lifting each end up and over the two metal guides and sliding the clip off (6-23).
4 Using needlenose pliers, pull the bottom of the bushing out (Figure 6-24, callout 1), then turn it counter clockwise to release it (Figure 6-24, callout 2). Figure 6-24 Pickup Roller Assembly Removal (2 of 2) 5 Lift the bushing out. 6 From inside the front of the printer, slide the right side of the Pickup Roller Assembly forward, then lift the left side out.
To reinstall Note It is important that the Pickup Roller is placed back in with the two Idler Roller tabs up, so that they fit into the underside of the metal chassis behind the Laser/Scanner assembly (Figure 6-25).
Paper Feed Frame 1 Remove the Printer Covers. 2 Remove the Pickup Roller Assembly (Figures 6-23 through 6-24). 3 Release the connectors from the Laser/Scanner, Top Cover/EP Cartridge Sensor (PS203), Switch 101, Front Control Panel (Figure 6-26). Disconnect the Solenoid from the DC Controller at J204 (Figure 6-22, callout 1).
4 Remove the (4) hex head screws from the Paper Feed Frame (Figure 6-27, callout 1). 5 Remove the self-tapping screw from the back sheet metal plate and lift it off (Figure 6-27, callout 2).
6 Release the sensor unit connector (Figure 6-28). Figure 6-28 Paper Feed Frame Removal (2 of 2) 7 Pull the frame straight back to remove it. To reinstall The Paper Feed Frame may be easier to reinstall if you place the printer on its front, so that you can apply pressure while putting the screws back in place.
Transfer Roller Guide & Transfer Roller 1 Remove the Printer Covers, Pickup Roller Assembly (Figures 6-23 through 6-25), and Paper Feed Frame (Figures 6-26 through 6-28). 2 Looking at the back of the printer, note the two small, hook-shaped release tabs on each end of the Transfer Roller guide. Using a small, flathead screwdriver, carefully pry each tab outward to release it (Figure 6-29). 3 Roll the released portion of the guide up.
Kick Plate 1 Remove the Printer Covers and the Pickup Roller Assembly (Figures 6-23 and 6-24). 2 Press the Separation Pad (Figure 6-30). Allow the Kick Plate to pivot upward (a spring underneath will push it up). Lift the Kick Plate off its mounting pins.
To reinstall If the spring on the Kick Plate doesn’t stay on the Kick Plate, replace the spring, making certain the diameter of the spring surrounds two lower pins on the Kick Plate and rests inside the third pin. Use needlenose pliers to place the spring correctly. (See Figure 6-31.) Figure 6-31 Kick Plate Spring Replacement While rotating the Kick Plate into place, guide the other end of the spring onto the silver grounding plate located on the Paper Feed Frame.
Separation Pad 1 Remove the Printer Covers, Pickup Roller Assembly (Figures 6-23 and 6-24), and Kick Plate (Figure 6-30). 2 Lift the bottom of the white plastic tab on the rear of the Paper Feed Frame up slightly and slide it up, toward the top of the Paper Feed Frame. This will release the Separation Pad (Figure 6-32). 3 Lift the Separation Pad 90 degrees and slide its mounting pins out of their retainers.
Subpads Note When you replace the Separation Pad, you should also replace the smaller subpads at the same time. 1 Place your index finger on the subpad. 2 Press toward the top of the printer.
Feed Assembly The Feed Assembly is located in the Paper Feed Frame. 1 Remove the Printer Covers, Pickup Roller Assembly (Figures 6-23 through 6-25), and Paper Feed Frame (Figures 6-26 through 6-28). 2 Turn the Paper Feed Frame upside down. 3 Remove the idler roller by lifting the plastic tab up (Figure 6-34, callout 1) and sliding it out the side of the Paper Feed Frame (Figure 6-34, callout 2).
4 Remove the self-tapping screw that holds the Feed Assembly in place (Figure 6-35, callout 1).
5 Remove the Feed Assembly. 6 Turn the unit over. Lift the paper feed roller out (Figure 6-36). Figure 6-36 Feed Assembly Removal (3 of 3) To reinstall Before securing the screw, ensure the tabs on the Feed Assembly are positioned in their slots on the Paper Feed Frame (Figure 6-35, callout 2). Failure to do so will cause paper feed problems.
Bottom Assemblies Memory Door Guide 1 Remove the Printer Covers. 2 Remove any extra memory. 3 Two tabs hold the memory door guide on the printer chassis. Press each tab inward (Figure 6-37). 4 Pull the memory door guide out.
Motor 1 2 3 4 5 Remove the Printer Covers. Remove the motor connector (Figure 6-38, callout 1). Remove the memory door guide to expose the two motor screws. Remove the motor screws (Figure 6-38, callout 2). Lift the Motor out.
DC Controller Remove the Printer Covers. Disconnect the motor connector from the motor (Figure 6-38, callout 1). Disconnect the Solenoid connector from the DC Controller (Figure 6-22, callout 1). Remove the back sheet metal plate and disconnect the PS202/PS204 connector (Figure 6-28). 5 Remove the AC Cable cover and disconnect the AC Cable from the DC Controller (Figures 6-13 and 6-14). 6 Tip the printer on its top, with the back facing you. 7 Remove the (4) screws (Figure 6-39, callouts 1 and 2).
8 Rotate the case forward slowly, about three or four inches, until you can see the Fusing Assembly connector (J206). Release the connector (Figure 6-40, callout 1).
9 Rotate the metal case around so that the case is sitting on your work surface. 10 Remove the (7) remaining connectors (Figure 6-41, callout 1). 11 Remove the screws (5) that secure the DC Controller to the metal case (Figure 6-41, callout 2). Figure 6-41 DC Controller Removal (3 of 3) 12 Remove the DC Controller by lifting gently on the side opposite the formatter, then sliding it out. Caution Be careful not to rotate the DC Controller as you remove it.
Formatter PCA ESD SENSITIVE!!! Caution 1 Remove the Printer Covers and complete the DC Controller removal direction up to 2 3 4 5 step 8 (Figures 6-39 and 6-40). Remove the two cable clips (Figure 6-42, callout 1). Remove all (4) screws from the formatter cover (Figure 6-42, callout 2). Lift the I/O shield to remove it. Remove the Control Panel display cable (Figure 6-42, callout 3). Slide the formatter away from the DC Controller PCA to remove it from the connector.
7 Troubleshooting Contents General Troubleshooting Flowchart . Paper Path and Components . . . . . DC Controller Diagram . . . . . . . Printer Error Troubleshooting . . . . Priority of Errors . . . . . . . . . Printer Status Messages . . . . . . Service and Error Messages . . . . Image Formation Troubleshooting . . Check the Toner Cartridge . . . . Image Defect Examples . . . . . . Troubleshooting Checks . . . . . . . Engine Test . . . . . . . . . . . . Half-Self Test Functional Check .
7-2 Troubleshooting
General Troubleshooting Flowchart When the ac power is first applied to the printer: START • Both the printer motor and the laser/scanner motor rotate for 6 seconds. • All of the LEDs illuminate for one second; the “Ready” LED will illuminate after 3 seconds.
General Troubleshooting Flowchart (continued) Perform an Engine Test Is the Engine Test image being printed clearly ? No Refer to the section “Image Formation Troubleshooting,” later in this chapter. No If the engine test produces a clear print image, yet a Self Test is not generated by initiating the Control Panel self-test procedure, replace the Formatter PCA.
Paper Path and Components Figure 7-1 Manual Input Slot Paper Input Bin SL1 Pick-up Roller Face-down Delivery Roller Face-down Delivery PS202 Fuser Deflector Face-up Delivery Fusing Unit Delivery Roller Paper Pick-up Solenoid Feed Sub Roller Photosensitive Drum PS201 Paper Exit Sensor Transfer Roller Paper Registration Sensor PAPER-OUT SENSOR signal (PAPERSNS) PICK-UP SOLENOID DRIVE signal (CPUD) PAPER PICK-UP SENSOR signal (PISNS) MOTOR DRIVE signal (MA, /MA, MB, /MB) PAPER DELIVERY SEN
DC Controller Diagram Figure 7-2 DC Controller PCA Components J3 Control Panel Connector (Formatter PCA) J202 Paper Registration and Paper-Out Photosensors (PS203 and PS202) J102 Fusing Assembly J206 Fusing Assembly (thermistor feedback) J201 Formatter PCA Connection J207 Scanner Motor J204 Paper Pickup Solenoid (SL1) J208 Laser Driver/Beam Detect Circuitry J301 Developer Bias Contact J209 Door Open/No Toner Cartridge Photosensor (PS204) J302 Transfer Roller Contact J401 Motor J304
Printer Error Troubleshooting Information regarding printer status is conveyed by two methods: 1) the printer’s Control Panel lights and 2) feedback through the bi-directional I/O that displays at the PC. The basic method of determining error messages uses patterns of lights on the Control Panel LED. Printer messages are categorized into two basic types: • Status Messages • Service and Error Messages Before troubleshooting the printer, cycle the power to the printer to see if the error persists.
Printer Status Messages The following table lists printer LED messages and their meanings and describes recommended actions. For more information on the Front Panel layout, refer to “Using the Control Panel” in Chapter 3, “Installation and Configuration.” Table 7-1 Printer Status Messages (1 of 2) LEDs Description Recommended Action Paper Out Error. Add paper. Door Open or No EP Cartridge. Close the printer door and/or verify that the EP cartridge is installed. Paper Jam. Clear paper jam.
Table 7-2 Printer Status Messages (Continued 2 of 2) LEDs Description Sleep Mode Recommended Action If the printer’s LEDs remain off: 1. The printer is in Sleep Mode. Press the Front Panel Button or open the EP Door. 2. Power is not supplied to the printer. Check power cord connections and the power source. 3. Print an engine test to determine if the print engine is functional. If the test is successful, replace the Formatter PCA. 4. See the General Troubleshooting Flowchart earlier in this chapter.
Service and Error Messages Service errors prevent further printer operation until some action is taken. When there is a service error, all of the lights will turn on in a steady state. Press and hold the Front Panel Button to see a pattern in the lights. (The error will only be displayed as long as this button is pressed.) Use Table 7-4, “Service and Error Messages,” to identify what type of service error has occurred. Table 7-4 Service and Error Messages (1 of 3) LEDs Description ROM/RAM Error.
Figure 7-3 Heating Element Resistance Check Table 7-4 LEDs Service and Error Messages (Continued 2 of 3 ) Description Beam Error. There are a number of causes for this error, and some of the causes may be transient. (They may disappear.) Recommended Action 1. Power-cycle the printer by unplugging the printer and plugging it back in. 2. Make certain the Laser/Scanner Assembly is correctly seated on the printer chassis. 3. Replace the Laser/Scanner cable (J208 on the DC Controller). 4.
Table 7-4 Service and Error Messages (Continued 3 of 3) LEDs Description Scanner Error. Caused by a scanner malfunction. Recommended Action 1. Power-cycle the printer by unplugging the printer and plugging it back in. 2. Ensure condensation caused by moving the printer from a cold to a warm environment hasn’t occurred. Allow the printer to acclimate to the warmer room. 3. Verify the two Laser/Scanner Assembly connectors are firmly seated. 4. Replace scanner cable J207 on the DC Controller PCA. 5.
Image Formation Troubleshooting Check the Toner Cartridge Image formation defects are many times the result of toner cartridge problems. If there is any doubt, always replace the toner cartridge before troubleshooting image defects. Use the following check list to ensure that the toner cartridge is still operable. • • • • Note Ensure that the toner cartridge is seated properly in the cavity. Inspect the toner cartridge for remaining toner.
Image Defect Examples This section illustrates some image defects and their possible causes. Since there are many variables in the printing process, you may encounter image defects that are not illustrated in the following examples. If you find a defect that is not illustrated, record the probable cause along with the printing environmental conditions and save a copy of the defect for future reference. Each example lists, in order, the probable causes of the image defect.
Vertical Lines Sometimes vertically aligned black streaks or smears can appear on successive pages. • The toner cartridge may be damaged. Replace it. • The printer may need cleaning. See “Cleaning Your Printer,” in Chapter 4. • Replace the heating element. Horizontal Stripes Sometimes horizontally aligned black streaks or smears can appear. • The toner cartridge may not be installed properly. Remove the cartridge and reinsert it. • The toner cartridge may be defective. Replace it.
Character Voids Character voids are white areas within the parts of characters that should be solid black. • If you are using transparencies when you experience this problem, try another type of transparency. Hewlett-Packard transparencies are designed to minimize character voids. (Because of the composition of transparency media, some character voids are normal.) • You may be printing on the wrong side of the paper. Remove the paper and turn it over.
Dropouts Dropouts are characters that are partially printed. • The Paper Input Bin may have been loaded with too much paper. Make sure that no more than 100 sheets of paper are loaded. • A single sheet of paper may be defective. Try reprinting the job. • Try adjusting the print density through your software or printer driver. • Try cleaning the rollers. • The moisture content of the paper may be inconsistent, or the paper may have moist or wet spots on the surface.
Blank Page (Occasional) A page is completely blank. If you get occasional blank pages: • Make sure your page length and margins are set correctly for the paper size you use. If you are printing on small media and your page is blank, try printing on larger media to see where the image is printing. Adjust margins accordingly. • Some sharing devices or networks may generate a blank page as a separator. Try connecting the printer directly to the computer.
Dots • Clean the static charge eliminator. (See Chapter 4, “Printer Maintenance.") • There may be discontinuities in the high-voltage contact points. Clean the high voltage contact points on the toner cartridge and transfer roller. • Replace the transfer roller. Dirt on the Back of the Page • Use the image defect ruler to determine if the rollers are dirty. If so, clean them. Replace the rollers if they cannot be cleaned sufficiently. • Clean the heating element.
Distorted Image or BD Failure • Make certain the printer is not facing the sunlight. • The paper may not meet HP’s paper specifications. Select different paper. • Clean the Laser/Scanner Assembly by blowing compressed air in the slot on the bottom of the assembly. • Make sure the two Laser/Scanner connectors are firmly seated. • Replace the Laser/Scanner unit. • Replace the DC Controller.
Troubleshooting Checks Engine Test The engine test print is used to verify that the print engine is functioning correctly. The Formatter PCA is completely bypassed during an engine test, so this test is useful for isolating printer problems. The engine test prints a full page of vertical lines down the entire printable area and is also useful for checking and adjusting registration. Engine Test Button Location The engine test print button is located on the DC Controller PCA.
Half-Self Test Functional Check The electrophotographic process can be subdivided into the following stages: • • • • • • Cleaning (removing excess toner from drum surface) Conditioning (placing a uniform electrical charge on drum) Writing (laser strikes surface of drum to create latent image) Development (formation of the toner image on drum) Transfer (charge to transfer the image to paper) Fusing (heat and pressure to produce a permanent image) The purpose of the Half-Self Test Check is to determine whic
Drum Rotation Functional Check The photosensitive drum, located in the toner cartridge, must rotate for the print process to work. The photosensitive drum receives its drive from the Main Drive assembly. To verify whether the drum is rotating: 1 Open the Printer Door. 2 Remove the toner cartridge. 3 Mark the cartridge’s drive gear with a felt-tipped marker. Note the position of the mark. 4 Install the toner cartridge and close the Printer Door.
High-Voltage Power Supply Check The High-Voltage Power Supply PCA provides the necessary voltages for the electrophotographic processes. A method for verifying the high-voltage system is given in the table below. Table 7-5 High-Voltage Power Supply Check Checks Action Toner Cartridge Connection Points Visually inspect the three connection points on the underside, right end of the toner cartridge. If they are dirty or corroded, clean the connections. Use alcohol only.
Figure 7-6 Toner Cartridge High Voltage Connection Points (2 of 2) • Charging (1) • Drum Ground (2) • Developing Roller (3) Troubleshooting 7-25
Paper Curl 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. The specification for maximum paper curl when the paper is lying flat before print is 5 mm (0.2 inches). Although paper curl cannot be totally eliminated, some steps can be taken to lessen its impact, as suggested in the following table.
Troubleshooting Tools Paper Path Check If paper is not being picked up or is not moving through the paper path, you may want to observe all of the paper motion activities. Overriding PS204 allows you to observe: • • • • • Motor rotation Solenoid action Kick plate motion Paper Pickup Roller motion Drive Roller, Transfer Roller, Fuser Roller and Gear, and Delivery Roller Motion. To override PS204 1 Remove the Printer Covers (Figures 6-2, 6-3, and 6-4).
Repetitive Image Defect Ruler Figure 7-8 Repetitive Image Defect Ruler 7-28 Troubleshooting
Main Wiring Diagram Figure 7-9 Main Wiring Diagram Troubleshooting 7-29
Table 7-7 Cable Pinouts Connector 7-30 Troubleshooting Signal Name Remarks J401 pin 1 MA Motor Drive Signal J401 pin 2 /MA Motor Drive Signal J401 pin 3 MB Motor Drive Signal J401 pin 4 /MB Motor Drive Signal J204 pin 1 +12 V J204 pin 2 CPUD J202 pin 1 +5V J202 pin 2 GND J202 pin 3 PAPSENS J202 pin 4 +5V J202 pin 5 GND J202 pin 6 PISNS J207 pin 1 +12 V J207 pin 2 SCNTAC J207 pin 3 FG J207 pin 4 /SCNON “L” to rotate scanner motor J207 pin 5 SCNCLK Scanner clock ref
Table 7-8 Cable Pinouts Connector Signal Name J209 pin 3 DOSNS J305 pin 1 +12A V J305 pin 2 N/U J305 pin 3 +12 V J206 pin 1 FRSTH J206 pin 2 FG Remarks “H” when cartridge is not installed or the front door is open at PS204.
7-32 Troubleshooting
8 Parts and Diagrams Contents How to Use the Part Lists and Diagrams Ordering Parts . . . . . . . . . . . . Ordering Consumables . . . . . . . Accessories and Supplies . . . . . . . Common Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2 Parts and Diagrams
How to Use the Part Lists and Diagrams The Figures in this chapter illustrate the major subassemblies in the printer and their component parts. A table (material list) follows each exploded assembly diagram. Each table lists the reference designator (item number) for each part, the associated part number for the item, the quantity, and a description of the part.
Ordering Consumables Consumables and accessories such as those listed on Table 8-1 may be ordered from Hewlett-Packard. The phone numbers are: U.S.: 1-800-538-8787 Canada: 1-800-387-3154 (Toronto) 516-671-8383 United Kingdom: 0734-441212 Germany: 0130-3322 Contact your local HP Parts Coordinator for other local phone numbers. Note Parts that have no reference designator or part number are not field replacement parts and cannot be ordered through SMO.
Accessories and Supplies The following items are available through your local authorized HP dealer. To find a dealer near you (or if your dealer is temporarily out of stock), call the HP Customer Information Center (800) 752-0900. Note Refer to “Related Documentation” in Chapter 1 for documentation and training media product numbers. Table 8-1 Accessories and Supplies Item Toner Cartridge Memory upgrades Parallel cable (IEEE 1284) Note Product Number Description C3906A Replacement toner cartridge.
Common Hardware Table 8-2 Common Fasteners Used in the Printer Example Description Screw, Machine, Trus Head M3x4, M3x6, M3x8 Screw, Star, 3x6 Screw, Self-tap, 4x10 Screw, Hex-head, 3x8 Screw, Hexhead, 3x6,m 3x8, 3x10 8-6 Parts and Diagrams
Figure 8-1 Major Assembly Locations Parts and Diagrams 8-7
Figure 8-2 Covers and Doors 8-8 Parts and Diagrams
Table 8-3 Covers and Doors Ref. Part No. Ref.
Figure 8-3 Internal Components (1 of 3) 8-10 Parts and Diagrams
Table 8-4 Internal Components (1 of 3) Ref Part No.
Figure 8-4 Internal Components (2 of 3) 8-12 Parts and Diagrams
Table 8-5 Internal Components (2 of 3) Ref Part No.
Figure 8-5 Internal Components (3 of 3) 8-14 Parts and Diagrams
Table 8-5 Internal Components (3 of 3) Ref Part No.
Figure 8-6 DC Controller/Formatter and Cables 8-16 Parts and Diagrams
Table 8-6 ECU Case Ref Part No.
Figure 8-7 Pickup Roller Assembly 8-18 Parts and Diagrams
Table 8-7 Ref Part No.
Figure 8-8 Feed Assembly 8-20 Parts and Diagrams
Table 8-8 Ref 9 Part No.
Figure 8-9 Separation Guide Assembly 8-22 Parts and Diagrams
Table 8-9 Ref Part No.
Figure 8-10 Delivery Assembly 8-24 Parts and Diagrams
Table 8-10 Ref Part No.
8-26 Parts and Diagrams
A Parts Index Parts Index A-1
Parts Index Table A-1 A-2 Parts Index Alphabetical Parts List Description Part No. Fig. Ref.
Table A-1 Alphabetical Parts List (continued) Description Part No. Fig. Ref.
Table A-1 A-4 Parts Index Alphabetical Parts List (continued) Description Part No. Fig. Ref.
Table A-1 Alphabetical Parts List (continued) Description Part No. Fig. Ref.
Table A-2 A-6 Parts Index Numerical Parts Index Part No. Description Fig. Ref.
Table A-2 Numerical Parts List (continued) Part No. Description Fig. Ref.
Table A-2 A-8 Parts Index Numerical Parts List (continued) Part No. Description Fig. Ref.
Table A-2 Numerical Parts List (continued) Part No. Description Fig. Ref.
A-10 Parts Index
B Regulatory Information Laser Safety (U.S.A.) The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration implemented regulations for laser products manufactured since August 1, 1976. Compliance is mandatory for products marketed in the United States. This printer is certified as a “Class 1” laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968.
Laser Statement (Finland) The following applies to printer operation and servicing in Finland. LASERTURVALLISUUS LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT HP LaserJet(s) 4V and 4MV laserkirjoitin on käyttäjän kannalta turvallinen luokan 1 laserlaite. Normaalissa käyt"ssä kirjoittimen suojakotelointi estää lasersäteen pääsyn laitteen ulkopuolelle. Kirjoittimen on hyväksynyt Suomessa laserturvallisuuden osalta Sähk"tarkastuskeskus.
Toner Safety Note In case of toner spills, skin and clothing are best cleaned by removing as much toner as possible with a dry tissue, then washing with cold water. Hot water causes toner to permanently set into clothing. MSDS Information A Material Safety Data Sheet (MSDS) for toner or any other chemical used in the printer is available through Hewlett-Packard’s Customer Information Center by either mail or fax.
FCC Statement (Class B) Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications.
Index A AC power distribution 5-6 circuitry 5-6 accessories and supplies 8-5 acoustic emissions 1-5 assistance,technical 1-11 AUDIO-TIPS, HP 1-11 B background scatter 7-16 black page 7-16 blank page all pages 7-18 occasional 7-18 bottom assembies memory door guide 6-41 bottom assemblies DC Controller 6-43 formatter PCA 6-46 motor 6-42 C cable pinouts 7-30 cables 8-17 replaceable 8-6 capacities: output tray 1-3 caution messages 6-3 CDRH B-1 Center for Devices and Radiological Health (CDRH) B-1 character void
image transferring 5-12, 5-14 image writing 5-12 - 5-13 installation DRAM 6-5 installing memory cards 6-5 printer 3-3 software 3-4 interfaces standard 1-3 internal assemblies 8-10, 8-12, 8-14 control panel 6-11 delivery assembly 6-13 exit roller assembly 6-12 face-up/face-down lever 6-21 fuser exit roller 6-22 fuser pressure plate 6-15 heating element 6-17 pressure roller 6-20 internal typefaces 1-3 INTR, printer timing 5-19 J Japanese VCCI Statement B-4 L laser and scanner drive 5-5 laser drive 5-5 laser s
error 7-8 manual feed 7-7 memory error 7-7 paper out 7-7 Ready 7-8 self test 7-8 status 7-8 toner cartridge 7-7 troubleshooting 7-7 printer space requirements 2-4 printer timing 5-19 INTR 5-19 LSTR 5-19 PRNT 5-19 STBY 5-19 WAIT 5-19 printing self test page 3-14 priority of errors 7-7 PRNT, printer timing 5-19 product information 1-1 - 1-14, 3-1 3-18 product overview 1-6 R radio frequency interference, RFI B-4 RAM 5-8 described 5-8 random access memory described 5-8 read only memory described 5-8 ready light
print quality problems 7-14 printer errors 7-7 troubleshooting checks 7-21 troubleshooting flowchart 7-3 troubleshooting tools 7-27 troubleshooting, preliminary 7-3 two-way communication, PJL 5-11 typefaces internal 1-3 V VCCI Statement, Japan B-4 vertical lines 7-15 vertical white stripes 7-15 voltage conversions 1-14 W WAIT, printer timing 5-19 warning messages 6-3 warranty exclusions 1-13 limitations 1-14 start date 1-14 voltage 1-14 warranty 1-13 wiring diagram 7-29 wiring diagrams, main 7-29 writing pr
