Combined Service Manual HP LaserJet 4 / 4M (C2001A / C2021A) HP LaserJet 4 Plus / 4M Plus (C2037A / C2039A) HP LaserJet 5 / 5M /5N (C3916A/C3917A/ C3952A)
© Copyright Hewlett-Packard Company 1996 All Rights Reserved. Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws. Publication number C3916-90984 First edition, March 1996 Printed in USA 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: Unless specifically stated otherwise, information applies to all seven printer models (LaserJet 4/4 Plus/4 M/4 M Plus/5/5 M/5 N). Most procedures are combined for all printers, except where they differ substantially. Color is used to emphasize items which are important to the material under discussion. The names of major printer parts and assemblies are Capitalized.
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Contents 1 Product Information Product Family Information . . . . . . Identification . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . HP LaserJet 4 and 4 Plus . . . . . . . Related Documentation . . . . . . . . . Safety Information . . . . . . . . . . . . . Product and Laser Safety . . . . . . . FCC RFI Statement . . . . . . . . . . Laser Statement (Sweden/Finland) . . Toner Safety . . . . . . . . . . . . . Ozone Statement . . . . . . . . . . . . Doing Business with HP . . . . . . .
Control Panel Keys . . . . . . . . . . . . . . . . . Reset Menu . . . . . . . . . . . . . . . . . . . . . Control Panel Menus . . . . . . . . . . . . . . . . . Printer Features . . . . . . . . . . . . . . . . . . . . . Page Protection (HP LaserJet 4 only) . . . . . . . . Resource Saving (HP LaserJet 4 Plus and 5 only) . I/O Buffering (HP LaserJet 4 Plus and 5 only) . . . EconoMode (HP LaserJet 4 Plus and 5 only) . . . . Resolution Enhancement (REt) . . . . . . . . . . .
Printer Drivers . . . . . . . . . . . . . . . . . . . . Install Printer Drivers and Utilities . . . . . . How to Obtain Printer Drivers . . . . . . . . . . DOS Utilities . . . . . . . . . . . . . . . . . . . . . Packing the Printer . . . . . . . . . . . . . . . . Repackaging Instructions . . . . . . . . . . . Packing Checklist . . . . . . . . . . . . . . . . . Installing The Optional Lower Cassette . . . . . Loading Paper into the Optional Lower Cassette Envelope Feeder Installation . . . . . . . . . . . .
Removing the Transfer Roller Replacing the Transfer Roller . . . . . . . . . . . . 4-16 . . . . . . . . . . . . 4-16 5 Functional Overview Introduction . . . . . . . . . . . . . . . . . . . . . DC Controller System . . . . . . . . . . . . . . DC Controller Loads . . . . . . . . . . . . . . . Serial Data Communication . . . . . . . . . . . Solenoids . . . . . . . . . . . . . . . . . . . . . Photosensors . . . . . . . . . . . . . . . . . . . Microswitches . . . . . . . . . . . . . . . . . .
6 Removal and Replacement Required Tools . . . . . . . . . . . . . . . . . . . . . . Hardware Review . . . . . . . . . . . . . . . . . . . . Removing the Covers . . . . . . . . . . . . . . . . . . Right Side Cover Removal . . . . . . . . . . . . . . Top Cover Removal . . . . . . . . . . . . . . . . . Left Side Cover Removal . . . . . . . . . . . . . . . Rear Door Removal . . . . . . . . . . . . . . . . . . Font Door Cover Removal (LJ 5 Right Front Cover Removal) . . . . . . . . . . . . . . . . . .
Removing the High Voltage Contact Assembly and Feed Guide Assembly . . . . . . . . . . . . . . . . 6-67 Replacing the High Voltage Contact Assembly/Feed Guide Assembly . . . . . . . . . . 6-68 Interconnect PCA Removal . . . . . . . . . . . . . . . 6-69 7 Troubleshooting LaserJet 5 Error Map . . . . . . . . . . . . . . . . . Pre-Troubleshooting Procedures . . . . . . . . . . Preliminary Operating Checks . . . . . . . . . . Printer Message Troubleshooting . . . . . . . . Printer Message Summary Table . . . .
Drum Rotation Functional Check . . . . . High Voltage Power Supply Assembly . . Interface Troubleshooting . . . . . . . . . . . Communications Check . . . . . . . . . . Test Message . . . . . . . . . . . . . . . . AUTOEXEC.BAT Standard Configurations Parallel DOS Commands . . . . . . . . . Serial MS-DOS Commands . . . . . . . . Communications Checks . . . . . . . . . . MIO Troubleshooting . . . . . . . . . . . . . Troubleshooting Hints . . . . . . . . . . . Explanation of Self Test Printout . . . . .
Removing the Paper Guide Assembly . . . . . . Removing the Paper Roller . . . . . . . . . . . Removing the Control PCA . . . . . . . . . . . Removing the Power PCA . . . . . . . . . . . . Removing the Holding Tray Center Paper Guide Removing the Holding Tray Belt . . . . . . . . Removing the Holding Tray Paper Sensor . . . Removing the Switchback Assembly . . . . . . Parts and Diagrams for the Duplexer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Print Using the Infrared Port . . . . . . . . . . . . B-36 Troubleshooting IR Printing Problems . . . . . . . . B-38 Infrared Port Not Responding . . . . . . . . . . . . .
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1 Product Information Table 1-1 Printer Features Features Model Printer Speed Resolution HP LJ 4 HP LJ 4M C2001A C2021A HP LJ 4 Plus HP LJ4M Plus C2037A C2039A 8 ppm 8 ppm 12 ppm 12 ppm 300/600 dpi 300/600 dpi 300/600 dpi 300/600 dpi Expandable I/O Buffer No No Yes Yes Resource Savings No No Yes Yes MEt No No Yes Yes REt Yes Yes Yes Yes Enhanced PCL5 Enhanced PCL5, Postscript Level 2 Enhanced PCL5 Enhanced PCL5, Postscript Level 2 Languages PostScript Upgradeable C2
Product Family Information The model HP C2021A is identical to the model HP C2001A from a hardware standpoint, as is the model HP C2039A to the model HP C2037A. The models HP C2021A and C2039A printers include the following features: • PostScript Level 2 SIMM • AppleTalk MIO Card • 4 MBytes of RAM In every instance the repair procedures for all products are similar. Some LaserJet 4 accessories are compatible with the LaserJet 4 Plus and some are not.
Identification The model number is on a label placed on the outside, rear cover of the printer. The model number (C2001A, C2021A, C2037A or C2039A) is found at the top of the label. The model number is the base number for all printers. The serial number contains information about the printer Country of Origin. The serial number Alpha section refers to the Country of Origin, the Revision Level and the Production Code. The Numeric section refers to the production number of the printer.
Figure 1-2 Printer Identification Label for the HP LaserJet 4/4M 1-4 Product Information
Specifications HP LaserJet 4 and 4 Plus Table 1-3 Printer Dimensions Dimension HP LaserJet 4/4M (C2001A/C2021A) HP LaserJet 4 Plus HP LaserJet 4M Plus (C2037A/C2039A) Width 16.4 in (416 mm) 16.4 in (416 mm) Depth 15.9 in (403 mm) 15.9 in (403 mm) Height 11.7 in (297 mm) 11.7 in (297 mm) Weight (with toner cartridge) 37 lbs. (18.3 kg) Table 1-4 37 lbs. (18.
Table 1-6 Electrical Specifications Status 4/4M 100/115 V 4 Plus/4M Plus 4/4M 220/240 V 4 Plus/4M Plus Product Rating 6.4 amps 7.8 amps 3.1 amps 4.0 amps Peak Inrush Current 22 amps 22 amps 22 amps 22 amps 25% Decay Time 13 msec 18 msec 11 msec 11 msec Peak Fuser Current 38 amps 51 amps 17 amps 22 amps Return-to Average Time 200 msec 200 msec 200 msec 200 msec Table 1-5 Environmental Specifications Operating Environment Temperature: 10° C to 32.5° C (50° F to 90.
Related Documentation The following manuals can be ordered from Hewlett-Packard’s Support Materials Organization (SMO). The phone number for SMO is (800) 227-8164.
Safety Information Product and Laser Safety HP printers are UL 1950 listed, CSA 22.2 950 certified, and manufactured in accordance with DIN IEC 950. The printers are certified as “Class 1” laser products 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. The printers do not produce hazardous laser radiation.
FCC RFI Statement 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 when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.
Laser Statement (Sweden/Finland) LASERTURVALLISUUS LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT HP LaserJet(s) 4/4M, 4 Plus/4M Plus laserkirjoitin on käyttäjän kannalta turvallinen luokan 1 laserlaite. Normaalissa käytössä kirjoittimen suojakotelointi estää lasersäteen pääsyn laitteen ulkopuolelle. Kirjoittimen on hyväksynyt Suomessa laserturvallisuuden osalta Sähkötarkastuskeskus. Laitteen turvallisuusluokka on määritetty valtioneuvoston päätöksen N:o 472/1985 ja standardin EN 60825 (1991) mukaisesti.
Toner Safety Note Toner may stain clothing. 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 melt and permanently fuse into clothing. A Material Safety Data Sheet (MSDS) for the toner cartridge used in the HP printers, is available through Hewlett-Packard by either mail or fax. Mail.
Doing Business with HP Technical Assistance HP ASAP 1-800-333-1917 (U.S.) HP ASAP (Automated Support Access Program) provides free technical support information 24 hours a day, 7 days a week. The ASAP system includes HP FIRST and HP AUDIO-TIPS, both explained below. The ASAP service requires a touch-tone phone. HP FIRST HP FIRST (Fax Information Retrieval Support Technology) is a phone-in fax service providing technical information for HP LaserJet users as well as service personnel.
HP AUDIO-TIPS HP AUDIO-TIPS, available within HP ASAP, is an interactive voice response system providing pre-recorded answers to the questions most frequently asked by HP LaserJet printer users. Helpful “System Maps” to the HP AUDIO-TIPS recordings are available by fax through HP FIRST. HP CompuServe Forum CompuServe members can download a variety of support materials including product data sheets, software application notes, and printer drivers for many popular software applications.
European Customer Support Center The HP European Customer Support Center, located in Amsterdam, Holland, is open from 8:30 am to 6:00 pm central European time (Wednesdays until 4:00 pm). Multilingual customer support representatives can answer technical questions similar to the U.S. CSC, described on the previous page. This service is available at no charge for a period equivalent to the original HP hardware warranty period.
2 Site Planning and Requirements Site Requirements The environmental specifications, listed in the Specifications section of Chapter 1, must be maintained to ensure the proper operation of this printer. Consider the following points before installing the printer: • Install the printer in a well-ventilated area. • Install the printer on a sturdy, level surface. • Install the printer where the temperature and humidity do not • • change abruptly.
Printer Space Requirements Figure 2-1 Space Requirements 2-2 Site Planning and Requirements
Print Media Specifications The complete media specifications are listed in the HP LaserJet Family Paper Specifications Guide (part no. 5961-0920), that came with this manual. Each tray has its own set of paper specifications. Do not use paper heavier than 36 pound from the MP tray (Tray 1), 28 pound from the PC tray (Tray 2), or 24 pound from the LC Tray (Tray 3).
Table 2-3 Media Paper Media Specifications for Optional LC Tray (Tray 3) Size Capacity Weight/Thickness Range Letter, A4, Executive 500 sheets at 20# (75 g/m2) 16# to 24# (60 to 90 g/m2) Note Printing heavy paper stock (greater than 24 lb. (90 g/m2) from the 500-sheet Lower Cassette specifically is not supported.
Adhesive Labels Note Printing labels using the Duplex Assembly , the 500-sheet Lower Cassette (Tray 3) or the PC tray (Tray 2) specifically is not supported. Always use the MP tray (Tray 1) to print labels. Label Construction When selecting labels, consider the quality of each component: • Adhesives: The adhesive material should be stable at the • • • 392° F (200° C) temperatures encountered in the printer’s fusing process. None of the adhesive should be exposed between the labels.
Overhead Transparencies Note Printing overhead transparencies using the Duplex Assembly, the 500-sheet Lower Cassette (Tray 3) or PC tray (Tray 2) specifically is not supported. Overhead transparencies used in HP LaserJet printers must be able to withstand the 392° F (200° C) temperature encountered in the printer’s fusing process. See the HP LaserJet Family Paper Specifications Guide for more information. Caution Use only overhead transparencies recommended for use in laser printers.
Envelope Construction The following table lists the kinds of envelopes you can print in the MP Tray (Tray 1). Table 2-5 Specifications for Envelopes Item Specifications Minimum envelope size 3.5 in x 7 in (86 mm x 178 mm) Maximum envelope size 7.4 in x 10.5 in (188 mm x 267 mm) Basis Weight 16 to 24 pound (60 to 90 g/m2) Quantity Maximum 10 envelopes Envelope Size Dimensions Commercial #10 (COM 10) 4.1 in x 9.5 in (105 mm x 241 mm) #7 3/4 (Monarch) 3.8 in x 7.
2-8 Site Planning and Requirements
3 Configuration Introduction The Configuration of the printer consists of setting hard and soft user defaults, and setting up the host computer to communicate with the printer (System Configuration). For installation instructions refer to Installation in the Getting Started Manual that is shipped with the printer. Hard defaults are the I/O Menu and Configuration Menu settings. These are set when the printer is installed and remain as configured.
Using The Control Panel (See Appendix B for LaserJet 5 information.) Figure 3-1 Control Panel Keys The control panel (see Figure 3-1) consists of eight keys, three indicator lights, and a 16-character display panel. The three indicator lights are described in Table 3-1. Control Panel Keys There are two rows of control panel keys. The upper row keys have one function each. The lower row keys have a second level of functions which are accessed by holding down [Shift].
Table 3-1 Indicator Ready On Line Form Feed Indicator Lights Mode Description On: Ready to print. Flashing: Processing a print job. Do not take off line or switch off. Off: Not ready; see display for message. On: Ready to receive data. Flashing: Going from on line to off line. Off: Off line. Other keys can be accessed. On: Data still in printer buffer. Flashing: Buffered data being printed. Off: No buffered data in printer.
Table 3-2 Control Panel Key Functions Key Function [On Line] Switches the printer between ON LINE (communicating with the computer or other data source) and OFF LINE (not communicating). For the printer to receive data, both the On Line and Ready indicator lights must be on. [Form Feed] Prints any data remaining in printer’s buffer. It cannot be used to send a blank sheet of paper through the printer.
Reset Menu Use Reset Menu function with caution. It can result in loss of buffered page data or printer configuration data. Reset Menu is activated by holding down both [Shift] and [Menu] for up to 10 seconds until RESET=MENU* appears. Use [+] or [-] to cycle through items and [Enter] to select the item. The reset is executed by pressing [On Line].
Control Panel Menus Figure 3-2 shows the menus and menu items available with the basic printer configuration. Not all menu items are discussed in this section. Only those items of specific interest from a service standpoint, or items new to the printers are discussed in this section. If options such as PostScript or a different I/O are installed, new menu items automatically are added at the appropriate location. For example, a PostScript Menu appears following the PCL Menu.
Figure 3-2 Control Panel Map Configuration 3-7
Table 3-3 Printer Menu Items Item Options Explanation COPIES 1* to 999 Select any number from 1 to 999. PAPER LETTER* (110V printers), LEGAL, A4* (220V printers) EXEC Sets default image size, unless software setting overrides it. ENVELOPES COM10* (110V printers), MONARCH, DL* (220V printers), C5, B5 ORIENTATION P*, L P means portrait (vertical) and L means landscape (horizontal) orientation.
Table 3-3 PCL Menu Items Item Options Explanation FONT SOURCE I* C S Mn (1-4) Internal fonts* Cartridge fonts Permanent soft fonts SIMM Module: n=slot number. Typefaces stored in one of the four ROM SIMM slots (M1=slot 1, for example). FONT NUMBER 0* to 999 Number assigned to each typeface. PITCH or PT. SIZE Pitch: 10.00* Point: 12.00* Depends on the FONT SOURCE and FONT NUMBER selected. SYM SET ROMAN-8 Many others A unique grouping of all characters in a font. *indicates factory default.
Table 3-5 Configuration Menu Items Item Options Explanation FIRST* Paper is selected first. CASS Operates as a PC tray. MANUAL Operates as a manual feed tray. LOCK NONE* MP PC LC and combinations No trays are locked out. The MP tray is locked out. The PC tray is locked out. The optional Lower Cassette is locked out. CLR WARN ON*, JOB Indicates a transient condition. AUTO CONT OFF* When an error is encountered, printer goes off line until [SHIFT] + [CONTINUE] are pressed.
Table 3-6 Memory Configuration Items Item Options IO BUFFER Memory is automatically determined by the printer. No memory is set aside. Size can be manually adjusted AUTO* OFF ON 10K and up IO SIZE With IO BUFER ON, adjust size in increments of 10. Saves resources and extra memory and personality SIMM are installed in printer. Printer automatically determines the amount of memory to allocate to personality. No memory is allocated. Additional memory management selections appear.
Table 3-8 Serial Menu Items Item Options Explanation SERIAL RS-232* RS-422 (HP LJ 4 only) Use the RS-422 when a longer cable is needed. PACING DTR/DSR* Use if the computer requires hardware flow control. Use if the computer requires software flow control. XON/XOFF BAUD RATE 9600* 300 to 57600 ROBUST XON ON* OFF DTR POLARITY HI* LO Tells how fast information will be transferred from the computer to the printer. Appears when pacing is set to XON/XOFF.
Printer Features Some of the important features of the HP LaserJet 4, 4 Plus, and LaserJet 5 printers are described below. Page Protection (HP LaserJet 4 only) Note The default is PAGE PROTECT=OFF*. Unless you frequently get 21 PRINT OVERRUN messages, you may not need to set a value for page protection. Page protection reserves additional memory for the page image process, allowing the printer to create an entire page image in memory before paper starts through the printer.
Resource Saving (HP LaserJet 4 Plus and 5 only) Resource Saving gives the printer the ability to save certain entities such as permanent soft fonts, macros, symbol sets and user-defined graphics patterns when the printer changes personalities, resolutions or page protect modes. For example, if a user switches the LaserJet 4 printer from PCL mode to PostScript mode, all PCL soft fonts macros are lost. The HP LaserJet 4 Plus/4M Plus printer would not clear these entities from memory.
I/O Buffering (HP LaserJet 4 Plus and 5 only) I/O buffering allows the user to allocate printer memory to hold the job while it prints, freeing up the host system sooner, like a print spooler. The standard printer has approximately 10 KBytes of memory allocated to I/O buffering and an additional 100 KBytes of memory is assigned to I/O buffering for each 1 MByte of memory added to the printer.
EconoMode (HP LaserJet 4 Plus and 5 only) The EconoMode setting uses approximately 50% less toner than standard mode printing by reducing dot density. EconoMode, which can also be thought of as “draft mode,” is user selectable via a front panel key, a Printer Job Language (PJL) sequence using HP Explorer’s Remote Control Panel or through application software. The default setting is OFF. EconoMode, Medium Density Normal Mode, Medium Density Note EconoMode does not affect print speed or memory usage.
Memory Enhancement technology (MEt) (HP LaserJet 4 Plus and 5 only) HP Memory Enhancement technology (MEt) effectively doubles the printer’s standard memory through a variety of font and data compression methods. MEt also automatically compresses fonts for desktop publishing applications. When printing graphics, MEt analyzes each page as it is being printed and automatically applies a variety of methods to print the complete page at the correct resolution.
Network Security The HP LaserJet 4 Plus and 5 printers allow the System Administrator to lock out other user’s ability to change most printer control panel settings. This is done by setting a password and turning LOCK on. The message MENU LOCKED will appear when a user tries to change the printer control panel settings. Note If you forget your password, you can perform a “Cold Reset” by holding down the [On Line] key (Go on LJ 5) while turning the printer on.
5 Under the Extras menu, select Set Printer Password. On the Printer Security screen, enter the new password (numeric values can be set from 0 to 65535), and click on the OK button. HP JetAdmin Utility (Novell Networks) 1 Run JETADMIN. 2 Select the printer you want to configure. It is listed under its “JetDirect Interface Name” which appears on the self test page/configuration plot. 3 Select Configuration.... The Printer I/O Configuration screen appears. 4 Select Advance....
Service Mode (Refer to Appendix B for LaserJet 5 information.) The Service Mode should be used only by authorized service personnel. The following can be executed while in the Service Mode: • Print a Service Mode Self Test. • Verify the Page Count, (the page count also is displayed on the standard self test). • Set the Page Count. • Set the Cold Reset Default (This sets the factory default paper • • • size. Use when replacing non-U.S. Formatters).
Setting the Page Count The page count is stored in the printer’s Non-Volatile Memory (NVRAM). If it is necessary to replace the Formatter PCA, the page count should be reset to the printer’s original page count to reflect the age of the print engine. Use the following procedure to set the page count: 1 Enter the Service Mode as described previously. 2 When SERVICE MODE is displayed, press the [MENU] key to access the Service Menu. Press the [ITEM] key to step through the menu. 3 PAGES=XXXXXX is displayed.
Setting the Cold Reset Default The default paper size outside of the U.S. is typically A4. Therefore, when replacing Formatters where the desired default is A4, the Customization Variable must be set to A4. This prevents the Cold Reset procedure from resetting the paper size to Letter. To set the Customization Variable: 1 2 3 4 5 6 Enter the Service Mode as described previously. Press the [Menu] key to display SERVICE MENU.
Cold Reset The Cold Reset feature of the printers allows the printer to be returned instantly to the factory default configuration settings. This feature is valuable because the the Dynamic I/O and PJL features of the printer enable any user connected to any I/O to access and change the default configuration as applications require. When setting up the printer in a new location, or when troubleshooting printer problems, always perform the Cold Reset before entering the selected user defaults.
Understanding the PCL Self Test Printout (Refer to Appendix B for LaserJet 5 information.) Table 3-10 Self Test Printout Items for the HP LaserJet 4/4M Item Explanation Figure 3-3 1 Standard Menu Selections: Shows standard menu selections, such as Printing Menu and PCL Menu, and menu items, such as Copies and MP tray, in the order they appear in the control panel display.
2 1 4 2 5 6 7 3 10 8 9 11 Figure 3-3 HP LaserJet 4/4M PCL Self Test Printout Configuration 3-25
Table 3-11 Self Test Printout Items - HP LaserJet 4 Plus/4M Plus Item Figure 3-4 Explanation 1 Standard menu selections: Lists selections in the order in which they appear in the control panel display. 2 Optional menus: Shows optional menu selections, such as the PostScript Menu, and menu items, in the order in which they appear in the control panel display. Optional menus automatically appear in the control panel display when options are added to the printer.
Figure 3-4 HP LaserJet 4 Plus/4M Plus PCL Self Test Printout Configuration 3-27
Changing the Control Panel Display Language The default control panel display language is set for English. Supported languages are: English, French, German, Italian, Spanish, Finnish, Danish, Dutch, Swedish, Norwegian, and Portuguese. Follow these instructions to change the display language. 1 Switch OFF the printer. 2 Press and hold [Enter] (or Select on the LJ 5) while switching the printer ON until CONFIG LANGUAGE appears in the display. 3 After the power-on self test, LANGUAGE=ENGLISH appears.
Test Print Button Figure 3-5 Test Print Button Location The Test Print button access hole is located on the side of the printer. Press the Test Print button using a tool similar to a paper clip (see Figure 3-5). The 15 ENGINE TEST only prints from the PC tray (Tray 2).
Figure 3-6 Test Print Pattern Pressing the Test Print button will initiate a 15 ENGINE TEST. This is an engine test only. The Format PCA is bypassed while printing this test, although a formatter problem can interfere with this test. A page of vertical lines is printed if the print engine is operating correctly (see Figure 3-6).
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. Add or modify the MODE command(s), depending on the interface configuration, as follows: Parallel DOS Commands Most IBM PC and AT compatible computers default to a parallel printer port.
Serial MS-DOS Commands Most IBM compatible computers default to a parallel printer port. To ensure that information is sent to your serial printer port, type the following MS-DOS commands at your MS-DOS prompt, or include them in your AUTOEXEC.BAT file. MODE COM1:9600,N,8,1,P MODE LPT1:=COM1 For MS-DOS version 4.0 or above, enter: MODE COM1:9600,N,8,1,B MODE LPT1:=COM1 Note These examples assume that you are using serial printer COM1.
Printer I/O Configuration Parallel Menu The default setting for the High Speed Parallel I/O is YES. If it is set to NO, the interface runs at a slower speed that is compatible with older computers. When the default is set to YES, the parallel interface runs at a higher rate supported by newer computers. Advanced Functions The Advanced Functions feature of the printer enables bi-directional communications between the printer and the host. The default setting is ON.
Pacing (Handshaking) Pacing (or “handshaking”) is a type of communication between the printer and the computer. This is an important item in the printer because it allows the printer to tell the computer when to send information. If the printer is unable to receive information, for example, when the print buffer is full or when the printer is out of paper, a signal is sent to the computer to stop sending information.
Serial Cable Pin-outs The following cable diagrams show the cable pinouts for the most common serial configurations. DB-9 RS-232 Serial Connection — HP LaserJet 4 If the computer has a serial port with 9 pins, use the cable or equivalent for the HP LaserJet 4.
DB-25 RS-232 Serial Connection — HP LaserJet 4 Plus/5 If the computer has a serial port with 9 pins, use the C2932A or equivalent cable for the HP LaserJet 4 Plus.
DB-25 Serial Connection — HP LaserJet 4 If the computer has a serial port with 25 pins, use the 17255D cable or equivalent for the HP LaserJet 4.
DB-25 RS-232 Serial Connection — HP LaserJet 4 Plus/5 If the computer has a serial port with 25 pins, use the C2933A or equivalent cable for the HP LaserJet 4 Plus.
RS-422A Serial Connection (Not available on the HP LaserJet 4 Plus or 5 printers) If you are configuring the computer to use an RS-422A serial port, you need a special cable. Contact the computer or printer network manufacturer to see if an RS-422A cable is available. If no cable is available, contact your computer manufacturer for your computer pin assignments and have a cable constructed.
Modular I/O Configuration The printers are equipped with a modular I/O slot. A modular I/O interface card can be plugged into that slot to increase the number of interfaces available. A modular I/O card can provide increased printer performance when printing from a network. In addition, a modular I/O card provides the ability to place the printer anywhere on the network.
Printer Drivers Install Printer Drivers and Utilities Printer drivers are specialized programs designed to allow specific software applications to function with the HP LaserJet printers. Printer utilities include such things as the HP Explorer program modules, which enhance the usability of the printer and provide convenient access to printer features outside of specific software applications.
DOS Utilities Use the DOS Utilities to install printer drivers for MS-DOS applications. Printer driver software for some common software applications are included the DOS Utilities. See the Doing Business With HP section of Chapter 1 for information on software drivers not included with the LaserJet DOS Utilities. A DOS Utilities disk is shipped with every printer.
Packing the Printer Repackaging Instructions The printer warranty is for one-year and must be returned to an Authorized HP service center for service. If the original packaging material is no longer available, replacement packing and shipping material is available from HP’s Support Material Organization (SMO) for a charge. To order replacement packing and shipping material, call: 1-800-227-8164 (U.S.
Installing The Optional Lower Cassette Note Please see also the Service Notes section for proper use and adjustment of the lower cassette. These printers have an optional 500-sheet Lower Cassette which is installed in the field. Follow these instructions to install the Lower Cassette. 1 Disconnect the cables from the printer. 2 Unpack the 500-sheet Lower Cassette Assembly. 3 Place the Lower Cassette base (without its paper tray) in the selected location.
Loading Paper into the Optional Lower Cassette Figure 3-13 Pull the cassette tray straight out of the printer. Figure 3-14 Adjust the cassette for the paper size you want to load.
Figure 3-15 Slide about 450 sheets of paper into the tray, up against the adjustable bracket that sets the paper length. Figure 3-16 Press down on the stack of paper until the top of the stack fits under the top edge of the back green bracket.
Figure 3-17 Push down the left corner of the stack until the paper is secured undered the metal clip. EXEC A4 Figure 3-18 LEGAL LETTER Set the knob on the top right of the cassette to the paper size you have loaded.
Figure 3-19 Note: cassette MUST be full before adjusting the tension. To adjust the tension, tap the stack of paper several times and turn the leftmost knob on the cassette until the arrows on the indicator align. Tap the stack again and verify the arrows are still aligned. Figure 3-20 Slide the cassette back into the Lower Cassette assembly.
Envelope Feeder Installation For complete information about installing the Envelope Feeder, see Envelope Feeder User’s Guide. This guide is provided with the envelope feeder. The instructions below are not intended to replace the information of the Envelope Feeder User’s Guide. Note The LaserJet 4, 4 Plus, and 5 printers all use different envelope feeder products. To install the Envelope Feeder: 1 Turn OFF the printer. 2 Open the MP tray.
Figure 3-22 Install the Envelope Feeder 4 Insert the Envelope Feeder firmly into the printer (see Figure 3-22). 5 Turn ON the printer. LaserJet 4 and 4 Plus The envelope size (EE TRAY=) appears on the display when the envelope feeder is installed and loaded with envelopes. The envelope size can be selected through the Control Panel. Paper jams can result if the envelope size selected does not match the envelopes loaded into the envelope feeder.
SIMM Installation SIMM installation is covered in detail in the the printer’s User’s Manual and in the kit that accompanies the SIMM. The instructions shown here are not intended to replace these sources. Follow these instructions to install memory, language, and flash SIMM boards. Install all types of SIMM boards in the same manner. Protecting the SIMM Board SIMM boards can be damaged easily by small amounts of static electricity.
Any SIMM board can be installed in any of the four SIMM slots. Because the slots are close together, we recommend installing them from right to left, starting with slot 1 and ending with slot 4.
Memory Requirements A page’s complexity (rules, graphics, or dense text) may exceed the printer’s ability to create the image rapidly enough to keep pace with the printing process. If a page is too complex, only part of the page prints, and some print data loss is likely. In such cases, a 21 PRINT OVERRUN message (signifying possible loss of print data) or a Clearable Warning message appears in the display.
Caution When removing a board from the antistatic package, avoid touching the metal traces on the SIMM board. For memory boards, compare the part number on the outside of the package to the part number in the table below. If you have not received the correct board, notify your authorized Hewlett-Packard dealer immediately.
Accessing the SIMM Slots Please refer to Chapter 6, Removal and Replacement, for instructions on removing the SIMMS door to access the slots. Note that access to the SIMM slots are slightly different for the various printer models. Installing the SIMM Boards Figure 3-24 Positioning the SIMM board with the notch at the bottom. 1 Through the open door, you can see the four SIMM board slots (see previous Figure 3-23).
Figure 3-25 Installing the SIMM Board 3 Hold the SIMM board at a 30-degree angle to the slot and push the edge of the board evenly and firmly into the slot (see Figure 3-25 callout (A) ). 4 Rotate the SIMM board to the right until the board “clicks” into the metal locking tabs, securing the board into place (see Figure 3-25 callout (B)). 5 Gently rock the SIMM board back and forth. If it is seated correctly, it will not lift away from the slot.
Testing a SIMM Board Use the procedures below to print a self-test page to verify SIMM board installation. Procedures are given for both memory and PostScript SIMMs. Memory SIMM Note For the LaserJet 5/5M/5N, the On Line key has been replaced by the Go key. The Enter key has been replaced by the Select key. Running a Self Test Printout 1 Plug in the power cord and turn ON the printer. 2 After a few seconds, 00 READY should appear in the control panel display.
Personality SIMM (PostScript) A personality (printer language) SIMM installation can be verified as outlined below (a PostScript SIMM is used in this example). Note For the LaserJet 5/5M/5N, the On Line key has been replaced by the Go key. The Enter key has been replaced by the Select key. 1 Plug in the power cord and turn ON the printer. 2 After a few seconds, the on line indicator should light and 00 READY should appear in the control panel display.
Troubleshooting a SIMM Board For more information about the service/error messages below, see Chapter 7, Troubleshooting. Service / Error Messages One of two messages can be generated when your printer is checking its SIMM internal memory. 61.X SERVICE where X = 1, 2, 3, or 4 This error indicates a SIMM parity error. The x indicates which SIMM slot generated the error. If these messages appear first, check the HP part number to make sure you have the right SIMM board. 62.
3-60 Configuration
4 Preventive Maintenance Introduction The printer requires minimum routine maintenance. Use this chapter for information on: • Service Checkpoints. These are the items that must be • • cleaned and checked when the Toner Cartridge is replaced, or before performing periodic 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 Selected Service Consumables DESCRIPTION QTY EST. LIFE (pages) REMARKS 1. Toner Cartridge 1 68001 When print becomes faint, shake cartridge to distribute remaining toner. 2. MP (Tray 1) Pickup Roller Assembly 1 200,000 Replace roller and separation pad together. 3.
Service Checkpoints This is a fold-out page 3 panels wide.
Cleaning Your Printer When it is time to replace the toner cartridge, perform the cleaning procedures outlined in Figure 4-1.
Toner Cartridge The toner cartridge in your printer contains the printing mechanism and a supply of toner. Your toner cartridge life depends on the amount of toner your jobs require. When you print word-processed text, a toner cartridge lasts approximately 6,800 pages, printed at 5% coverage. (A typical business letter, as shown in Figure 4-2, is about 5% coverage.) This assumes that the print density setting is in the middle range (set to 3 in your printer’s control panel).
Saving Toner with EconoMode (HP LaserJet 4 Plus and 5 Only) Toner cartridge life can be extended dramatically by using the EconoMode printing feature of the printer. EconoMode can be turned on or off via the printer control panel, through HP’s Remote Control Panel or through a software application with the appropriate printer driver. Note EconoMode is recommended in portrait orientation only. Some software applications may refer to this as “draft mode”.
Installing the Toner Cartridge The toner cartridge is empty and must be replaced when the toner low message cannot be cleared, as described in “Clearing the 16 TONER LOW Message” later in this section. To replace the toner cartridge: 1 Open the printer’s top cover and remove the empty toner cartridge. Note Inside the new HP toner box is a document which explains HP’s toner cartridge recycling policy. Follow the instructions to package the empty toner cartridge and return it for recycling.
3 Remove the sealing tape by firmly grasping the tab on the right side of the toner cartridge and pulling it straight out the side of the cartridge. (See Figure 4-3.) Note Pulling the toner cartridge at an angle may damage the toner cartridge seals. Figure 4-4 Inserting the Toner Cartridge 4 Position the cartridge with the arrow pointing into the printer as shown in Figure 4-4. 5 Insert the toner cartridge fully into the printer (press firmly).
Non-HP Toner Cartridges While Hewlett-Packard does not prohibit the use of Non-HP toner cartridges during the warranty period or while under a maintenance contract, we do not recommend their use. The reasons for this are: • Hewlett-Packard has no control or process to ensure that a • • Non-HP toner cartridge functions at the high level of reliability of an HP LaserJet toner cartridge.
Clearing the TONER LOW Message If the 16 TONER LOW message appears in the control panel display, the toner level in the toner cartridge is getting low. The print becomes lighter and white streaks may appear. (This message means that it is time to replace the toner cartridge). If the control panel Config Menu Toner Low item is set to TONER LOW=ON (or CONT on the LJ4+ and LJ5 printers), the printer continues to print with the 16 TONER LOW message in the control panel display.
Periodic Maintenance Procedures Each paper source has a Paper Pickup Roller that should be replaced when paper no longer feeds reliably. The MP Tray (Tray 1) Paper Pickup Roller is shown in Figure 4-5. The PC tray (Tray 2) Pickup Roller is shown in Figure 4-7, the LC (Tray 3) Pickup Roller is shown in Figure 4-8.
Figure 4-6 Removing the MP Tray (Tray 1) Separation Pad 4 Insert a small screwdriver into the indent at the front of the separation pad and gently lift the pad from its seat (see Figure 4-6). 5 Discard the used roller and pad.
Removing the PC (Tray 2) Pickup Roller The PC Pickup Roller is underneath the printer (see Figure 4-7). To remove the Pickup Roller: 1 Turn OFF and unplug the power cord from the rear of the printer. If your interface cable is long enough, it may stay attached, if not, remove it also. 2 Remove the Toner Cartridge and the PC tray (Tray 2). 3 Lay the printer on its left side. 4 Remove the PC (Tray 2) Pickup Roller by pinching the release clips and sliding the roller off the shaft.
Removing the Lower Cassette (LC) or (Tray 3) Pickup Roller Figure 4-8 Removing the Lower Cassette Pickup Roller If your printer is equipped with the Lower Cassette Assembly, proceed as follows: 1 Remove the Lower Cassette Tray. 2 Press the retainers that hold the roller in place (see Figure 4-8). 3 Slide the Pickup Roller off the shaft.
Removing and Replacing the Transfer Roller Figure 4-9 Replacing the Transfer Roller The Transfer Roller is the black sponge-rubber roller located inside the printer just to the front of the black plastic Paper Feed Guide (see Figure 4-9). To remove and replace the Transfer Roller, follow these steps. Note Do not handle the new Transfer Roller unnecessarily. Oils will build up on the roller and cause print quality problems.
Removing the Transfer Roller 1 Turn OFF and unplug the printer. 2 Open the printer’s top cover. 3 Remove the Toner Cartridge. 4 Use the hook inside the top cover to remove the Transfer Roller as follows. Hook the left side of the chrome rod beside the sponge roller, and lift the roller out. 5 Discard the used roller. Replacing the Transfer Roller 1 Slide the right end of the new roller (the end without the gear), onto the right slot. Press the rod into the slot.
5 Functional Overview Introduction This section of the manual presents a functional overview of the printers. It provides the Service Representative with an understanding of the printing process. Refer to the block diagram of Figure 5-1 to see the relationship of the parts as a whole.
DC Controller System The DC Controller PCA is responsible for coordinating all activities involved in the printing process. The DC Controller enables the drive circuitry for the laser beam, and coordinates print data from the Formatter PCA with paper size, laser beam motion, the high voltage system, fuser temperature, and motors. The DC Controller also shares machine status information with the Formatter PCA so that proper diagnostic messages are displayed on the control panel.
DC Controller Loads Figure 5-1 DC Controller Loads Functional Overview 5-3
Serial Data Communication The printer communicates with and controls the Paper Feeder, the Lower Cassette Assembly, and the Envelope Feeder through serial data lines SLI and SLO. In addition, the DC Controller uses information encoded on SLI from the High Voltage Transformer to monitor the toner level.
Solenoids Solenoids are controlled by the DC Controller. Each solenoid drives a specific roller (see Table 5-1). The DC Controller outputs +24B VDC to energize the solenoids at the proper time. When either of the doors are open, the +24B VDC is removed and the solenoids are disabled.
Photosensors Photosensors, monitored by the DC Controller, are responsible for detecting the presence of paper, paper motion, and timing. (See Table 5-2.) Photosensor PS2 senses paper in the PC tray; photosensor PS4 senses paper in the MP tray. The message PC LOAD or MP LOAD is displayed when either the PC tray or the MP tray is selected as the primary tray and is out of paper. PS6 and PS7 (respectively) sense the presence of paper in the Lower Cassette and the Envelope Feeder.
Table 5-2 Sensor Photosensor Signals Description PCA PS1 Input/Registration Sensor - detects paper in pickup area Paper Control PCA (J605) PS2 PC tray (Tray 2) Paper-out Sensor - detects the presence of paper in the PC tray. Paper Control PCA (J605) PS3 Output/Fuser Exit Sensor - detects paper in fuser. DC Controller (J208) PS4 MP Tray (Tray 1) Paper Out Sensor - detects the presence of paper in the MP tray (Tray 1).
Microswitches All microswitch conditions are monitored by the DC Controller over serial data lines SLI and SLO. The State Machines on the individual control PCAs, (for example the Paper Control PCA) convert the switch condition to a digital logic level, and encode that information on the data stream for the DC Controller to use. SW601 (Door Open Sensing switch) monitors the top cover. If the top cover is open, the printing process stops and the 12 PRINTER OPEN message is displayed.
Table 5-3 Microswitch Signals Switch Description PCA SW601 Door Open Sensing Switches (front and rear) Paper Control PCA SW602 Test Print Switch Paper Control PCA SW603 PC tray (Tray 2) Size Sensing Switches Paper Control PCA SW604 PC tray (Tray 2) Size Sensing Switches Paper Control PCA SW605 PC tray (Tray 2) Size Sensing Switches Paper Control PCA SW851 Lower Cassette (Tray 3) Size Sensing Switches Lower Cassette SW852 Lower Cassette (Tray 3) Size Sensing Switches Lower Cassette SW
Motors The DC Controller controls the Exhaust Fan, the Main Motor, and the Laser/Scanner Motor. The remaining motors and solenoids are controlled by State Machines on the motor’s assembly. The condition of these motors and solenoids is monitored by the DC Controller through serial data lines. The Main Motor (M1) rotates after any printer door is opened and closed, during the Warm-up period, the Initial Rotation period, the Print period, or the Last Rotation Period.
Table 5-5 Motors Motors Description M1 Main Motor (Gear Train Drive Motor) M2 Paper Input Assembly Drive Motor M3 500-sheet Lower Cassette Pickup Motor M4 Envelope Feeder Drive Motor M5 Scanner Motor FM1 Exhaust Fan Motor Paper Jam Detection The Input/Registration Sensor (PS1) and the Paper Exit Sensor (PS3) detect paper moving through the printer.
Formatter System The formatter is responsible for the following: • Receiving and processing ASCII data from printer interfaces. • Monitoring front panel input and relaying printer status information (through the front panel and bi-directional I/O). • Developing/coordinating data placement and timing with the print engine. • Storing font information. • Communicating with the host computer.
Figure 5-5 Formatter PCA—Functional Areas Functional Overview 5-13
Memory Management The printer uses several different types of memory. This memory can be divided into two different categories, Read Only Memory (ROM) and Random Access Memory (RAM). ROM memory consists of the memory located on the Formatter PCA and any font cartridges that may be installed in the printer. RAM memory consists of RAM memory resident on the Formatter PCA, SIMM memory installed in the printer, and the Non-Volatile Memory (NVRAM) located on the Formatter PCA.
PJL Overview Printer Job Language (PJL) is an integral part of configuration, in addition to the standard Printer Command Language. With standard I/O cabling, PJL allows the printer to perform functions such as: • Allowing the printer to talk to the host computer through a • • • • Bi-directional parallel connection. The printer can tell the host such things as the control panel settings, and allow the control panel settings to be set from the host.
Image Formation System Laser printing requires the interaction of several different technologies (such as electronics, optics, and electro-photographics) to provide a printed page. Each process functions independently and must be coordinated with all other printer processes. The image formation process centers around the photosensitive drum and consists of six stages: 1. Cleaning 2. Conditioning 3. Writing 4. Developing 5. Transferring 6.
Photosensitive Drum The photosensitive drum is the “heart” of the Image Formation System. The special properties of this drum allow an image to be formed on the drum’s surface and then transferred to paper. The drum is an extruded aluminum cylinder. The outside of the cylinder is coated with a layer of organic-photoconductive material (OPC) which is non-toxic. The aluminum base of the photosensitive drum is electrically connected to ground potential (see Figure 5-7).
Cleaning Stage During the cleaning stage of the image formation process, the drum’s surface is physically cleaned, preparing it to hold an image. During printing, the drum is rotating constantly making several complete rotations per printed page. Before forming the image for a given section of print, a cleaning blade removes toner from the previous rotation of the drum. The excess toner is stored in the toner cartridge where it is prevented from being used in later print jobs.
Conditioning Stage After the drum is physically cleaned, it must be conditioned. This process consists of applying a uniform negative charge on the surface of the drum with the primary charging roller, located in the toner cartridge. 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 potential.
Writing Stage At the writing station, the laser beam is used to discharge the drum’s negative potential by focusing laser light onto areas of the photosensitive drum. This creates a latent electrostatic image, which later is developed into a visible image. Laser light is produced by a small modulated laser diode. The beam created by the diode shines onto a rotating polygonal mirror. As the mirror rotates, the beam reflects off the mirror and sweeps the page from left to right (see Figure 5-10).
At the beginning of each sweep (before the beam reaches the drum), the beam is reflected off the beam detect mirror. The momentary pulse of light is sent to the DC Controller, where it is converted to an electrical signal used to synchronize the output of data (VDO) for one sweep (scan line). This pulse, referred to as the Beam Detect signal (BD), is used to diagnose problems with the laser diode or scanner motor also.
Developing Stage The developing station 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 attracted to the magnetic core of the cylinder. A rubber blade “brushes” the toner on the developing cylinder to a uniform thickness.
The DC bias of the developing cylinder is adjusted to change the force of attraction between the toner and drum by changing the print density setting from the control panel. A change in DC bias causes either more or less toner to be attracted to the drum, which in turn either increases or decreases the print density. The print density variation is approximately ±10% (see Figure 5-13). Both the primary and developer DC bias voltages are changed in response to the density setting.
Transferring Stage At the transferring station, the toner image on the drum’s 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’s surface to be attracted to the page. The small radius of the drum and the stiffness of the paper peel the paper away from the drum. The static charge eliminator also helps separate the paper from the drum.
Fusing Stage At the fusing station, 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. To keep the toner or paper from sticking, the upper fusing roller is covered with a non-stick, “Teflon-type” sleeve. The fusing roller contains an halogen quartz lamp that provides heat for the fusing process.
Paper Feed System Note LJ 4 / 4 Plus LJ 5 The LJ 5 printer designators differ as follows.
The Paper Feed Assembly performs horizontal registration of the print media through the Oblique Rollers. As the print media passes through the Oblique Rollers, the media is moved uniformly to the left side of the print path. The movement ensures that each print image is oriented properly on the horizontal axis.
Figure 5-17 Paper Feed Assembly (Sectional View) Table 5-6 Part Description PS1 Leading Edge Registration Sensor PS2 PC Tray (Tray 2) Paper Out Sensor PS3 Exit Sensor PS4 MP Tray (Tray 1) Paper Out Sensor PS5 MP Tray (Tray 1) Paper End Sensor SL1 Cassette (Tray 2) Pickup Roller Clutch Solenoid SL2 MP (Tray 1) Tray Pickup Roller Clutch Solenoid 5-28 Functional Overview
Printing from the MP Tray (Tray 1) MP tray selection is provided by the Formatter PCA, as configured by the operator’s control panel or by a software application. The MP tray (Tray 1) feed system’s paper motion begins when the DC Controller PCA, after receiving a PRNT signal, starts the Scanner Motor (M5) and the Main Motor (M1).
Printing from the PC Tray (Tray 2) PC tray selection is provided by the Formatter PCA, as configured by the control panel or by software. When the DC Controller PCA receives a PRNT signal, it starts the Scanner Motor (M5) and the Main Motor (M1). When the fusing roller reaches the minimum operating temperature (approximately 183° C), the PC tray (Tray 2) pickup roller clutch solenoid (SL1) is energized for 1 second, allowing the roller to make one rotation.
Power System When the main power switch is turned ON, the AC Power Supply provides AC voltage to the DC Power Supply and the fuser assembly heat lamp. The paper path doors must be closed to activate the AC power supply door switches before voltage is provided to the heat lamp. The DC Power Supply generates +5V DC, and +24V DC for use by the Formatter PCA and the DC Controller PCA. The DC Controller PCA distributes voltages to the remaining electrical assemblies.
Figure 5-20 Power System Block Diagram 5-32 Functional Overview
Basic Sequence of Operation The Formatter PCA and the DC Controller PCA share information during printer operation. Connector J7 on the formatter and connector J207 on the DC controller form a link which operates as a serial data bus. This allows printer status, command information, and dot-image data to be passed between both controllers.
6 Each time the formatter receives a synchronized BD signal from the DC controller, the formatter sends a VIDEO data stream (VDO) to the DC controller. 7 After the DC controller receives the VDO data, the DC controller translates it into a VIDEO OUT signal (VDOUT) that switches the laser diode ON and OFF. 8 The laser beam, created by the laser diode, reflects off the scanner mirror onto the photosensitive drum to form a latent electrostatic image, writing a single line of print (dot) data.
This a 2 panel pull-out.
This a 2 panel pull-out.
Warmup Period The Warmup period begins when the printer’s power is turned ON, and ends when the fusing roller temperature reaches 172° C. When the printer is switched ON, the exhaust fan (FM1) begins low-speed rotation and the fusing roller maintains 172° C. The DC controller then switches the main motor (M1) ON, and applies AC high voltage to the primary charging roller to remove any residual charge from the photosensitive drum.
Initial Rotation Period When the DC controller receives a PRINT signal (PRNT) from the formatter, the DC controller allows the fusing roller to begin warming up to approximately 183° C, and starts the main motor (M1), the pickup motor (M2), and scanner motor (M5). Next, the laser diode turns ON and generates a sweep beam used to adjust the laser power (APCIN). After the DC controller receives a BEAM DETECT signal (BD) initiated by the sweep beam, the laser power stabilizes and the sweep beam turns OFF.
If a failure occurs during this period, the following errors may be displayed: 50 SERVICE This error occurs when the fusing roller fails to reach the correct temperature in the required time (see “50 SERVICE”) in Chapter 7). 51 ERROR This error occurs when the BD signal is not received by the DC controller, (see “51 ERROR BEAM DETECT)” in Chapter 7). 52 ERROR This error occurs when the scanner motor fails (see “52 ERROR,” Chapter 7).
Print Period When the leading edge of the paper activates the input/registration sensor (PS1), the DC controller forces the laser diode ON until a BD signal is received. Next, the DC controller receives a VIDEO data stream (VDO) from the formatter.
The formatter then sends VDO data to the DC controller. The DC controller translates the VDO signal into a VIDEO OUT signal (VDOUT), which modulates the laser diode ON and OFF, creating intermittent bursts of laser light that are reflected off the scanner mirror and onto the photosensitive drum to form a latent electrostatic image. Upon receipt of a BD signal from the DC controller, VDO data is sent from the formatter for each scan line of print data on a page.
Last Rotation Period After printing is complete, the Last Rotation period begins, during which residual static charges are eliminated from the photosensitive drum to prepare for the next printed page. About 1.7 seconds after the Last Rotation period begins, a nominal standby voltage is applied to the transfer roller to stop the toner attraction. Then, 4.
6 Removal and Replacement This chapter describes the complete disassembly of the printer from the beginning. In every instance, tasks that must be performed before beginning the procedure are listed first. Remove the assemblies in the order listed to prevent damage during re-assembly. Removal and replacement of user-replaceable maintenance items is shown in Chapter 4, “Preventive Maintenance.
Required Tools Table 6-1 Required Tools QTY TOOL 1 #2 Magnetized Phillips Screwdriver (6-inch shaft) 1 Small Needle Nose Pliers 1 Small Flat-head Screwdriver (6-inch shaft) 1 5mm Nut driver Hardware Review All screws used in the printer are Phillips head, which require a Phillips screwdriver. Figure 6-1 shows the difference between a Phillips and a Pozidriv screwdriver. Note that the Phillips tip has more beveled surfaces. Use of a Pozidriv screwdriver will damage the screw heads.
Table 6-2 describes the screws used in the printers, and provides guidelines to help determine where each type of screw is used. The screws can vary in length depending on the thickness of the material being fastened. Typically, plated screws are used in areas visible to the customer, and black screws are used in all other areas of the printer. Always note where each type of screw is located and replace each one into its original location.
Removing the Covers Right Side Cover Removal Figure 6-2 Right Side Cover Release Points LJ 4/4 Plus 1 Open the Top Cover and release the Right Side Cover by pressing at the points shown in Figure 6-2. 2 Fold the cover away from the printer to release the bottom supports and lift the door off of the printer frame. LJ 5 1 Open the Top Cover and loosen the retaining screw on the right side cover located at the upper right rear of the printer.
Top Cover Removal Figure 6-3 Front Top Cover Screws and Latches Open the Top Cover. Remove the Right Side Cover. Open the Rear Door. Remove the (3) screws shown in Figure 6-3, callout 1. Release the (2) latch points with a flat screwdriver while lifting the Top Cover (see callout 2.) 6 Carefully lift the top cover to access the Control Panel cable.
Figure 6-4 Control Panel Cable 7 Disconnect the Control Panel Ribbon Cable and remove the top cover (see Figure 6-4).
Left Side Cover Removal Figure 6-5 Left Side Cover Latches 1 Remove the Right Side Cover and the Top Cover. 2 Release the 2 latch points on the Left Side Cover (front latch first) see Figure 6-5. The latches are on the inside of the Left Side Cover. 3 Fold out the cover and remove. Note When removing the LJ 5 left side cover, you must gently push the Tray 1 cover forward to enable the left side cover to be folded out and removed.
Rear Door Removal Figure 6-6 Releasing the Door Support 1 Remove the PC tray (Tray 2). 2 Open the Rear Door. Support the door with one hand. 3 Release the door support from the rear of the printer frame as follows: (see Figure 6-6) a Using needle-nose pliers, squeeze the tabs on the end of the retaining strap. Slide the strap up and out of the printer frame. b Release the retaining strap tab from the slot in the printer frame. c Lift the tab to free it from the slot.
Figure 6-7a Releasing the Door Hinge (LaserJet 4/5) 4 LaserJet 4/5: Flex the Rear Door to release it from its hinges. Press the middle of the door while lifting either side (Figure 6-7a). LaserJet 4 Plus: Remove the Rear Door Attaching Clip (Figure 6-7b, callouts 1 through 3). Slide the Rear Door as far as possible toward the left, then rotate to remove (Figure 6-7b, callouts 4 and 5).
Font Door Cover Removal (LJ 5 Right Front Cover Removal) Figure 6-8 Font Door Removal (LaserJet 4 shown) LJ 4/4 Plus 1 Remove the Right Side Cover, the Top Cover,and the PC Tray. 2 Release the top latch (see Figure 6-8, callout 1). 3 Release the (2) lower latches through the access hole in the metal cover (see Figure 6-8, callout 2 and Figure 6-9, callout 1). 4 Remove the Font Door Cover. Note Figure 6-9 shows the metal side cover removed in order to show the Font Door latches.
Figure 6-9 Font Door Cover Latches Removal and Replacement 6-11
Multi-Purpose (MP) Tray (Tray 1) Door Removal Figure 6-10 Removing the MP Tray Door 1 Remove the PC Tray. 2 Open the MP Tray door and extend the MP Tray. 3 Bend the Door Slides out to release the tray from the door slides (see Figure 6-10). Place the inner door in the “up” position. LJ 4/4 Plus 4 Flex the MP tray at the lower middle and release the door from its hinges (seeFigure 6-10). LJ 5 4 Slide Tray 2 to the right to release it from its hinges.
Multi-Purpose (MP) Tray (Tray 1) Removal Figure 6-11 Remove the Crossmember Bracket 1 Remove the Right Side Cover, Top Cover, Left Side Cover, MP Tray Door (Tray 1), and the Font Door Cover. 2 Remove the PC Tray (Tray 2). 3 Remove the (2) screws in the Cross-member Bracket as shown in Figure 6-11, callout 1. Remove the Cross-member Bracket.
Figure 6-12 Rotate the Tray Down to Release the Hinge from its Slots 4 On the LJ 4+ and LJ 5 you must release the tray tension spring located at the left side of the tray. Use a pair of needlenose pliers to remove the spring from the tray. 5 Rotate the tray down until it slides off its slotted hinges (about 120°)(see Figure 6-12).
Assemblies Removal Power Supply Removal Figure 6-13a Remove the Sheet Metal Plate (LaserJet 4) 1 Remove the Right Side Cover. 2 Remove the (3) or (2) screws from the metal cover at the lower right corner of the printer (see Figure 6-13a or b, callout 1.) Remove the metal cover. Note which end of the connecting rod is installed into the Power Supply and which end connects into the Rocker Switch. Note 3 Remove the Power Switch Connecting Rod (callout 2.
Figure 6-13b Remove the Sheet Metal Plate (LaserJet 4 Plus/5) Figure 6-14 Power Supply Screws 4 Remove the (2) screws from the bottom frame (see Figure 6-14, callout 1). 5 Slide the power supply out the right side of the printer to access the power supply connectors.
Figure 6-15 6-wire and 3-wire Connectors for the Power Supply 6 Remove the (2) connectors (6 wire and 3 wire). (See Figure 6-15, callout 1.) Squeeze the release tab on the 6-wire connector. Pull the 3-wire connector straight up. 7 Remove the power supply. Note When replacing the power supply, be sure to use the screws with the star washers to ensure proper grounding and RFI shielding.
Paper Feed Assembly Removal Figure 6-16 Paper Feed Assembly Screws and Connectors 1 Remove the Right Side Cover, the MP opening cover, (see Figure 6-17), the Top Cover and the Left Side Cover, the Font Door Cover, and the PC tray (Tray 2). The MP tray need not be removed, but is shown removed for clarity. 2 Remove the MP Tray (Tray 1) door, the Front Cross-member (Figure 6-11), and the MP Tray.
Figure 6-17 MP Tray Opening Cover (continued on next page) Removal and Replacement 6-19
Figure 6-18 Paper Feed Assembly Screws (numbered) 5 Remove the (3) screws from the left side of the printer (see Figure 6-18, callout 1). 6 Remove the Paper Feed Assembly by lifting it and sliding it out the front of the printer. Note Replace the screws in order as shown. (1-2-3 is also scribed on the printer chassis.) Tightening these screws in the wrong order can cause paper skew problems.
High Voltage Power Supply (HVPS) Removal Figure 6-19 HVPS Screws (2) and Latches (2) (Bottom View) 1 Remove the Toner Cartridge and PC tray. 2 Lay the printer on its left side. (Place a cloth under the printer to prevent marking the cover.) 3 Remove the (2) screws that hold the HVPS in place (see Figure 6-19, callout 1). 4 Release the (2) latches that hold the High Voltage Power Supply (see Figure 6-19, callout 2).
Fuser Assembly Removal Figure 6-20 Fuser Assembly Screws Caution The Fuser Assembly may be hot. Allow plenty of time for the fuser to cool before beginning the fuser removal procedure. 1 Open the rear door. 2 Remove the (2) screws that hold the Fuser to the printer frame (see Figure 6-20, callout 1). 3 Slightly lift the Fuser by both the right and left sides to clear the locator points. 4 Pull the Fuser from the printer.
Control Panel and Overlay Removal Figure 6-21 Control Panel Latches 1 Remove the Right Side Cover and the Top Cover. 2 Turn the Top Cover over and place it on flat surface. 3 Release the (3) latches that contain the Control Panel (see Figure 6-21, callout 1). 4 Carefully pivot the Control Panel away from the Top Cover. (continued on next page) Note To remove the LaserJet 5 Control Panel, first remove the black screw securing the grounding leaf spring and the Control Panel plate to the Top Cover.
Figure 6-22 Changing the Control Panel Overlay 5 If you must replace the Control Panel Overlay, release the (2) retaining tabs from the Control Panel and separate the overlay from the Control Panel (see Figure 6-22, callout 1). 6 Squeeze the sides of the Control Panel Overlay to release the (2) tabs (see Figure 6-22, callout 1). 7 Tilt the Overlay up and out.
Removing the SIMMs Door Figure 6-23a Removing the SIMMs Door (LaserJet 4) 1 Remove the Right Side Cover. LaserJet 4: 2 Remove the (2) screws that hold the SIMMs cover (see Figure 6-23a, callout 1). 3 Open the SIMMs cover, lift the door slightly to remove the door from the hinge.
Figure 6-23b Opening the SIMMs Door (LaserJet 4 Plus) LaserJet 4 Plus/5: 2 Remove the (1) screw that holds the SIMMs cover (see Figure 6-23b, callout 1). 3 Swing open the SIMMs cover.
Formatter Cage Removal Figure 6-24a Formatter Cage Screws (Right Side View LaserJet 4 and 5) Note You may wisht to remove the metal cover (on the lower right side) and the power supply for easier access to the Formatter Cage screws. 1 Remove the Right Side Cover and the Top Cover. 2 LaserJet 4 and 5: Remove the (7) screws (6 screws in the LJ 5) shown in Figure 6-24a. (2) screws are on the right rear of the printer, (1) screw is under the lower front of the Formatter Cage (except LJ 5).
Figure 6-24b Formatter Cage Screws (Right Side View LaserJet 4 Plus) Figure 6-24c Formatter Cage Screws (Rear View - LaserJet 4 Plus) 6-28 Removal and Replacement
Formatter PCA Removal Caution The Formatter PCA is very sensitive to Electrostatic Discharge (ESD) damage. Observe proper ESD procedures when servicing the printer. Note Before removing the old Formatter PCA, print a 05 SELF TEST to check the current printer page count, if possible. If a self test is not possible, enter the Service Mode, if possible, to display the page count (see “Service Mode” in Chapter 3).
LaserJet 4 Formatter PCA: 1 Remove any MIO or SIMM modules from the Formatter Assembly. 2 Remove the (2) black screws from the side of the Formatter Cage (see Figure 6-25a, callout 1). 3 Remove the MIO Connector Support Bracket (see Figure 6-25a, callout 2). 4 Remove the (2) Formatter PCA mounting screws (see Figure 6-25a callout 3).
5 Remove the (4) Interface Connector Support Screws from the rear of the Formatter Cover. The RS-232 connector is held with 5mm hex-head cap screws (see Figure 6-25b, callout 1). The parallel connector (see Figure 6-25b, callout 2.) is held in place with Phillips screws. 6 Remove the Formatter PCA. Figure 6-25b Interface Connector Support Screws (LaserJet 4) Note When replacing the Formatter Assembly be sure to reinstall all SIMM modules and MIO cards.
LaserJet 4 Plus and 5 Formatter PCA 1 Remove any MIO or SIMM modules from the Formatter Assembly. 2 Remove the MIO Connector Support Bracket (see Figure 6-25a, callout 2). 3 Remove the (4) I/O screws (see Figure 6-26 callout 1). 4 Remove the (2) Formatter PCA mounting screws (see Figure 6-26 callout 2). Figure 1-26 Interface Connector Support Screws (LaserJet 4 Plus and 5) Note When replacing the Formatter Assembly be sure to re-install all SIMM modules and MIO cards.
DC Controller Removal Figure 1-27a DC Controller Connectors/Retaining Clips (LaserJet 4) Note Note the cable routing before beginning this disassembly procedure. Be careful not to damage the cables during re-assembly. Remove the Right Side and the Top Cover Assemblies. Remove the Formatter Cage Assembly. Remove the 6-wire connector from the Power Supply. Remove the plastic DC Controller cover (LaserJet 4 Plus). Remove the DC Controller connectors (see Figure 6-27a or 6-27b, callout 1).
Figure 1-27b DC Controller Connectors/Retaining Clips (LaserJet 4 Plus/5) 6-34 Removal and Replacement
DC Controller Installation Caution When reinstalling the DC Controller PCA it is extremely important that all cables be properly routed. If cables are not routed properly, it is difficult to reinstall the Formatter Cage and cable damage may result. When replacing the DC Controller, be sure to set the leading edge adjustment as shown in the following procedure. Note The Leading Edge Adjustment is set at the factory and is not required as a maintenance procedure.
Figure 1-28 Leading Edge Registration Adjustment Dimensions Figure 1-29 VR202 Settings (LaserJet 4 shown) 6-36 Removal and Replacement
Main Motor Assembly Removal Figure 1-30 Main Motor Assembly 1 Remove the Right Side Cover, Top Cover, and the Formatter Cage Assembly. 2 Unplug the Main Motor connector from the Main Motor Assembly (see Figure 6-30, callout 1). 3 Remove the (4) Main Motor screws (see Figure 6-30, callout 2). 4 Remove the Main Motor.
Gear Assembly Removal 1 Remove the Top Cover, the Right Side Cover, the Fuser Assembly, and the Formatter Assembly. 2 Remove the Main Motor Assembly (see Figure 6-30). 3 Remove the (2) screws that hold the Gear Assembly (see Figure 6-31 callout 1). 4 Slide the Gear Assembly from the rear of the printer. Note Before tightening down the mounting screws, be sure the shoulder around the upper left mounting screw hole on the gear assembly protrudes through the frame.
Fan Removal Figure 1-32 Fan Connector Note Note the cable routing before beginning this disassembly procedure. Be careful not to damage the cables during re-assembly. 1 Remove the Right Side Cover, the Top Cover, and the Formatter Cage Assembly. 2 Unplug the fan connector (J209 on the LaserJet 4, J211 on the LaserJet 4+/5). (See Figure 6-32, callout 1.
Figure 1-33 Exhaust Fan Removal (Laser Jet 4 shown) 3 Remove the RFI shield (LJ 4 only) by releasing the retaining tab and sliding the shield up (see Figure 6-33, callout 1). 4 Laser Jet 4: Release the (4) clips from the fan ducting to provide clearance and remove the fan from the top of the printer (see Figure 6-33, callout 2). Laser Jet 4 Plus/5: Remove (1) screw on the right-rear and release the tabs on the lower left adjacent to the Output Paper Assembly 5 Remove the fan.
Output Assembly Removal Figure 1-34 Output Assembly Removal 1 Remove the Right Side Cover, the Top Cover, and the Left Side Cover. 2 Release the grounding strap from the left side of the frame. 3 Rotate the top of the Output Assembly toward the front of the printer while releasing the two retaining latches (see Figure 6-34, callout 1) until the locating tabs are free. Slide the assembly to the rear and lift it out of the printer.
Paper Exit Sensor (PS3) Removal Figure 1-35 Exit Sensor 1 Remove the Right Cover, Top Cover, and the Output Assembly. 2 Disconnect the Sensor Cable. 3 Lift the Sensor Retaining Latch and slide the sensor forward (see Figure 6-35). 4 Remove the Paper Exit Sensor.
Scanner Assembly Removal Figure 1-36 Scanner Assembly Removal 1 Remove the Right Side Cover, Top Cover, Left Side Cover, and the Output Assembly. 2 Remove all cables from the Scanner retaining clips. 3 Remove the (3) connectors (see Figure 6-36, callout 2). Note Be careful not to flex the Laser PCA when removing or installing the cables. The Laser PCA can be damaged easily. 4 Remove the (4) screws from the Scanner Assembly. (see Figure 6-36, callout 1). 5 Remove the Scanner Assembly.
Lower Cassette Assemblies The field-replaceable assemblies of the Lower Cassette are: • Lower Cassette Sensor PCA Assembly • Lower Cassette Pickup Motor Assembly Lower Cassette Sensor PCA Removal 1 Release the Sensor PCA cover latches (see Figure 6-37 callout 1). 2 Cut the tie-wrap and remove the (3) sensor connectors (see Figure 6-37 callout 2). 3 Release the catch at the bottom rear of the Sensor PCA. (Use a slender object like a flat-blade screwdriver.) 4 Remove the Sensor PCA.
Lower Cassette Pickup Motor Removal Figure 1-38 Lower Cassette Upper Front Cover 1 Open the sensor cover and disconnect the center and rear connectors (see Figure 6-37, callout 2). 2 Release the (2) tabs that hold the Upper Front Cover (access the tabs through the slots with a small screwdriver - see Figure 6-38 callout 1). Remove the cover by rotating it toward the front. 3 Remove the (2) screws from the front and rear left side (see Figure 6-38 callout 2).
Figure 1-39 Lower Cassette Motor 5 Lift the motor assembly straight up out of the the Lower Cassette Base (see Figure 6-39). Note Note the ground connector underneath the Motor Assembly. Be careful not to damage this connector during reassembly.
Replacing Fuser Assembly Parts The following procedures describe the removal and replacement of major Fuser Assembly Components (Fusing Roller, Thermistor, Thermoswitch, and Heater Lamp). When performing these procedures, note the order in which the parts were removed and their orientation. Caution Handle the Heater Bulb by the ceramic ends. Do not touch the Heater Bulb, or allow it to become contaminated. If contamination occurs, clean the bulb thoroughly with isopropyl alcohol.
Fuser Assembly Configuration Figure 6-40 provides an overview of the orientation of the major Fuser Assembly components. Before beginning the fuser disassembly procedures, become familiar with the location and orientation of the various Fuser Assembly parts (see Table 6-1).
Removing the Fuser Roller Heat Lamp Figure 1-41 Fuser End Cap Removal (LaserJet 4 only) 1 Laser Jet 4 only: Remove the (2) latches that hold the right side cover. (There is a gear exposed on the right side of the fuser, see Figure 6-41, callout 1.) 2 Release the (7) latches on the LaserJet 4 or the (5) latches on the LaserJet 4 Plus that hold the wire cover to the Fuser Assembly. These latches can be accessed through slots on top of the fuser.
Figure 1-42 Fuser Wire Harness Cover Removal (LaserJet 4) 3 LaserJet 4: With a screwdriver, release the latches by first pressing to clear the lower latch, then lifting to release the upper latch (see Figure 6-42a). LaserJet 4 Plus: With a screwdriver, release the latches by first pressing to clear the lower latch, then lifting to release the upper latch. Repeat until all (4) latches are free, then rotate the cover to release the latch on the side (see Figure 6-42b and 6-42c).
Figure 1-42b Fuser Cover End Latches (LaserJet 4 Plus) Figure 1-42c Fuser Wire Harness Cover Removal (LaserJet 4 Plus) (continued on next page) 6-51 Removal and Replacement
Figure 1-43 Left Side Fuser Cover 5 Remove the (1) Heat Lamp lead (thermoswitch screw)(see Figure 6-43 callout 1). 6 Press the thermoswitch tab towards the paper exit flag to release the tab (see Figure 6-43 callout 2). Slide the Thermoswitch off the fuser frame (see Figure 6-43, callout 3). 7 LaserJet 4: Remove the cable retainer from the fuser frame, and free the heat lamp lead from the cable retainer. Note the orientation of the cable retainer.
Figure 1-44 Gear Side Heat Lamp Connector Note LaserJet 4 and 5 only: Note the orientation of the bushing on the left side of the Fusing Roller. 8 Squeeze the lamp connector to release the slip-on connector locking tab from the right side of the heat lamp (see Figure 6-44, callout 1).
Figure 1-45 Fuser Gear Cap Removal Note Before removing the gear cover, note the routing of the wires in the gear cover slots. 9 Remove the (2) screws from the right side gear cover (see Figure 6-45, callouts 1 and 2). Note the wavy washer on the (1) screw (callout 1) touching the copper contact. Remove the cover. 10 Remove the Heat Lamp (see Figure 6-45, callout 3), from the roller. Pull the lamp out the side of the assembly.
Fuser Assembly Thermoswitch Removal Note Six of the seven latches are accessed from the top of the wire cover. These latches are beneath the felt pad. The slot on the front left side of the wire harness cover is the best place to begin removing the cover. 1 Remove the Wire Harness Cover as shown in Figure 6-42a (LaserJet 4) or Figure 6-42b and c (LaserJet 4 Plus). 2 Remove the (2) screws from the Thermoswitch connector (see Figure 6-46, callout 1).
Thermistor Removal Figure 1-47 Thermistor Connector 1 Remove the Wire Harness Cover as shown in Figure 6-47. 2 Remove the (2) screws from the thermoswitch connector (see Figure 6-47, callout 1). 3 Release the thermoswitch latch from the paper sensor flag side of the Fuser Assembly (behind the side cover, see Figure 6-47, callout 2). 4 Slide the thermoswitch to the gear side of the fuser and release it from the fuser frame (callout 3).
Figure 1-48a Upper Fuser Frame Removal (LaserJet 4) 5 Release the (2) springs from the Upper Fusing Frame (see Figure 6-48a, callout 1). 6 Release the tabs that hold the Upper Fusing Frame to the Fuser Body (see Figure 6-48a). Rotate the Upper Frame backwards to release and access the Thermistor (see Figure 6-48b, callout 1).
7 Remove the (1) screw that holds the Thermistor (see Figure 6-48b, callout 2). Note Ensure the thermistor cable is routed correctly when assembling the fuser (see Figure 6-47).
Paper Control PCA Removal Figure 1-49 Paper Control PCA Retaining Screws and Latches 1 Remove the Right Side, Top, Left Side, and Font Door Covers, then Paper Feed Assembly. 2 Disconnect the cables from the sensors (see Figure 6-49, callout 1). 3 Remove the (2) self-tapping screws from the Paper Control PCA (see Figure 6-49, callout 2). 4 Release the (5) latches that retain the Paper Control PCA (see Figure 6-49, callout 3).
Sensor PCA Removal Figure 6-50 Sensor PCA Removal 1 Remove the Right, Left, Top, and Font Door covers. You need not remove the MP Tray. 2 Perform the Paper Control PCA removal procedure, as shown in the preceding section. 3 Disconnect the connectors for SL1, SL2, and M2 from the left end of the Sensor PCA. 4 Release the (3) clips that hold the Sensor PCA cover. Remove the cover (see Figure 6-50, callout 1). 5 Remove the Sensor PCA by sliding it to the left and dropping it down.
PS1 and PS2 Sensor Assembly Removal Figure 6-51 Removing the PS1/PS2 Sensor Assembly The PS1 and PS2 sensors are located under the Paper Feed Assembly. 1 Remove the Paper Feed Assembly and place it on a flat surface, with the MP Tray side down. Note You need not remove the MP Tray from the Paper Feed Assembly. Use a cloth to protect the MP Tray door from scratches. Remove the PC Tray Pickup Roller. Disconnect blue-wired connector on the bottom, (callout 1). Remove the center pin from the dowel post.
High Voltage Contact Plate (HVCP) and Paper Guide Removal This procedure involves removing many subassemblies and difficult disassembly processes. Because this procedure is complex, it is separated into three sections: • Accessing the HVCP and Feed Guide Assembly. • Removing the HVCP and Feed Guide Assembly. • Replacing the HVCP and Feed Guide Assembly. Allow plenty of time to perform this procedure, and be careful not to damage any parts during reassembly.
After removing the Fuser Assembly, remove the contact plate from the rear of the printer, as follows: 1 Remove the (1) screw from the sheet metal Guide Plate Cover. (This screw is behind the Fuser Assembly, see Figure 6-52, callout 1). 2 Remove the Guide Plate Cover by freeing the front edge, lifting upward, and sliding the cover out the rear of the printer. Note Do not lose any of the (6) rollers the Guide Plate Cover holds in place.
Figure 6-53 Paper Guide Rollers 3 Remove the (6) rollers from the High Voltage Contact Plate (see Figure 6-53 callout 1).
Figure 6-54 Cross Member Screws 4 From the front of the printer, remove the (2) black self-tapping screws that hold the Inner Cross-member. Remove the cross-member (see Figure 6-54 callout 1).
Figure 6-55 Left Toner Cartridge Guide Plate Screw 5 From the left side of the printer, remove the (1) or (2) black, self-tapping screw(s) that holds the Left Toner Cartridge Guide Plate (see Figure 6-55, callout 1). 6 Release the guide plate latch (see Figure 6-55, callout 2). 7 Remove the Laser Shutter Pivot Pin from its seat in the Left Toner Cartridge Guide Plate (see Figure 6-55, callout 3). These two steps (5 & 6) are required for the next stage of the HVCP removal process.
Removing the High Voltage Contact Assembly and Feed Guide Assembly Note The following procedures are difficult and the components are damaged easily. The tolerances between the parts are close and several attempts may be necessary before the procedure is complete. Figure 6-56 High Voltage Contact and Feed Guide Assembly Latches 1 Perform all the steps of “Accessing the High Voltage Contact Plate/Feed Guide Assembly” in the order given. 2 Press the tab shown in Figure 6-56 to release the gear cover.
Replacing the High Voltage Contact Assembly/Feed Guide Assembly The Toner Cartridge Guide Plate and the High Voltage Contact Assembly/Feed Guide Assembly must be installed together. Allow plenty of time to perform this procedure because several iterations of the process may be necessary. 1 Set the contact assembly over its mounting holes. 2 Slide the Toner Cartridge Guide Plate into position on a diagonal line (see Figure 6-57).
Interconnect PCA Removal The Interconnect PCA is a connector board that connects the Power Supply and the DC Controller with the the Fuser Assembly. The Fuser Assembly connects directly into the Interconnect PCA. The Power Supply and the DC Controller have wiring harnesses that connect them to the Interconnect PCA. Note Re-assembly of the the Interconnect PCA requires a small tie-wrap. Be sure to have a tie-wrap available before beginning the disassembly.
Note Access the Interconnect PCA Housing by laying the printer on the rear of the printer chassis. Figure 6-59 Interconnect PCA latches and AC Connector Mounting Pins 4 Disconnect the Interconnect Cable connector from the DC Controller (J210 on LJ4, J213 on LJ4+/5). Remove the cable from its retainer. 5 Release the bottom or rear-most latch (see Figure 6-59), callout 1) holding the arm of the Interconnect PCA housing to the sheet metal.
Note The AC Connector has polarity. Note the orientation of the AC Connector before removing it. This is required in order to install the connector with the same polarity during assembly (see Figure 6-60). 7 Release the AC Connector from the sheet metal with needle-nose pliers. Service Hint: Use a 5mm nut driver to press the AC Connector retaining pins from the sheet metal.
6-72 Removal and Replacement
7 LaserJet 5 Error Map The LaserJet 5/5M/5N printer has error messages that are similar to the LaserJet 4/4M/4+/4M+. Use the following table to look up the LJ5 error and take the recommended action. If the recommendation is to see another error, for example See 00 POWERSAVE, look up the recommendation for that error in the Printer Message Troubleshooting section (Tables 7-1 and 7-2).
Message on LJ 5/5M/5N Recommendations INCOMPATIBLE TRAY 3 INSTALLED Indicates that a lower cassette has been installed that is not compatible with the LJ5. Press GO to clear the error. The tray will not appear in any control panel or PJL messages.
Message on LJ 5/5M/5N Recommendations REMOVE PAPER JAM See 13 PAPER JAM REQUESTED LANGUAGE NOT AVAILABLE See W2 INVALID PERS RESETTING ACTIVE I/O See 07 RESET RESETTING ALL I/O See 07 RESET RESTORING FACTORY SETTINGS See 08 COLD RESET TONER LOW See 16 TONER LOW TRAY 2/3 EMPTY Indicates Tray 2 or 3 has run out of paper and has not been selected as the current job’s paper source. If the problem persists, check for a binding sensor flag or replace the appropriate sensor.
7-D LaserJet 5 Error Map
7 Troubleshooting Pre-Troubleshooting Procedures Preliminary Operating Checks Prior to troubleshooting a specific printer problem, you should ensure that: • The printer is being maintained on a regular basis as described in Chapter 4. • The customer is using acceptable media as specified in the User’s Manual. • The printer is installed on a solid, level surface. • The line voltage does not vary more than 10% from the nominal rated value as specified on the Power Rating Label.
Printer Message Troubleshooting Printer Message Summary Table Table 7-1 is a list of all status, attendance, error, and service messages affecting the printers. The table also identifies the action required to correct the situation identified by the message. When the action requires removal and replacement of an assembly or PCA, refer to the applicable section of Chapter 6 for instructions. For general location of components, refer to Troubleshooting Aids at the end of this chapter.
Table 7-1 Printer Messages (continued) Message Symptoms and Recommendations 07 RESET RESETTING [xxx] Returns all printer settings to Printing Menu settings, and clears buffered pages, temporary soft fonts, and macros. Wait for the printer to display the 00 READY message. See the Reset Menu section in Chapter 3 for more details. 08 NVRAM_INIT Printer is initializing non-volatile RAM. This allows other personalities to access non-volatile RAM.
Table 7-1 Printer Messages (continued) Message Symptoms and Recommendations 18 AUX IO INIT This message is displayed when the MIO (AUX IO) card is in the process of initializing. During initialization the MIO is not active, but since the printer supports I/O switching, the printer remains on line and this becomes a status message. Display clears automatically (this may take up to a minute, depending upon the card). 18 AUX IO NT RDY The MIO (AUX IO) card is not ready.
Table 7-1 Printer Messages (continued) Message 22 ERROR 22 SERIAL I/O ERROR 22 PARALLEL I/O ERROR 22 HP MIO ERROR 40 ERROR 40 BAD SERIAL DATA FORMAT 40 HP MIO ERROR Symptoms and Recommendations For serial/Bi-Tronics parallel configuration, the computer and printer are not communicating because of improper signal protocols. This is an I/O buffer overrun error. Parallel configuration: may mean a loose cable connection. Serial configuration: wrong pacing option may be selected.
Table 7-1 Printer Messages (continued) Message 53.XY.
Table 7-1 Message 55 ERROR 55 PRINTER ERROR Printer Messages (continued) Symptoms and Recommendations Indicates a communications problem between the DC Controller PCA and the Formatter PCA. Pressing [Continue]* clears the error and resumes printing. Perform the Test Print operation to verify DC Controller functionality. If the message persists, check for any cable damage, and check the DC voltages, or replace the DC Controller. 57 SERVICE 57 MOTOR FAILURE 57.
Table 7-1 Printer Messages (continued) Message 64 64 65 67 SERVICE PRINTER ERROR SERVICE SERVICE Symptoms and Recommendations The printer identified an internal service error. If this error appears, turn the printer OFF, and then back ON. If the problem persists, replace the Formatter PCA. 68 ERROR 68 NVRAM ERROR The printer detected an error in the nonvolatile memory (NVRAM). Press [Continue]*, then check your Control Panel settings. If the problem persists, replace the Formatter PCA.
Table 7-1 Printer Messages (continued) Message Symptoms and Recommendations FR REMOVE CART An accessory cartridge was installed while the printer was in an error state. To clear this message, remove the cartridge, clear the pending error condition, then install the cartridge. ME FEED [envelope size] MANUALLY FEED [envelope size] This message is displayed when there is a request for a manually fed envelope. envelope size may be: COM10, MONARCH, DL, C5, B5, or ENVELOPE.
Clearable Warnings A clearable warning indicates a transient condition in the printer. The printer continues on line while the message is displayed in place of 00 READY. A clearable warning appears each time the printer alters resolution or page protection (this causes reconfiguration of memory), or aborts a job due to an invalid or uninstalled personality, or insufficient memory. Clear the message by pressing [Shift] + [Continue] (or Go for the LaserJet 5).
Table 7-2 Clearable Warning Messages Message Displayed W1 IMAGE ADAPT MEMORY LOW, PAGE SIMPLIFIED Meaning The printer received a graphics print file that was too complex to print at the requested resolution. The printer automatically processed the file in the highest resolution possible with the memory installed. Add additional memory to print the file at full resolution. Check the printout for loss of data or print quality.
Printer Message Troubleshooting Procedures When the following procedures require removing and replacing an assembly or PCA, refer to the applicable section in Chapter 6 for instructions. Blank Display Table 7-3 Blank Display Checks Is the power on? Action 1. Check the ON/OFF switch and verify the power is plugged in. 2. Press a Control Panel key to verify problem still exists. Is the fan working? 1. If the fan is working, check the cabling to the Control Panel.
MP/PC/LC (Tray 1/2/3) LOAD Message The conditions that result in MP/PC/LC LOAD or (TRAY 1/2/3) messages are: • The absence of any input tray. • The absence of media in either tray. • The tray size switches may be defective and not recognize • the presence of the paper tray. The tray is sensed as the tray-identifier tabs contact one or more of the three tray identifier microswitches. The Universal Tray paper size dial setting does not match the installed paper.
Table 7-4 “MP/PC/LC (Tray 1/2/3) LOAD” Message Checks Checks Action Is media present in the tray(s). Install media. Are the proper trays fully inserted in the printer? Reseat the cassettes. Make sure each cassette is fully seated into the printer. Ensure that the Universal Paper tray selector knob setting matches the installed paper. Does the Control Panel’s or application’s Paper size setting match the tray being used? Correct the setting to match tray.
Cassette Size Switches (SW603, SW604, SW605) Functional Check Before beginning this test, remove the Lower Cassette Base and the Envelope Feeder. Also, PS2 (PC or Tray 2 Paper Out sensor) must be engaged for this test to be performed reliably. Push PS2 up towards the rear of the printer with your hand. 1 Power ON the printer with the PC tray removed. Wait for the PC LOAD XXX message. Set PAPER=LETTER in the Printing Menu using the Control Panel.
Table 7-5 Switch Logic for Cassette Size Cassette Cassette Size Sensing Switch SW603/851 SW604/852 SW605/853 Upper Middle Lower Legal ON ON OFF Letter ON OFF ON A4 OFF OFF ON Executive OFF ON ON No Cassette OFF OFF OFF Paper Size Sensing Lower Cassette The operator must set the appropriate paper size for the Lower Cassette using a dial which, in turn, activates switches on the cassette base. This setting is sent to the DC Controller on the serial data bus (SLI).
PC Empty Sensor (PS2) Functional Check 1 Power on the printer with the PC tray (Tray 2) empty. 2 After the 05 SELF TEST and the 02 WARMING UP cycles, the PC LOAD LETTER (or A4) or TRAY 2 EMPTY message appears. 3 Add paper to the PC tray and re-install the tray. 4 The display should read 02 WARMING UP, then 00 READY. If the PC LOAD or TRAY 2 EMPTY message persists, replace PS2.
12 Printer Open Message The 12 PRINTER OPEN (or CLOSE PRINTER COVER) display tells the operator to close the printer’s top cover. The DC Controller detects the Printer Open condition through the position of SW601, which is located on the Paper Feed Assembly PCA . A tab underneath the top cover Door engages SW601 through a slot in the Top Cover Assembly.
SW601 Functional Check 1 Open the Top Cover Assembly. 2 The message 12 PRINTER OPEN (or CLOSE PRINTER COVER) should appear. 3 Close the top cover. The 02 WARMING UP message should appear. 4 If the messages do not occur, check the switch actuator (see Figure 7-2, callout 1) on the top cover, and check that the plunger that covers the switch is in place (see also Figure 7-14 for switch locations). 5 Replace the Paper Control PCA.
13 PAPER JAM Message Paper jams occur when paper fails to arrive at or clear the paper path sensors in the allotted time. Paper movement is monitored primarily by two paper sensors. These are described below and illustrated in Figure 7-3). 1 PS1, the Input/Registration Sensor, located in the Paper Feed Assembly. 2 PS3, Exit Sensor, monitors paper in the Fuser Assembly.
Table 7-7 Jam Location Input Area Jams (Sensed by PS1.) Paper Jam Troubleshooting Checklist Checks and Action Required 1. Check that the Transfer Roller is fully seated and shows no sign of wear. 2. Check that the Toner Cartridge is fully seated. 3. Check that the cassettes are not overfull and the media is loaded correctly. 4. Ensure that the media meets specs. (media is not too smooth or rough), and it has been stored properly. 5.
PS1 (Input/Registration Sensor) Check 1 Power ON the printer with the top cover open. Wait for the 12 PRINTER OPEN (or CLOSE PRINTER COVER) message. 2 Engage PS1 by taping it down. a For the LaserJet 5, install the toner cartridge. 3 Close the top cover. The 02 WARMING UP message should display. 4 After the fuser warms up, the main motor should turn on. 5 The 13 PAPER JAM message appears if the sensor is working correctly.
PS3 (Exit Sensor) Check 1 Open the rear door (cover) of the printer. 2 The display should read 13 PAPER JAM (or REMOVE PAPER JAM) immediately after the door is opened. 3 Close the rear cover. The display should change from 02 WARMING UP to 00 READY. a If the 00 READY message does not appear, check that the rear door is not damaged, and the the door closes and latches properly. b If the PAPER JAM message does not appear, replace PS3.
Lower Cassette Functional Check When troubleshooting a Lower Cassette failure, always prove the failure by removing the Lower Cassette from the printer. Next, test the printer’s ability to move and print media satisfactorily without the Lower Cassette installed. The Lower Cassette is a field-serviceable item. The procedures for removing and replacing the Lower Cassette components are in Chapter 6. Replacement parts for the Lower Cassette Assembly are listed in Chapter 8.
14 NO EP CART Message The printer detects the presence of the Toner Cartridge and the level of toner present in the cartridge through the condition of the ANTIN signal. The ANTIN signal becomes part of the serial data stream used to communicate with the DC Controller (see Figure 7-5 for cartridge components). Troubleshoot the 14 NO EP CART (or INSTALL TONER CARTRIDGE) message as follows: 1 Reseat the Toner Cartridge. Try a new or known good Toner Cartridge. 2 Check the High Voltage Contacts for damage.
6 1 5 4 2 3 Figure 7-5 Toner Cartridge Components Table 7-8 Toner Cartridge Components Callout Assembly 1 Toner Low Voltage Contact 2 Developer Roller High Voltage Contact 3 Developer Roller 4 Photoconductive Drum 5 Charge Roller High Voltage Contact 6 Charge Roller 7-26 Troubleshooting
41.X ERROR Message A 41.X ERROR (misprint) indicates that a temporary malfunction has occurred with the print engine (NOT a Formatter error). Occasional occurrences of this message can be expected. However, persistent 41 ERROR messages indicate a problem requiring attention. The 41.X ERROR is usually accompanied by a blank, or partially printed page. Pressing the [Continue] (or Go) key re-prints the page, and continues the print job.
Table 7-9 41.X ERROR Checks Error Message Recommended Action Reseat all connectors on the DC Controller, the Laser 41.1 ERROR Noisy Vertical Sync (VS) Drive PCA, the Scanner Connector and the Beam Detect Connector. 41.2 ERROR Beam Detect (BD) weak or unstable. Reseat all connectors on the DC Controller. Also check the Laser Scanning Assembly connections. 41.3 ERROR Paper Multifeed 1. Incorrect size selection on the cassette. 2. One of the cassettes is overfull.
50 SERVICE Error - Fuser Malfunction Warning The Fuser Assembly is HOT. Allow the assembly time to cool before servicing. The purpose of the fusing system is to maintain a constant temperature on the fuser roller. A high intensity fusing lamp, located inside the fuser roller, provides the high temperature required for the fusing process. While the printer is in standby mode, a temperature of approximately 172° C is maintained on the fuser roller.
Table 7-10 50 SERVICE Fuser Malfunction Checks Checks Action Is the Fuser Assembly correctly seated? Reseat the Fuser Assembly. Allow adequate time for the error message to clear (10 minutes) and turn the printer ON. Is the Fuser Bulb/ Thermoswitch open? The fuser bulb and thermoswitch are wired in series. To check if one or the other is defective, perform the following: 1. Remove the Fuser Assembly from the printer. 2.
Figure 7-6 Fuser Assembly Connector 51 ERROR Message The 51 ERROR, and the 41.2 ERROR are caused by Beam Detect failures. If the beam detect signal is lost for more than 2 seconds the error is posted as a 51 ERROR. The 41.2 ERROR can be cleared by pressing [Continue] (or Go). The 51 ERROR may be cleared by power cycling the printer. Table 7-11 51 ERROR Beam Detect Checks Checks Action 1. Are all connectors on the DC Controller properly seated? Inspect connectors and wiring.
52 ERROR Scanner Malfunction The scanner motor is a flat, brushless, DC motor. Motor operation is completely controlled by the DC Controller. The scanner motor is enabled when the printer is powered-up (during the printer’s power-on self test), or whenever the PRINT command is received by the Formatter PCA. The scanner motor makes a distinctive sound when starting. The sound can be described as a “variable pitch whirring” sound. Listen for the sound of the scanner motor when troubleshooting the 52 ERROR.
57 (or 57.1) SERVICE Message (Main Motor Failure) The 57 SERVICE indicates that the DC Controller PCA detected a general motor failure. The Main Motor drives all moving components in the printing process. The Main Motor is a 4-phase, DC servo motor controlled by the DC Controller PCA. The formatter detects a Main Motor failure when: • The Main Motor does not come up to speed within one second of receiving drive voltage.
58 (or 57.2) SERVICE (Fan Failure) The 58 SERVICE indicates that the DC Controller detected a failure in the Exhaust Fan (FM1) in the printer or the optional duplexer. When troubleshooting this problem, perform the following steps in the order given. 1 Check that the fan is mounted correctly in its shroud. 2 Check that the fan blades are not blocked. 3 Check that the Cooling Fan connector is firmly seated on the DC Controller (see Figure 7-16 or Figure 7-17 for location).
Image Defect Summary The quality of the printer’s 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 figures illustrate some print quality defects. Keep copies of print quality defects encountered in the field with an explanation of their causes for future reference. The image defects listed below are covered in the following tables.
Figure 7-7 Image Defect Summary 7-36 Troubleshooting
Figure 7-8 Image Defect Summary Troubleshooting 7-37
Table 7-12 Black Pages Possible Cause Action The HVPS connections are dirty. Clean the HVPS terminals (see Figure 7-18 for layout). The HVPS is installed improperly. If the HVPS has been removed and replaced, it may not be seated properly. Remove the HVPS, and check the connectors for damage. Reseat the HVPS, being certain to fully seat the connectors. Bad Primary Charging Roller. Replace the Toner Cartridge. The HVPS is defective. Replace the HVPS. DC Controller PCA.
Table 7-14 Faulty Registration Possible Cause Action Paper. The surface of the paper may be too smooth for the pickup roller to move the paper through the paper path. Change paper. Try a brand of paper known to be good. Worn Pickup Roller and Separation Pad. If the Paper Pickup Roller, or the Separation Pad are sufficiently worn, the leading edge of the paper may not reach the registration assembly in time. Replace the Pickup Roller and Separation Pad together. PS1 faulty.
Table 7-15 Right-Hand Image Missing Possible Cause Action No toner available for print. Shake/replace the EP Toner Cartridge. Laser shutter may be blocking the beam Ensure that the mechanism that lifts the shutter is functional, for example, the shutter doesn’t stick in its travel, and is lifted evenly. Table 7-16 Small Print Voids Possible Cause Small voids on black, or near-black printed images may be caused by imbedded toner on the electro-photographic drum.
Table 7-19 Repetitive Defects Possible Cause Action Toner Cartridge. The circumference of the photoconductive drum is 3.75 inches (94mm). The circumference of the developer roller is 2 inches (51mm). If a defect appears in the print image at these intervals, assume the defect is associated with the Toner Cartridge. Replace the Toner Cartridge. Fuser Assembly. The Fuser Roller’s circumference is approximately 2.5 inches (63mm) for the LJ4, and 3-1/8 (79mm) for the LJ4+/5.
Table 7-20 Smeared Print/Improper Fusing Possible Cause Action Fuser levers not in place. (All LJ4, some LJ4+, N/A on LJ5) The Fuser Assembly has shipping levers that must be lowered during the setup process. See Chapter 3 for instruction on how to lower the fusing levers. Media. The media may not be acceptable for laser printing. Heavy paper stock is a common cause of smeared print and improper fusing.
Table 7-22 Black Pages with Horizontal White Strips Possible Cause Laser/Scanning Assembly or DC Controller PCA. Table 7-23 Action Replace the Laser/Scanning Assembly followed by the DC Controller PCA, if necessary (see Figure 7-12 for locations). Image Skew Possible Cause Action Input/Registration Sensor (PS1). The Replace the Input/Registration Sensor. Paper Pickup Roller positions the leading Skew tolerance for the printer is 1.5mm edge of the paper at the over 260mm page length.
Table 7-24 Improperly Sized Image Possible Cause Action PC tray Microswitches. The paper tray microswitches indicate the paper size of the installed tray. This information is used to format the print image to the size of the paper installed in the tray. If the paper tray microswitches are defective, the image is formatted incorrectly. Perform the “Cassette Size Switches (SW603, SW604, SW605) Functional Check” on page 7-15. Ensure that the correct envelope size is selected if appropriate.
Figure 7-9 PS5 Test Sheet Troubleshooting 7-45
Table 7-25 Vertical Dark Streaks Possible Cause Action Dirty Primary Charge roller. Change the Toner Cartridge. Bad Toner Cartridge. Replace the Toner Cartridge. Incompatible media. During media manufacture, inks, or other finishing processes may interfere with the electro-photographic or fusing process. Change type of media. Table 7-26 Large Print Voids Possible Cause Action Defective laser shutter. Check the laser shutter for free operation when inserting the EP Toner Cartridge.
Table 7-27 Background Scatter Possible Cause Action Defective Toner Cartridge. The Toner Cartridge may be internally damaged. Replace the Toner Cartridge. Bad paper lot. The paper moisture content, conductivity, or surface finish may be incompatible with the electro-photographic process. Try a different paper lot (see the HP LaserJet Family Paper Specifications Guide) for paper specifications. Print density set incorrectly.
Table 7-28 White or Blank Pages Possible Cause Action Defective laser shutter. Check the laser shutter for free operation when inserting the EP Toner Cartridge. EP Cartridge Support damaged, improperly positioned, or missing. Refer to item 4 in Figure 8-4a. Guide must be installed properly above the EP Cartridge, between the laser shutter opening and the fuser stop plate. Toner Cartridge. No toner is available for print. Remove sealing tape or replace the Toner Cartridge.
Image Formation Troubleshooting Half Self-Test Functional Check The electro-photographic process can be subdivided into the following stages: • Cleaning (Physical and Electrostatic). • Conditioning (Primary Charge Roller). • Writing (Laser Modulation). • Development (Formation of the Toner Image). • Transfer (Charge to transfer the image to paper). The purpose of the Half Self Test Check is to determine which process is malfunctioning. Perform the test as follows: 1 Initiate an 05 SELF TEST.
Drum Rotation Functional Check The photoconductive drum, located in the Toner Cartridge, must rotate for the print process to work. The photoconductive drum receives its drive from the Main Motor gear train. To verify whether the drum is rotating: 1 Open the printer’s Top Cover Assembly. 2 Remove the Toner Cartridge. Open the Toner Cartridge’s drum shield (cover) to view the photoconductive drum. 3 Mark the gear with a felt-tipped marker. Note the position of the mark.
High Voltage Power Supply Assembly The High Voltage Power Supply Assembly provides the necessary voltages for the printer’s electro-photographic processes. The +24B 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 the table below (see Figure 7-18 for High Voltage PCA layout).
Interface Troubleshooting This section provides an overview of the printer interface requirements. Refer to Chapter 3 for detailed information about the printer interfaces and configuration. Communications Check Note Communication problems are normally the customer’s responsibility. Time spent attempting to resolve these problems may not be covered by the product’s Hewlett-Packard warranty. The Customer Service Center (CSC) is available to the customer to help them through these problems.
AUTOEXEC.BAT Standard Configurations Parallel DOS Commands If the previous check did not produce the desired result, ensure that the AUTOEXEC.BAT file contains the following statements for parallel interface communications: MODE LPT1:,,P For MS-DOS version 4.0 and above, enter: MODE LPT1:,,B Note This example assumes that you are using parallel printer port LPT1. If you are using LPT2 or LPT3, replace LPT1 in the example with the appropriate printer port.
Communications Checks Table 7-30 Communications Checks Checks Is your computer configured to the parameters described in the configuration instructions? Action These parameters are required to communicate with the printer. Verify your computer’s communications port configuration matches these parameters. Note: If these parameters are not set properly, they may yield a 40, 20, or 22 ERROR on the printer’s Control Panel.
Table 7-30 Communications Checks (continued) Checks Action If using a serial interface, is the cable longer than 50 feet (15 meters)? The maximum recommended cable length for RS-232 serial communications is 50 feet. Use RS-422 for the HP LaserJet 4/4M printer, or move the printer closer to the host. If using a Centronics parallel cable, is it over 10 feet (3 meters) long? Use a serial interface connection, or move the printer closer to the host.
MIO Troubleshooting The Self Test Printout and explanation shown on the following pages contain valuable information regarding the current status of the MIO. Before attempting to troubleshoot a network problem or notifying your network consultant of a problem, always obtain a Self Test Printout. Troubleshooting Hints The JetDirect Card Status Block (see Figure 7-10, status block 2) indicates the functionality of the JetDirect Card. An I/O NOT READY STATUS indicates a problem.
Explanation of Self Test Printout 1 Multiple Environment Information. General information about your JetDirect MIO. 2 JetDirect Card Status. I/O CARD READY indicates the interface is correctly configured and capable of communicating. I/O CARD NOT READY indicates there is a problem with the interface, configuration, or server. 3 Network Statistics. A list of network statistics is generated by the JetDirect MIO. All statistic counters are reset to zero when the printer is turned OFF.
Figure 7-10 MIO Staus Information on the Self Test Printout 7-58 Troubleshooting
Troubleshooting Aids Component Locations The following illustrations help you quickly find the parts discussed in this chapter.
2 1 3 6 5 4 Figure 7-12 Major Assembly and Connector Locations (2 of 3) Table 7-32 Number Part 1 Laser/Scanner Assembly 2 DC Controller PCA 3 Interconnect PCA Assembly 4 Paper Control PCA 5 High Voltage Power Supply PCA 6 Exit Sensor Assembly 7-60 Troubleshooting
1 2 3 4 Figure 7-13 Major Assembly and Connector Locations (3 of 3) Table 7-33 Number Part 1 Power Supply Assembly 2 Envelope Feeder Main Motor (M4) 3 Lower Cassette Drive PCA 4 Lower Cassette Main Motor (M3) Troubleshooting 7-61
Figure 7-14 Switch Locations Table 7-34 Number Part SW101 AC Input ON/OFF Switch (Power Supply Assembly) SW 601 Top Cover Open Sensing Switch SW602 TEST PRINT Switch SW603 SW604 PC (Tray 2) Tray Size Switches SW605 7-62 Troubleshooting
Figure 7-15 Optional 500 Sheet Lower Cassette Table 7-35 Number Part SW851 Optional 500 Sheet Paper Feeder Paper Tray (Tray 3) SW852 Size Switches SW853 Troubleshooting 7-63
VR202 5 1 J203 J206 7 26 2 25 1 1 18 6 J204 1 1 J207 J208 1 3 1 J205 J202 J213 3 1 4 1 J209 3 J201 13 CP202 1 J212 1 TB201 J211 6 4 3 10 J210 1 1 CP201 Figure 7-16 DC Controller PCA Layout—LaserJet 4/4M Table 7-36 Number Part J201 Paper Control PCA J205 Scanner/Beam Detect J206 Laser Drive PCA J207 Formatter PCA J208 Deliver/Exit Sensor PS3 J210 Interconnect PCA J209 Cooling Fan J211 Main Motor J212 Power Supply/Fuser Drive VR202 Registration Adjustment
VR201 5 1 J204 J205 5 1 32 2 1 9 31 J207 1 1 1 J206 J209 J208 7 8 1 J210 3 1 J201 3 J212 1 1 J211 3 J215 3 1 1 TB201 7 6 J214 1 10 J213 1 13 Figure 7-17 DC Controller PCA Layout —LaserJet 4 Plus/5 Table 7-37 Number Part J201 Paper Control PCA J208 Scanner/Beam Detect J209 Laser Drive PCA J207 Formatter PCA J210 Deliver/Exit Sensor PS3 J213 Interconnect PCA J211 Cooling Fan J214 Main Motor J215 Power Supply/Fuser Drive VR201 Registration Adjustment TB201 DC
TB401 TB402 TB403 TB404 VR401 TB405 3 1 J402 TB406 J401 A B A B 5 Figure 7-18 1 High Voltage PCA Layout Table 7-38 Number J401 Part High Voltage PS Connection To DC Controller PCA via Interconnect PCA TB401 Transfer Roller Contact TB402 Drum Ground Contact TB403 Toner Low/EP Toner Cartridge-in-Place Contact TB404 GND TB405 Developer Roller Contact TB406 Charge Roller Contact VR401 Factory Adjustment Only 7-66 Troubleshooting
Repetitive Defect Template Repetitive print defects usually are associated with a specific roller within the printer, or the Toner Cartridge. The following templates are provided to help quickly isolate the cause of repetitive print defects. Align the first occurrence of the defect with the top of the “ruler”, and measure to the next occurrence of the defect to determine the roller in question. When you are certain that your defect pattern matches the pattern of the template, replace the indicated roller.
Figure 7-20 Main Wiring Diagram (LJ 4+/5 only) 7-68 Troubleshooting
Voltage Test Points The operating voltages of the printer can be verified by: 1 Listening for the exhaust fan. A rotating fan indicates that the +5 VDC and +24A VDC voltages are present. (The fan runs on +24A VDC. The +5 VDC enables the +24A VDC.) 2 Listen for the Main Motor. If the Main Motor runs, the +24B VDC is enabled, therefore +24A VDC must be present. Measuring the DC Voltage Levels The DC voltage levels can be measured directly on the DC Controller TB 201.
7-70 Troubleshooting
8 Parts and Diagrams How To Use the Parts Lists The figures in this chapter illustrate the major subassemblies and component parts of the HP LaserJet 4/4M, LaserJet 4 Plus/ 4M Plus, and LaserJet 5/5M/5N printers. When ordering an electrical part, pay special attention that the part chosen has the correct voltage rating for the machine under repair. Part numbers with no indicator in the Notes column are stocked and can be ordered through Hewlett-Packard’s Support Materials Organization (SMO).
Parts Lists and Illustrations Figure 8-1a Field-Replaceable Assemblies (1 of 2) 8-2 Parts and Diagrams
Figure 8-1b Field-Replaceable Assemblies ( 2 of 2) Parts and Diagrams 8-3
Table 8-1 Part # Field-Replaceable Assemblies Ref Exchng # 1 C2001-69003 C2037-69001 Fusing Ass’y (100/110V) LaserJet 4 LaserJet 4 Plus/5 8-10 RG5-0454-000CN RG5-0879-130CN 1 C2001-69004 C2037-69002 Fusing Ass’y (220/240V) LaserJet 4 LaserJet 4 Plus/5 8-10 RG5-0455-000CN RG5-0880-130CN 2 Main Motor LaserJet 4 LaserJet 4 Plus/5 8-4b RH7-1151-000CN RH7-1169-000CN 3 Paper Feed Assembly LaserJet 4 LaserJet 4 Plus LaserJet 5 8-6 RG5-0451-000CN RG5-0877-000CN RG5-2195-000CN 4 Main Switch Ass
Table 8-1 Part # Field-Replaceable Assemblies (continued) Ref Exchng # Description Fig.
Figure 8-2 Covers and Panels 8-6 Parts and Diagrams
Table 8-2 Ref Covers and Panels Part # Notes Description 1 RB1-2143-000CN RB1-3558-000CN RB1-7885-000CN LJ4 LJ4+ LJ5 MP Tray Extender 2 RB1-2346-000CN RB1-3470-000CN RF5-1644-000CN LJ4 LJ4+ LJ5 Right Cover 3 RB1-2347-000CN RB1-3471-000CN RB1-7881-000CN LJ4 LJ4+ LJ5 Left Cover 4 RF5-0533-000CN RF5-0733-000CN RF5-1645-000CN LJ4 LJ4+ LJ5 Rear Door Assembly 4A RB1-2354-000CN 4B RB1-2335-000CN RB1-7890-000CN LJ4/4+ Rear Door Latch LJ5 4C RS5-2219-000CN RS5-2571-000CN LJ4/4+ Rear Door S
Figure 8-3a Top Cover Assembly for LaserJet 4/4+ 8-8 Parts and Diagrams
Table 8-3a Ref Top Cover Assembly Part # Notes Description 1 RB1-2330-000CN S 3 RG5-0458-000CN RG5-0872-000CN LJ4 LJ4+ Spring, Leaf Upper Cover Assembly 3A RB1-2322-000CN RB1-3474-000CN LJ4 LJ4+ Top Cover Door 3B RB1-2323-000CN 3C RB1-2324-000CN 2 ea. Hinge, Pin 3D RB1-2329-000CN RB1-3473-000CN LJ4 LJ4+ Hinge, Arm Hinge, Bracket 3E RB1-2364-000CN 3F RF5-0360-000CN RF5-0732-000CN LJ4 LJ4+ Cover, Upper 3G RB1-2314-000CN 2 ea.
Ref Part # Notes 4A C2037-40001 C2037-40002 C2037-40003 C2037-40004 C2037-40005 C2037-40006 C2037-40007 C2037-40008 C2037-40009 C2037-40010 C2037-40011 C2037-40012 C2037-40013 C2037-40014 LJ4+ English French German Italian Spanish Norwegian Swedish Danish Finnish Dutch Polish Turkish Portugese European English RG5-0478-000CN RG5-1076-000CN LJ4 LJ4+ Display Ass’y (W/O overlay) 5 6 RB1-2260-000CN 7 RG5-0519-000CN RG5-0982-000CN 8 XA9-0591-000CN Description Brush, cleaning LJ4 LJ4+ 8-10 Parts
Figure 8-3b Top Cover Assembly for LaserJet 5 Parts and Diagrams 8-11
Table 8-3b Ref Top Cover Assembly Part # 1 RB1-7895-000CN 2 RB1-7893-000CN Notes Description Tool, Hook S Spring, Leaf 3 RG5-2186-000CN Upper Cover Assembly 3A RB1-7894-000CN Hinge Stop 3B RB1-7883-000CN Top Cover Door 3C RF5-1643-000CN Cover, Upper RG5-0982-000CN Cable, Control Panel (not shown) 5 RG5-2238-000CN Display Ass’y (W/O overlay) 6 RB1-7887-000CN Display Cover (part of item 3) Part Numbers 7 C3916-40005 C3916-40006 C3916-40007 C3916-40008 C3916-40009 C3916-40010 C391
Figure 8-4a Internal Components (1 of 4) Table 8-4a Internal Components (Section 2) Ref Part # Notes Description 1 RB1-2080-000CN Shutter, laser 2 RB1-2100-000CN RB1-5730-000CN LJ4/4+ Guide, Cartridge LJ5 3 RB1-2101-020CN Guide, Cartridge 4 RB1-2105-030CN Support, Cartridge 5 RB1-2106-000CN 6 RB1-2107-000CN RB1-7913-000CN S Plate, grounding LJ4/4+ Guide, Cassette, Left LJ5 Parts and Diagrams 8-13
7 RB1-2111-030CN 8 RB1-2114-000CN 9 RS5-2218-000CN Spring, Compression 10 RB1-2122-000CN Shutter Spring, Torsion 11 RB1-5732 -000CN Spring, Torsion 12 RB1-2141-000CN RB1-7888-000CN LJ4/4+ Cover, Inner LJ5 13 RB1-2353-000CN RF5-1648-000CN LJ4/4+ Holding Plate LJ5 13A RB1-7901-000CN Shutter, arm Qty 5 LJ5 Foot Mount, Tray 1 Door (not shown-part of 13) 14 RB1-2358-000CN RB1-2966-000CN LJ4/4+ Spring, Switch LJ5 15 RF5-0363-000CN RF5-1079-000CN RF5-1657-000CN 16 RF5-0365-000CN RB1-7
Figure 8-4b Internal Components (2 of 4) Parts and Diagrams 8-15
Table 8-4b Ref lnternal Components (Section 2) Part # Notes Description 1 RB1-2112-000CN RB1-3544-000CN LJ4 LJ4+/5 Exhaust Duct 2 RB1-2113-000CN RF5-0748-000CN LJ4 LJ4+/5 Exhaust Duct Cover 3 RB1-2350-000CN RB1-3547-000CN LJ4 LJ4+/5 Exhaust Fan Cover 4 RB1-2352-000CN RB1-7896-000CN LJ4/4+ LJ5 Rod 5 RF5-0470-000CN RF5-0743-000CN RF5-1653-000CN LJ4 LJ4+ LJ5 6 RG5-0511-000CN RG5-0966-030CN LJ4 LJ4+/5 DC Controller PCA 6 C2001-69002 C2037-69004 LJ4 LJ4+/5 DC Controller PCA (excha
Figure 8-4c Internal Components (3 of 4) Parts and Diagrams 8-17
Table 8-4c Ref Internal Components (Section 3) Part # Notes Description 1 RS5-8219-000CN S 2 RB1-2357-000-CN RB1-7897-000CN LJ4/4+ LJ5 Cover, Connector 4 XA9-0584-000CN XA9-0670-000CN LJ4 LJ4+/5 Screw, w/ spring washer 5 XA9-0574-000CN 6 RF5-0471-000CN RF5-0746-000CN RF5-1647-000CN LJ4 LJ4+ LJ5 Plate, Shield 7 RF5-0355-000CN LJ4 Panel, I/O 7A RB1-2312-000CN LJ4 Sheet 7B RB1-2313-000CN LJ4 Sheet 8 RB1-2341-000CN S 9 RB1-2343-000CN RF5-0739-000CN RF5-1654-000CN LJ4 LJ4+
Ref Part # Notes Description 22 C2002-67901 C2038-60004 C3919-67901 LJ4 LJ4+ LJ5 Formatter PCA 22 C2002-69001 C2038-69004 C3919-69001 LJ4 LJ4+ LJ5 Formatter PCA (Exchange) 23 RB1-3494-000CN RB1-7892-000CN LJ4+ LJ5 Plate, Reinforcement Parts and Diagrams 8-19
Figure 8-4d Internal Components (4 of 4) 8-20 Parts and Diagrams
Table 8-4d Ref Internal Components (Section 4) Part # Notes Description 1 RB1-2236-000CN Guide, Feeder 2 RB1-2253-000CN Roller, Guides (6) 3 XA9-0623-000CN Hex Head Screw 4 RG5-0468-000CN RG5-2192-000CN 5 RB1-2251-000CN 6 RG5-0521-000CN RG5-0979-000CN 7 RG5-0515-000CN 8 RG5-0513-000CN RG5-0969-040CN LJ4 High Voltage PCA LJ4+/5 8 C2001-69009 C2037-69009 LJ4 High Voltage PCA (exchng) LJ4+/5 9 RB1-2226-000CN Cover, High Voltage 10 RF5-0369-040CN Holder, Paper, Front 11 RB1-225
Figure 8-5 Main Switch Assembly 8-22 Parts and Diagrams
Table 8-5 Ref Main Switch Assembly Part # Notes Description 1 RB1-2118-000CN RB1-7906-000CN LJ4/4+ Base, Switch Mounting LJ5 S 2 RB1-2119-000CN RB1-7907-000CN LJ4/4+ Switch LJ5 S 3 RB1-2345-000CN 4 RG5-0524-000CN J201/ Cable, Paper Control PCA/ J601 DC Controller 5 RG5-0530-000CN J603/ Cable, Lower Feed Assembly J135 S Cover (LJ4/4+ only) Parts and Diagrams 8-23
Figure 8-6a Paper Feed Assembly (1 of 2) 8-24 Parts and Diagrams
Figure 8-6b Paper Feed Assembly (2 of 2) Parts and Diagrams 8-25
Table 8-6 Ref 1 Paper Feed Assembly Part # Notes Description RG5-0451-000CN RG5-0877-000CN RG5-2195-000CN LJ4 LJ4+ LJ5 Paper Feed Assembly C2001-69005 C2037-69003 C3916-69005 LJ4 LJ4+ LJ5 Paper Feed Ass’y (exchng) RB1-2126-000CN RB1-3477-000CN RB1-7911-000CN LJ4 LJ4+ LJ5 Roller, Pickup, PC Tray Roller, Pickup, Tray 2 2 RB1-2127-000CN RB1-2205-000CN LJ4/4+ Roller, MP Tray Pickup LJ5 Roller, Tray 1 Pickup 5 RB1-2138-000CN Lever, Switch 14 RG5-0529-000CN Cable, Env.
Figure 8-7 MP Tray (Tray 1) Assembly Table 8-7 MP Tray (Tray 1) Assembly Part # RG5-0472-000CN RG5-0888-000CN RG5-2199-000CN Notes LJ4 LJ4+ LJ5 Description Multi-Purpose Tray Assembly Tray 1 Assembly Parts and Diagrams 8-27
Figure 8-8 Paper Output Assembly Table 8-8 Paper Output Assembly Ref Part # Notes Description RG5-0456-000CN RG5-0886-000CN RG5-2189-000CN LJ4 LJ4+ LJ5 Paper Output Assembly 2 RB1-2299-030CN 4 ea. Rollers, Delivery 3 RB1-2302-000CN 4 ea. Spring, Roller 4 ea. Holder, Roller 7 RF5-0425-040CN 13 RS5-2185-000CN RS5-2267-000CN LJ4 Spring, Compression LJ4+/5 4 ea.
Figure 8-9 Delivery Sensor Assembly Table 8-9 Delivery Sensor Assembly Ref Part # Notes Description RG5-0475-060CN Assembly, Delivery Sensor 5 WG8-0291-000CN Photosensor, (PS3) 6 RG5-0522-000CN RG5-0980-000CN LJ4 Cable, Delivery Sensor LJ4+/5 Parts and Diagrams 8-29
Figure 8-10 Fuser Assembly 8-30 Parts and Diagrams
Table 8-10 Ref Fuser Assembly Part # Notes Description RG5-0454-000CN RG5-0879-130CN LJ4 LJ4+/5 Fuser Assembly 110/115V C2001-69003 C2037-69001 LJ4 LJ4+/5 Fuser Assembly (Exchange) 110/115V RG5-0455-000CN RG5-0880-130CN LJ4 LJ4+/5 Fuser Assembly 220/240V C2001-69004 C2037-69002 LJ4 LJ4+/5 Fuser Assembly (Exchange) 220/240V 1 RA1-7584-000CN RB1-0253-000CN LJ4 LJ4+/5 S Ring, Roller (2 ea.
Ref Part # Notes Description 20 RS5-0232-000CN RS5-0393-000CN LJ4 LJ4+/5 S Gear, 23T 21 RS5-1063-000CN RS5-1097-020CN LJ4 LJ4+/5 Bushing, Roller 22 RS5-1064-000CN RS5-1098-000CN LJ4 LJ4+/5 S Bushing, Roller 23 RS5-1065-000CN RS5-1099-000CN LJ4 LJ4+/5 S Bushing, Lower Roller (2) 24 RS5-2168-000CN RS5-2265-020CN LJ4 LJ4+/5 Spring, Compression (2) 25 RS5-2180-000CN S Spring, Tension 26 RB1-2286-000CN S Spring, Guide 28 RH7-7045-000CN RH7-7054-000CN LJ4 LJ4+/5 S Thermistor 29
Accessory Parts Figure 8-11 Lower Cassette Base Assembly Parts and Diagrams 8-33
Table 8-11 Ref Lower Cassette Base Assembly Part # C2083A Notes LJ4 Description LC Base Assembly w/non-Legal Cassette C2083B C2083D C3921A LJ4 LC Base Assembly with Legal Universal LJ/4+ Cassette LJ5 Tray 3 4 RB1-2606-000CN RB1-7977-000CN LJ4/4+ Cover, Front LJ5 5 RB1-2628-000CN S Cover 6 RB1-2647-000CN S Plate, Grounding 8 RF5-0374-000CN S Click, Spring 9 RF5-0375-000CN S Shaft 10 RG5-0482-000CN RG5-2207-000CN LJ4/4+ Frame, Lower Assembly LJ5 10A RB1-2620-000CN 11 Foot, Rubber
Figure 8-12 Lower Cassette Drive Assembly Table 8-12 Lower Cassette Drive Assembly Ref 1 Part # RG5-0481-000CN RG5-1099-000CN RG5-2209-000CN 1a RB1-2627-020CN 1b RB1-2632-000CN RB1-2650-000CN RB1-7983-000CN Notes LJ4 LJ4+ LJ5 Description Drive Assembly, Lower Cassette Drive Assembly, Tray 3 Weight LJ4 LJ4+ LJ5 Roller, Pickup Parts and Diagrams 8-35
Figure 8-13 Lower Cassette Assembly Table 8-13 Lower Cassette Assembly Ref Part # Notes Description 1 C2084A C2084C LJ4 LJ4\4+ Universal 500 sheet Lower Cassette Tray (non-Legal) 1 C2084B C2084D C3923A LJ4 LJ4/4+ LJ5 Universal 500 sheet Lower Cassette Tray (Legal) 16 RB1-2645-000CN RB1-8009-000CN LJ4/4+ LJ5 Cover, Rear Cassette 21 RF5-0446-000CN RF5-1675-000CN LJ4/4+ LJ5 Plate, End 8-36 Parts and Diagrams
Figure 8-14 Universal Cassette Parts and Diagrams 8-37
Table 8-14 Ref Universal Cassette Part # Notes Description C2085A C2085D C3924A LJ4 LJ4+ LJ5 250 sheet Universal Tray (Legal, Letter, Exec, A4) C2085B C2085E C3925A LJ4 LJ4+ LJ5 250 sheet PC Tray (letter) C2085C C2085F C3926A LJ4 LJ4+ LJ5 250 sheet PC Tray (A4) 2 RB1-2370-020CN Plate, Length Adjustment (part of tray assy) 21 RF5-0430-000CN Plate (part of tray assy) 24 RB1-2391-000CN RB1-7969-000CN LJ4/4+ Cover, Legal LJ5 SIMM Memory Table 8-15 Simm Modules Part # Notes Size Type
Miscellaneous Parts and Accessories Table 8-16 Miscellaneous Parts and Accessories Part # Notes 92298A Description Toner Cartridge J2341A J2552A (J2552-69001) LJ4 LJ4+/5 AppleTalk MIO Interface J2550A (J2550-69001) LJ5 10-BaseT MIO Interface C2082B C3927A LJ4/4+ LJ5 Envelope Feeder (new) C2082-69001 C3927-69001 LJ4/4+ LJ5 Envelope Feeder (exchange) C2809A LJ4+/5 9-25 Pin Adaptor C2929A LJ5 Infrared Transceiver Pod Parts and Diagrams 8-39
Parts List Table 8-17 Alphanumeric Parts List Description Part # Fig. # Printer 10-BaseT MIO Interface J2550A (J2550-69001) 5 16 Mbytes C3146A 4+/5 250 Sheet PC Tray (A4) C2085C 8-14 4 250 Sheet PC Tray (A4) C2085F 8-14 4+ 250 Sheet PC Tray (A4) C3926A 8-14 5 250 Sheet PC Tray (letter) C2085B 8-14 4 250 Sheet PC Tray (letter) C2085E 8-14 4+ 250 Sheet PC Tray (letter) C3925A 8-14 5 250 Sheet Univ. Tray (Legal, letter, exec, A4) C2085A 8-14 4 250 Sheet Univ.
Description Part # Fig.
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Description Part # Fig. # Printer Lower Cassette Tray, Univ. 500 sheet C2084A 8-13 4 Lower Cassette Tray, Univ. 500 sheet C2084C 8-13 4+/5 Lower Cassette Tray, Univ. 500 sheet Legal C2084B 8-13 4 Lower Cassette Tray, Univ. 500 sheet Legal C2084D 8-13 4+/5 Lower Cassette Tray, Univ.
Description Part # Fig.
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Description Part # Fig. # Printer Screw, w/Spring Washer XA9-0584-000CN 8-4c 4 Screw, w/Spring Washer XA9-0670-000CN 8-4c 4+/5 Screw, w/Washer, 2 ea XA9-0267-000CN 8-4b 4+/5 Screw, w/Washer, 4 ea.
Description Part # Fig.
A Duplexer This Appendix contains a functional overview of the Optional Duplexer, as well as step-by-step Installation and Removal & Replacement instructions. The Optional Duplexer, when used with the LaserJet 4 Plus/5 printer, allows printing on both sides of the paper. It may be used with the optional 500-sheet Lower Cassette or with the printer alone. Note The Duplexer works only with the LaserJet 4 Plus or LaserJet 5 printer. It is not supported on the LaserJet 4.
Functional Overview The Duplexer consists of two major assemblies; the Switchback Assembly that is attached to the back of the printer and the Holding Tray located directly under the printer (see Figure A-1.
Duplex Printing Note The bold text and numbers in the following description refer to parts shown in Figure A-2. When the printer is operating in duplex mode, the print images are printed in reverse order. Page two prints on the first pass of the paper through the printer and page one prints on the second pass through. Switchback Assembly To print the first pass, the paper goes through the printer paper path, where it is developed and fused.
As the paper moves from the Switchback Assembly, it is picked up by the rollers that are operated by the Holding Tray Input Stepper Motor. The Input Stepper Motor moves the paper into the Holding Tray. When the paper moves the flag that controls the Holding Tray Paper Sensor, the Duplex Control PCA turns off the Input Stepper Motor, and the paper stops moving. The paper remains in the Holding Tray until the print engine signals the Duplex Control PCA that it is ready to print the second side.
Electrical Overview The block diagram in Figure A-3 shows the Duplexer electrical components.
Installing the Optional Duplexer The optional Duplexer can be installed by the customer. There are no fasteners securing the units together. The printer simply rests in place on top of the Duplexer, which, in turn, rests on top of the optional 500-sheet Lower Cassette, if used. To install the Duplexer, first turn power OFF and disconnect all cables from the printer. Follow the steps below, referring to the corresponding steps illustrated in Figure A-4.
1 1 2 2 5 1 6 2 3 3 4 7 1 2 Figure A-4 Duplexer Installation/Removal Duplexer A -7
Removal and Replacement This section describes the complete disassembly of the Duplexer. Tasks that must be performed before beginning the procedure are listed first. Remove the assemblies in the order listed to prevent damage. The assembly procedure is the reverse of the removal procedure, except where specific instructions are provided. In the removal and replacement procedures that follow, the number inside the parentheses, such as (4), refers to the number of screws to remove.
Removing the Covers Removing the Switchback Covers Figure A-5 Switchback Cover 1 Remove the (2) screws shown in Figure A-5, callout 1. 2 Lift the cover off the Switchback Assembly.
Removing the Side Cover on Power Side Figure A-6 Side Cover 1 Open the front door. 2 Remove the (1) screw shown in Figure A-6, callout 1. 3 Release the (3) latch points with a flat screwdriver and rotate the cover downward (see Figure A-6, callout 2).
Removing the Side Cover on Gear Side Figure A-7 Side Cover on Gear Side 1 Remove the (2) screws on top and the (1) screw on the front (see Figure A-7, callout 1). 2 Turn the Duplexer on its side to access the latch location on the underside. 3 Release the (1) latch point with a flat screwdriver and lift the cover off (see Figure A-8).
Figure A-8 Latch Location on Underside of Duplexer A -12 Duplexer
Removing the Back Cover Figure A-9 Back Cover 1 Place the duplexer on a table or bench so that the back overhangs the edge by a few inches. 2 Release the (2) locating pins as shown in Figure A-9. 3 Rotate the cover downward until it is free. Removing the Front Cover With the side covers removed, the front cover is only attached by the holding tray arm. 1 With both side covers removed, open the holding tray. 2 Rotate the front cover 90 degrees to release the holding tray arm.
Removing Internal Duplexer Components Removing the Fan/Motor/Solenoid/Sensor Figure A-10 Switchback Assembly - Stepper Motor Side Access to the electronic components of the switchback assembly is easy once the covers are removed. Note the location of the switchback stepper motor (Figure A-10, callout 1), the switchback fan assembly (callout 2) and the switchback solenoid (callout 3).
Removing the Switchback Paper Guide Figure A-11 Switchback Paper Guide 1 Remove the (1) E-clip from the shaft on the stepper motor side shown in Figure A-11, callout 1. 2 Pull the shaft toward the left and out of its track. 3 Rotate the shaft 90 degrees to remove it from the metal paper guide solenoid arm.
Removing the Paper Guide Assembly Figure A-12 Wire Routing and Upper Switchback Guide Screw 1 Remove the (4) screws shown in Figure A-11, callout 2. 2 Lift the switchback assembly and clear the wires. 3 Remove the assembly. Note: When re-assembling, verify proper wire routing as shown in Figure A-12, callout 1.
Removing the Paper Roller Figure A-13 Solenoid Arm 1 Remove the (1) screw below the Switchback Solenoid Arm on the gear side as shown in Figure A-13, callout 1. 2 Remove the sensor, squeezing the tabs on the underside of the sensor (see Figure A-13, callout 2).
Figure A-14 Upper Paper Guide Sheet Metal 3 Remove the (1) screw shown previously in Figure A-12, callout 2. Remove the upper switchback paper guide by releasing its latch with a flat screwdriver and pushing to the side. 4 Remove the (4) screws on top of the sheet metal part of the upper paper guide shown in Figure A-14, callout 1.
Figure A-15 Gears on Paper Roller 5 Remove the (1) E-clip from the gears on the shaft on the Power PCA side shown in Figure A-15, callout 1. 6 Rotate the bushings and lift the roller out.
Removing the Control PCA Figure A-16 Cover Plate 1 Remove the (2) screws shown in Figure A-16, callout 1. 2 Remove the cover plate.
Figure A-17 Control PCA 3 Unplug all connectors from the Control PCA. Note The Control PCA connectors are keyed. 4 Remove the (4) screws shown in Figure A-17. 5 Disconnect the connector from the power supply. 6 Remove the PCA.
Removing the Power PCA Figure A-18 Power PCA 1 Remove the (6) cover screws, (4) on the top and (2) on the side. Remove the cover. 2 Remove the (4) screws from the Power PCA (see Figure A-18, callout 1). 3 Unplug the connector (see Figure A-18, callout 2). 4 Lift the Power PCA out of the duplexer.
Removing the Holding Tray Center Paper Guide Figure A-19 Plate on Power PCA Side of Duplexer 1 Remove the Control PCA as described earlier. 2 Remove the (2) screws from the plate located on the power PCA side of the duplexer (see Figure A-19, callout 1). 3 Lift off the guide.
Removing the Holding Tray Belt Figure A-20 Holding Tray Belt Cover Plate 1 Remove all the screws securing the plate (see Figure A-20, callout 1). 2 Remove (1) E-clip shown in Figure A-20, callout 2. 3 Remove the bushing underneath the E-clip. 4 Release (2) latch points shown in Figure A-20, callout 3. Note: The (2) washers on the gear beside the bushing are now loose. Remove and set aside. 5 Release the wires from the wire holder, allowing the cover to move aside to access the gears.
Figure A-21 Holding Tray Gears and Belt 6 Remove the (1) one-way gear shown in Figure A-21, callout 1. Note The one-way gear must be reassembled correctly. With the gear on the shaft, turn the gear clockwise. The shaft should move the belt. Turning the gear counter clockwise should result in no movement of the shaft and belt. 7 Remove the (1) E-clip from behind the first gear (see Figure A-21, callout 2). 8 Remove the (2) gears shown in Figure A-21, callouts 3 and 4. 9 Slip the belt off the gears.
Removing the Holding Tray Paper Sensor Figure A-22 Holding Tray Paper Sensor 1 Release the output holding tray. 2 Remove the (2) screws from the stepper motor mount and remove mount. (This provides access to the paper sensor latches.) 3 Squeeze the (2) latch points of the paper sensor to release (see Figure A-22). 4 Disconnect the connector and remove the paper sensor.
Removing the Switchback Assembly Figure A-23 Switchback Assembly Hinge Pins 1 Pull out the pin located on the Power PCA side (see Figure A-23, callout 1). 2 Release the (1) E-clip on the upper pin near the retaining arm (see Figure A-23, callout 2). 3 Pull the retaining arm off the pin. 4 Rotate the switchback assembly and remove. 5 Unplug the connectors.
Parts and Diagrams for the Duplexer The figures in this section illustrate the major subassemblies and component parts of the HP LaserJet 4+/5 Duplexer. Note Not all duplexer parts are orderable. The parts listed are the only orderable parts. Parts that have no reference designator or part number are not field-replaceable and cannot be ordered through HP.
Figure A-24 Duplex External Covers Duplexer A -29
Table A-24 Duplex External Covers Ref Part # Notes Description 1 RA2-2061-000CN RA2-2231-000CN LJ4+ LJ5 Front Cover 2 RA2-2096-000CN RA2-2232-000CN LJ4+ LJ5 Left Cover 3 RA2-2097-000CN RA2-2233-000CN LJ4+ LJ5 Right Cover 4 RA2-2098-000CN RA2-2237-000CN LJ4+ LJ5 Rear Lower Cover 5 RG1-3508-000CN RG1-3570-000CN LJ4+ LJ5 Rear Cover Assembly 5A RA2-2100-000CN LJ4+ Latch 5B RS1-2413-000CN RS5-2571-000CN LJ4+ LJ5 Compression Spring A -30 Duplexer
Figure A-25a Duplex Feeder Assembly (1 of 2) Duplexer A -31
Figure A-25b Duplex Feeder Assembly (2 of 2) A -32 Duplexer
Table A-25 Ref Duplex Feed Assembly Part # Notes Description 1 RA2-2069-000CN LJ4+/5 PCA Shield Plate 2 RA2-2070-000CN LJ4+/5 Static Eliminator sml 3 RA2-2072-000CN LJ4+/5 Timing Belt 4 RA2-2076-000CN LJ4+/5 Sensor Arm 5 RA2-2078-000CN LJ4+/5 Rod Crank 6 RA2-2079-000CN LJ4+/5 Front Cover Rod 7 RA2-2081-000CN LJ4+/5 Hold Tray Rear Guide 8 RA2-2082-000CN LJ4+/5 Hold Tray Front Guide 9 RA2-2085-000CN LJ4+/5 Front Guide 10 RA2-2115-000CN LJ4+/5 Stepped Scr M3 by 6.
Ref Part # Notes Description 25 RS1-2406-000CN LJ4+/5 Torsion Spring (Qty 3) 26 RS1-2407-000CN LJ4+/5 Torsion Spring 27 RS1-2409-000C N LJ4+/5 Tension Spring 28 RS1-7010-000CN LJ4+/5 Shaft 29 WG8-5210-000CN LJ4+/5 Photo Interrupter 30 RG1-3501-000CN RG1-3582-000CN LJ4+ LJ5 Duplex Control PCA 31 RF1-3817-00017 LJ5 Duplex Roller Holder A -34 Duplexer
Figure A-26a Duplex Switchback Assembly (1 of 2) Duplexer A -35
Figure A-26b Duplex Switchback Assembly (2 of 2) A -36 Duplexer
Table A-26 Duplex Switchback Assembly Ref Part # Notes Description 1 RA2-2083-000CN LJ4+/5 Static Eliminator 2 RA2-2087-000CN LJ4+/5 Deflector Linkage 3 RA2-2094-000CN LJ4+/5 Upper Feed Guide 4 RA2-2095-000CN LJ4+/5 Lower Feed Guide 5 RA2-2112-000CN LJ4+/5 Cable Cover 6 RA2-2116-000CN LJ4+/5 Stepped Screw 3 By 6.
Ref Part # Notes Description 25 RS1-0591-000CN LJ4+/5 Gear 39T/22T (Qty 2) 26 RS1-0592-000CN LJ4+/5 Gear 29T/54T 27 RS1-2408-000CN LJ4+/5 Switchback Tension Spring 28 RS1-2410-000CN LJ4+/5 Deflector Tension Spring 29 RS1-7009-000CN LJ4+/5 Switchback Hinge Pin 30 WG8-5210-000CN LJ4+/5 Photo Interrupter (PS1) A -38 Duplexer
B LaserJet 5/5M/5N Printer The Combined Service Manual contains information to be used with the LaserJet4/4+/4M/4M+/5/5M/5N. In special circumstances, the information in Chapters 1 and 3 will not pertain specifically to the LaserJet 5/5M/5N printer (such as the control panel information). This Appendix contains the information that is specific for the LaserJet 5/5M/5N printers.
Product Information Table B-1 Features Model Printer Speed Printer Features HP LJ 4+ HP LJ4M+ HPLJ5 HPLJ5M HPLJ5N C2037A C2039A C3916A C3917A C3952A 12 ppm 12 ppm 12 ppm 12 ppm 12 ppm 300/600 dpi 300/600 dpi 300/600 dpi 300/600 dpi 300/600 dpi Expandable I/O Buffer Yes Yes Yes Yes Yes Resource Savings Yes Yes Yes Yes Yes Resolution MEt Yes Yes Yes Yes Yes REt Yes Yes Yes Yes Yes Languages Enhanced PCL5 Enhanced PCL5, Postscript Level 2 HP PCL 6 HP PCL 6, P
Features Interfaces MIO Slots HP LJ 4+ HP LJ4M+ HPLJ5 HPLJ5M HPLJ5N Serial (9 pin) Parallel Serial (9 pin) Parallel Local Talk Serial (9 pin) Parallel Local Talk Ethernet Serial Infrared*** Serial (9 pin) Parallel Local Talk Ethernet Serial Infrared*** Serial (9 pin) Parallel 10-baseT Serial Infrared*** 1 1 1 1 1 EconoMode Yes Yes Yes Yes Yes Cartridge Slot Yes Yes No No No Power Save Monthly Usage (pages) Yes Yes Yes Yes Yes Up to 20,000 Up to 20,000 Up to 35,000 Up to
Table B-2 Accessory Product Family Compatibility Matrix Description Work in the LaserJet 4? Work in the LaserJet 4 Plus? Work in the LaserJet 5? C2082A Envelope Feeder Yes No No C2082B Envelope Feeder Yes Yes No C3927A Envelope Feeder No No Yes C2083A Optional 500 Sheet Feeder Assembly Yes No No C2083D Optional 500 Sheet Feeder Assembly Yes Yes No C3921A Optional 500 Sheet Feeder Assembly No No Yes C2085A 250 Sheet Universal PC tray Yes No No C2085D 250 Sheet Univers
Identification The model number is on a label placed on the outside, rear cover of the printer. The model number (C3916A, C3917A, or C3952A) is found at the top of the label. The model number is the base number for all printers. The serial number contains information about the printer. The serial number Alpha section refers to the Country of Origin, the Revision Level and the Production Code. The Numeric section refers to the production number of the printer.
Specifications HP LaserJet 5 / 5M / 5N Table B-3 Printer Dimensions Dimension HP LaserJet 5 Width 16.4 in (415mm) Depth 15.9 in (403 mm) Height 11.7 in (297 mm) Weight (with toner cartridge) 37 lbs. (16.
Table B-6 Electrical Specifications Status 100/115 V 220/240 V Recommended Minimum Circuit Capacity 11.2 amps 5.0 amps Peak Inrush Current 19-34 amps 17-40amps 25% Decay Time 8.7-16.9 ms 1.4-9.9 ms Peak Fuser Current 65-71 amps 29-34 amps Return-to Average Time 375-475 ms 220-300 ms Table B-5 Environmental Specifications Operating Environment Temperature: 10° C to 32.5° C (50° F to 90.
Related Documentation The following manuals can be ordered from Hewlett-Packard’s Support Materials Organization (SMO). The phone number for SMO is (800) 227-8164.
Laser Statement (Sweden/Finland) LASERTURVALLISUUS LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT HP LaserJet(s) 5/5M/5N laserkirjoitin on käyttäjän kannalta turvallinen luokan 1 laserlaite. Normaalissa käytössä kirjoittimen suojakotelointi estää lasersäteen pääsyn laitteen ulkopuolelle. Kirjoittimen on hyväksynyt Suomessa laserturvallisuuden osalta Sähkötarkastuskeskus. Laitteen turvallisuusluokka on määritetty valtioneuvoston päätöksen N:o 472/1985 ja standardin EN 60825 (1991) mukaisesti.
Control Panel Layout The LaserJet 5 control panel consists of a 16-character scrolling display panel and six keys, three of which have forward and backward scrolling functions. Figure B-2 shows the display panel. Figure B-2 Control Panel Keys Control Panel Keys The table on the following page explains how the control panel keys work.
Table B-8 Key Go Control Panel Keys Explanation The Go key replaces the On Line, Form Feed, and Continue keys from previous HP LaserJet printers. The Go key performs five main functions: Switches the state of communication between computer and printer either on (on line) or off (off line). Prints any data remaining in printer’s buffer. Does not send a blank sheet of paper through the printer. Allows the printer to resume printing after a printer message (such as 20 MEM OVERFLOW) has placed it off line.
Key Item Explanation Press Item to cycle through the selected menu’s items. Press the > end of the key to move forward through the items. Press the < end of the key to move backward through the items. Menu items vary depending on options installed and configuration of other menu choices. - Value + Press - Value + to cycle through the selected item’s values. Press the > end of the key to move forward through the values. Press the < end of the key to move backward through the values.
Control Panel Menus Figure B-3 shows the menus and menu items available with the basic printer configuration. Not all menu items are discussed in this section. Only those items of specific interest from a service standpoint, or items new to the printers are discussed in this section. If options such as PostScript or a different I/O are installed, the new menu items automatically are added at the appropriate location. For example, a PostScript Menu appears following the PCL Menu.
Figure B-3 Control Panel Menu Map B-14 LaserJet 5/5M/5N Printer
Printing Menu TableB-10 Printing Menu Items Item Options Explanation PRINT MENU MAP No options available When PRINT MENU MAP is displayed, press Select to print a configuration page and a menu map. The message PRINTING CONFIGURATION PAGE is displayed. PWRSAVE OFF, 15 MIN, 30 MIN*, 1 HR, 2 HRS, 3 HRS PWRSAVE stands for PowerSave. This menu item sets the amount of time you want the printer to be idle before the printer cools down.
Item ORIENTATION Options P* L Explanation P stands for portrait (vertical) and L stands for landscape (horizontal) orientation of type on the page. FORM 60* (110V printers) (5 TO 128 LINES) 64* (220V printers) Sets vertical spacing, from 5 to 128 lines, for default paper size. Press - Value + once to change setting by increments of 1 or hold down to scroll by increments of 10. MANUAL FEED OFF* ON Available only through Tray 1.
PCL Fonts Menu Table B-11 Item PCL Fonts Menu Items Options Explanation PCL FONT LIST No options available Press Select to print a list of the PCL fonts. SOURCE INTERNAL* SOFT SLOT N Internal fonts* Permanent soft fonts SIMM Module: n=slot number. Typefaces stored in one of the four ROM SIMM slots (SLOT=slot 1, for example). FONT NUMBER 0 to 999 The printer assigns a number to each typeface and lists them on the PCL Font List, which you can print out.
PostScript Menu Table B-12 Item PostScript Menu Items Options Explanation PS FONT LIST No options available Press Select to print a list of the fonts. While the list is being printed, the message PRINTING FONT LIST is displayed. PRT PS ERRS OFF* ON PRT PS ERRS stands for PRINT POSTSCRIPT ERRORS. This setting allows PostScript error messages to be printed. JAM RECOVER PostScript can be set to automatically reprint jammed pages after a paper jam is cleared. OFF* ON * Indicates factory default.
Configuration Menu Table B-14 Configuration Menu Items Item TRAY 1 Options FIRST* CASSETTE Explanation When set to FIRST, Tray 1 is configured as the default tray and will be used first during printing if any media is loaded into the tray. TRAY 1=FIRST is not recommended for networked (shared) environments. When set to CASSETTE, Tray 1 no longer operates as a universal tray. A paper size must be assigned to Tray 1 using the SIZE 1 option (the next item in the Configuration Menu when TRAY 1=CASSETTE.
Item AUTO CONT Options Explanation OFF* Determines how the printer reacts to data errors and printer errors. When auto continue is set to OFF, the printer displays an error message and goes off line until you press Go . ON When auto continue is set to ON, the printer displays a message and goes off line for about 10 seconds, then comes back on line. If your printer is part of a network or remote spooling system, set auto continue to ON.
Memory Configuration Menu Table B-15 Memory Configuration Menu Items Item I/O BUFFER I/O SIZE Options AUTO* Memory set aside for I/O buffering is automatically determined by the printer. OFF No memory is set aside for I/O buffers. ON Size can be manually adjusted. 10K and up When IO BUFFER is set to ON, this item appears in the menu. Press - Value + to add or reduce I/O buffer memory in increments of 0 KBytes up to 100 KBytes, then in 100 KByte increments.
Parallel Menu Table B-16 Item Parallel Menu Items Options The speed at which data is transmitted to the printer. If the default value (YES) results in I/O errors or no communications, set this value to NO. HIGH SPEED ADV FNCTNS Explanation YES* Sets the parallel interface to run at a higher data rate NO Sets the parallel interface to run at a slower speed.
Resets Menu Table B-18 Menu Selection Resets Menu Items Printer Response Explanation MEMORY RESET CLEARING MEMORY Press Select to perform a MEMORY RESET. This will clear the printer buffer and return all printing environment parameters to those values set in the Control Panel menus. FACTORY DEFAULT FACTORY DEFAULTS BEING RESTORED Press Select to perform FACTORY DEFAULT. This restores most of the printer’s factory default settings and performs a memeory reset.
Test Menu Table B-19 Test Menu Items Item Explanation PRINT SELF TEST When PRINT SELF TEST is displayed, press Select to print a self test. PRINT LJ5 DEMO Prints a page that illustrates the LJ5 printer features. PRINT CONFIG Prints a PostScript configuration page. PRINT LJ5M DEMO Prints a page that illustrates the LJ5M printer features. CONT SELF TEST Prints a series of PCL Configuration Pages.
Service Mode The Service Mode should be used only by authorized service personnel. The following can be executed while in the Service Mode: • Print a Service Mode Self Test. • Verify the Page Count, (the page count also is displayed on the standard self test). • Set the Page Count. • Set the Cold Reset Default (This sets the factory default paper size. Use when replacing non-U.S. Formatters). • Set the Diagnostic Functions ON or OFF (for software developers use only). • Demo Page=On/Off.
Setting the Page Count The page count is stored in the printer’s Non-Volatile Memory (NVRAM). If it is necessary to replace the Formatter PCA, the page count should be reset to the printer’s original page count to reflect the age of the print engine. Use the following procedure to set the page count: 1 Enter the Service Mode as described previously. 2 When SERVICE MODE is displayed, press the [Menu+] key to access the Service Menu. Press the [Item+] key to step through the menu.
Setting the Cold Reset Default A Cold Reset procedure returns most user-selectable Control Panel Menu selections to their factory defaults, including Paper Size and Tray 1 Size settings. All 220/240 printers are set from the factory to default to A4 paper size settings when the user performs either a Cold Reset or Factory Default Reset procedure.
Skip Demo If set to TRUE, will disable any test and demo pages containing the HP logo. This setting should only be used by OEMs not wishing to give user-access to these pages. Big Data This item will allow a user to increase the amount of status readback buffer if the item is set to ON. The default for this item is OFF. The printer must be power-cycled after changing this value in order for the new buffer size to take effect. Diagnostics Allows a diagnostic mode for firmware developers.
Programming a Flash SIMM A flash SIMM may be programmed while installed in the printer. To program a flash SIMM. 1 Hold down the Menu> , Item< , Value+ , and Select keys while powering on the printer. 2 The printer will display “PROGRAM SLOT 4”. To change the slot number, press Value+/-. 3 Once the desired slot number is displayed, press Select. 4 The printer will display “OK”, followed by “ERASING SIMM.” If the SIMM is correcly earased, the printer will display “START DOWNLOAD.
Changing the Control Panel Display Language The default control panel display language is set for English. Supported languages are: English, French, German, Italian, Spanish, Finnish, Danish, Dutch, Swedish, Norwegian, Turkish, Polish, and Portuguese. Follow these instructions to change the display language. 1 Switch OFF the printer. 2 Press and hold Select while switching the printer ON until SELECT LANGUAGE appears in the display. 3 After the power-on self test, LANG=ENGLISH appears.
NVRAM Init NVRAM Init clears the NVRAM to its initial state. This reset is used when the NVRAM becomes full and the user would like to add additional personalities. It is possible to reconfigure the NVRAM so the new personalities have higher priority and the older personalities, while they can still be run with factory defaults, run without NVRAM. This is done by clearing the NVRAM and then adding the new personalities before adding the older personalities.
Understanding the PCL Self Test Printout Table B-20 Reference 1 Self Test Printout Items for the HP LaserJet 5 Explanation (Refer to Figure B-4) Printer Information lists printer specific statistics. Formatter Number shows the unique number assigned to the formatter board. Firmware Datecode is the eight-digit date (YYYYMMDD) code of the Formatter ROM. Page Count shows the number of pages the printer has printed.
Figure B-4 HP LaserJet 5 PCL Self Test Printout LaserJet 5/5M/5N Printer B-33
Infrared Communication The HP LaserJet 5, 5M, and 5N printers are equipped with an Infrared Datalink Association (IrDA) compliant port. The IrDA specification allows “wireless” transmission of print data between a wide variety of hosts (primary) and peripheral (secondary) devices. A primary device — such as a PC or laptop computer — is capable of reading and writing data to another primary device or writing to a secondary device, such as a printer.
primary device secondary device Application ASCII Data GDI Windows System Formatter ASCII to Raster Data Ptr DVR Standard Windows LJ Printer Driver (SW) I/O Buffer ASCII Data Buffer IRLMP IR Redirector (Software) IRLMP Unpacks Data IRLAP IR Driver Packetizes Data (SW or FW) IRLAP Checks Packets Protocol Serializer IR Chip IR Physical Protocol Deserializer IR Chip DDI IR Physical Transmitter Data Packets & Queries Responses Receiver Figure B-5 Receiver Transmitter IR Data Flow
To Print Using the Infrared Port The C2929A Infrared Transceiver must be plugged into the infrared (IR) port on your HP LaserJet 5, 5M, or 5N printer, located at the rear of the printer (Figure B-6). This port is compliant with the specifications determined by the Infrared Data Association (IrDA). On top of the transceiver pod is a status light that indicates when the port is activated.
3 Send the print job. The status light on top of the IR pod turns on. (Printing a complex document or using a software print spooler on your PC may delay the time it takes for the IR status light to turn on.) If the status light does not turn on, realign the port on your portable equipment with the pod, resend the print job and stay within the range of operation during printing.
If you still have problems printing, make sure you are using an IrDA-compliant device and proper software and have selected the proper port for printing. Note The IrDA standard for infrared communications represents an emerging technology. Older non-IrDA-compliant portable devices may not be compatible with your HP LaserJet 5/5M/5N printer.
If all these elements are properly installed and configured, use the IR test tool to test the IrDA protocol transmission and device operation. This tool for troubleshooting IR communication problems, shown in Figure 10, has been developed by Genoa Technology, Inc., in cooperation with Hewlett-Packard. The part number is 5062-4661 and can be ordered through HP Parts Direct Ordering. The IR test tool can be used with any IrDA-compliant primary or secondary device, regardless of manufacturer.
On HP Laser-Jet printers, a self-test page will be initiated by the test. If the “TEST” LED goes out and the “PASS” LED fails to light, the printer’s IR port is not functioning correctly; check the operator’s instructions included with the IR test tool. To test the host computer: 1 Place the test tool on a table in front of the PC’s IR port. 2 Press the “computer Test button. The test tool will sequence the LEDs.
Infrared Port Not Responding Table B-21 Solutions for Infrared Not Responding Situation The connection cannot be established or the transmission seems to be taking longer than usual. Solution Make sure the device you are using is IrDA-compliant; look for an IrDA symbol on the device or refer to the manual for the device for IrDA specifications. Make sure that the operating system on your computer includes an IR driver and your application uses a HP LaserJet 5/5M/5N compatible printer driver.
Situation The printer prints only part of a page or document. Solution The connection has been broken during transmission. If you move the portable device during transmission, the connection can be broken. IrDA-compliant devices are designed to recover from temporary connection interruptions.
Index ! 12 PRINTER OPEN 7-18 13 PAPER JAM 7-20 14 NO EP CART 7-25 16 TONER LOW 4-10, 7-25 21 PRINT OVERRUN 3-53 41.1 ERROR 7-28 41.2 ERROR 7-28, 7-31 41.3 ERROR 7-28 41.4 ERROR 7-28 41.
defect Ruler 7-67 defect template 7-67 developing station, drum 5-22 DHHS laser safety 1-8 Diagnostics B-28 diagrams, timing 5-34 disassembly, fuser 6-47 display language, changing 3-28, B-30 distorted print 7-35, 7-42 documentation, related 1-7, B-8 DOS commands serial 7-53 DOS Utilities 3-42 Drum cleaning station 5-18 conditioning station 5-19 developing station 5-22 photosensitive 5-17 Rotation Check 7-50 sensitivity 5-17 transferring station 5-24 writing station 5-20 dtr polarity 3-34 dtr/dsr 3-34 Duple
high voltage contact assembly 6-68 contact plate 6-62 contactor removal 6-62 contactor/paper guide removal 6-62 High Voltage Power Supply assembly 7-51 checks 7-51 removal 6-21 troubleshooting 7-51 high voltage system 5-2 HP ASAP (Automated Support Access Program) 1-12 HP AUDIO TIPS 1-13 HP FIRST (Fax Information Retrieval Support Technology) 1-12 I I/O buffering 3-15 information 3-26 image defect summary 7-35 formation system 5-1, 5-16 formation troubleshooting 7-49 skew 7-35 image skew 7-43 improperly siz
lower cassette assemblies removal 6-44 assembly 5-4 drive motor (M3) 5-10 functional check 7-24 installing 3-44 paper loading 3-45 pickup motor 7-24 pickup motor removal 6-45 sensor board removal 6-44 tray switches 5-9 LPT1 3-31 M M1, main motor 5-10 M2 functional test 7-23 M2, paper feed motor 5-10 m3 lower cassette drive motor 5-10 lower cassette pickup motor 7-24 M4, envelope feeder drive motor 5-10 M5, scanner motor 5-11 machine status 5-2 Macintosh 3-18 main motor (M1) 5-10 assembly removal 6-37 drive
paper feed assembly removal 6-18 paper feed guide removal 6-62 paper feed system 5-1, 5-26 paper jam 7-20 detection 5-11 PS1 7-20 troubleshooting 7-20 paper motion 5-2 paper path MP tray 5-29 PC tray 5-30 paper pickup motor 5-10 paper pickup rollers 4-11 paper sensors 7-20 paper size sensing, lower cassette 7-16 paper specifications 2-3 paper tray switch settings 5-9 paper, loading optional lower cassette 3-45 parallel communication 3-31 DOS commands 7-53 parallel menu 3-33, B-22 parts list 8-40 PC LOAD Mes
PS5 check 7-44 MP tray trailing edge sensor 5-7 PS6, lower cassette paper-out sensor 5-7 PS7, envelope feeder paper-out sensor 5-7 R RAM size 3-24 Random Horizontal Black Lines 7-40 READY 7-B rear door removal 6-8 recycling program Toner Cartridge 4-7 registration adjustment 6-35 leading edge adjustment 6-35 related documentation 1-7, B-8 removal font door cover 6-10 formatter pca 6-29 gear assembly 6-38 left side cover 6-7 MP tray separation 4-11 PC tray pickup roller 4-13 top cover 6-5 transfer roller 4-1
service checkpoints 4-1, 4-3 Service Mode 3-20, B-25 service/error messages 3-59 setting the cold reset B-27 setting the page count 3-21, B-26 setting up the envelope feeder 3-50 settings, tray switch 5-9 sheet feeder installation 3-44 signals fan motor 5-10 main motor 5-10 Microswitch 5-8 Photosensor 5-6 scanner motor 5-10 solenoid 5-5 site requirements 2-1 Skip demo B-28 SL1, PC pick-up roller clutch solenoid 5-5 SL2, MP pick-up roller clutch solenoid 5-5 SL3 lower cassette pickup roller clutch solenoid 5
Error messages 7-2 general information 7-1 infrared B-38 Message Summary Table 7-2 messages 7-2 preliminary 7-1 Printer messages 7-2 quick checks 7-1 Status messages 7-2 Troubleshooting, IR port B-38 U unpacking the printer 3-43 user maintenance 4-2 V variable, customization 3-22 version number 3-26 vertical dark streaks 7-35, 7-46 vertical sync late (41.
SN-1 Service Notes
SN-2 Service Notes
SN-3 Service Notes
SN-4 Service Notes
SN-5 Service Notes
SN-6 Service Notes
SN-7 Service Notes
SN-8 Service Notes
Copyright© 1996 Hewlett-Packard Company Printed in USA 3/96 Manual Part No.