hp LaserJet 4100 service manual
HP LaserJet 4100 Series Printer Service Manual _____________
Copyright Information Warranty Trademark Credits © 2001 Hewlett-Packard Company The information contained in this document is subject to change without notice. ENERGY STAR® is a U.S. registered mark of the United States Environmental Protection Agency. All Rights Reserved. Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws.
Contents 1 Printer description Printer features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Product compatibility matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 I/O menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 EIO menu (networked printers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Resets menu . . . . .
DIMM slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 PJL overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 PML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separation rollers for trays 2, 3, and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Tray 2 paper-feed module disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Tray 3 and 4 paper-feed module disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 7 Troubleshooting Troubleshooting process . . . . . . . . . .
Figures Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Figure 44. Figure 45. Figure 46.
Figure 53. Figure 54. Figure 55. Figure 56. Figure 57. Figure 58. Figure 59. Figure 60. Figure 61. Figure 62. Figure 63. Figure 64. Figure 65. Figure 66. Figure 67. Figure 68. Figure 69. Figure 70. Figure 71. Figure 72. Figure 73. Figure 74. Figure 75. Figure 76. Figure 77. Figure 78. Figure 79. Figure 80. Figure 81. Figure 82. Figure 83. Figure 84. Figure 85. Figure 86. Figure 87. Figure 88. Figure 89. Figure 90. Figure 91. Figure 92. Figure 93. Figure 94. Figure 95. Figure 96. Figure 97. Figure 98.
Figure 112. Figure 113. Figure 114. Figure 115. Figure 116. Figure 117. Figure 118. Figure 119. Figure 120. Figure 121. Figure 122. Figure 123. Figure 124. Figure 125. Figure 126. Figure 127. Figure 128. Figure 129. Figure 130. Figure 131. Figure 132. Figure 133. Figure 134. Figure 135. Figure 136. Figure 137. Figure 138. Figure 139. EN Location of PCAs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Figures EN
Tables Table 1. Table 2. Table 3. Table 4. Table 5. Table 6. Table 7. Table 8. Table 9. Table 10. Table 11. Table 12. Table 13. Table 14. Table 15. Table 16. Table 17. Table 18. Table 19. Table 20. Table 21. Table 22. Table 23. Table 24. Table 25. Table 26. Table 27. Table 28. Table 29. Table 30. Table 31. Table 32. Table 33. Table 34. Table 35. Table 36. Table 37. Table 38. Table 39. Table 40. Table 41. Table 42. Table 43. Table 44. Table 45. Table 46. Table 47. Table 48. Table 49. Table 50. Table 51.
Table 53. Table 54. Table 55. Table 56. Table 57. Table 58. Table 59. Table 60. Table 61. Table 62. Table 63. Table 64. Table 65. Table 66. Table 67. Table 68. Table 69. Table 70. Table 71. Table 72. Table 73. Table 74. Table 75. Table 76. 12 Tables Screws used in the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 Replaceable cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Printer description Chapter contents Printer features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Product compatibility matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Site requirements . . . . . . . . . . . . . . . . .
Printer features Table 1.
Table 1.
Table 1. Printer features for the HP LaserJet 4100 series printers (continued) Paper trays 100-sheet tray 1 ! Standard and custom sizes: from 76 by 127 mm (3 by 5 inches) to 216 by 356 mm (8.5 by 14 inches) 500-sheet tray 2 ! Letter: 216 by 279 mm (8.5 by 11 inches) ! A4: 210 by 297 mm (8.3 by 11.7 inches) ! Executive: 191 by 267 mm (7.3 by 10.5 inches) ! Legal: 216 by 356 mm (8.5 by 14 inches) ! B5 (JIS): 182 by 257 mm (7.2 by 10 inches) ! A5: 148 by 210 mm (5.8 by 8.
Table 1. Printer features for the HP LaserJet 4100 series printers (continued) HP genuine toner cartridge ! ! ! Printer languages ! ! ! ! EN No-shake cartridge design. HP UltraPrecise toner for crisp, sharp output. Supplies status page—provides information about the toner gauge, page count, and paper sizes used in the printer. HP PCL6 HP PCL5e PostScript 3 emulation Automatic language switching Duty cycle Up to 150,000 pages per month.
Product compatibility matrix Table 2.
Table 2.
Identification Model and serial numbers The model number and printer serial number are listed on an identification label located under the top cover on the right side of the printer. The model number is alphanumeric, such as C8049A for the HP LaserJet 4100 printer. The serial number contains information about the country of origin, the revision level, the production code, and production number of the printer. An example of a serial number is USBB123456.
Site requirements The following environmental specifications must be maintained to ensure the correct operation of the printer. Consider the following points before installing the printer: ! Install in a well-ventilated, dust-free area. ! Install on a hard, flat, continuous surface, with all four printer feet level. Do not install on carpet or other soft surfaces. ! Ensure adequate power is supplied. Printer power requirements are listed in table 3.
Installation requirements 390 mm (15.4 inches) Install the printer with enough space around it to open trays and bins, install toner, and perform maintenance. If the duplexer is installed, the printer needs 101 mm (4 inches) of ventilation space on the left side (fan side) and rear of the printer. 1043 mm (41.1 inches) Figure 3. Side view, HP LaserJet 4100/4100N printer 22 Printer description 475 mm (18.
595 mm (23.4 inches) with top cover open 465 mm (18.3 inches) with top cover closed Figure 4.
Environmental requirements Table 4. Printer and toner cartridge environmental conditions Item Operating Storage Temperature 10° to 32° C (50 to 91° F) Toner cartridge: 0° to 35°C (32 to 95° F) Printer: -20 to 60°C (-4° to 140° F) Relative humidity 20 to 80 percent relative humidity (RH) (with no condensation) 10 to 95 percent RH Table 5. Operating sound power or pressure (Per ISO 9296) Note Sound power level LWAd= 6.6 Bels (A) printing, LWAd= 4.
Print media specifications The following tables show print media specifications for the HP LaserJet 4100 series printer. Table 6. Print media specifications, tray 1 Supported media Dimensions1 Minimum size (custom3) 76 by 127 mm (3 by 5 inches) Maximum size (custom3) 216 by 356 mm (8.5 by 14 inches) Transparencies Same as minimum and maximum paper sizes listed above Labels Envelopes Weight Capacity2 60 to 199 g/m2 (16 to 53 lb) 100 sheets of 75 g/m2 (20 lb) paper Thickness: 0.10 to 0.
Table 7. Print media specifications, trays 2, 3, and 4 Supported media Dimensions1 Letter 216 by 279 mm (8.5 by 11 inches) A4 210 by 297 mm (8.3 by 11.7 inches) Executive 191 by 267 mm (7.3 by 10.5 inches) Executive (JIS) (custom3) 216 by 330 mm (8.5 by 13 inches) 16K (custom3) 197 by 273 mm (7.75 by 10.75 inches) Legal 216 by 356 mm (8.5 by 14 inches) B5 (ISO) (custom3) 176 by 250 mm (6.9 by 9.9 inches) B5 (JIS) 182 by 257 mm (7.2 by 10 inches) A5 148 by 210 mm (5.8 by 8.
Table 9. Print media specifications, optional duplexer Supported media EN Dimensions Letter 216 by 279 mm (8.5 by 11 inches) A4 210 by 297 mm (8.3 by 11.7 inches) Executive 184 by 267 mm (7.3 by 10.5 inches) Legal 216 by 356 mm (8.5 by 14 inches) B5 (JIS) 182 by 257 mm (7.
Supported types of print media The printer supports the following types of print media: Note ! plain ! preprinted ! letterhead ! transparency (see page 32) ! prepunched ! labels (see page 31) ! bond ! recycled ! color ! card stock ! rough Transparencies and labels must be specified for use in laser printers.
Types of print media to avoid The following characteristics can affect the performance of the HP LaserJet printer unless the paper or other print media used is specifically designed to work with the HP LaserJet printer. Note EN ! Print media that is very rough, highly textured, or heavily embossed. ! Print media with multipart forms. ! Print media that offsets materials or discolors. ! Print media that is damaged, curled, wrinkled, or irregularly shaped.
Weight equivalence table The following table shows equivalent weights for different grades of paper. A boldface type value indicates a commonly available standard weight for that grade. Shaded boxes indicate a commonly available standard weight for that grade. Note Text and book grades marked with an asterisk (*) actually calculate to 51, 61, 71, and 81 but are rounded to standard book or text weights of 50, 60, 70, and 80. Table 10.
Adhesive labels When printing on labels, use of tray 1 is recommended. Labels are multiple-layer media typically consisting of a face sheet (the printable surface), pressure-sensitive adhesive, and a liner (a carrier sheet coated with a release agent). Labels used in the HP LaserJet printer must be specifically designed for laser printers.
Overhead transparencies When printing transparencies, use of tray 1 is recommended. Overhead transparency film must be designed specifically for use with laser printers. Photocopy transparency film might not be compatible with laser printers because of higher temperature and stiffness requirements. Overhead transparency film is very smooth and must have a topcoat to provide the proper electrical and toner adhesion properties.
Envelopes Envelope construction Envelopes can only be printed from tray 1 or from the optional envelope feeder. Because of their construction, some envelopes will not feed through the printer dependably. Observe the following guidelines when purchasing and using envelopes: ! Make sure the envelope’s leading edge, which enters the printer first, is straight, with a sharp, well-creased fold that has no more than two thicknesses of paper. Envelopes that exceed 105 g/m2 (28 lb) basis weight can cause jamming.
Envelope specifications The table below summarizes the envelope specifications that provide the best performance. Table 13. Envelope specifications Property Specifications Basis weight 64 g/m2 to 105 g/m2 (17 lb to 28 lb) typical. See the user guide for specific printer and input limits. Caliper (thickness) 0.09 mm to 0.14 mm (3.6 mil to 5.5 mil) typical single-layer thickness. Surface roughness 100 to 200 Sheffield.
Card stock and heavy paper Many types of card stock and paper can be printed from tray 1, including index cards and postcards. For optimum printer performance, do not use paper heavier than 199 g/m2 (53 lb) in tray 1 or 105 g/m2 (28 lb) in other trays. Paper that is too heavy might cause misfeeds, stacking problems, jams, poor toner fusing, poor print quality, or excessive mechanical wear. Note Before loading card stock, make sure it is regular in shape and not damaged or wrinkled.
Safety information Toner safety Handling and storage WARNING! Keep toner cartridges and toner particles away from excessive heat, sparks, and open flames. If toner is spilled, avoid breathing in toner particles. Inhalation of toner particles can cause respiratory tract irritation. Vacuum or sweep the material into a bag or other sealed container. If a vacuum is used, the motor must be rated as dust-tight. Dispose of waste toner in accordance with local requirements.
Laser safety Do not open the laser scanner assembly. Avoid direct exposure to the laser beams. WARNING! Using controls, making adjustments, bypassing safety switches, or performing procedures other than those specified in this service manual can result in exposure to hazardous radiation. Regulatory information For regulatory information and requirements, please see the user guide.
38 Printer description EN
2 Service approach Chapter contents Service approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Parts and supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Ordering information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Printer documentation . . . . . . . . . . . . . . . . . . . . . . . .
Service approach Repair of the printer normally begins with use of the printer’s internal diagnostics in conjunction with the troubleshooting procedures in chapter 7. When a faulty part is located, repair is generally accomplished by assembly-level replacement of field-replaceable units (FRUs). Some mechanical assemblies might be repaired at the subassembly level. Hewlett-Packard does not support replacement of components on printed circuit boards.
Printer documentation The table below lists part numbers to use when ordering documentation. For information about ordering, see page 42. Note Some of the materials listed in table 15 are also available online at http://www.hp.com. Table 15.
HP direct ordering for genuine HP parts Customer Services and Support Organization (CSSO): ! (1) (800) 227-8164 (U.S. only) ! (49 7031) 142253 (Europe only) ! See chapter 8 for additional information. Exchange program HP offers remanufactured assemblies for some parts. These are identified in chapter 8 and can be ordered through CSSO. Consumables Paper and toner cartridges can be ordered directly from Hewlett-Packard. See chapter 8 for ordering information.
HP support assistant compact disc This support tool offers a comprehensive online information system designed to provide technical and product information about Hewlett-Packard products. To subscribe to this quarterly service in the U.S. or Canada, call (1) (800) 457-1762. In Hong Kong, Indonesia, Malaysia, or Singapore, call Mentor Media at (65) 740-4477.
Toner cartridge information The toner cartridge is designed to simplify replacement of the major “consumable” parts. The toner cartridge contains the printing mechanism and a supply of toner. At five percent page coverage, a toner cartridge will print approximately 6,000 or 10,000 pages, depending on the toner cartridge model installed.
Warranty statement The warranty for this product gives the customer specific legal rights. There might also be other rights that vary from area to area. Printer warranty Hewlett-Packard warrants the HP LaserJet 4100 series printer for one year. For detailed information about the printer warranty, see the limited warranty statement in the user guide. Limited warranty for toner cartridge life Note The warranty below applies to the toner cartridge that came with this printer.
46 Service approach EN
3 Printer operation Chapter contents Using the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Control panel layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Control panel lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Control panel keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initialization of the hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 MS-DOS system configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Parallel DOS commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the control panel Control panel layout The printer control panel consists of a two-line display and lights and keys as shown below: 2-line display READY Go Ready Data Item Attention – Value + Cancel Job Figure 5. Menu Select Control panel layout Control panel lights Table 16. Control panel lights EN Light Indication Ready The printer is ready to print. Data The printer is processing information. Attention Action is required. See the control panel display.
Control panel keys Table 17. Control panel keys Key Function GO ! ! ! ! ! ! ! Places the printer either online or offline. Prints any data in the printer’s buffer. Allows the printer to resume printing after being offline. Clears most printer messages and places the printer online. Allows the printer to continue printing with an error message such as TRAY X LOAD [TYPE] [SIZE] or UNEXPECTED PAPER SIZE.
Settings and defaults The printer makes most printing decisions based on either temporary settings or permanent defaults. Note Settings sent from software applications override printer defaults. Table 18. Settings and defaults Setting or default Explanation Temporary setting A value set for the current print job by the software application. For example, a request from the software to print three copies instead of the control panel default value of one copy is a temporary setting.
Control panel menus Press MENU for access to all control panel menus. When additional trays or other accessories are installed in the printer, new menu items might automatically appear. Changing a control panel setting Note 1 Press MENU until the menu you want appears on the control panel display. 2 Press ITEM until the item you want appears. 3 Press – VALUE + until the setting you want appears. 4 Press SELECT to save the selection.
Quick copy jobs menu This menu provides a list of the quick copy jobs stored on the printer. The user can print or delete these jobs from the control panel. Note This menu appears only if you have an optional hard-disk accessory or 32 MB of memory installed and quick copy jobs are stored on it. Table 19. Quick copy jobs menu Item Value [USERNAME] [JOBNAME] COPIES=1 EN Explanation The name of the person who owns the quick copy job and the job name.
Private/stored jobs menu This menu provides a list of the stored jobs on the printer. The user can print or delete these jobs from the control panel. See the user guide for more information. Note This menu appears only if you have an optional hard-disk accessory or 32 MB of memory installed and there are private or stored jobs on it. Table 20. Private/stored jobs menu Item Value Explanation [USERNAME] [JOBNAME] The name of the person who owns the quick copy job and the job name.
Information menu This menu contains printer information pages that give details about the printer and its configuration. To print an information page, use the ITEM key to scroll to the desired page and then press SELECT. Table 21. Information menu Item Explanation PRINT MENU MAP The menu map shows the layout and current settings of the control panel menu items. PRINT CONFIGURATION The configuration page shows the printer’s current configuration.
Table 21. Information menu (continued) Item Explanation PRINT PAPER PATH TEST The paper-path test can be used to verify that the paper path is working correctly, or to troubleshoot problems with a type of paper. Choose the input tray, output bin, duplexer (if available), and number of copies.
Paper-handling menu When paper-handling settings are correctly configured through the control panel, you can print by choosing the type and size of media from the printer driver or software application. Some items in this menu (such as duplex and manual feed) are available from a software application, or from the printer driver (if the appropriate driver is installed). Printer driver and software application settings override control panel settings. Table 22.
Table 22. Paper handling menu (continued) Item/Default value Values TRAY 3 TYPE= PLAIN For supported print media This item appears only when a types, see page 28. third paper tray is installed. Set the value to correspond with the media type currently loaded in tray 3. TRAY 4 TYPE= PLAIN For supported print media This item appears only when a types, see page 28. fourth paper tray is installed. Set the value to correspond with the media type currently loaded in tray 4.
Table 22. Paper handling menu (continued) EN Item/Default value Values Explanation CONFIGURE FUSER MODE MENU=NO NO YES Configure the fuser mode associated with each print media type. (This is only necessary if you experience loose toner problems, excessive curl, or other print-quality issues when printing on certain media types.) NO: The fuser-mode menu items are not available. YES: Additional items appear (see below).
Printing menu Some items in this menu can be used from a software application or from the printer driver (if the appropriate driver is installed). Printer driver and software application settings override control panel settings. Table 23. Printing menu Item Values Explanation COPIES=1 1 TO 999 Set the default number of copies by selecting any number from 1 to 999. Press – VALUE + once to change the setting by increments of 1, or hold down – VALUE + to scroll by increments of 10.
Table 23. Printing menu (continued) EN Item Values Explanation FORM LENGTH=60 LINES (110 V printers) or 64 LINES (220 V printers) 5 to 128 Sets vertical spacing from 5 to 128 lines for default paper size. Press – VALUE + once to change the setting by increments of 1, or hold down – VALUE + to scroll by increments of 10. PCL FONT SOURCE=INTERNAL INTERNAL SOFT SLOT 1, 2, OR 3 (depends on location of available fonts) INTERNAL: Internal fonts. SOFT: Permanent soft fonts.
Table 23. Printing menu (continued) Item Values Explanation COURIER FONT=REGULAR REGULAR DARK Select the version of Courier font to use: REGULAR: The internal Courier font available on the HP LaserJet 4 series printers. DARK: The internal Courier font available since the HP LaserJet III series printers. Both fonts are not available at the same time. WIDE A4=NO NO YES The WIDE A4 setting changes the number of characters that can be printed on a single line of A4 paper.
Print quality menu Some items in this menu can be used from a software application, or from the printer driver (if the appropriate driver is installed). Printer driver and software application settings override control panel settings. Table 24.
Table 24. Print quality menu (continued) Item Values Explanation ECONOMODE=OFF OFF ON Turn EconoMode on (to save toner) or off (for high quality). EconoMode creates draftquality printing by reducing the amount of toner on the printed page by up to 50 percent. Caution Hewlett-Packard does not recommend constant use of EconoMode. If EconoMode is always used, the toner supply might outlast the mechanical parts in the toner cartridge.
Table 24. Print quality menu (continued) EN Item Values Explanation CREATE CLEANING PAGE No value to select. Press SELECT to print a cleaning page (for cleaning excess toner from the fuser assembly). In order for the cleaning page to work correctly, print the page on copier-grade paper (not bond or rough paper). Follow the instructions on the cleaning page. PROCESS CLEANING PAGE No value to select. This item appears only after a cleaning page has been created (as described above).
Configuration menu Items in this menu affect the printer’s behavior. Configure the printer according to printing needs. Table 25. Configuration menu Item Values Explanation POWERSAVE TIME= 30 MINUTES 1 MINUTE 15 MINUTES 30 MINUTES 1 HOUR 2 HOURS 4 HOURS Set the printer to enter PowerSave after it has been idle for a specified amount of time. Turning PowerSave off is not recommended. The PowerSave feature does the following: ! Minimizes the amount of power consumed by the printer when it is idle.
Table 25. Configuration menu (continued) EN Item Values Explanation CLEARABLE WARNINGS=JOB JOB ON Set the length of time that a clearable warning appears on the printer control panel. JOB: Warning messages appear on the control panel until the end of the job from which they were generated. ON: Warning messages appear on the control panel until GO is pressed. AUTO CONTINUE= ON ON OFF Determine how the printer reacts to errors.
Table 25. Configuration menu (continued) Item Values Explanation RAM DISK=AUTO OFF AUTO Determine how the RAM disk is configured. This item appears only if there is no optional hard-disk accessory installed and the printer has at least 16 MB of memory. OFF: The RAM disk is disabled. Configure the amount of memory to be used through the following item: RAM DISK SIZE. Note If the setting is changed from OFF to AUTO or from AUTO to OFF, the printer will automatically reinitialize.
I/O menu Items in the I/O (input/output) menu affect the communication between the printer and the computer. Table 26. I/O menu EN Item Values Explanation PARALLEL ADV COMMUNICATN=ON ON OFF Turn the bidirectional parallel communication on or off. The default is set for a bidirectional parallel port (IEEE-1284). This setting allows the printer to send status readback messages to the computer. (Turning on the parallel advanced functions might slow language switching.
EIO menu (networked printers) The EIO (enhanced input/output) menu appears only when an EIO device is installed in an EIO slot on the printer (such as an HP JetDirect print server). The items in the menu depend on the particular accessory product installed. If the printer contains an HP JetDirect print server EIO card, you can configure basic networking parameters using the EIO menu. These and other parameters can also be configured through HP Web JetAdmin. Table 27.
Table 27. EIO menu (continued) EN Item Values Explanation CFG IPX/SPX=NO NO YES Select whether you want to use the IPX/ SPX menu and set IPX/SPX protocol parameters. NO: Bypass the IPX/SPX menu items. YES: Use the IPX/SPX menu items. In the IPX/SPX menu, you can specify the frame-type parameter used on your network. The default is AUTO, to automatically set and limit the frame type to the first one detected. For Ethernet cards, frame type selections are EN_8023, EN_II, EN_8022, EN_SNAP.
Table 27. EIO menu (continued) Item Values Explanation CFG LINK=NO NO YES Select whether you want to manually configure the HP JetDirect 10/100BaseTX print server’s network link speed and communication mode. The HP JetDirect settings must match the network. NO: Bypass the link configuration menu items. YES: Use the link configuration menu items.
Resets menu Use the reset and restore options on this menu with caution. You can lose buffered page data or printer configuration settings when you select these items. Only reset the printer under the following circumstances: ! You want to restore the printer’s default settings. ! Communication between the printer and computer has been interrupted. The items in the resets menu will clear all memory in the printer, while CANCEL JOB clears only the current job. Table 28.
Service mode Service mode should be used only by authorized service personnel. The following can be done in service mode: ! Verify and set the page count and serial number. These are shown on the configuration page. ! Set the cold reset paper size default. (This sets the factory default paper size to either Letter or A4). ! Turn the diagnostic functions on or off (for software developers only). ! Clear the event log.
Service menu To enter the service menu, see “Service mode” on page 74. Figure 6. Service menu Changing settings The item-count value is changed using a different method than is used for other control panel values. Instead of increasing the entire value by increments, each digit can be selected and modified individually.
Table 29 shows the sequence of keystrokes used to change the page count from a value of 000000 to a value of 0010480. Table 29. Changing the page count (example) Key press Display Description SERVICE MODE MENU+ SERVICE MENU Enter the SERVICE MENU. ITEM+ PAGES=0000000 * Advance to the first item in the SERVICE MENU. SELECT PAGES=0000000 * Advance the cursor one digit to the right. SELECT PAGES=0000000 * Advance the cursor one digit to the right.
Page count The page count that is stored in nonvolatile memory (NVRAM) and is shown on the configuration page printout represents the number of pages the printer has printed (excluding engine test prints). If it is necessary to install a new formatter in the printer, the page count must be reset so that it represents the age of the printer engine rather than the age of the formatter.
Clear event log This item deletes all items that have been recorded in the internal event log. Top margin This item can be used to adjust the margin between the top of the page and the top of the printed image. Note Adjust the top margin value in the software application first. This top margin value does not affect the engine test top margin. Before adjusting the top margin through the service menu, first ensure the engine test top margin register is properly adjusted (page 175).
Resetting the printer Cold reset Cold reset clears all data from the printer memory and sets many of the defaults back to the factory settings. CAUTION Performing a cold reset resets the HP JetDirect configuration. To avoid making changes to your configuration, remove the HP JetDirect card before performing a cold reset. If possible, print a configuration page and a menu map to verify the current printer settings. Use the information on these pages to reset the customer’s printer settings.
Initialization of the hard disk To initialize the hard disk 1 Print a configuration page and a menu map. 2 Turn off the printer. 3 While turning on the printer, hold down SELECT and CANCEL JOB until all of the lights on the control panel are lit. 4 Press MENU-, and then VALUE-. 5 Press SELECT. System configuration MS-DOS system configuration To communicate properly with the printer, the MS-DOS® environment requires the addition or modification of mode commands in the AUTOEXEC.BAT file.
4 Printer maintenance Chapter contents Cleaning the printer and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Using the printer cleaning page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Using the auto-cleaning page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Cleaning spilled toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the printer and accessories To maintain superior print quality and performance, thoroughly clean the printer and the paperhandling accessories: ! after printing approximately 10,000 pages. ! whenever print quality problems occur. Also, run a cleaning page every time you change the toner cartridge. Clean the outside surfaces of the printer and accessories with a water-dampened cloth. Clean the inside parts as indicated in table 30 on page 83. Observe the warning and caution below.
Table 30. Cleaning the printer EN Component Cleaning method/notes Outside covers Use a water-dampened cloth. Do not use solvents or ammonia-based cleaners. Inside With a dry, lint-free cloth, wipe any dust, spilled toner, and paper particles from the paper path area, the registration roller, and the toner cartridge cavity. Do not touch the transfer roller with bare hands. Paper pickup, feed, and separation rollers Use a water-dampened, lint-free cloth.
Using the printer cleaning page If toner specks appear on the front or back side of print jobs, follow the procedure below. From the printer control panel, do the following: Note 1 Press MENU until PRINT QUALITY MENU appears. 2 Press ITEM until CREATE CLEANING PAGE appears. 3 Press SELECT to create the cleaning page. 4 Follow the instructions on the cleaning page to complete the cleaning process.
Cleaning spilled toner Defective or worn out toner cartridges can develop leaks. Also, after a jam has occurred, there might be some toner remaining on the rollers and guides inside the printer. The pages that print immediately after the jam might pick up this toner. Clean spilled toner with a cloth dampened with cold water. Do not touch the transfer roller with the damp cloth or with your fingers. Do not use a vacuum cleaner unless it is equipped with a micro-fine particle filter.
Performing printer maintenance The printer maintenance cycle for this printer is every 200,000 pages. The kit contains the following replacement parts: ! one fuser ! one transfer roller ! one transfer roller tool ! one pickup roller (for tray 1) ! six feed and separation rollers (for trays 2, 3, and 4) ! one pair of disposable gloves ! instructions See the instructions included in the kit for detailed replacement procedures.
Expected life of components The following table shows the expected life of certain components in the printer. To order parts, see chapter 8. Table 32. Life of components Note EN No.
88 Printer maintenance EN
5 Theory of operation Chapter contents Power supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 AC/DC power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Overcurrent/overvoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 High-voltage power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printing from tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Printing from tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Printing from the optional 500-sheet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 Envelope feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power supply system AC/DC power distribution In this circuit, the AC power input from the power receptacle is converted into DC power. The DC power is supplied to the loads. The AC power is supplied to the low-voltage power supply circuit in the engine controller board when the power switch (SW1) is turned on. The AC power is converted into +24 VDC, +5 VDC, and +3.3 VDC in the circuit.
Overcurrent/overvoltage protection If a short-circuit or other problem on the load side causes an excessive current flow or generates abnormal voltage, the overcurrent/overvoltage protection systems automatically cut off the output voltage to protect the power supply circuit. If the overcurrent or overvoltage protection system are activated and the power supply circuit does not generate DC voltage, it is necessary to turn the power off, correct the problem, and then turn the printer on again.
High-voltage power distribution Figure 9. Engine controller board In response to the instructions from the microprocessor (CPU:IC502) on the engine controller board, the high-voltage power supply circuit applies high voltage to the primary charging roller, developing cylinder, transfer roller, and the fuser film unit. The circuit also detects the toner level and the presence or absence of the toner cartridge.
Toner-cartridge detection This printer has cartridge detection and toner-level detection. For the cartridge detection, the CPU checks the voltage of the cartridge detection signal (CRGSNS), which is a feedback signal for the primary charging. The CPU checks the voltage of the CRGSNS signal several times while the primary charging AC bias is applied to the primary charging roller. When the average of the voltage is 1 V or less, the CPU recognizes a "cartridge out" situation.
Engine controller system The following systems and functions are controlled by the engine controller board: ! DC power distribution (+3.3 V DC, +5 V DC, +24 VA) ! Laser and scanner drive ! Paper-motion monitoring and control (photosensors and flags) ! Clutches (tray pickup and tray 1 feed) ! Engine test ! Motors (main drive, scanner, and fans) Printer operations are controlled by the CPU on the engine controller board.
Engine controller board inputs and outputs Figure 12.
Figure 13.
Figure 14.
Figure 15.
Figure 16.
Laser/scanner drive The HP LaserJet 4100 series printer has two diodes in the laser/scanner assembly. The printer uses a twin-beam method to scan two lines simultaneously. Based on information received from the formatter, the engine controller board sends signals to the laser scanner assembly to modulate the laser diodes on and off and to drive the laser scanner motor. See “Image formation system” on page 108 for more information.
Figure 17.
The main motor is a DC brushless motor with hall elements, and is unified with the motor drive circuit. The CPU (IC502) sets the main motor drive signal (/MON) to “L” and rotates the main motor. When the main motor rotates and reaches the specified speed, the main motor sets the main motor ready signal (/MRDY) to "L". When the /MRDY signal is "L," the CPU determines that the main motor is rotating correctly. Note When the printer is idle, the main motor comes on every seven hours for 500 milliseconds.
Formatter system The formatter is responsible for the following: ! Controlling the PowerSave mode ! Receiving and processing print data from the various printer I/Os ! Monitoring control panel inputs and relaying printer status information (through the control panel and the bidirectional I/O) ! Developing and coordinating data placement and timing with the print engine ! Storing font information ! Communicating with the host computer through the bidirectional interface The formatter receives a p
EconoMode The EconoMode setting uses up to 50 percent less toner than standard mode printing by reducing the dot density. However, EconoMode does not extend toner cartridge component life. EconoMode, which can be thought of as “draft mode,” can be selected from the control panel (print-quality menu) and through some software applications and printer drivers. The default setting is OFF. CAUTION HP does not recommend full-time use of EconoMode.
Printer memory If the printer encounters difficulty managing available memory, a clearable warning message will appear on the control panel. Some printer messages are affected by the auto-continue and clearable warning settings from the configuration menu on the printer control panel. If CLEARABLE WARNING=JOB is set on the control panel, warning messages appear on the control panel until the end of the job from which they were generated.
PJL overview Printer job language (PJL) is an integral part of configuration, in addition to the standard printer command language (PCL). With standard cabling, PJL allows the printer to perform functions such as: ! Two-way communication with the host computer through a bidirectional parallel connection. The printer can tell the host about such things as the control panel settings, and it allows the control panel settings to be changed from the host.
Image formation system The image formation system is the main system in the printer. It consists of five stages: 1. Conditioning 2. Developing 3. Transferring 4. Fusing 5. Cleaning When the formatter board sends the print signal to the engine controller board, it drives the main motor to rotate the photosensitive drum, the developing cylinder, the primary charging roller, the transfer charging roller, and the fuser pressure roller.
Toner cartridge Figure 19. Toner cartridge A major portion of the image formation system is contained in the cartridge as shown in figure 19. The toner cartridge is the “heart” of the image formation system. It houses the cleaning, conditioning, and developing steps of the process. The toner cartridge contains the photosensitive drum, primary charging roller, developing roller, toner cavity, and cleaner blade.
Photosensitive drum The special properties of the photosensitive drum allow an image to be formed on the drum surface and then transferred to paper. The drum is an aluminum cylinder coated with a layer of organicphotoconductive material (OPC) which is non-toxic. The OPC material has properties similar to a photoresistor. It becomes electrically conductive when exposed to light. (The negative charges deposited on the drum are conducted to the ground potential of the drum base.
Conditioning the drum The conditioning process consists of applying a uniform negative charge on the surface of the drum with the primary charging roller. The primary charging roller is coated with conductive rubber with an AC bias applied to erase any residual charges and maintain a constant drum surface charge. The amount of DC voltage is modified by the print density setting. Figure 22.
Writing the image The laser/scanner of this printer has two diodes in the laser unit. During the writing process, the modulated laser diodes project two beams onto the rotating six-sided scanning mirror. As the mirror rotates, the beams reflect off the mirror, through a set of focusing lenses, through a slot in the top of the toner cartridge, and onto the photosensitive drum. The beams sweep the drum from left to right, discharging the negative potential wherever the beams strike the surface.
Developing the image The developing process develops the latent electrostatic image into a visible image on the drum. The developing unit consists of a metallic cylinder that rotates around a fixed magnetic core inside the toner cavity. Toner is a powdery substance made of black plastic resin bound to iron particles, which is uniformly attracted to the magnetic core of the cylinder.
Transferring the image During the transferring process the toner image on the drum surface is transferred to the paper. A positive charge applied to the back of the paper by the transfer roller causes the negatively charged toner on the drum surface to be attracted to the page. The small diameter of the drum, combined with the stiffness of the paper, causes the paper to peel away from the drum. The static eliminator teeth also help separate the paper from the drum.
Image fusing/variable fusing temperature During the fusing process, the toner is fused into the paper by heat and pressure to produce a permanent image. The paper passes between a heated fusing roller and a soft pressure roller. This melts the toner and presses it into the paper. This printer utilizes an on-demand fusing method, which uses fusing film with small heat capacity. This method has fast temperature-rising time. It is not necessary to supply power to the fuser heater during the standby mode.
Variable fusing temperature Figure 27. Fusing temperature control Variable fusing temperature is a feature that gives the user or service technician the ability to adjust the fusing temperature based on the media being used in the printer. The default mode is normal and should be optimal for most users. There are optional fuser-mode selections. If very heavy or rough media is being used, then high fuser mode is beneficial.
Paper feed system The printer in figure 29 on page 119 has two standard paper sources: the 100-sheet tray (tray 1) and the 500-sheet tray (tray 2). Up to two additional optional paper trays can be included. Both the size of the paper in the tray and the presence of a tray are detected by the three switches (SW600, 601, 602) on the paper size detection circuit assembly. All of the rollers on the paper path are driven by the main motor (M101).
Figure 28.
Figure 29.
Clutches and sensors See chapter 7 for locations of switches, sensors, and clutches. Printing from tray 1 The presence of paper in tray 1 is detected by the tray 1 paper sensor (PS105). When the engine controller board receives the /PRNT signal from the formatter, the printer starts the initial rotation phase. (This consists of main motor warm-up, scanner motor warm-up, high-voltage control sequence and fuser warm-up.) When the initial rotation phase ends, the tray 1 pickup solenoid (SL102) is activated.
1 2 5 3 4 Figure 31.
Printing from tray 2 When the formatter sends the /PRNT signal to the printer, the main motor (M101) and scanner motor start rotation. When the main motor reaches its prescribed speed, the feed roller clutch (CL101) and tray 2 pickup solenoid (SL101) are activated. (The tray 2 pickup roller, tray 2 feed roller, tray 2 separation roller, and paper feed rollers are driven by the main motor rotation.) The tray 2 pickup roller, activated by the pickup solenoid, rotates once and picks up the media in the tray.
Figure 33.
Multiple-feed prevention mechanism The printer uses the separation roller in tray 2 to prevent multiple-feeding. Normally, the separation roller rotates in the same direction as the feed roller. The separation roller is equipped with a torque limiter, but because the force of the feed roller exceeds that of the torque limiter, the separation roller is actually driven by the feed roller.
Figure 35. Paper-feeder driver I/O Pickup and feeding The media size and the presence of the 500-sheet tray are detected by three switches (SW1001, 1002, 1003) on the paper-feeder driver. The relationship between the switch combinations and the paper sizes is the same as for the printer. The paper feeder is driven by the main motor (M101) of the printer. When a print command is sent to the paper feeder from the formatter, the main motor of the printer starts rotation.
Figure 36.
Envelope feeder The operation sequences of the envelope feeder are controlled by the envelope-feeder driver. A 4-bit microprocessor is used in the envelope feeder driver, which controls the envelope-feeder sequence and the communication with the engine controller board of the printer. The engine controller board sends the pickup command to the envelope-feeder driver with the necessary timing. The envelope-feeder driver activates the solenoid in response to the command.
Figure 37. Paper path for the duplexer Jams The following paper sensors are installed to detect whether or not the print media is present and whether or not it is fed normally.
Other controls Environmental detection This printer is capable of detecting the ambient environment using the environment temperature sensor (TH3). The sensor, installed on the left side of the printer, measures the air temperature.
Basic sequence of operation The operation sequences of this printer are controlled by the microprocessor on the engine controller board. The purposes of periods from power on until the main motor stops after the completion of printing are described below. Table 33. Printer timing Period Timing Purpose WAIT From power on until the main motor completes the initial rotation. Clears the drum surface potential and cleans the transfer roller.
Figure 38.
132 Theory of operation EN
6 Removing and replacing parts Chapter contents Removal and replacement strategy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Other helpful tools . . . . . . . . . . . . . . . . . . . .
Removing tray assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177 Paper-feed rollers for trays 2, 3, and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177 Separation rollers for trays 2, 3, and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 Tray 2 paper-feed module disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and replacement strategy This chapter describes how to remove and reassemble major assemblies. Replacement is generally the reverse of removal. Occasionally, hints and 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 can result.
Required tools Tools ! Phillips #2 magnetized screwdriver with 6-inch shaft ! Flat-blade screwdriver with 6-inch shaft ! Needle-nose pliers ! ESD mat Other helpful tools ! A container (such as an ice cube tray) to hold printer screws ! Masking tape and pen to tag and identify connectors and screws ! Penlight ! Gloves (when removing or replacing the transfer roller) Screws used in the printer All screws used in the printer are Phillips head, which require a Phillips screwdriver.
Table 34. Screws used in the printer Drawing and description Phillips machine screw with captive star washer Purpose Used to fasten metal to metal when good electrical contact is needed Self-tapping Phillips screw Used to fasten metal or plastic to plastic frames Phillips machine screw with lock and flat washer Used to fasten metal or plastic to threaded plastic or metal Long screw (116 mm/4.
Removing covers CAUTION Before removing covers, turn off the printer and unplug the power cord and any cables. Hint Left and right are indicated as you face the front of the printer unless otherwise noted. Rear right side cover Figure 40. Removing the rear right side cover The formatter assembly and dual inline memory modules (DIMMs) are located underneath the right side cover. 1 Grasp the cover by its rear lip and pull it firmly toward the rear of the printer until it stops.
Control panel Control panel overlay Figure 41. EN Removing the control panel overlay 1 Using a flat-blade screwdriver, gently pry upward and outward on the right side of the control panel overlay to loosen it. 2 Remove the control panel overlay from the tabs on the left and lift it upward, off of the printer.
Control panel board Tab Figure 42. CAUTION Removing the control panel board 1 Remove the control panel overlay (page 139). 2 Using a flat-blade screwdriver, release the claws on each side of the control panel board shown, and then lift upward. To prevent damage to the control panel board, release the claws before prying upward. 3 Remove the top of the control panel board from the top tab. 4 Disconnect the ribbon cable from the control panel board.
Top cover CAUTION Do not remove the toner cartridge when the top cover interlock is overridden. Cartridge memory will be damaged. CAUTION To prevent damage to the toner cartridge, do not expose it to light for more than a few minutes. 1 To remove the top cover: a Open the top cover and remove the toner cartridge. b Remove the rear right side cover (page 138). c Remove the control panel (page 139). Figure 43.
2 1 2 Figure 44. Figure 45. Removing the top cover 3 Open the rear output bin, and then remove two screws (callout 1) from the top cover, near the top of the bin. 4 Remove two more screws (callout 2) located under the top cover door. Releasing tabs to lift the top cover 5 Squeeze the frame below the tab to release the top cover. It might be necessary to use a small flat-blade screwdriver to release the tab inside the small hole.
Left side cover 2 1 Figure 46. Removing the left side cover 1 To remove the left side cover: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). EN 2 Open tray 1. 3 Lift the left side cover upward off of the catch (callout 1), and then pull the cover away from the printer.
Front right side cover 2 1 Figure 47. Removing the front right side cover 1 To remove the front right side cover: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). Hint 2 Open tray 1. 3 Release the latch (callout 1) at the top center of the cover. 4 Lift the cover straight up until it is free of the locating pins at the bottom and the power switch rod, then pull it away from the printer.
Rear cover/rear output bin Figure 48. Hint EN Removing the rear cover/rear output bin 1 Remove the tray 2 dust cover if installed. 2 Facing the rear of the printer, press the left side (formatter side) of the rear output bin and release the hinge from the slot. 3 Rotate the bin upward and slide it to the left to release the right hinge. Before reinstalling the dust cover, ensure the claws at the top of the dust cover are not damaged, and then snap the claws into place.
Tray 1 2 1 Figure 49. Figure 50. Removing tray 1 from the front cover 1 Open tray 1. 2 Push outward on the two slot hinges (callout 1) to release the pins on tray 1. 3 Slide the front cover to the right and remove it from the three hinges on the bottom. Removing the tray 1 sensor arm cover 4 Firmly pull both sides of the tray 1 sensor arm cover toward you until it releases from the shaft.
Figure 51. Detail of the tray 1 sensor arm cover Hint When you reinstall the tray 1 sensor arm cover, be sure the sensor arms move freely. 5 Figure 52. EN Rotate tray 1 upward and release the hinge spring from the bottom of tray 1 located on the right tray 1 hinge pin. Note the position of the hinge spring before proceeding.
6 Rotate tray 1 downward completely and remove the tray from the left hinge. 7 Slide tray 1 to the left to remove the tray from the right hinge. Hint Tape the hinge spring to tray 1. Hint When you reinstall the hinge spring, place the long side of the spring in the slot underneath tray 1, and hook the short end of the spring in the small notch located directly below the pivot point.
Removing internal assemblies Fuser WARNING! Figure 53. Let the fuser assembly cool before removal. 1 If a duplexer is installed, remove it. If a duplexer is not installed, remove the tray 2 dust cover from the rear of the printer by pulling from the bottom. 2 Remove the rear cover/rear output bin (page 145). Unlocking the fuser assembly 3 Rotate the two blue levers on the fuser assembly up to the unlocked position. 4 Pull the fuser assembly straight out of the printer.
Firmware DIMM CAUTION Note Static electricity can damage dual inline memory modules (DIMMs). When handling DIMMs, either wear an antistatic wrist strap or frequently touch the surface of the DIMM’s antistatic package, and then touch bare metal on the printer. 1 Print a configuration page, a menu map, and an event log. The information is necessary to reconfigure the printer after you replace the firmware DIMM. 2 Turn off the printer. 3 Unplug the power cord and disconnect any other cables.
Formatter assembly 2 2 1 Figure 55. Removing the formatter assembly 1 Print a configuration page and menu map. The information is necessary to reconfigure the printer after you replace the formatter. 2 Remove the rear right side cover (page 138). The formatter assembly is directly underneath. 3 Pull outward on the large metal tab (callout 1) to open the DIMM access door. Remove and transfer any DIMMs or EIO accessories to the new formatter assembly.
Output delivery assembly Brass White Figure 56. Removing the output delivery assembly 1 To remove the output delivery assembly: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). Figure 57. Left end of output delivery assembly (brass arm) 2 Facing the rear of the printer, rotate the brass arm up 90° located on the gear-end of the output delivery assembly.
Figure 58. Right end of output delivery assembly (white tab) 3 CAUTION Facing the rear of the printer, carefully release the white tab located on the right end of the output delivery assembly. The white tab is fragile. Use minimum deflection when releasing the tab. 4 Lift the assembly up and out of the printer. CAUTION Lift the assembly carefully to avoid damaging the top output-bin-full sensor flag. Hint When the assembly is replaced, the flag must be able to rotate freely.
Laser/scanner 2 1 2 3 2 Figure 59. Removing the laser/scanner 1 To remove the laser/scanner: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). The laser/scanner is on top of the printer, tilted toward the rear. CAUTION 2 Unplug the three connectors (callout 1) as shown. 3 Remove the screw to disconnect the grounding cable (callout 2). 4 Remove the four recessed screws around the edges of the laser/scanner.
Cartridge memory Cartridge memory controller 1 To remove the cartridge memory controller PCA: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). d Remove the laser/scanner assembly (page 154). CAUTION Do not loosen the Allen screw on the rear of the laser/scanner assembly. 2 Disconnect the two wires from the cartridge memory controller PCA. 3 Remove the two self-tapping screws from the cartridge memory controller PCA.
Fan 2 1 Figure 60. Removing the fan 1 To remove the fan: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). d Remove the left side cover (page 143). 2 Unplug the fan’s connector (callout 1) to the engine controller board on the left side of the printer.
Figure 61. Hint EN Detail of the plastic fan clip 3 Using a flat-blade screwdriver, press the retaining claw behind the left edge of plastic fan clip, and then remove the clip from the fan. 4 Slide the fan toward the rear of the printer and remove it. When replacing the fan, be sure the airflow arrow on the fan points inward.
Main motor 2 1 Figure 62. Removing the main motor 1 To remove the main motor: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). d Remove the front right side cover (page 144). 2 While holding the main motor board, unplug the main motor connector (callout 1) on the right front side of the printer. 3 Remove the three screws around the corners of the metal plate. 4 Remove the main motor from the printer.
Transfer roller Figure 63. Removing the transfer roller CAUTION Do not remove the toner cartridge when the top cover interlock is overridden. Cartridge memory will be damaged. CAUTION To prevent damage to the toner cartridge, do not expose it to light for more than a few minutes. 1 CAUTION Do not touch the black rubber part of the roller. Skin oils on the roller can cause problems with print quality. Use of gloves is recommended. 2 Hint EN Open the top cover and remove the toner cartridge.
Tray 1 pickup roller Figure 64. Removing the pickup roller (shown with envelope entrance cover removed) 1 Open tray 1. The tray 1 pickup roller is in the center of the tray 1 pickup assembly. 2 Grasp the envelope entrance cover directly above the pickup roller and pull it straight away from the printer. 3 Use a flat-blade screwdriver to pry open the blue latch on the roller. 4 Lift the roller out. Hint To replace the roller, make sure the pin in the roller lines up with the hole in the shaft.
Tray 1 pickup assembly 1 To remove the tray 1 pickup assembly: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). d Remove the left side cover (page 143). e Remove the front right side cover (page 144). f Remove tray 1 (page 146). 2 1 2 Figure 66. Removing the gear cover 2 Remove the gear cover as follows: a. Remove the self-tapping screw (callout 1) at the bottom of the gear cover. b. Remove the long screw (116 mm/4.
2 1 Figure 67. Removing the tray 1 pickup assembly—right side 3 Note Disconnect the three-pin solenoid connector (callout 1) on the right side of the tray 1 pickup assembly and unroute the cable from the cable guide. (Note the way the cables are routed for replacement.) The solenoid connector is a three-part connector. Do not lose the gender-changer (center piece). 1 2 Figure 68.
2 1 Figure 69. Removing the tray 1 pickup assembly—front side 6 Remove the four screws (callout 1) shown, and carefully pull the tray 1 pickup assembly straight out. CAUTION Do not damage the solenoid cable on the right side of the tray 1 pickup assembly. Note The left side toner cartridge might become dislodged while removing the tray 1 pickup assembly. Ensure the left side toner cartridge guide is installed before reinstalling the four screws that secure the tray 1 pickup assembly.
Right side toner cartridge guide Remove the right side toner cartridge guide to get to the printer drive assembly. Follow the steps below: 1 To remove the tray 1 pickup assembly: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). d Remove the front right side cover (page 144). e Remove tray 1 (page 146). f Remove the tray 1 pickup assembly (page 161). 3 2 1 2 2 Figure 70.
Registration assembly 1 2 Figure 71. Removing the registration assembly 1 To remove the registration assembly: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). d Remove the left side cover (page 143). e Remove the front right side cover (page 144). f Remove tray 1 (page 146). g Remove the tray 1 pickup assembly (page 161). h Lift aside the right side toner cartridge guide (page 164). It is not necessary to unplug the connectors.
1 2 Figure 72. Detail of screws for the registration assembly CAUTION Do not remove the silver, hex-headed screw (callout 1) closest to the registration assembly! It holds the spring in place. Take out the silver screw farther from the registration assembly (the one that is under the green handle). 3 Lift the green handle. Remove the two self-tapping screws and the rearmost silver screw shown. See the caution above. 4 Lift the registration assembly from the printer.
Paper feed assembly 1 To remove the paper feed assembly: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). d Remove the left side cover (page 143). e Remove the front right side cover (page 144). f Remove tray 1 (page 146). g Remove the tray 1 pickup assembly (page 161). The paper feed assembly is on the front of the printer. Note wire routing 1 2 Figure 73.
1 2 Figure 74. Removing the upper screws from the paper feed assembly 3 Remove the two upper screws (callout 1), and then remove the paper feed assembly. Hint After replacing the paper feed assembly, make sure to insert the two upper screws only. The two lower screws are for holding the tray 1 pickup assembly in place. Ensure the lower sheet-metal guide hangs down loosely. Hint For replacement of the paper feed assembly, orient the clutch properly by inserting the tab into the slot, as shown.
Printer drive assembly (gear train) 1 2 Figure 76. Removing the printer drive assembly 1 To remove the printer drive assembly: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). d Remove the left side cover (page 143). e Remove the front right side cover (page 144). f Remove the rear cover/rear output bin (page 145). g Remove the fuser assembly (page 149). h Remove tray 1 (page 146). i Remove the tray 1 pickup assembly (page 161).
Delivery drive assembly 2 1 2 Figure 77. Removing the delivery drive assembly 1 To remove the delivery drive assembly: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). d Remove the rear cover/rear output bin (page 145). e Remove the fuser assembly (page 149). f Remove the output delivery assembly (page 152) g Remove the formatter assembly (page 151). 2 Remove the two screws (callout 1).
Separating the engine module from the paper-feed module 1 To separate the engine module from the paper-feed module: a Remove the tray 2 dust cover or the duplexer (if installed). a Remove the rear right side cover (page 138). b Remove the formatter assembly (page 151). c Remove the two long screws from the tray 1 pickup assembly (page 161 and 162). 2 1 2 Figure 78.
1 2 Figure 79. Separating the engine from the paper-feed module 4 CAUTION Remove the single, self-tapping screw (callout 1) from the left side of the printer, below the fan. Lift the engine carefully, being sure that all cables are disconnected. 5 Lift the engine away from the paper-feed module.
Engine controller board Note Figure 80. After you replace the engine controller board, readjust the top margin as described on page 175. 1 Remove the fuser assembly (page 149). 2 Separate the engine from the paper-feed module (page 171). The engine controller board is on the underside of the engine. Removing the engine controller board 3 Remove the seven screws shown.
Figure 81. Hint Removing the engine controller board 5 Disconnect the three connectors on the fan side. 6 Lifting from the fan side, tip the board up. Use masking tape and a pen to identify all cables, if necessary. 7 Hint Unplug all connectors from the engine controller board. The black cable holder in the middle of the engine controller board can be folded aside with the cables intact. When you replace the board, reconnect and route all cables before reconnecting the power switch rod.
Adjusting the top margin When you replace the engine controller board, you must readjust the top margin as follows: Figure 82. Location of VR501 1 After setting the VR501 on the engine controller board to the center position (0), load letter or A4 paper in tray 2, 3, or 4. Press the engine test print button (located on the left side of the printer, below the vent) to make several test prints. Measure this distance Figure 83.
Paper-feed guide assembly 1 To remove the paper-feed guide assembly: a Remove the rear right side cover (page 138). b Remove the control panel (page 139). c Remove the top cover (page 141). d Remove the left side cover (page 143). e Remove the front right side cover (page 144). f Remove the rear cover/rear output bin (page 145). g Remove the fuser assembly (page 149). h Remove tray 1 (page 146). i Remove the tray 1 pickup assembly (page 161). j Remove the right side toner cartridge guide (page 164).
Removing tray assemblies Paper-feed rollers for trays 2, 3, and 4 Figure 84. Hint EN Removing the paper feed roller 1 Remove the paper tray(s) from the paper feeder(s). The paper-feed roller is inside the feeder, on top of the paper feeder assembly. 2 Pinch the release at the left side of the roller and slide it off the shaft. When reinstalling the feed roller, ensure it locks into place. Otherwise, repeated paper jams might occur.
Separation rollers for trays 2, 3, and 4 Figure 85. Removing the separation roller The separation roller is inside the paper trays. 1 Release the latch and lift the access cover inside the tray. 2 Pinch the release at the left side of the roller and slide it off the shaft. CAUTION To prevent damage to the printer, ensure the access cover is securely locked into position. Note When reinstalling the separation roller, ensure it locks into place. Otherwise, repeated paper jams might occur.
Tray 2 paper-feed module disassembly Remove the paper-feeder plate to gain access to the paper pickup drive assembly. It is not necessary to separate the engine module from the paper-feed module to gain access to the paper-size detection PCB, although it will provide easier access. Figure 86. EN Removing the tray 2 paper-feeder plate 1 Separate the engine module from the paper-feed module (page 171). 2 Remove the tray from the paper-feed module.
Tray 3 and 4 paper-feed module disassembly Remove the paper-feeder plate to gain access to the paper pickup drive assembly. It is not necessary to remove the paper-feeder plate to access the feeder controller PCA, although it will provide easier access. Figure 87. Removing the paper-feeder plate 1 Lift the printer from the optional feeder. 2 Remove the tray from the paper feeder. 3 Remove the four self-tapping screws from the side rails as shown, and then lift the side rails from the paper feeder.
1 2 Figure 88. Detail of clutch release Hint Pull the clutch release (callout 1) towards the front of the tray. Hold the clutch in place as you reinstall the paper-feeder plate. Figure 89. Detail of spring and lever Note If the spring and lever dislodge when removing the paper-feeder plate, use needle-nose pliers to reattach the spring before replacing the lever.
Figure 90.
7 Troubleshooting Chapter contents Troubleshooting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Troubleshooting flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Troubleshooting the printing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Preliminary operating checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting process The troubleshooting process is a systematic approach that addresses the major problems first, and then other problems, as you identify the causes for printer malfunctions and errors. The troubleshooting flowchart on page 185 illustrates the major steps for troubleshooting the printing system. Each heading depicts a major troubleshooting step.
Troubleshooting flowchart A “yes” answer to the questions below allows you to proceed to the next major step. A “no” answer indicates that additional testing is needed. Proceed to the referenced location and follow the directions for that area. After completing the additional testing, proceed to the next major step. Figure 91.
Troubleshooting flowchart (continued) Figure 92.
Troubleshooting the printing system Preliminary operating checks Before troubleshooting a specific printer problem, you should ensure that: Note EN ! The printer is being maintained on a regular basis as described in chapter 4. ! The customer is using acceptable print media as specified in the HP LaserJet Printer Family Print Media Guide. ! The printer is positioned on a solid, level surface.
Power on Note It is important to have the printer control panel functional as soon as possible in the troubleshooting process so that the printer’s diagnostics can assist in locating printing errors. Table 36. Power on defect or blank display Problem Action The power cord is not plugged into the wall outlet and the printer. Make sure the power cord is firmly plugged into the printer and the outlet. Proper AC power is not available. Measure the voltage at the outlet.
Table 36. Power on defect or blank display (continued) Problem Action The fan does not turn on Note when the printer is first An operational fan indicates the following: powered up. 1. AC power is present in the printer. 2. DC power supply is functional (both 24 VDC and 3.5 VDC are being generated). 3. The engine controller board’s microprocessor is functional. If the fan is not working: 1. Turn the printer off and remove the formatter. Disconnect the optional accessories. 2.
Engine test The printer has a built-in test pattern (pairs of vertical lines). The test print can be made by pressing the test print switch located on the left side of the printer (see figure 93 on page 190) once—after the photosensitive drum has stopped and the printer has entered the standby mode. If the switch is held down, the test pattern is printed continuously. The switch can be used when paper is loaded in any tray other than tray 1.
Display The control panel should display READY, OFFLINE, or POWERSAVE ON. If the display is blank, see page 188. If an error message is displayed, refer to the printer messages table starting on page 194 and perform the necessary actions to correct the error condition. Event log Use the event log to diagnose and troubleshoot printer errors and intermittent failures. You can either display or print the event log. Access the event log from the control panel information menu.
Print the event log The printer’s internal event log stores the last 20 errors and can be printed at any time. To print the event log: 1 Press MENU until INFORMATION MENU appears. 2 Press ITEM until PRINT EVENT LOG appears. 3 Press SELECT to print the event log. Display the event log If the printer cannot print or move any media, follow these steps to display the event log. 1 Press MENU until INFORMATION MENU appears. 2 Press ITEM until SHOW EVENT LOG appears.
Printer messages The following table explains messages that might appear on the printer control panel. Numerical and alphabetical printer messages and their meanings are listed in the following table. Hint If a message persists in requesting that you load a tray, or if a message indicates that a previous print job is still in the printer memory, press GO to print or press CANCEL JOB to clear the job from the printer memory. Note Not all messages are described (many are self-explanatory).
Table 37. Printer messages Control panel message Explanation ACCESS DENIED MENUS LOCKED The control panel function Ask the network administrator to you are trying to use has unlock the function. been locked by the network administrator to prevent unauthorized access. BAD DUPLEXER CONNECTION The duplexer is not correctly installed. BAD ENV FEEDER CONNECTION The envelope feeder is not 1. Remove and reinstall the connected properly to the envelope feeder. printer. 2. Turn the printer off and back on. 3.
Table 37. Printer messages (continued) Control panel message Explanation Recommended action CHECK INPUT DEVICE alternates with PAPER PATH OPEN PLEASE CLOSE IT The optional input tray cannot feed print media to the printer because a door or paper guide is open. 1. Check the doors and paper guides and close any that are open. 2. If doors and trays are closed, check tabs and sensor levers in the tray for proper operation. Replace any defective tabs or sensors. 3. Replace the PCA controller in the feeder.
Table 37. Printer messages (continued) Control panel message Explanation Recommended action DISK FILE SYSTEM IS The disk file system is full. 1. Delete all unnecessary files from the EIO disk and then try FULL again. Use HP Resource Manager to download or delete files and fonts. (See the software help for more information.) 2. Advise the customer to increase the permanent storage (use a larger EIO disk or add a RAM DIMM).
Table 37. Printer messages (continued) EN Control panel message Explanation Recommended action ENV FEEDER LOAD [TYPE] [SIZE] A job has been sent to the envelope feeder and the feeder is empty, the wrong size is loaded in the feeder, or the type and size are set incorrectly on the control panel. 1. Load the requested envelope type and size into the envelope feeder. 2. Make sure the envelope size and type are set correctly from the paper-handling menu in the printer control panel. 3.
Table 37. Printer messages (continued) Control panel message Explanation FLASH FILE SYSTEM IS FULL The flash file system is full. Delete unnecessary files from the flash DIMM and try again. Use HP Resource Manager to download or delete files and fonts. (See the software help for more information.) FLASH IS WRITE PROTECTED The flash DIMM is Disable the write protection protected and no new files through HP Resource Manager. can be written to it. INPUT DEVICE CONDITION [XX.
Table 37. Printer messages (continued) EN Control panel message Explanation Recommended action LOADING PROGRAM [NUMBER] alternates with DO NOT POWER OFF Programs and fonts can be Wait for the program to load. stored on the printer’s file system. At startup time, these entities are loaded into RAM. (These entities can take a long time to load into RAM depending on the size and number of entities being loaded.) The specifies a sequence number indicating the current program being loaded.
Table 37. Printer messages (continued) Control panel message Explanation Recommended action MEMORY SHORTAGE JOB The printer did not have enough free memory to CLEARED print the entire job. The remainder of the job will not print and will be cleared from memory. 1. Press GO to continue. 2. Advise the customer to add more memory to the printer or to simplify the print job. MEMORY SHORTAGE PAGE SIMPLIFIED The printer had to compress the job to fit it in available memory.
Table 37. Printer messages (continued) Control panel message Explanation Recommended action PAPER WRAPPED AROUND FUSER Print media is wrapped around the fuser. 1. Turn the printer off to keep the media from wrapping more firmly around the fuser. 2. Open the top cover and remove the toner cartridge. 3. Remove all the visible media. 4. Leave the printer turned off and remove the fuser to remove any remaining print media.
Table 37. Printer messages (continued) Control panel message Explanation RAM DISK FILE SYSTEM IS FULL The RAM disk file system 1. Delete unnecessary files and is full. then try again, or turn the printer off, and then turn the printer on to delete all files on the device. (Delete files using HP Resource Manager or another software utility. See the software online help for more information.) 2. If the message persists, increase the size of the RAM disk.
Table 37. Printer messages (continued) EN Control panel message Explanation Recommended action TRAY [X] EMPTY [TYPE] [SIZE] The specified tray is empty, but the current job does not need this tray in order to print correctly. If this message appears and the tray contains print media, a sensor could be damaged. PS105 detects paper in tray 1. PS101 detects paper in tray 2. PS1001 detects paper in the optional 500-sheet feeder. See figure 113 on page 263 and figure 114 on page 264 for sensor locations.
Table 37. Printer messages (continued) Control panel message Explanation Recommended action TRAY 1 LOAD [TYPE] [SIZE] The print job has requested a size and/or type of media that is not loaded. 1. Load the requested print media into tray 1 (or any other desired tray). ! Ensure that the trays are correctly adjusted for size. ! The tray type settings (and size for tray 1) must be set from the paper-handling menu. 2.
Table 37. Printer messages (continued) Control panel message Explanation Recommended action TRAY 1 SIZE = [xxxx] The printer is asking what In response, you can take either size of media has been of the following actions: loaded in tray 1. 1. Press SELECT to accept the paper size. 2. Press -VALUE+ to change the size and then press SELECT to accept the new size. The printer will first display the TRAY 1 TYPE = XXXX message (see the description of that message).
Table 37. Printer messages (continued) Control panel message Explanation Recommended action UNSUPPORTED SIZE IN An external paper-handling Verify the media meets the device detected an supported size specifications in TRAY [yy] unsupported media size. table 7 on page 26. The printer will go offline until the condition is corrected. USE [TYPE] [SIZE] INSTEAD? If the requested media size or type is not loaded, the printer asks if it should use another size or type instead. 1.
Table 37. Printer messages (continued) EN Control panel message Explanation Recommended action 13.0 PAPER JAM [LOCATION] A non-specific paper jam occurred. 1. Remove jammed media from the specified location. 2. Verify the paper tray is fully closed. 3. Inspect and/or replace the feed and separation rollers. 4. Ensure there is no obstruction in the path, such as a torn piece of paper. 5. Open and close the top cover to clear the message. 6. Check sensors and flags for proper operation (page 263). 13.
Table 37. Printer messages (continued) Control panel message Explanation Recommended action 13.2 PAPER JAM OPEN INPUT TRAYS Paper-stopped jam at paper-feed area. 1. Check the input area for obstructions such as paper in the path. Also check to see if the registration assembly is damaged or if the transfer roller is out of place. 2. Check PS102 and PS103 for proper operation. Replace any defective sensors or flags. For sensor locations, see page 263. 3.
Table 37. Printer messages (continued) EN Control panel message Explanation Recommended action 13.20 PAPER JAM CHECK REAR DOOR alternates with OPEN AND CLOSE TOP COVER OPEN INPUT TRAYS Media stopped in the paper path during poweron or when the top door was closed. 1. Remove all media in the paper path, and then open and close the top cover. 2. If the message persists after all media is removed: ! Check if media is jammed in the prefeed area (PS102).
Table 37. Printer messages (continued) Control panel message Explanation 41.x PRINTER ERROR alternates with PRESS GO TO CONTINUE A temporary printing error Press GO. The page containing the error will automatically be has occurred. reprinted. If the error persists: 1. Reseat the connections to the laser scanner and then to the engine controller board. 2. Replace the laser scanner. 3. Replace the engine controller board. 41.
Table 37. Printer messages (continued) Control panel message Explanation 49.XX PRINTER ERROR A firmware error occurred. alternates with CYCLE POWER TO CONTINUE EN Recommended action 1. Press CANCEL JOB to clear the print job from the printer memory. 2. Turn the printer off, and then turn the printer on. 3. Try printing a job from a different software application. If the job prints, go back to the first application and try printing a different file.
Table 37. Printer messages (continued) Control panel message Explanation 50.X FUSER ERROR A fuser error has occurred. 1. Turn the printer off, wait 20 X description: minutes, and then turn the printer 1 = Low fuser on. temperature 2. If the message persists, reseat 2 = Fuser warm-up the fuser. service ! If that does not work, replace the fuser. 3 = High fuser temperature ! To check the fuser, turn the printer off and remove the fuser. Measure the resistance between the fuser connectors J132-1 and J132-2.
Table 37. Printer messages (continued) Control panel message Explanation Recommended action 52.X PRINTER ERROR alternates with CYCLE POWER TO CONTINUE The laser scanner speed is 1. Press GO. The page containing the error will automatically be incorrect. reprinted. X description: 1 = Scanner startup error 2. Turn the printer off and then 2 = Scanner rotation error on. 3. Reseat cables to the laser/ scanner and engine controller. 4. Replace the laser/scanner. 53.XY.
Table 37. Printer messages (continued) Control panel message Explanation Recommended action 54.4 PRINTER ERROR alternates with CYCLE POWER TO CONTINUE A problem exists with the customer’s line voltage. 1. Remove the printer from any UPS supplies, additional power supplies, or power strips. 2. Plug the printer into a wall outlet and see if this resolves the problem. 3.
Table 37. Printer messages (continued) EN Control panel message Explanation Recommended action 59.X PRINTER ERROR alternates with CYCLE POWER TO CONTINUE A main motor error occurred. X description: 0 = Motor error 1 = Motor startup error 2 = Motor rotation error 1. Turn the printer off, and then turn the printer on. 2. Check and reseat the fuser and toner cartridge to make sure they are not hindering gear movement in the drive train. 3.
Table 37. Printer messages (continued) Control panel message Explanation Recommended action 68 NVRAM FULL CHECK SETTINGS An error occurred in the printer’s NVRAM and one or more printer settings has been reset to its factory default. 1. Print a configuration page and check the printer settings to determine which values have changed. 2. Hold down CANCEL JOB while turning the printer on. This will clean up the NVRAM by removing old areas that are not being used. 68.
Table 37. Printer messages (continued) EN Control panel message Explanation Recommended action 79 SERVICE [XXXX] The printer detected an error. 1. Press CANCEL JOB to clear the print job from the printer memory. 2. Turn the printer off, and then turn the printer on. 3. Try printing a job from a different software application. If the job prints, go back to the first application and try printing a different file.
Table 37. Printer messages (continued) Control panel message Explanation Recommended action 8X.YYYY EIO [Z] ERROR The EIO accessory in slot [z] has encountered a critical error. [z] description: 1 = EIO slot 1—The printer detected an error with the EIO accessory. 2 = EIO slot 2—The printer detected an error with the EIO accessory. 6 = EIO slot 1—The EIO accessory detected an error. 7 = EIO slot 2—The EIO accessory detected an error. 1. Turn the printer off, and then turn the printer on. 2.
Table 38. Mopy disk error messages Disk error number Error description EN Solution 24 Unexpected internal error The data might be corrupted. Delete the job that prompted the error. Disk-media problem: Initialize the hard disk or restart the printer to reinitialize the RAM disk. If the problem persists on a hard disk, replace the hard disk. 55 Bad file system Data might be corrupted. Delete the job that prompted the error.
General paper-path troubleshooting Jams occur in the printer when print media does not either reach or clear a photosensor along the printer paper path in a specific amount of time. If a jam occurs, a 13.XX PAPER JAM message appears on the printer control panel. The following table contains general questions you might ask and topics to explore before troubleshooting. Table 39.
Table 39. General paper-path troubleshooting questions (continued) Troubleshooting check Action Are the paper tray guides set correctly? For tray 1, ensure the guides are adjusted correctly with the sides of the media. Make sure the media fits under the tabs on the guides and not above the load-level indicators. For trays 2, 3, and 4: 1. Squeeze the lever on the left guide and slide the guides into place to match the width of the paper. 2.
Paper-path test To perform a paper-path test: 1 Press MENU until INFORMATION MENU appears. 2 Press ITEM until PRINT PAPER PATH TEST appears. 3 Press SELECT. INPUT=TRAY 1 is displayed 4 Press VALUE+ to cycle selections until the desired paper tray appears. 5 Press SELECT. OUTPUT=TOP BIN is displayed. 6 Press VALUE+ until the desired output bin appears (open the rear output bin to print to it). 7 Press SELECT. DUPLEX=ON is displayed. This selection only appears when a duplexer is installed.
Figure 95. Sample menu map (1 of 2) Figure 96.
Embedded Web server The embedded Web server allows you to view printer and network status and to manage printing functions from your computer instead of from the printer control panel. This service is designed for offices using an IP network and a standard Web browser. Below are examples of what you can do using the embedded Web server: ! View printer control panel messages. ! Determine the remaining life of all consumables. ! Order consumables. ! View and change tray configurations.
Home page set The home pages of the embedded Web server are the informational pages for the printer. These include: ! Printer status page This page displays printer capabilities, control panel messages, and status lights that currently appear on the printer control panel. From here, you can set the frequency at which the embedded Web server will check the printer status. This page also displays consumable life levels and the input tray configurations.
! Language page Determine the language in which to display the embedded Web server information. ! Device Identification page Name the printer and assign an asset number to it. Input the name and e-mail address of the primary point of contact for information about the printer. This page also shows the printer’s network names, addresses, and printer model information.
Printer Information Lists the serial number, HP JetSend IP addresses, page counts, and other information for the printer. Memory Lists printer memory, PCL driver work space (DWS), and I/O buffering and resource-saving information. 4100 Series printers Figure 97. Event Log Lists the number of entries in the log, the maximum number of entries viewable, and the last three entries. Security Lists the status of the printer control panel lock, control panel password, and disk drive.
Table 40. Image quality checks Image quality checks Action Does the problem repeat on Use the repetitive defect ruler on page 243. the page? Is the toner cartridge full and Check the toner cartridge using the checklist on page 228. is it manufactured by HP? Is the customer using print media that meets all HP paper specification standards? For more information about HP’s paper specification standards, see chapter 1 of this manual and the HP LaserJet Printer Family Print Media Guide.
Note Toner cartridges are rated for 6,000 or 10,000 images at 5 percent coverage (depending on the model). It is possible to wear out the gears and the cartridge seals before TONER LOW appears if the number of images exceeds 6,000 or 10,000 (depending on the model). See “EconoMode” below. A depleted cartridge will often create print defects. ! Check the surface of the photosensitive drum in the cartridge to see if it has been damaged or scratched.
Image defects The quality of the printer output is subject to the judgment of the user. This section of the manual helps you define print quality defects and understand what factors affect print quality. The print samples shown in the following tables illustrate some print quality defects. For future reference, retain copies of print quality defects encountered in the field with an explanation of their causes. The image defects listed below are covered in the following tables.
Table 42. Image defects Problem Cause Solution Black page The high-voltage power supply connections are contaminated. Clean the high-voltage power supply terminals. (See “Engine controller board layout,” figure 105 on page 254.) Also clean the high-voltage springs where they contact the toner cartridge. The high-voltage power supply is installed improperly. If the high-voltage power supply has been removed and replaced, it might not be seated properly.
Table 42. Image defects Problem Cause Solution White page No toner is available for print. Remove sealing tape or replace the toner cartridge. Defective laser shutter. Check the laser shutter for free operation when inserting the toner cartridge. Toner cartridge guide damaged, Make sure the guide is installed improperly positioned, or missing. properly above the toner cartridge. 232 Troubleshooting No transfer roller voltage.
Table 42. Image defects Problem Cause Solution Blank spots Print media does not meet printer 1. Print a few more pages to see specifications or is stored if the problem corrects itself. improperly. 2. Turn over the stack of media in the tray. Also try rotating the media 180°. 3. If the print media does not meet HP specifications, replace the paper, and advise the customer to use the recommended print media and store it properly. Contaminated or deformed transfer roller. Replace the transfer roller.
Table 42. Image defects Problem Cause Solution Curl Print media does not meet printer 1. Print a few more pages to see specifications or is stored if the problem corrects itself. improperly. 2. Turn over the stack of media in the tray. Also try rotating the media 180°. 3. If the print media does not meet HP specifications, replace the paper, and advise the customer to use the recommended print media and store it properly. Printer’s operating environment does not meet specifications.
Table 42. Image defects Problem Cause Solution Distorted image Print media does not meet printer 1. Print a few more pages to see specifications or is stored if the problem corrects itself. improperly. 2. Turn over the stack of media in the tray. Also try rotating the media 180°. 3. If the print media does not meet HP specifications, replace the paper, and advise the customer to use the recommended print media and store it properly. Printer’s operating environment does not meet specifications.
Table 42. Image defects Problem Cause Solution Faded print/ bubbles No drum ground path. With no ground path, the drum cannot discharge. The negative charge on the drum repels toner and leaves a white page with bubble print. 1. Check the drum ground spring and reconnect it, if necessary. 2. Replace the engine controller board. Engine controller board. Replace the engine controller board. Gray background Print media does not meet printer 1.
Table 42. Image defects Problem Cause Solution Horizontal smudges Paper-path contamination or damage. 1. See the “Repetitive defect ruler” on page 243. 2. Check the toner cartridge and replace it if necessary. 3. Check the fuser and replace it, if necessary. Horizontal white lines EN 1. Check the toner cartridge and replace it if necessary. 2. Check the fuser and replace it if necessary. 3. Replace the laser/scanner assembly, followed by the engine controller board, if necessary.
Table 42. Image defects Problem Cause Solution Light print, dark print, or fade Wrong toner density setting. From the print-quality menu on the control panel, adjust the toner density setting. Make sure EconoMode is off. Toner cartridge is low. Replace the toner cartridge. Transfer roller is defective. Replace the transfer roller. Print media does not meet printer 1. Print a few more pages to see specifications or is stored if the problem corrects itself. improperly. 2.
Table 42. Image defects Problem Cause Solution Loose toner Contamination in the printer. 1. Print a few more pages to see if the problem corrects itself. 2. Clean the inside of the printer or use the printer’s cleaning page. (See “Cleaning the printer and accessories” starting on page 82.) Toner cartridge is defective. Replace the toner cartridge. Paper might be too smooth. Check the paper (or other print media) type and quality. Wrong fuser setting for paper type.
Table 42. Image defects Problem Cause Solution Toner smear Contamination in the printer. 1. Print a few more pages to see if the problem corrects itself. 2. Clean the inside of the printer or use the printer’s cleaning page. (See “Cleaning the printer and accessories” starting on page 82.) Paper might be too smooth. Check the paper (or other print media) type and quality. Defective toner cartridge. Replace the toner cartridge. (See instructions with the toner cartridge.
Table 42. Image defects Problem Cause Solution Vertical black lines Defective toner cartridge. Replace the toner cartridge. Contaminated fuser entrance guide. Clean the guide. Scratches on the fuser. Replace the fuser. Worn fuser film. 1. Set the fuser to a lower temperature mode. 2. Replace the fuser. Note To prevent the print-quality problem, reduce printing on large volumes of narrow media, such as envelopes. Instead, alternate smaller volumes of narrow media with full-page printing jobs.
Table 42. Image defects Problem Cause Solution Repeating image This type of defect might occur when using preprinted forms, a large quantity of narrow media, or a fuser mode that is set too high for your media. 1. Print a few more pages and see if the problem corrects itself. 2. Make sure that print media type and quality meet HP specifications. 3.
Table 42. Image defects Problem Cause White spots on black Solution 1. Print a few more pages to see if the problem corrects itself. 2. Make sure that print media type and quality meet HP specifications. 3. Make sure that the environmental specifications for the printer are being met. 4. Replace the toner cartridge. Repetitive defect ruler Repetitive print defects are usually associated with a specific roller within the printer or the toner cartridge.
Image system troubleshooting Half self-test functional check The electrophotographic process can be subdivided into the following stages: ! Cleaning (removes excess toner from drum surface) ! Conditioning (places a uniform electrical charge on drum) ! Writing (laser strikes surface of drum and creates latent image) ! Developing (forms the toner image on drum) ! Transferring (charge transfers the image to print media) ! Fusing (heat and pressure produces a permanent image) The purpose of the half
High-voltage power supply functional check The high-voltage power supply assembly provides the necessary voltages for the printer’s electrophotographic processes. The +24 B VDC supply is used to power the high-voltage power supply assembly. A summary of the major components of the high-voltage system is given in table. Table 43.
Reference diagrams Locations of components Figure 99.
Table 44.
Figure 100.
Figure 101.
Figure 102.
Figure 103.
Paper path Figure 104. Paper sensors and the paper path Table 45.
Table 45.
Engine controller board Figure 105. Engine controller board layout Table 46.
Paper-size detection switches Figure 106. Paper-size detection switches (1 of 2) Figure 107.
Table 47.
Motors and fans Figure 108. Location of motors Table 48.
Connectors Figure 109.
Figure 110.
Figure 111.
PCAs Figure 112.
Table 49.
Sensors, switches, and thermistors Figure 113.
Figure 114. Location of sensors, switches, and thermistor (2 of 2) Table 50.
Table 50.
Solenoids and clutch Figure 115.
Table 51.
Timing Figure 116. Pickup timing for tray 2 (and lower trays) Figure 117.
8 Parts and diagrams Chapter contents How to use the parts lists and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Accessories and supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Common screws and replacement cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 Illustrations and parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to use the parts lists and diagrams The figures in this chapter illustrate the major subassemblies in the printer and their component parts. A table accompanies each exploded-view diagram. Each table lists the item number for the replaceable part, the associated part number for the item, the quantity, and a description of the part.
Accessories and supplies The following items are available through your local authorized HP dealer. To find a dealer near you, call the HP Customer Information Center at (1) (800) 752-0900. Note See page 41 for documentation product numbers. Table 52. Accessories and supplies Description Part no. 500-sheet paper feeder and tray C8055-67901 Product no.
Table 52. Accessories and supplies (continued) Description Part no. Maintenance kit 110 V 220 V Exchange no. Product no. C8057-69001 C8058-69001 C8057A C8058A Common screws and replacement cables Table 53. Screws used in the printer Description Part no. Screw, M4x10, self-tapping XA9-0870-000CN Screw, M3x6, washer head, engine controller board XA9-1016-000CN Screw, M4x12, self-tapping, pan head XB4-7401-207CN Screw, M4x8.
Table 54. Replaceable cables EN Description Part no. Cable and power receptacle 110 V 220 V RG5-5111-000CN RG5-5280-000CN Cable, tray 1 sensor RG5-5341-000CN Table 58 on 7 page 281 Cable, laser scanner RG5-5348-000CN Table 59 on 7 page 283 Cable, envelope feeder connect RG5-5344-000CN Table 58 on 9 page 281 Cable, top cover switch Table 58 on 10 page 281 RG5-5345-000CN Table no. Item no.
Illustrations and parts lists 4 5 1 3 2 Figure 118.
6 5 1 2 4 Figure 119.
Table 55. Assemblies (listed alphabetically) and their part numbers Description Part no.
6 7 2 8 1 2 3 5 4 Figure 120. External covers and panels Table 56. External covers and panels Item no. Part no.
3 2 1 Figure 121.
Table 57. Top cover assembly Item no. EN Part no.
13 12 15 16 23 11 21 2 24 1 24 5 6 8 17 10 3 7 9 22 20 19 24 18 4 14 Figure 122.
Table 58. Internal components (1 of 4) Item no. Part no. EN Quantity Description 1 FA9-1449-000CN 4 Screw, truss head, w/washer, grounding 2 RB2-5013-000CN 2 Screw, M4 x 8.
17 16 7 16 16 9 8 4 11 3 1 2 16 14 12 5 6 15 13 10 Figure 123.
Table 59. Internal components (2 of 4) EN Item no. Part no.
19 19 17 18 23 11 8 1 6 5 9 2 19 4 7 19 15 16 3 10 14 20 19 22 19 19 13 21 12 19 Figure 124.
Table 60. Internal components (3 of 4) EN Item no. Part no.
2 2 2 4 12 6 10 9 1 7 8 11 5 3 2 2 Figure 125.
Table 61. Internal components (4 of 4) EN Item no. Part no.
1 (FU1) Figure 126. 2 (FU2) Engine controller board assembly Table 62. Engine controller board assembly Item no. Part no. Exchange no.
1 Figure 127. Delivery drive assembly Table 63. Delivery drive assembly Item no. 1 EN Part no.
1 Figure 128. Printer drive assembly Table 64. Printer drive assembly Item no. 1 290 Parts and diagrams Part no.
5 1 4 6 3 2 Figure 129. Tray 2 paper pickup guide assembly Table 65. Paper pickup guide assembly Item no. EN Part no.
5 7 4 8 6 3 1 2 Figure 130.
Table 66. Tray 1 pickup assembly Item no. EN Part no.
1 2 3 Figure 131. Paper feed guide assembly Table 67. Paper feed assembly Item no. Part no.
1 3 2 Figure 132. Delivery assembly Table 68. Delivery assembly Item no. EN Part no.
2 1 Figure 133. Fuser assembly (1 of 2) Table 69. Fuser assembly Item no. Part no. Exchange no.
Figure 134.
15 1 18 4 2 4 19 14 4 4 17 5 16 12 10 9 6 11 8 7 3 13 4 4 Figure 135.
Table 70. Internal components of optional 500-sheet feeder EN Item no. Part no.
1 7 3 6 4 5 Figure 136.
Table 71. Paper pickup guide assembly, optional 500-sheet feeder Item no. EN Part no.
4 5 3 1 2 8 9 6 7 Figure 137. 500-sheet tray Table 72. 500-sheet tray Item no. Part no.
2 1 Figure 138. Envelope feeder Table 73. Envelope feeder Item no. Part no. C8053A EN Exchange no.
2 3 4 1 5 Figure 139.
Table 74. Internal components of duplexer Item no. Part no. C8054A EN Exchange no.
Alphabetical parts list Table 75.
Table 75.
Table 75.
Table 75.
Table 75.
Table 75. Alphabetical parts list (continued) Description Part number Table number and page Screw, M4x10, self-tapping XA9-0870-000CN Table 53 on page 272 Table 61 on page 287 Screw, M4x10, self-tapping XA9-0606-000CN Table 53 on page 272 Screw, M4x10, self-tapping, feeder assembly FA9-2753-000CN Table 53 on page 272 Screw, M4x12, self-tapping, pan XB4-7401-207CN head Table 53 on page 272 Screw, M4x8.
Table 75.
Numerical parts list Table 76.
Table 76.
Table 76.
Table 76.
Table 76.
Table 76.
Table 76.
320 Parts and diagrams EN
Index Numerics 500-sheet feeder internal components 248, 298, 299 part numbers 271 pickup solenoid (SL1001) 267 500-sheet tray components 302 error messages 194 operations 124 paper sizes 16 part numbers 271, 302 A A4 paper, settings 62 AC bias, drum conditioning 111 AC potential, developing stage 113 AC power distribution 91 accessories, ordering 271 acclimating printer 187 accounting information 55 acoustic emissions 24 adhesive labels, specifications 25, 31 agreements, service 43 air temperature, sensor
cold reset paper size 77 performing 79 commands, MS-DOS 80 communications error messages 214 interface 105 Printer Job Language (PJL) 107 settings 69 compact discs.
drivers resolution features 15 settings 52 websites 42 dropouts, troubleshooting 235 drum. See photosensitive drum dual in-line memory modules.
feeding problems, envelopes 33 See also jams feed-roller clutch (CL101) 122, 247 field replaceable units (FRUs) 40 file directory, printing 55 file system full 196 film, transparency.
inhalation, toner 36 initializing hard disk 80 NVRAM 79 input trays.
locked 194 Paper-handling 57 Print quality 63 Printing 60 Private/stored jobs 54 quick copy jobs 53 Resets 73 Service 75 settings for 52 messages alphabetical list 194 clearing 193 maintenance 67 numerical list 206 PowerSave 104 warning 67 MEt (Memory Enhancement technology) 106 metal edges, cautions for 135 Microsoft Internet Explorer 224 millimeters 60 mirror, scanning 112 misformed characters, troubleshooting 242 mode commands, MS-DOS 80 model number 20 models, printer 18 /MON (main motor drive signal) 1
paper feed module disassembly separating from engine module 171 tray 2 179 tray 3 180 tray 4 180 paper feed module plate, removing 180 paper feed rollers cleaning 83 life expectancies 87 removing 177 paper-feeder 500-sheet trays 124, 125 driver PCA 262 pickup solenoid (SL801) 125 sensor (PS801) 264 paper guides, adjusting 221 Paper-handling menu 57 paper input trays.
Q quality, troubleshooting 227, 230 Quick copy jobs menu 53, 68 R RAM (random-access memory) 106 RAM disk error messages 201, 202, 206 settings 68 random-access memory (RAM) 106 read/write timing, cartridge memory 94 read-only memory (ROM) 106 Ready light 49 rear cover, removing 145 rear output bin capacity 16 removing 145 rear right side cover, removing 138 recovery, jam 67 recycling toner cartridges 44 refilled toner cartridges 44 registration assembly operations 117, 123 removing 165 registration roller
small media, settings for 58 smeared toner, troubleshooting 240 smudges, troubleshooting 237 soft fonts 61 software settings 52 Software Technical Reference, ordering 41 solenoids locations 266 paper-feeder pickup (SL1001) 125 tray pickup (SL101, 102) 120, 122, 247 sound power 24 sources, paper 117 space requirements 22 spacing settings 61 specifications acoustic emissions 24 duplexer, media 27 electrical 21 envelope feeder, media 26 environmental 21, 24 features 14 media 25 space requirements 22 specks, to
toner gauge, resetting 73 tools, required 136 top cover assembly diagram 278 open, error message 195 part numbers 279 removing 141 top margin, settings 78, 175 top of page sensor (PS103) 117 top output bin, capacity 16 top output-bin-full sensor (PS104) 247, 252 top output-bin-full sensor flag 153 TOP signal 117 top-of-page adjustment (VR501) 254 top-of-page sensor (PS103) 247, 252 torque limiter 124 training kits, ordering 41 transfer roller cleaning 82, 83 life expectancy 87 removing 159 transferring stag
websites drivers 42 hardware education 41 Material Safety Data Sheet (MSDS) 36 parts information 42 weight envelopes 26, 34 equivalence table, paper 30 heavy paper 35 paper, duplexer 27 paper, tray 1 25 paper, trays 2, 3, and 4 26 printer 23 toner cartridges 228 white lines, troubleshooting horizontal 237 vertical 241 white pages, troubleshooting 232 white spots, troubleshooting 243 Wide A4 setting 62 width, printer 22 wrinkled pages, troubleshooting 233 writing, image 112 EN Index 331
332 Index EN
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