Manual Part No. C3990-90991 *C3990-90991* *C3990-90991* Printed on Recycled Paper C3990-90991 HP LaserJet 5L and 6L Printer (C3941/C3990) Service Manual Copyright© 1997 Hewlett Packard Co.
Service Manual HP LaserJet 5L (C3941A) HP LaserJet 6L (C3990A)
© Copyright Hewlett-Packard Company 1997 All Rights Reserved. Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws. Publication number C3990-90991 First edition, May 1997 Hewlett-Packard Company 11311 Chinden Boulevard Boise, Idaho 83714 Warranty The information contained in this document is subject to change without notice.
Conventions This manual uses the following conventions: Color is used to emphasize items which are important to the material under discussion. The names of major printer parts and assemblies are CAPITALIZED. Bold is used for emphasis, particularly in situations where italic type would be confusing. Italic type is used to indicate related documents or emphasis. Note Notes contain important information set off from the text.
Chapter Descriptions 1 Product Information Orientation to the printer, as well as the service and repair philosophy, is discussed. Information on obtaining assistance and warranty is also here. 2 Site Requirements Here are recommendations pertaining to installation requirements. 3 Operating Overview This chapter has detailed information about the Control Panel. Sample self tests and printer reset information are also included.
List of Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 2-1 Figure 2-2 Figure 3-1 Figure 3-2 Figure 3-3 Figure 4-1 Figure 4-2 Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 6-1 Figure 6-2 Figure 6-3 Figure 6-4 Figure 6-5 Figure 6-6 Figure 6-7 Figure 6-8 Figure 6-9 Figure 6-10 Figure 6-11 Figure 6-12 Figure 6-13 Figure 6-14 Figure 6-15 Figure 6-16 Figure 6-17 Figure 6-18 Figure 6-19 Figure 6-20 Figure 6-21 Figure 6-22 Figure 6-23 HP Laser
Figure 6-24 Figure 6-25 Figure 6-26 Figure 6-27 Figure 6-28 Figure 6-29 Figure 6-30 Figure 6-31 Figure 6-32 Figure 6-33 Figure 6-34 Figure 6-35 Figure 6-36 Figure 6-37 Figure 6-38 Figure 6-39 Figure 6-40 Figure 6-41 Figure 6-42 Figure 6-43 Figure 7-1 Figure 7-2 Figure 7-3 Figure 7-4 Figure 7-5 Figure 7-6 Figure 7-7 Figure 7-8 Figure 7-9 Figure 8-1 Figure 8-2 Figure 8-3 Figure 8-4 Figure 8-5 Figure 8-6 Figure 8-7 Figure 8-8 Figure 8-9 Figure 8-10 Figure B-1 vi Pickup Roller Assembly Removal (2 of 2) . . .
List of Tables Table 1-1 Table 1-2 Table 1-3 Table 1-4 Table 1-5 Table 1-6 Table 2-1 Table 2-2 Table 3-1 Table 3-1 Table 3-2 Table 4-1 Table 4-2 Table 5-1 Table 5-2 Table 7-1 Table 7-2 Table 7-3 Table 7-4 Table 7-4 Table 7-4 Table 7-5 Table 7-6 Table 7-7 Table 7-8 Table 8-1 Table 8-2 Table 8-3 Table 8-4 Table 8-5 Table 8-5 Table 8-6 Table A-1 Table A-2 Printer Features . . . . . . . . . . . . . . . . . Paper Capacities and Sizes . . . . . . . . . . . Performance Specifications . . . . . . . . . . .
viii
1 Product Information Contents Printer Features . . . . . . . . . . . Paper Capacities and Sizes . . . . Identification . . . . . . . . . . . . . Model and Serial . . . . . . . . . Specifications . . . . . . . . . . . . Product Overview . . . . . . . . . . Front/Side Views of the Printer . . Front Door Assemblies . . . . . . Back View of the Printer . . . . . Service Approach . . . . . . . . . . Parts Exchange Program . . . . . Ordering Parts . . . . . . . . . . Ordering Consumables . . . . . .
1-2 Product Information
Table 1-1 Printer Features Features Descriptions Print Speed 4 ppm (HP LaserJet 5L); 6 ppm (HP LaserJet 6L) Text & Graphics Resolution 300 or 600 dpi Printer Language Enhanced PCL 5 Monthly Usage (pages) 4,000 pages (HP LaserJet 5L); 6,000 pages (HP LaserJet 6L) Memory: Standard1 Maximum Memory Capacity 1 Mbyte RAM (70nsec) 9 Mbyte total (available in increments of 1, 2, 4, and 8 Mbytes) 5 V JEDIA card2 Internal Typefaces 26 Scalable Typefaces Standard Interfaces Parallel (Bi-tronics) Power
Identification Model and Serial The model number and serial numbers are listed on identification labels located on the bottom of the printer. The model number is alphanumeric, such as C3941A for the HP LaserJet 5L printer, and C3990A for the HP LaserJet 6L printer. The serial number contains information about the Country of Origin, the Revision Level, the Production Code, and production number of the printer. The labels also contain power rating and regulatory information.
Figure 1-2 Product 1 Information HP LaserJet 6L Model and Serial Numbers Product Information 1-5
Specifications Table 1-3 Performance Specifications Category Specification Print Speed*: HP LaserJet 5L Print Speed*: HP LaserJet 6L 4 ppm 6 ppm Monthly Usage (Duty Cycle): HP LaserJet 5L Monthly Usage (Duty Cycle): HP LaserJet 6L 4,000 pages 6,000 pages Life Expectancy of Toner Cartridge (pages)** 2,500 pages @ 5% coverage First Print A4 <23 seconds Letter <23 seconds * Actual speed depends on data complexity and software handling efficiency.
Product 1 Information Product Overview Figure 1-3 Front/Side Views of the Printer 1. Paper Input Support 7. Front Panel Button 13. Front Output Slot (face-up) 2. Paper Output Support 8. Paper Output Bin 3. Paper Guides 9. Paper Path Lever 4. Error (top) Light 10. Serial and Model Number (under printer) 5. Data (middle) Light 11. Paper Input Bin 6. Ready (bottom) Light 12.
Figure 1-4 Front Door Assemblies 14. Paper Release Lever 16. Transfer Roller (do not touch) 15. Toner Cartridge Compartment 17.
Figure 1-5 I Product 1 Information Back View of the Printer 18. Power Cable Connector 20. Memory Expansion Cover 19.
Service Approach Repair of the printer normally begins with the use of the printer’s internal diagnostics in conjunction with the troubleshooting procedures in Chapter 7. Once a faulty part is located, repair is generally accomplished by assembly level replacement of Field Replaceable Units (FRUs). Some mechanical assemblies may be repaired at the subassembly level. PCA component replacement is not supported by Hewlett-Packard. Part numbers for all FRUs are located in Chapter 8 of this manual.
Table 1-6 Related Documentation Part Number PDO PCE 5021-0369 X X HP LaserJet 5L Printer User’s Manual C3941-90901 X HP LaserJet 6L Printer User’s Manual C3990-90901 X HP PCL5 Printer Language Technical Reference Information Package 5010-3994 X X HP LaserJet Printer Family Paper Specifications Guide 5021-0368 X X LaserJet Basic Hardware Training Course 5961-0880 X X C3990+49A-60001 (NTSC) C3990+49A-60002 (PAL) X X X HP LaserJet 6L Printer Service Manual Bundle includes: Service M
Technical Assistance Online Services: for 24-hour access to information over your modem, we suggest these services. World Wide Web URL—Printer drivers, updated HP printer software, and product and support information may be obtained from http://www.hp.com, or in Europe from http://www2.hp.com. In Japan printer drivers may be obtained from ftp://www.jpn.hp.com/drivers/. Korea: www.hp.co.kr. Taiwan: www.hp.com.tw, with a local driver website of www.dds.com.tw.
U.S. and Canada: Customer Support & Product Repair Assistance (Please refer to the warranty chapter of this manual for additional product repair information.) Call (208) 323-2551 Mon-Fri 6 am to 10 pm and Saturday 9 am to 4 pm (Mountain Time) free of charge during the Warranty Period; however, your standard long-distance phone charges still apply. Please have your serial number ready when calling. Post-warranty telephone assistance is available to answer your product questions. Call (900) 555-1500 ($2.
Warranty This warranty gives you specific legal rights. You may also have other rights, which may vary from area to area. Hewlett-Packard warrants the 5L and 6L LaserJet printers against defects in materials and workmanship for a period of one year from the date of purchase by the end user and is not transferable. During the warranty period, Hewlett-Packard will, at its option, either repair or replace hardware products that prove to be defective.
The warranty period begins either on the date of delivery or, where the purchase price includes installation by Hewlett-Packard, on the date of installation. Warranty Limitations The warranty set forth above is exclusive and no other warranty, whether written or oral, is expressed or implied. Hewlett-Packard specifically disclaims the implied warranties of merchantability and fitness for a particular purpose.
1-16 Product Information
2 Site Requirements Contents Site Requirements . . . . . . . . . . . . Operating Environment . . . . . . . . Printer Space Requirements . . . . . . . The HP C3906A/F Toner Cartridge . . . Storage Conditions . . . . . . . . . . Storing Opened Toner Cartridges . . Toner Cartridge Handling Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 -2 Site Requirements
Site Requirements Operating Environment The environmental requirements listed in the table below must be maintained to ensure the proper operation of this printer. Table 2-1 Environmental Requirements LaserJet 5L/6L & Cartridge Humidity Storage 50 to 90.5° F (10 to 32.
Printer Space Requirements Figure 2-1 Printer Space Requirements Table 2-2 Printer Dimensions Description Dimension Width 13.2 in. (335.5 mm) Depth 12.3 in. (311.2 mm) Height (storage) (operational) 8.9 in. (227.5 mm) 14.6 in. (372.7 mm)* Weight (with toner cartridge) 15.9 lbs. (7.2 kg) Toner cartridge weight** 1.5 lbs. (.7 kg) * With letter input assembly extended. ** Some quantity of toner will reside in the waste toner area of a toner cartridge when the toner supply is exhausted.
The HP C3906A/F Toner Cartridge Toner cartridges contain components that are sensitive to light, temperature, and humidity. Follow the recommendations in this section to ensure the highest quality and longest life of HP toner cartridges. Keep the printer within the following environmental conditions for optimum performance. The toner cartridge is affected by its environment. Packaging protects the toner cartridge from light and increases its storage life.
Toner Cartridge Handling Suggestions • Before installing a cartridge, distribute the toner evenly by rotating the cartridge back and forth five to six times. (See Figure 2-2.) Repeat this action when toner begins to run low. Figure 2-2 Ton erC artri dge C39 06A Toner Cartridge Distribution • Do not touch the surface of the photosensitive drum in the cartridge. Protect the drum from light and contamination. • Do not expose the cartridge to unnecessary vibrations or shock.
3 Operating Overview Contents Using the Control Panel . Control Panel Layout . LED Lights . . . . . . The Front Panel Button Printing a Self-Test Page . Continuous Self Test . Printing an Engine Test . Resetting the Printer . . . To Reset the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 Operating Overview
Using the Control Panel Control Panel Layout The Control Panel consists of three status lights and a Front Panel Button located at the front of the printer. The Control Panel consists of one button and three status lights.
LED Lights The LED lights provide a quick way to check the printer’s status. Table 3-1 When this Indicator: Indicator Lights (1 of 2) Looks like this: It means this: Do this: On Ready Ready to print. Blinking Print job in progress. Let job finish printing. On Form Feed There is unprinted data in the buffer. Briefly press the Front Panel Button to print the remaining data. Blinking Manual Feed The printer is in manual feed mode.
Table 3-1 When this indicator: Indicator Lights (Continued 2 of 2) Looks like this: Blinking It means this: Error (light blinking) Page Too Complex Do this: Briefly press and release the Front Panel Button to continue printing. There may be some data loss on the page. The page may be too complex for the printer’s memory capacity Hint: To avoid this in the future: or the printer may not be able to create the image fast enough to 1.
The Front Panel Button Depending on what state the printer is in, pressing the Front Panel Button allows you to control printing tasks by either starting or resuming a printer function. Use the Front Panel Button to accomplish the following tasks: Table 3-2 Front Panel Button Usage Function Lights Action Result Wake Up All lights are off while plugged into power source. Briefly push and release the button. The printer will wake up to a ready state.
Printing a Self-Test Page A self-test page can be useful in troubleshooting printer problems and determining which fonts have been downloaded to the printer.
Figure 3-2 Self-test Page for HP LaserJet 6L The self-test page lists the current printer configuration. (If any fonts have been downloaded to the printer a second page will print.) To print a self-test page: 1 Make sure the Ready (bottom) Light is on, and all other lights are off. Wake up the printer if necessary by pressing the Front Panel Button. 2 Briefly press and release the Front Panel Button. The Data (middle) Light comes on, the Ready (bottom) Light blinks. Wait for a self-test page to print.
Continuous Self Test A continuous self test can be useful for troubleshooting paper path and other problems. To print a continuous self test: 1 Disconnect the printer from the power source. 2 Press and hold down the Front Panel Button while connecting power. 3 Continue holding the button for about five seconds. All lights will illuminate at once, then each will light in sequence. 4 Release the button.
Printing an Engine Test The engine test print can be used to verify that the print engine is functioning correctly. The Formatter PCA is completely bypassed during an engine test. Consequently, this test is useful for isolating engine printer problems. The engine test prints a full page of vertical lines down the entire printable area. This page is useful for checking and adjusting registration. Note Perform the engine test with the printer covers in place, as shown in Figure 3-6.
Resetting the Printer Resetting the printer accomplishes the following: • Clears all data from the printer’s memory (including unprinted data, downloaded fonts, and macros). • Stops any printing that is taking place and ejects the page. • Removes some error conditions. • Resets the printer to its factory default settings. To Reset the Printer Press and hold the Front Panel Button until the three control panel lights blink quickly in succession (about 5 seconds), then let go of the button.
3-12 Operating Overview
4 Printer Maintenance Contents Life Expectancy of Consumables . Toner Cartridge Life . . . . . . . Saving Toner with EconoMode Refilled Toner Cartridges . . . Recycling Toner Cartridges . . Cleaning the Printer . . . . . . . . Cleaning Printer Components . Cleaning Spilled Toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 Printer Maintenance
Life Expectancy of Consumables Always inspect the components listed in Table 4-1 for wear when servicing the printer. Replace these components as needed, based on printer failures or wear, not strictly on usage. Table 4-1 Life Expectancy of Consumables Description HP LaserJet 5L Part Number HP LaserJet 6L Part Number Est Life (pgs) Remarks Toner Cartridge (user replaceable) C3906A C3906A 2,500* When print becomes faint, shake cartridge to distribute remaining toner.
Toner Cartridge Life The toner cartridge has been designed to simplify the replacement of the printer’s major “consumable” parts. The toner cartridge contains the printing mechanism and a supply of toner. When using a typical word-processing application, a toner cartridge will print approximately 2500 pages where the text covers about 5% of the page. Figure 4-1 Five Percent Text Coverage When regularly printing pages with less coverage, such as short memos, a toner cartridge should print over 2500 pages.
proofs. EconoMode can be set through your printer driver. See Chapter 3 for information. Notes Some software applications may refer to this as “draft mode." Refilled Toner Cartridges While Hewlett-Packard does not prohibit the use of refilled toner cartridges during the warranty period or while under a maintenance contract, we do not recommend their use.
Cleaning the Printer To maintain the print quality, thoroughly clean the printer: • Every time you change the toner cartridge. • After printing approximately 2,500 pages. • Whenever print quality problems occur. Clean the outside of the printer with a lightly water-dampened cloth. Clean the inside with only a dry, lint-free cloth. Observe the warnings and cautions below. WARNING! Before you begin these steps, unplug the printer to avoid shock hazard.
Cleaning Printer Components CAUTION To avoid permanent damage to the toner cartridge, do not use ammonia-based cleaners on or around the printer. Do not touch the transfer roller with your fingers. Contaminants on the roller can cause print quality problems. Table 4-2 Cleaning Printer Components COMPONENT CLEANING METHOD/NOTES Outside Covers Use a water-dampened cloth. Do not use solvents or ammonia-based cleaners. Inside General Use a dry, lint free cloth.
Figure 4-2 Static Eliminator Teeth (located in front of the transfer roller) Cleaning Spilled Toner Defective toner cartridges can develop leaks. In addition, after a paper jam has occurred, there may be some toner remaining on the rollers and guides inside the printer. The pages that print immediately after the jam may pick up this toner. Clean spilled toner with a cloth slightly dampened in cold water. Do not touch the Transfer Roller with the damp cloth or with your fingers.
5 Functional Overview Contents Basic Printer Functions . . . . . . . . . . . DC Controller/Power System . . . . . . . . Print Engine Control System . . . . . . . Power System (on DC Controller PCA) . Formatter System . . . . . . . . . . . . . . CPU . . . . . . . . . . . . . . . . . . . . Read Only Memory (ROM) . . . . . . . Random Access Memory (RAM) . . . . Parallel Interface . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . . Resolution Enhancement (REt) . . . . . . EconoMode . . . . . .
5-2 Functional Overview
Basic Printer Functions This chapter presents a generalized functional overview of the printer and the printing processes.
DC Controller/Power System The DC Controller PCA coordinates all print engine activities, drives the laser, and coordinates print data from the Formatter PCA with the image formation process. The DC Controller also includes both AC and DC power supply and distribution circuitry.
Print Engine Control System Laser and Scanner Drive Based on information received from the Formatter, the DC Controller sends signals to the Laser/Scanner Assembly to modulate the laser diode ON and OFF and to drive the Laser/Scanner motor. Refer to “Image Formation System,” later in this chapter for more information.
Power System (on DC Controller PCA) The AC, DC, and high voltage power supply circuits are all contained within the DC Controller PCA. AC Power Distribution The AC power circuitry supplies AC voltage whenever the power cord is connected to the AC power source. AC voltage is distributed to the DC power supply circuitry and to the AC driver circuitry, which controls AC voltage to the fusing assembly’s heating element.
The printer exits SleepMode and all of the lights power on when any of the following occur: • A job is received. • The Front Panel Button is pressed. • The printer front door is opened. Note The printer will not enter SleepMode if there is a printer error. High Voltage Power Distribution The High Voltage Power Supply PCA applies an overlap of DC and AC voltage to the primary charging roller and the developing roller.
Formatter System The Formatter PCA is responsible for the following: • • • • • Receiving and processing print data from the printer interface. Monitoring Front Panel Button and relaying printer status information. Developing and coordinating data placement and timing with the print engine. Storing font information. Communicating with the host computer through the Bi-Directional Interface. The Formatter PCA receives print data from the Bi-Tronics Interface and converts it into a dot image.
Control Panel Status LED Lights The Formatter uses three LEDs mounted under the printer cover to communicate printer status to the user. Refer to “Using the Control Panel” in Chapter 3 and “Printer Error Troubleshooting” in Chapter 7 for more information on the lights. Front Panel Button The Formatter PCA is connected to a microswitch located on the control panel PCA. The single button is used for such functions as self test, reset, and to display error codes.
EconoMode The EconoMode setting uses approximately 50% less toner than standard mode printing by reducing the dot density. However, EconoMode does not extend toner cartridge component life. EconoMode, which can also be thought of as “draft mode,” is user-selectable through some software applications. The default setting is Off. Figure 5-3 EconoMode vs Normal Mode Note EconoMode does not affect print speed or memory usage.
Enhanced I/O The Enhanced I/O feature allows printer memory to be used for storing data received from the host computer. When Enhanced I/O is enabled, you can send more data to your printer in shorter amounts of time, which allows you to return to your application sooner. Enhanced I/O has the following options: • Auto—allows the printer to use Enhanced I/O memory allocation to increase the speed of data transfer from the host computer to the printer, if necessary.
Image Formation System Laser printing requires the interaction of several different technologies (such as electronics, optics, and electrophotographics) to provide a printed page. Each process functions independently and must be coordinated with the other printer processes. Image formation consists of six processes: • • • • • • Step 1. Drum Cleaning Step 2. Drum Conditioning Step 3. Image Writing Step 4. Image Developing Step 5. Image Transferring Step 6.
Toner Cartridge As the “heart” of the Image Formation System, the toner cartridge houses the cleaning, conditioning, and developing steps of the process. The toner cartridge contains the photosensitive drum, primary charging roller, developing station, toner cavity, and cleaning station. Including these components, which wear, degrade, or are consumed in the replaceable toner cartridge, eliminates the need for a service call when replacement is required.
Step 4: Image Developing At this stage of the process, the latent electrostatic image is present on the drum. The toner particles obtain a negative surface charge by rubbing against the developing cylinder which is connected to a negative DC supply. The negatively charged toner is attracted to the discharged (exposed, grounded) areas of the drum, and repelled from the negatively charged (non-exposed) areas.
Paper Feed System Both the Paper Input Bin and the Single Sheet Input Slot merge into one, main input area. Paper placed in either of these areas enables the Paper Out Sensor (sensor 202), which informs the DC Controller that paper is present. When the printer receives a print job and is ready to print, the DC Controller enables the Laser/Scanner Assembly and the Motor. Paper motion begins when the DC Controller energizes solenoid SL1. This causes the paper pick up roller to rotate once.
Figure 5-5 shows a simplified paper path and the locations of the photosensors and rollers.
Figure 5-6 shows the locations of the photosensors, switches, solenoid, and other important printer elements. Table 5-1 describes the function of each photosensor and the solenoid. Figure 5-6 Solenoid and Sensors Table 5-1 Solenoid and Photosensors No. Name Description Paper Pick-up Solenoid Enables the Paper Pickup Roller. PS201 Paper Exit Sensor Senses when paper has successfully moved out of the fusing area and the next sheet of paper can be fed.
Paper Jam Detection The Paper Out Sensor (PS202), Paper Registration Sensor (PS203), and the Paper Exit Sensor (PS201) detect when paper is moving through the printer. (See Figure 5-5 for roller and sensor locations.) If a paper jam is detected, the DC Controller immediately stops the printing process and causes a paper jam indication on the front panel. A paper jam can be detected under any of the following conditions: • Power-On Jams. Paper is present under either PS201 or PS203 at power-on.
Basic Sequence of Operation The Formatter PCA and the DC Controller PCA share information during printer operation. The DC Controller-to-Formatter Connector (J201) forms a link which operates as a serial data bus. This allows printer status, command information, and dot-image data to be passed between the two PCAs. Figure 5-7 shows the general timing of the printer events.
Figure 5-7 General Timing Diagram - HP LaserJet 5L 5 - 20 Functional Overview
Figure 5-8 Functional 5 Overview General Timing Diagram - HP LaserJet 6L Functional Overview 5 - 21
5 - 22 Functional Overview
6 Removal and Replacement Contents Removal and Replacement Strategy . . . . Required Tools . . . . . . . . . . . . . . . Installing Memory Cards (DRAM) . . . . Covers and Doors . . . . . . . . . . . . . Back Cover . . . . . . . . . . . . . . . EP Door Assembly . . . . . . . . . . . Memory Door . . . . . . . . . . . . . . Main Cover and Paper Input Assembly Internal Assemblies . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . Exit Roller Assembly . . . . . . . . . . Delivery Assembly . . . .
6-2 Removal and Replacement
This chapter documents removal and replacement of Field Replaceable Units (FRUs) only. Exchange assemblies should be sent to SMO for repair. Replacement is generally the reverse of removal. Occasionally, notes are included to provide direction for difficult or critical replacement procedures. WARNING! Unplug the power cord from the power outlet before attempting to service the printer. If this warning is not followed, severe injury may result.
Required Tools • • • • Caution #2 Phillips screwdriver with a magnetic tip 5.5 mm hexhead nutdriver small flathead screwdriver needlenose pliers A Posidriv screwdriver will damage the printer’s screw heads. Use Phillips only. Figure 6-1 shows the difference between a Phillips and a Posidriv screwdriver. Note that a Phillips tip has more beveled surfaces.
1 Unplug the power cord from the printer. You 2 3 4 5 should not install a memory card while the printer is in SleepMode. Open the Printer Door, remove the toner cartridge, and close the Printer Door. Protect the toner cartridge from light while you are working on the printer. Remove any paper in the paper tray. Gently tip the printer onto its side so that the memory cover is on top as shown in Figure 3.
Covers and Doors Back Cover 1 Unplug the power cord and remove the parallel cable from the back of the printer. 2 Remove the toner cartridge. 3 Lift the Input Extender assembly. Caution You must lift the Input Extender when the covers are removed or it will break. After you have removed the covers, leave the Input Extender in this lifted position for ease of replacement. 4 Remove the (3) screws (Figure 6-2, callout 1).
5 Separate the rear panel from the main cover, pulling the lower corners away from Figure 6-3 Back Cover Removal (2 of 2) To reinstall Make certain the Input Extender is up. Removal and Replacement 6-7 Removal and 6 Replacement the printer first. Then, insert the small flathead screwdriver into the openings at the top to pop the upper corners (Figure 6-3, callout 1). 6 Remove the cover by grabbing it on both sides and pulling it straight back with a firm pull (Figure 6-3, callout 2).
EP Door Assembly 1 2 3 4 Unplug the power cord and remove the parallel cable from the back of the printer. Open the EP door. Remove the toner cartridge. Along the door hinge, there is a flex point. Firmly press the left tab inward to release it. The right tab will fall out easily (Figure 6-4).
Memory Door Unplug the power cord and remove the parallel cable from the back of the printer. Remove the toner cartridge. Gently tip the printer onto its side so that the Control Panel is on top. Carefully pull the door tab out (Figure 6-5, callout 1) and away from the printer in a gentle rocking motion (Figure 6-5, callout 2).
Main Cover and Paper Input Assembly 1 Remove the toner cartridge. 2 Remove memory door. Remove the memory door first. The door will break if you remove the Main Cover without removing the memory door. Caution Remove the EP Door Assembly. Remove the Back Cover. Remove the (2) screws from the top of the printer (Figure 6-6, callout 1). Grasp the two lower, front corners of the printer and pull gently outward to release the front of the Main Cover. 7 Lift the cover straight off.
Removal and 6 Replacement Internal Assemblies Control Panel 1 Remove the Printer Covers. 2 Use the needlenose pliers to release the Control Panel connector (Figure 6-7, callout 1). 3 Press the tab on the top of the Control Panel downward (Figure 6-7, callout 2). The Control Panel will pop out of the printer chassis. 4 Lift the Control Panel out.
Exit Roller Assembly 1 Remove Printer Covers. 2 Grasp both tabs at the lower ends of the Exit Roller bushings and pull inward. This will release the tabs from the printer chassis (Figure 6-8, callout 1). 3 Rotate the tabs 90 degrees, clear of the printer chassis (Figure 6-8, callout 2). 4 Lift the roller out. Figure 6-8 Exit Roller Removal To reinstall The end of the Exit Roller that has a gear attached must fit into the gear train.
Delivery Assembly and sliding the assembly toward the front of the printer (Figure 6-9, callout 2). Note The EP Right-Hand assembly must be removed to access any fuser components. Figure 6-9 Delivery Assembly Removal (1 of 2) Removal and Replacement 6 - 13 Removal and 6 Replacement 1 Remove the Printer Covers and Exit Roller Assembly.
3 Use the magnetic screwdriver to remove the (2) screws (Figure 6-10, callout 1). Once the screws have been removed, rotate the rear of the Delivery Assembly up and forward and lift it out of the printer. Figure 6-10 Delivery Assembly Removal (2 of 2) Note 6 - 14 Upon reinstallation, the tabs on the front end of the Delivery Assembly must fit under the sheet metal fuser plate below to correctly reseat the Delivery Assembly.
Fuser Pressure Plate callout 2). 4 Rotate the plate around and toward the back and lift up to remove it (Figure 6-11, callout 3). Figure 6-11 Fuser Pressure Plate Removal Removal and Replacement 6 - 15 Removal and 6 Replacement 1 Remove Printer Covers and Delivery Assembly (Figures 6-9 and 6-10). 2 Remove the (2) screws (Figure 6-11, callout 1).
To reinstall: The Fuser Pressure Plate is kept in place by four locking mechanisms in each corner. Place the rear slits in the plate over the rear brackets that hold the Fusing Assembly (Figure 6-12, callout 1). Lower the plate over the retaining clips, pressing on both sides of the Fuser Pressure Plate (Figure 6-12, callout, 2). It is important that the spring is placed over the positioning pin (callout 3) because inadequate pressure will cause fusing problems. Replace the screws.
Heating Element Pressure Plate (Figure 6-11). 2 Remove the wire cover (on the right side of the printer) for the Heating Element wires by pressing in on the tab and pulling outward (Figure 6-13, callout 1).
3 Disconnect the AC voltage to the Heating Element by releasing the connector located on the DC Controller. Press down on the connector release with a small, flathead screwdriver (Figure 6-14, callout 1). (Since this is a small space, it is much easier to reach the connector with a screwdriver.) Pull straight out (Figure 6-14, callout 2).
Assembly (Figure 6-15). Figure 6-15 Heating Element Removal (3 of 3) 6 Lift the Heating Element out. To reinstall Make sure the connectors are properly reattached. Removal and Replacement 6 - 19 Removal and 6 Replacement 4 Remove the wire from the wire guides along the right-side of the printer.
Pressure Roller 1 Remove Printer Covers, Delivery Assembly (Figures 6-9 and 6-10), Fuser Pressure Plate (Figure 6-11), and Heating Element (Figures 6-13 through 6-15). 2 Remove the Pressure Roller guide by lifting the edge (Figure 6-16, callout 1) and then rolling it gently backward (Figure 6-16, callout 2). Figure 6-16 Pressure Roller Guide Removal 3 Lift the right end of the Pressure Roller up and out of the printer chassis. Note The right end of the Pressure Roller is greased.
Face-Up/Face-Down Lever Plate (Figure 6-11), and Heating Element (Figures 6-13 through 6-15), and Pressure Roller (Figure 6-16). 2 Rotate the lever forward 90 degrees (past the spring) and pull it straight out the front of the printer. To reinstall 1 Make sure the lever arm is on the left and is initially pointing downward. 2 Pull the spring forward using needlenose pliers. 3 Slide the short, round tabs into the grooves on the Separation Guide Assembly. The machined ridges on the lever will face you.
Fuser Exit Roller Assembly 1 Remove Printer Covers, Delivery Assembly (Figures 6-9 and 6-10), Fuser Pressure Plate (Figure 6-11), and Heating Element (Figures 6-13 through 6-15), Pressure Roller (Figure 6-16), and Face-Up/Face-Down Lever (Figure 6-17). 2 Remove the gear from the left end of the roller shaft by pressing down on the catching mechanism with the small flathead screwdriver and pulling the gear away.
Paper Exit Sensor Flag Pressure Plate (Figure 6-11). Caution Before proceeding to Step 2, examine the Paper Exit Sensor flag. It is important to note the position of the spring mechanism on the flag. The spring must be reinstalled to exactly this position. 2 Remove the Paper Exit Sensor flag by pressing down on the left side and pulling up on the right side.
Top Assemblies Laser/Scanner Assembly 1 Remove the Printer Covers. 2 Remove both Laser/Scanner connectors (Figure 6-20, callout 1). 3 Remove all (4) screws and lift the assembly straight off (Figure 6-20, callout 2). One of the four screws is longer than the other three. Upon reinstallation, the longer screw must be replaced in its original location.
Solenoid by pressing the tabs in the center of the gear outward and pulling the gear off (Figure 6-21). Figure 6-21 Solenoid Removal (1 of 2) Removal and Replacement 6 - 25 Removal and 6 Replacement 1 Remove the Printer Covers.
3 Remove the Solenoid connector (J204) from the DC Controller (Figure 6-22, callout 1). 4 Remove the self-tapping screw that holds the Solenoid in place (Figure 6-22, callout 2). 5 Unthread the wires from the printer chassis. 6 Lift the Solenoid off. Figure 6-22 Solenoid Removal (2 of 2) Note 6 - 26 When reinstalling this part, the Paper Pickup Gear is keyed to go on the shaft in only one way.
Pickup Roller Assembly Removal and 6 Replacement 1 Remove the Printer Covers. 2 Remove the paper pickup gear (Figure 6-21). Note This gear is keyed to go on the shaft in only one way. 3 Remove the pickup roller grounding clip on the right of the printer by lifting each end of the clip up and over the two metal guides and sliding the clip off. Figure 6-23 depicts the clip from an HP LaserJet 5L. The clip from an HP LaserJet 6L (and some HP LaserJet 5Ls) is shaped differently.
4 Using needlenose pliers, pull the bottom of the bushing out (Figure 6-24, callout 1), then turn it counter clockwise to release it (Figure 6-24, callout 2). Figure 6-24 Pickup Roller Assembly Removal (2 of 2) 5 Lift the bushing out. 6 From inside the front of the printer, slide the right side of the Pickup Roller Assembly forward, then lift the left side out.
To reinstall Note It is important that the Pickup Roller is placed back in with the two Idler Roller tabs up, so that they fit into the underside of the metal chassis behind the Laser/Scanner assembly (Figure 6-25). Figure 6-25 Paper Pickup Roller Assembly Replacement (Inside/Front View) Removal and Replacement 6 - 29 Removal and 6 Replacement After placing the Pickup Roller shaft through on the left side, line up the Idler Roller tabs while repositioning the right side.
Paper Feed Frame 1 Remove the Printer Covers. 2 Remove the Pickup Roller Assembly (Figures 6-23 through 6-24).
4 Release the catch on the control panel cable guide by using the small flathead Removal and 6 Replacement screwdriver to push on the tab (Figure 6-27). Then slide the guide off.
5 Remove the self-tapping screw from the back sheet metal plate and lift it off (Figure 6-28, callout 1). 6 Remove the (4) hex head screws from the Paper Feed Frame (Figure 6-28, callout 2).
7 Release the sensor unit connector (Figure 6-29). Removal and 6 Replacement Figure 6-29 Paper Feed Frame Removal (4 of 4) 8 Verify that all cables are clear of the frame and pull the frame straight back to remove it. To reinstall The Paper Feed Frame may be easier to reinstall if you place the printer on its front, so that you can apply pressure while putting the screws back in place.
Transfer Roller Guide & Transfer Roller 1 Remove the Printer Covers, Pickup Roller Assembly (Figures 6-23 through 6-25), and Paper Feed Frame (Figures 6-26 through 6-29). 2 Looking at the back of the printer, note the two small, hook-shaped release tabs on each end of the Transfer Roller guide. Using a small, flathead screwdriver, carefully pry each tab outward to release it (Figure 6-30). 3 Roll the released portion of the guide up.
Kick Plate Be careful working with the Kick Plate and Separation Pad. The spring underneath the Kick Plate may stay attached to the Kick Plate, but it is also likely to spring away from the Kick Plate. Place the spring aside for Separation Plate disassembly. 1 Remove the Printer Covers and the Pickup Roller Assembly (Figures 6-23 and 6-24). 2 Press the Separation Pad (Figure 6-31). Allow the Kick Plate to pivot upward (a spring underneath will push it up). Lift the Kick Plate off its mounting pins.
To reinstall If the spring on the Kick Plate doesn’t stay on the Kick Plate, replace the spring, making certain the diameter of the spring surrounds two lower pins on the Kick Plate and rests inside the third pin. Use needlenose pliers to place the spring correctly. (See Figure 6-32.) Figure 6-32 Kick Plate Spring Replacement While rotating the Kick Plate into place, guide the other end of the spring onto the silver grounding plate located on the Paper Feed Frame.
Separation Pad Kick Plate (Figure 6-31). 2 Lift the bottom of the white plastic tab on the rear of the Paper Feed Frame up slightly and slide it up, toward the top of the Paper Feed Frame. This will release the Separation Pad (Figure 6-33). 3 Lift the Separation Pad 90 degrees and slide its mounting pins out of their retainers.
Subpads When you replace the Separation Pad, you should also replace the smaller subpads at the same time. Note 1 Place your index finger on the subpad. 2 Press toward the top of the printer.
Feed Assembly 1 Remove the Printer Covers, Pickup Roller Assembly (Figures 6-23 through 6-25), and Paper Feed Frame (Figures 6-26 through 6-29). 2 Turn the Paper Feed Frame upside down. 3 Remove the Feed Roller Shaft by lifting the plastic tab up (Figure 6-35, callout 1) and sliding it out the side of the Paper Feed Frame (Figure 6-35, callout 2). Figure 6-35 Feed Assembly Removal (1 of 3) Removal and Replacement 6 - 39 Removal and 6 Replacement The Feed Assembly is located in the Paper Feed Frame.
4 Remove the self-tapping screw that holds the Feed Assembly in place (Figure 6-36, callout 1). Before proceeding to Step 5, examine the tabs and how they fit into their slots (Figure 6-36, callout 2). The tabs must be reinstalled to exactly this position. Note 5 Remove the Feed Assembly.
6 Turn the Feed Assembly over and place it in one hand with the roller-side down. Figure 6-37 Feed Assembly Removal (3 of 3) To reinstall Before securing the screw, ensure the tabs on the Feed Assembly are positioned in their slots on the Paper Feed Frame (Figure 6-35, callout 2). Failure to do so will cause paper feed problems. Removal and Replacement 6 - 41 Removal and 6 Replacement Pop one of the tabs on the other side and the feed roller should fall into your hand (Figure 6-37).
Bottom Assemblies Memory Door Guide 1 Remove the Printer Covers. 2 Remove any extra memory. 3 Two tabs hold the memory door guide on the printer chassis. Press each tab inward (Figure 6-38). 4 Pull the memory door guide out.
Motor Removal and 6 Replacement 1 2 3 4 5 Remove the Printer Covers. Remove the motor connector (Figure 6-39, callout 1). Remove the memory door guide to expose the two motor screws. Remove the motor screws (Figure 6-39, callout 2). Lift the Motor out.
DC Controller Remove the Printer Covers. Disconnect the motor connector from the motor (Figure 6-39, callout 1). Disconnect the Solenoid connector from the DC Controller (Figure 6-22, callout 1). Remove the back sheet metal plate and disconnect the PS202/PS204 connector (Figure 6-29). 5 Remove the AC Cable cover and disconnect the AC Cable from the DC Controller (Figures 6-13 and 6-14). 6 Tip the printer on its top, with the front facing you. 7 Remove the (4) screws (Figure 6-40, callout 1).
8 Lift the bottom plate, rotating the plate toward you from the back as if hinged on the Caution Removal and 6 Replacement front. Release the Fusing Assembly connector (J206) (Figure 6-41, callout 1).
9 Remove the (7) remaining connectors (Figure 6-42, callout 1). 10 Remove the screws (5) that secure the DC Controller to the metal case (Figure 6-42, callout 2). Figure 6-42 DC Controller Removal (3 of 3) 11 Remove the DC Controller by lifting gently on the side opposite the formatter, then sliding it out. Caution Be careful not to rotate the DC Controller as you remove it. Note When ordering, the DC Controller does not come with any connectors.
Formatter PCA 1 Remove the Printer Covers and complete the DC Controller removal direction up to 2 3 4 5 step 8 (Figures 6-40 and 6-41). Remove the two cable clips (Figure 6-43, callout 1). Remove all (4) screws from the formatter cover (Figure 6-43, callout 2). Lift the I/O shield to remove it. Remove the Control Panel display cable (Figure 6-43, callout 3). Slide the formatter away from the DC Controller PCA to remove it from the connector.
6 - 48 Removal and Replacement
7 Troubleshooting Contents General Troubleshooting Flowchart . . Paper Path and Components . . . . . . DC Controller Diagram . . . . . . . . Printer Error Troubleshooting . . . . . Priority of Errors . . . . . . . . . . Printer Status Messages . . . . . . . Service and Error Messages . . . . Image Formation Troubleshooting . . Check the Toner Cartridge . . . . . Image Defect Examples . . . . . . Troubleshooting Checks . . . . . . . . Engine Test . . . . . . . . . . . . . Half-Self Test Functional Check . .
7-2 Troubleshooting
General Troubleshooting Flowchart When the AC power is first applied to the printer: START AC Power is applied to the printer If no error message is displayed, the Printer Door is firmly closed, and the toner cartridge is installed, but the motor does NOT rotate when AC power is applied to the printer: 1 Verify that AC power is present at the input Does the Printer Motor rotate for about 6 seconds ? No 3 4 Yes Is the Front Panel functional ? 2 5 No If the Control Panel is not functional: 1 Verif
General Troubleshooting Flowchart (continued) Perform an Engine Test Is the Engine Test image being printed clearly ? No Refer to the section “Image Formation Troubleshooting,” later in this chapter. No If the engine test produces a clear print image, yet a Self Test is not generated by initiating the Control Panel self-test procedure, replace the Formatter PCA.
Paper Path and Components Figure 7-1 SL1 Pick-up Roller Face-down Delivery Roller Face-down Delivery PS202 Fuser Deflector Face-up Delivery Fusing Unit Delivery Roller Paper Pick-up Solenoid Feed Sub Roller Photosensitive Drum PS201 Paper Exit Sensor Transfer Roller Paper Registration Sensor PAPER-OUT SENSOR signal (PAPERSNS) PICK-UP SOLENOID DRIVE signal (CPUD) PAPER PICK-UP SENSOR signal (PISNS) MOTOR DRIVE signal (MA, /MA, MB, /MB) Manual Input Slot Paper Input Bin PS203 Paper Out S
DC Controller Diagram Figure 7-2 DC Controller PCA Components J3 Control Panel Connector (Formatter PCA) J202 Paper Registration and Paper-Out Photosensors (PS203 and PS202) J102 Fusing Assembly J206 Fusing Assembly (thermistor feedback) J201 Formatter PCA Connection J207 Scanner Motor J204 Paper Pickup Solenoid (SL1) J208 Laser Driver/Beam Detect Circuitry J301 Developer Bias Contact J209 Door Open/No Toner Cartridge Photosensor (PS204) (HP LaserJet 5L only) J302 Transfer Roller Cont
Printer Error Troubleshooting Information regarding printer status is conveyed by two methods: 1) the printer’s Control Panel lights and 2) feedback through the bi-directional I/O that displays at the PC. The basic method of determining error messages uses patterns of lights on the Control Panel LED. Printer messages are categorized into two basic types: • Status Messages • Service and Error Messages Priority of Errors Each error has a priority in relation to the others.
Printer Status Messages The following table lists printer LED messages and their meanings and describes recommended actions. For more information on the Front Panel layout, refer to “Using the Control Panel” in Chapter 3, “Installation and Configuration.” Table 7-1 Printer Status Messages (1 of 2) LEDs Description Recommended Action Paper Out Error. Add paper. Door Open or No EP Cartridge. Close the printer door and/or verify that the EP cartridge is installed. Paper Jam. Clear paper jam.
Table 7-2 Printer Status Messages (Continued 2 of 2) LEDs Description Sleep Mode Recommended Action If the printer’s LEDs remain off: 1. The printer is in Sleep Mode. Press the Front Panel Button or open the EP Door. 2. Power is not supplied to the printer. Check power cord connections and the power source. 3. Print an engine test to determine if the print engine is functional. If the test is successful, replace the Formatter PCA. 4. See the General Troubleshooting Flowchart earlier in this chapter.
Service and Error Messages Service errors prevent further printer operation until some action is taken. When there is a service error, all of the lights will turn on in a steady state. Press and hold the Front Panel Button to see a pattern in the lights. (The error will only be displayed as long as this button is pressed.) Use Table 7-4, “Service and Error Messages,” to identify what type of service error has occurred. Table 7-4 Service and Error Messages (1 of 3) LEDs Description ROM/RAM Error.
Figure 7-3 7 Troubleshooting Heating Element Resistance Check Table 7-4 LEDs Service and Error Messages (Continued 2 of 3 ) Description Beam Error. There are a number of causes for this error, and some of the causes may be transient. (They may disappear.) Recommended Action 1. Power-cycle the printer by unplugging the printer and plugging it back in. 2. Make certain the Laser/Scanner Assembly is correctly seated on the printer chassis. 3. Replace the Laser/Scanner cable (J208 on the DC Controller). 4.
Table 7-4 Service and Error Messages (Continued 3 of 3) LEDs Description Scanner Error. Caused by a scanner malfunction. Recommended Action 1. Power-cycle the printer by unplugging the printer and plugging it back in. 2. Ensure condensation caused by moving the printer from a cold to a warm environment hasn’t occurred. Allow the printer to acclimate to the warmer room. 3. Verify the two Laser/Scanner Assembly connectors are firmly seated. 4. Replace scanner cable J207 on the DC Controller PCA. 5.
Image Formation Troubleshooting Check the Toner Cartridge Image formation defects are many times the result of toner cartridge problems. If there is any doubt, always replace the toner cartridge before troubleshooting image defects. Use the following check list to ensure that the toner cartridge is still operable. Note Ensure that the toner cartridge is seated properly in the cavity. Inspect the toner cartridge for remaining toner.
Image Defect Examples This section illustrates some image defects and their possible causes. Since there are many variables in the printing process, you may encounter image defects that are not illustrated in the following examples. If you find a defect that is not illustrated, record the probable cause along with the printing environmental conditions and save a copy of the defect for future reference. Each example lists, in order, the probable causes of the image defect.
Vertical Lines Sometimes vertically aligned black streaks or smears can appear on successive pages. • The toner cartridge may be damaged. Replace it. • The printer may need cleaning. See “Cleaning Your Printer,” in Chapter 4. • Replace the heating element. Horizontal Stripes Sometimes horizontally aligned black streaks or smears can appear. • The toner cartridge may be defective. Replace it. • If the printer still has print quality problems, the printer may require cleaning. • Replace the heating element.
Character Voids Character voids are white areas within the parts of characters that should be solid black. • If you are using transparencies when you experience this problem, try another type of transparency. Hewlett-Packard transparencies are designed to minimize character voids. (Because of the composition of transparency media, some character voids are normal.) • You may be printing on the wrong side of the paper. Remove the paper and turn it over.
Dropouts Dropouts are characters that are partially printed. • The Paper Input Bin may have been loaded with too much paper. Make sure that no more than 100 sheets of paper are loaded. • A single sheet of paper may be defective. Try reprinting the job. • Try adjusting the print density through your software or printer driver. • Try cleaning the rollers. • The paper may have been damaged by inconsistent manufacturing processes. Try paper from a different source.
Blank Page (Occasional) A page is completely blank. If you get occasional blank pages: • Make sure your page length and margins are set correctly for the paper size you use. If you are printing on small media and your page is blank, try printing on larger media to see where the image is printing. Adjust margins accordingly. • Some sharing devices or networks may generate a blank page as a separator. Try connecting the printer directly to the computer.
Dots • Clean the static charge eliminator. (See Chapter 4, “Printer Maintenance.") • There may be discontinuities in the high-voltage contact points. Clean the high voltage contact points on the toner cartridge and transfer roller. • Replace the transfer roller. Dirt on the Back of the Page • Use the image defect ruler to determine if the rollers are dirty. If so, clean them. Replace the rollers if they cannot be cleaned sufficiently. Blank Spots • The paper may not meet HP’s paper specifications.
Distorted Image or BD Failure • Make certain the printer is not facing the sunlight. • The paper may not meet HP’s paper specifications. Select different paper. • Clean the Laser/Scanner Assembly by blowing compressed air in the slot on the bottom of the assembly. • Make sure the two Laser/Scanner connectors are firmly seated. • Replace the Laser/Scanner unit. • Replace the DC Controller.
Troubleshooting Checks Engine Test The engine test print is used to verify that the print engine is functioning correctly. The Formatter PCA is completely bypassed during an engine test, so this test is useful for isolating printer problems. The engine test prints a full page of vertical lines down the entire printable area and is also useful for checking and adjusting registration. The engine test print button is located on the DC Controller PCA.
Half-Self Test Functional Check The electrophotographic process can be subdivided into the following stages: • • • • • • Cleaning (removing excess toner from drum surface) Conditioning (placing a uniform electrical charge on drum) Writing (laser strikes surface of drum to create latent image) Development (formation of the toner image on drum) Transfer (charge to transfer the image to paper) Fusing (heat and pressure to produce a permanent image) The purpose of the Half-Self Test Check is to determine whic
Drum Rotation Functional Check The photosensitive drum, located in the toner cartridge, must rotate for the print process to work. The photosensitive drum receives its drive from the Main Drive assembly. To verify whether the drum is rotating: 1 Open the Printer Door. 2 Remove the toner cartridge. 3 Mark the cartridge’s drive gear with a felt-tipped marker. Note the position of the mark. 4 Install the toner cartridge and close the Printer Door.
High-Voltage Power Supply Check The High-Voltage Power Supply PCA provides the necessary voltages for the electrophotographic processes. A method for verifying the high-voltage system is given in the table below. Table 7-5 High-Voltage Power Supply Check Checks Action Toner Cartridge Connection Points Visually inspect the three connection points on the underside, right end of the toner cartridge. If they are dirty or corroded, clean the connections. Use alcohol only.
Figure 7-6 7 Troubleshooting Toner Cartridge High Voltage Connection Points (2 of 2) • Charging (1) • Drum Ground (2) • Developing Roller (3) Troubleshooting 7-25
Paper Curl Paper curl is inherent to the laser printing processes, and occurs when paper is subjected to heat. Paper curl tends to relax as the paper cools while resting on a flat surface. The specification for maximum paper curl when the paper is lying flat before print is 5 mm (0.2 inches). Although paper curl cannot be totally eliminated, some steps can be taken to lessen its impact, as suggested in the following table.
Troubleshooting Tools Paper Path Check If paper is not being picked up or is not moving through the paper path, you may want to observe all of the paper motion activities. Overriding PS204 (5L) or SW101 (6L) allows you to observe: Motor rotation Solenoid action Kick plate motion Paper Pickup Roller motion Drive Roller, Transfer Roller, Fuser Roller and Gear, and Delivery Roller Motion. To override PS204 and SW101 1 Remove the Printer Covers (Figures 6-2, 6-3, and 6-4).
Repetitive Image Defect Ruler Figure 7-8 Repetitive Image Defect Ruler 7-28 Troubleshooting
Main Wiring Diagram 7 Troubleshooting Figure 7-9 Main Wiring Diagram Troubleshooting 7-29
Table 7-7 Cable Pinouts Connector 7-30 Troubleshooting Signal Name Remarks J401 pin 1 MA Motor Drive Signal J401 pin 2 /MA Motor Drive Signal J401 pin 3 MB Motor Drive Signal J401 pin 4 /MB Motor Drive Signal J204 pin 1 +12 V 5L only J204 pin 2 CPUD Solenoid SL1 Pickup Drive (5L only) J202 pin 1 +5V J202 pin 2 GND J202 pin 3 PAPSENS J202 pin 4 +5V J202 pin 5 GND J202 pin 6 PISNS J207 pin 1 +12 V J207 pin 2 SCNTAC J207 pin 3 FG J207 pin 4 /SCNON “L” to rotate scanne
Table 7-8 Cable Pinouts Connector Signal Name DOSNS J305 pin 1 +12A V J305 pin 2 N/U J305 pin 3 +12 V J206 pin 1 FRSTH J206 pin 2 FG “H” when cartridge is not installed or the front door is open at PS204.
7-32 Troubleshooting
8 Parts and Diagrams Contents How to Use the Part Lists and Diagrams Ordering Parts . . . . . . . . . . . . Ordering Consumables . . . . . . . . Accessories and Supplies . . . . . . . . Common Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2 Parts and Diagrams
How to Use the Part Lists and Diagrams The Figures in this chapter illustrate the major subassemblies in the printer and their component parts. A table (material list) follows each exploded assembly diagram. Each table lists the reference designator (item number) for each part, the associated part number for the item, the quantity, and a description of the part.
Ordering Consumables Consumables and accessories such as those listed on Table 8-1 may be ordered from Hewlett-Packard. The phone numbers are: U.S.: 1-800-538-8787 Canada: 1-800-387-3154 (Toronto) 516-671-8383 United Kingdom: 0734-441212 Germany: 0130-3322 Contact your local HP Parts Coordinator for other local phone numbers. Note Parts that have no reference designator or part number are not field replacement parts and cannot be ordered through SMO.
Accessories and Supplies The following items are available through your local authorized HP dealer. To find a dealer near you (or if your dealer is temporarily out of stock), call the HP Customer Information Center (800) 752-0900. Note Refer to “Related Documentation” in Chapter 1 for documentation and training media product numbers. Table 8-1 Accessories and Supplies Item Toner Cartridge Memory upgrades Parallel cable (IEEE 1284) Description C3906A Replacement toner cartridge.
Common Hardware Table 8-2 Common Fasteners Used in the Printer Example Description Screw, Machine, Trus Head M3x4, M3x6, M3x8 Screw, Star, 3x6 Screw, Self-tap, 4x10 Screw, Hex-head, 3x8 Screw, Hexhead, 3x6,m 3x8, 3x10 8-6 Parts and Diagrams
Figure 8-1 Parts and 8 Diagrams Major Assembly Locations Parts and Diagrams 8-7
Figure 8-2 Covers and Doors 8-8 Parts and Diagrams
Table 8-3 Covers and Doors Ref LaserJet 5L Part No. LaserJet 6L Part No.
Figure 8-3 Internal Components (1 of 3) 8-10 Parts and Diagrams
Table 8-4 Internal Components (1 of 3) Ref LaserJet 5L Part No. LaserJet 6L Part No.
Figure 8-4 Internal Components (2 of 3) 8-12 Parts and Diagrams
Table 8-5 Internal Components (2 of 3) Ref LaserJet 5LPart No. LaserJet 6LPart No.
Figure 8-5 Internal Components (3 of 3) 8-14 Parts and Diagrams
Table 8-6 Internal Components (3 of 3) Ref LaserJet 5LPart No. LaserJet 6LPart No.
Figure 8-6 DC Controller/Formatter and Cables 8-16 Parts and Diagrams
Table 8-7 DC Controller Case Ref LaserJet 6L Part No.
Figure 8-7 Pickup Roller Assembly 8-18 Parts and Diagrams
Table 8-8 Ref LaserJet 6L Part No.
Figure 8-8 Feed Assembly 8-20 Parts and Diagrams
Table 8-9 Ref 9 LaserJet 5L Part No. LaserJet 6L Part No.
Figure 8-9 Separation Guide Assembly 8-22 Parts and Diagrams
Table 8-10 Ref LaserJet 5L Part No. LaserJet 6L Part No.
Figure 8-10 Delivery Assembly 8-24 Parts and Diagrams
Table 8-11 Ref LaserJet 5L Part No. LaserJet 6L Part No.
8-26 Parts and Diagrams
A Parts Index Parts Index A-1
Parts Index Table A-1 A-2 Parts Index Alphabetical Parts List Description Part No. Fig. Ref.
Table A-1 Alphabetical Parts List (continued) Part No. Fig. Ref.
Table A-1 A-4 Parts Index Alphabetical Parts List (continued) Description Part No. Fig. Ref.
Table A-1 Alphabetical Parts List (continued) Part No. Fig. Ref.
Table A-1 A-6 Parts Index Alphabetical Parts List (continued) Description Part No. Fig. Ref.
Table A-2 Numerical Parts Index Description Fig. Ref.
Table A-2 A-8 Parts Index Numerical Parts List (continued) Part No. Description Fig. Ref.
Table A-2 Numerical Parts List (continued) Description Fig. Ref.
Table A-2 A-10 Parts Index Numerical Parts List (continued) Part No. Description Fig. Ref.
Table A-2 Numerical Parts List (continued) Description Fig. Ref.
A-12 Parts Index
B Regulatory Information Laser Safety (U.S.A.) The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration implemented regulations for laser products manufactured since August 1, 1976. Compliance is mandatory for products marketed in the United States. This printer is certified as a “Class 1” laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968.
Laser Statement (Finland) The following applies to printer operation and servicing in Finland. LASERTURVALLISUUS LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT HP LaserJet(s) 4V and 4MV laserkirjoitin on käyttäjän kannalta turvallinen luokan 1 laserlaite. Normaalissa käyt"ssä kirjoittimen suojakotelointi estää lasersäteen pääsyn laitteen ulkopuolelle. Kirjoittimen on hyväksynyt Suomessa laserturvallisuuden osalta Sähk"tarkastuskeskus.
Toner Safety Note In case of toner spills, skin and clothing are best cleaned by removing as much toner as possible with a dry tissue, then washing with cold water. Hot water causes toner to permanently set into clothing. MSDS Information A Material Safety Data Sheet (MSDS) for toner or any other chemical used in the printer is available through Hewlett-Packard’s Customer Information Center by either mail or fax.
FCC Statement (Class B) Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications.
C Service Notes Fuser Accordian Jams C3941A-01 SERVICE NOTE SUPERSEDES: NONE HP C3941A LaserJet 5L Serial Numbers:
To remove the paper jam the fuser area of the printer must be disassembled. Fusers and pressure rollers should be checked for damage from the paper jam or the customers attempts to remove the paper jam. The output tray fin should be installed in all LaserJet 5L’s in the affected serial number range that are returned for any service, paper jam or other. Solution: The out try fin (RB1-7332-000CN) should be placed in the output tray of the printer.
C3941A-02A SERVICE NOTE SUPERSEDES: C3941A-02 HP C3941A LaserJet 5L Serial Numbers: JPBK000000 / JPBK016388 JPBL000000 / JPBL055374 JPCW000000 / JPCW043448 JPVW000000 / JPVW081157 USCB000000 / USCB302011 JPBV000000 / JPBV010501 JPVV000000 / JPVV216255 CNVM000000 / CNVM175233 CNVN000000 / CNVN189964 LaserJet 5L Printer Fuser Jam Clearing Countermeasure To Be Performed By: HP-Authorized Personnel Parts required: RB1-7334-000CN JP (Jam Prevention) Protector General Description: When a paper jam occurs in th
To remove this type of paper jam the fuser area of the printer must be disassembled. The fuser and pressure roller should be checked for damage from the paper jam or the customer’s attempts to remove the paper jam. See chapter 6 in the service manual for disassembly instructions. This JP protector and the output tray fin (from service note C3941A-01) should be installed in all LaserJet 5L’s in the affected serial number range that are being serviced.
Index D data light 3-3 DC Controller 8-16 diagram 7-6 DC Controller system 5-5 DC power distribution circuitry 5-6 explained 5-6 defect ruler, repetitive image 7-28 delivery assembly 8-24 Department of Health and Human Services (DHHS) B-1 DHHS B-1 diagrams 8-3 dimensions, printer 1-3, 1-6, 2-4 distribution system AC 5-6 documentation related 1-10 to 1-11 doors 8-7 DRAM installation 6-5 dropouts 7-17 drum photosensitive 5-13, 7-13, 7-22 to 7-23 drum cleaning process described 5-12 to 5-13 drum conditioning d
Index standard 1-3 internal assemblies 8-10, 8-12, 8-14 control panel 6-11 delivery assembly 6-13 exit roller assembly 6-12 face-up/face-down lever 6-21 fuser exit roller 6-22 fuser pressure plate 6-15 heating element 6-17 pressure roller 6-20 internal typefaces 1-3 INTR, printer timing 5-19 J Japanese VCCI Statement B-4 L laser and scanner drive 5-5 laser drive 5-5 laser safety information B-1 Laser Safety, USA B-1 laser statement, Finland B-2 loss of detail 7-17 LSTR, printer timing 5-19 M main wiring di
site 2-1 to 2-6 space 2-4 resetting the printer 3-11 Resolution Enhancement technology 1-3, 5-9 described 5-9 resolution, print 1-3 REt, Resolution Enhancement technology 1-3, 5-9 ROM 5-8 character sets 5-8 dot patterns 5-8 S safety toner B-3 scanner drive 5-5 self test engine 3-10 microswitch SW201 5-5 self test page 3-7 sensors 5-17 separation guide assembly 8-22 sequence of operation 5-19 serial number information 1-4 service approach 1-10 service errors 7-7 service or error messages beam error 7-11 engi
Index warning messages 6-3 warranty exclusions 1-14 limitations 1-15 start date 1-15 voltage 1-15 warranty 1-14 wiring diagram 7-29 wiring diagrams, main 7-29 writing process 5-13 Index-4
Manual Part No. C3990-90991 *C3990-90991* *C3990-90991* Printed on Recycled Paper C3990-90991 HP LaserJet 5L and 6L Printer (C3941/C3990) Service Manual Copyright© 1997 Hewlett Packard Co.