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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)

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   Also See for HP LaserJet 4 - Plus/m Plus Printer

   Related Manuals for HP LaserJet 4 - Plus/m Plus Printer

   Summary of Contents for HP LaserJet 4 - Plus/m Plus Printer

  • Page 1

    Combined Service Manual HP LaserJet 4 / 4M (C2001A / C2021A) HP LaserJet 4 Plus / 4M Plus (C2037A / C2039A) HP LaserJet 5 / 5M (C3916A/C3917A/ C3952A)

  • Page 2

    All Rights Reserved. change without notice. use only supplied power Reproduction, adaptation, cords and connect only to or translation without Hewlett-Packard makes properly grounded prior written permission no warranty of any kind (3-hole) wall outlets. is prohibited, except as with regard to this...

  • Page 3

    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.

  • Page 5: Table Of Contents

    Contents Product Information Product Family Information ....1-2 Identification ..... . . 1-3 Specifications .

  • Page 6: Table Of Contents

    Control Panel Keys ....3-2 Reset Menu ..... . . 3-5 Control Panel Menus .

  • Page 7: Table Of Contents

    Printer Drivers ..... . . 3-41 Install Printer Drivers and Utilities ..3-41 How to Obtain Printer Drivers .

  • Page 8: Table Of Contents

    Removing the Transfer Roller ... . 4-16 Replacing the Transfer Roller ... . 4-16 Functional Overview Introduction ......5-1 DC Controller System .

  • Page 9: Table Of Contents

    Removal and Replacement Required Tools ......6-2 Hardware Review ..... . 6-2 Removing the Covers .

  • Page 10: Table Of Contents

    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 .

  • Page 11: Table Of Contents

    Drum Rotation Functional Check ... 7-50 High Voltage Power Supply Assembly ..7-51 Interface Troubleshooting ....7-52 Communications Check .

  • Page 12: Table Of Contents

    Removing the Paper Guide Assembly ..A-16 Removing the Paper Roller ....A-17 Removing the Control PCA ....A-20 Removing the Power PCA .

  • Page 13

    To Print Using the Infrared Port ... . B-36 Troubleshooting IR Printing Problems ..B-38 Infrared Port Not Responding ... . . B-41 Contents-9...

  • Page 14

    Contents-10...

  • Page 15: Product Information

    Product Information Table 1-1 Printer Features Features HP LJ 4 HP LJ 4M HP LJ 4 Plus HP LJ4M Plus Model C2001A C2021A C2037A C2039A Printer Speed 8 ppm 8 ppm 12 ppm 12 ppm Resolution 300/600 dpi 300/600 dpi 300/600 dpi 300/600 dpi Expandable I/O Buffer...

  • Page 16: Product Family Information

    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...

  • Page 17: Identification

    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.

  • Page 18

    Figure 1-2 Printer Identification Label for the HP LaserJet 4/4M 1-4 Product Information...

  • Page 19: Specifications, Hp Laserjet 4 And 4 Plus

    Specifications HP LaserJet 4 and 4 Plus Table 1-3 Printer Dimensions Dimension HP LaserJet 4/4M HP LaserJet 4 Plus (C2001A/C2021A) 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)

  • Page 20: Electrical Specifications, Environmental Specifications

    Table 1-6 Electrical Specifications Status 100/115 V 220/240 V 4/4M 4 Plus/4M 4/4M 4 Plus/4M Plus 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...

  • Page 21: Related Documentation

    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. Table 1-7 Printer Documentation HP LaserJet 4 Documents—Description Part Number Your Guide to Setting Up the HP LaserJet 4...

  • Page 22: Safety Information, Product And Laser Safety

    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.

  • Page 23: Fcc Rfi Statement

    Consult the dealer or an experienced radio/TV technician for help. Any changes or modifications not expressly approved by Hewlett-Packard could void the user’s authority to operate this equipment. N o t e Use of a shielded interface cable is required to comply with the Class B limits of Part 15 of the FCC rules.

  • Page 24: Laser Statement (sweden/finland)

    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.

  • Page 25: Toner Safety, Ozone Statement

    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. To obtain a MSDS for the 92298A LaserJet Toner Imaging System through the mail, call the Customer Information Center (CIC) at 1-800-752-0900 between 6 A.M.

  • Page 26: Doing Business With Hp, Technical Assistance, Hp Asap 1-800-333-1917 (u.s.), Hp First, Hp First, U.s

    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...

  • Page 27: Hp Audio-tips, Hp Compuserve Forum, Customer Information Centers, Customer Support Center (assist Line), Printer Drivers

    1-800-524-3388. Customer Information Centers For further technical assistance, service-authorized HP and dealer service personnel can contact the nearest Hewlett-Packard Customer Information Center, 1-800-752-0900 in North America. Customer Support Center (Assist Line) The HP Customer Support Center, (208-323-2551) is available to...

  • Page 28: European Customer Support Center, Other Areas

    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.

  • Page 29: Site Requirements

    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.

  • Page 30: Printer Space Requirements

    Printer Space Requirements Figure 2-1 Space Requirements 2-2 Site Planning and Requirements...

  • Page 31: Print Media Specifications

    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).

  • Page 32

    Table 2-3 Media Specifications for Optional LC Tray (Tray 3) Media Size Capacity Weight/Thickness Range Paper Letter, A4, Executive 500 sheets at 20# 16# to 24# (60 to 90 g/m (75 g/m N o t e Printing heavy paper stock (greater than 24 lb. (90 g/m ) from the 500-sheet Lower Cassette specifically is not supported.

  • Page 33: Adhesive Labels, Label Construction

    Adhesive Labels Printing labels using the Duplex Assembly , the N o t e 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°...

  • Page 34: Overhead Transparencies, Envelopes

    Hewlett-Packard Company neither warrants nor recommends the use of a particular brand of envelope. Envelope properties are subject to change by envelope manufacturers, and Hewlett-Packard Company has no control over such changes. 2-6 Site Planning and Requirements...

  • Page 35: Envelope Construction

    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/m...

  • Page 36

    2-8 Site Planning and Requirements...

  • Page 37: Introduction

    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.

  • Page 38: Using The Control Panel, Control Panel Keys

    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.

  • Page 39

    Table 3-1 Indicator Lights Indicator Mode Description Ready Ready to print. Flashing: Processing a print job. Do not take off line or switch off. Off: Not ready; see display for message. On Line Ready to receive data. Flashing: Going from on line to off line. Off: Off line.

  • Page 40

    Table 3-2 Control Panel Key Functions 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.

  • Page 41: Reset Menu

    Reset Menu Use Reset Menu function with caution. It can result in loss of buffered page data or printer configuration data. Reset Menu is [Shift] [Menu] activated by holding down both for up to 10 seconds until RESET=MENU* appears. Use to cycle through [Enter] items and...

  • Page 42: Control Panel Menus

    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.

  • Page 43

    Figure 3-2 Control Panel Map Configuration 3-7...

  • Page 44

    Table 3-3 Printer Menu Items Item Options Explanation 1* to 999 Select any number from 1 to COPIES 999. LETTER* (110V printers), Sets default image size, PAPER LEGAL, A4* (220V printers) unless software setting overrides it. EXEC COM10* (110V printers), ENVELOPES MONARCH, DL* (220V printers), C5, B5...

  • Page 45

    Table 3-3 PCL Menu Items Item Options Explanation Internal fonts* FONT SOURCE Cartridge fonts Permanent soft fonts Mn (1-4) SIMM Module: n=slot number. Typefaces stored in one of the four ROM SIMM slots (M1=slot 1, for example). Number assigned to each FONT NUMBER 0* to 999 typeface.

  • Page 46

    Table 3-5 Configuration Menu Items Item Options Explanation Paper is selected first. MP TRAY FIRST* Operates as a PC tray. CASS Operates as a manual feed tray. MANUAL No trays are locked out. LOCK NONE* The MP tray is locked out. The PC tray is locked out.

  • Page 47

    Table 3-6 Memory Configuration Items Item Options Explanation Memory is automatically determined IO BUFFER AUTO* by the printer. No memory is set aside. Size can be manually adjusted 10K and up With IO BUFER ON, adjust size in IO SIZE increments of 10.

  • Page 48: Test Menu Items

    Table 3-8 Serial Menu Items Item Options Explanation Use the RS-422 when a longer cable SERIAL RS-232* is needed. RS-422 (HP LJ 4 only) Use if the computer requires PACING DTR/DSR* hardware flow control. Use if the computer requires software XON/XOFF flow control.

  • Page 49: Printer Features, Page Protection (hp Laserjet 4 Only)

    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) The default is PAGE PROTECT=OFF*. Unless you N o t e frequently get 21 PRINT OVERRUN messages, you may not need to set a value for page protection.

  • Page 50: Resource Saving (hp Laserjet 4 Plus And 5 Only)

    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.

  • Page 51: I/o Buffering (hp Laserjet 4 Plus And 5 Only)

    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.

  • Page 52: Economode (hp Laserjet 4 Plus And 5 Only), Resolution Enhancement (ret)

    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.

  • Page 53: Memory Enhancement Technology (met Hp Laserjet 4 Plus And 5 Only), Density

    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.

  • Page 54: Network Security, Remote Control Panel (dos), Hp Laserjet Utility (macintosh)

    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.

  • Page 55: Hp Jetadmin Utility (novell Networks)

    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) Run JETADMIN. Select the printer you want to configure. It is listed under its “JetDirect Interface Name”...

  • Page 56: Service Mode

    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).

  • Page 57: Setting The Page Count

    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: Enter the Service Mode as described previously.

  • Page 58: Setting The Cold Reset Default

    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.

  • Page 59: Cold Reset

    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.

  • Page 60: Understanding The Pcl Self Test Printout

    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 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.

  • Page 61

    Figure 3-3 HP LaserJet 4/4M PCL Self Test Printout Configuration 3-25...

  • Page 62

    Table 3-11 Self Test Printout Items - HP LaserJet 4 Plus/4M Plus Item Explanation Figure Standard menu selections: Lists selections in the order in which they appear in the control panel display. 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.

  • Page 63

    Figure 3-4 HP LaserJet 4 Plus/4M Plus PCL Self Test Printout Configuration 3-27...

  • Page 64: Changing The Control Panel Display Language

    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. Switch OFF the printer. [Enter] Select Press and hold...

  • Page 65: Test Print Button

    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).

  • Page 66

    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).

  • Page 67: System Configuration, Ms-dos System Configuration, Parallel Dos Commands

    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.

  • Page 68: Serial Ms-dos Commands

    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:...

  • Page 69: Printer I/o Configuration, Parallel Menu, Advanced Functions, Serial Configuration, Serial Protocol, Baud Rate

    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.

  • Page 70: Pacing (handshaking)

    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.

  • Page 71: Serial Cable Pin-outs, Db-9 Rs-232 Serial Connection — Hp Laserjet 4

    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. Figure 3-7 24542G Cable Pinout for 25 to 9 Pin Connector Configuration 3-35...

  • Page 72: Db-25 Rs-232 Serial Connection — Hp Laserjet 4 Plus/5

    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. Figure 3-8 C2932A Cable Pinout for 9 to 9 Pin Connector 3-36 Configuration...

  • Page 73: Db-25 Serial Connection — Hp Laserjet 4

    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. Figure 3-9 17255D Cable Pinout for 25 to 25 Pin Connector Configuration 3-37...

  • Page 74

    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. Figure 3-10 C2933A Cable Pinout for 9 to 25 Pin Connector 3-38 Configuration...

  • Page 75: Rs-422a Serial Connection (not Available On The Hp Laserjet 4 Plus Or 5 Printers)

    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.

  • Page 76: Modular I/o Configuration

    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.

  • Page 77: Printer Drivers, Install Printer Drivers And Utilities, How To Obtain Printer Drivers

    Check the Printing Software package to see if it includes a driver for your software. Order an updated driver from the software vendor. Call Hewlett-Packard at 970-339-7009. Obtain a driver request form by fax through HP FIRST (call 1-800-333-1917) U.S. only.

  • Page 78: Dos Utilities

    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.

  • Page 79: Packing The Printer, Repackaging Instructions, Packing Checklist

    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.

  • Page 80: Installing The Optional Lower Cassette

    Installing The Optional Lower Cassette Please see also the Service Notes section for N o t e 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.

  • Page 81: Loading Paper Into The Optional Lower Cassette

    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. Configuration 3-45...

  • Page 82

    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.

  • Page 83

    Figure 3-17 Push down the left corner of the stack until the paper is secured undered the metal clip. LEGAL EXEC LETTER Figure 3-18 Set the knob on the top right of the cassette to the paper size you have loaded. Configuration 3-47...

  • Page 84

    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.

  • Page 85: Envelope Feeder Installation

    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. The LaserJet 4, 4 Plus, and 5 printers all use N o t e different envelope feeder products.

  • Page 86: Laserjet 4 And 4 Plus, Laserjet 5

    Figure 3-22 Install the Envelope Feeder Insert the Envelope Feeder firmly into the printer (see Figure 3-22). 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.

  • Page 87: Simm Installation, Protecting The Simm Board

    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.

  • Page 88

    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. Figure 3-23 Identifying the Four SIMM Slots 3-52 Configuration...

  • Page 89: Memory Requirements

    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.

  • Page 90

    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. Table 3-13 SIMM boards Part Number...

  • Page 91: Accessing The Simm Slots, Installing The Simm Boards

    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.

  • Page 92

    Figure 3-25 Installing the SIMM Board 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) ). 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)).

  • Page 93: Testing A Simm Board, Memory Simm, Running A Self Test Printout

    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 On Line N o t e For the LaserJet 5/5M/5N, the key has Enter been replaced by the...

  • Page 94

    Personality SIMM (PostScript) A personality (printer language) SIMM installation can be verified as outlined below (a PostScript SIMM is used in this example). On Line For the LaserJet 5/5M/5N, the key has N o t e Enter been replaced by the key.

  • Page 95: Troubleshooting A Simm Board, Service / Error Messages

    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.

  • Page 96

    3-60 Configuration...

  • Page 97

    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. Toner Cartridge information, such as: Storing and installing the Toner Cartridge Refilled Toner Cartridges 16 TONER LOW message...

  • Page 98: Life Expectancy Of Consumables

    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 REMARKS (pages) When print becomes faint, shake...

  • Page 99: Service Checkpoints

    Service Checkpoints This is a fold-out page 3 panels wide. Figure 4-1 Maintenance Checkpoints Preventive Maintenance 4-3...

  • Page 100: Cleaning Your Printer

    Cleaning Your Printer When it is time to replace the toner cartridge, perform the cleaning procedures outlined in Figure 4-1. 4-4 Preventive Maintenance...

  • Page 101: Toner Cartridge

    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.

  • Page 102: Saving Toner With Economode (hp Laserjet 4 Plus And 5 Only), Storing The Toner Cartridge

    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.

  • Page 103: Installing The Toner Cartridge

    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: Open the printer’s top cover and remove the empty toner cartridge.

  • Page 104

    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.) Pulling the toner cartridge at an angle may N o t e damage the toner cartridge seals.

  • Page 105: Non-hp Toner Cartridges

    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.

  • Page 106: Clearing The Toner Low Message

    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...

  • Page 107: Periodic Maintenance Procedures, Removing The Mp Tray (tray 1) Pickup Roller And Separation Pad

    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.

  • Page 108

    Figure 4-6 Removing the MP Tray (Tray 1) Separation Pad 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). Discard the used roller and pad. 4-12 Preventive Maintenance...

  • Page 109: Removing The Pc (tray 2) Pickup Roller

    Removing the PC (Tray 2) Pickup Roller The PC Pickup Roller is underneath the printer (see Figure 4-7). To remove the Pickup Roller: 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.

  • Page 110: Removing The Lower Cassette (lc) Or (tray 3 Pickup Roller

    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: Remove the Lower Cassette Tray. Press the retainers that hold the roller in place (see Figure 4-8).

  • Page 111: Removing And Replacing The Transfer Roller

    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.

  • Page 112: Removing The Transfer Roller, Replacing The Transfer Roller

    Removing the Transfer Roller Turn OFF and unplug the printer. Open the printer’s top cover. Remove the Toner Cartridge. 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.

  • Page 113

    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. This chapter discusses the following printer functions: DC Controller System Formatter System...

  • Page 114: Dc Controller System

    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.

  • Page 115: Dc Controller Loads

    DC Controller Loads Figure 5-1 DC Controller Loads Functional Overview 5-3...

  • Page 116: Serial Data Communication

    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.

  • Page 117: Solenoids

    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.

  • Page 118: Photosensors

    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.

  • Page 119: Functional Overview

    Table 5-2 Photosensor Signals Sensor Description Input/Registration Sensor - detects paper in Paper Control pickup area PCA (J605) PC tray (Tray 2) Paper-out Sensor - detects the Paper Control presence of paper in the PC tray. PCA (J605) Output/Fuser Exit Sensor - detects paper in DC Controller fuser.

  • Page 120: Microswitches

    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.

  • Page 121: Pc (tray 2) And Lc (tray 3) Tray Size Sensing System

    Table 5-3 Microswitch Signals Switch Description 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...

  • Page 122: Motors

    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.

  • Page 123: Paper Jam Detection

    Table 5-5 Motors Motors Description Main Motor (Gear Train Drive Motor) Paper Input Assembly Drive Motor 500-sheet Lower Cassette Pickup Motor Envelope Feeder Drive Motor Scanner Motor Exhaust Fan Motor Paper Jam Detection The Input/Registration Sensor (PS1) and the Paper Exit Sensor (PS3) detect paper moving through the printer.

  • Page 124: Formatter System, I/o Control

    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.

  • Page 125

    Figure 5-5 Formatter PCA—Functional Areas Functional Overview 5-13...

  • Page 126: Memory Management, Data Processing

    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.

  • Page 127: Pjl Overview

    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.

  • Page 128: Image Formation System

    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.

  • Page 129: Photosensitive Drum, Drum Sensitivity

    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.

  • Page 130: Cleaning Stage

    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.

  • Page 131: Conditioning Stage

    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.

  • Page 132: Writing Stage

    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.

  • Page 133

    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).

  • Page 134: Developing Stage

    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.

  • Page 135

    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.

  • Page 136: Transferring Stage

    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.

  • Page 137: Fusing Stage

    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”...

  • Page 138: Paper Feed System

    Paper Feed System The LJ 5 printer designators differ as follows. N o t e LJ 4 / 4 Plus Multipurpose (MP) Tray Paper Cassette (PC) Tray Lower Cassette (LC) Tray LJ 5 Tray 1 Tray 2 Tray 3 The following paper paths are described in this section of the manual: PC Tray (Tray 2) to Output Trays MP Tray (Tray 1) to Output Trays...

  • Page 139

    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.

  • Page 140

    Figure 5-17 Paper Feed Assembly (Sectional View) Table 5-6 Part Description Leading Edge Registration Sensor PC Tray (Tray 2) Paper Out Sensor Exit Sensor MP Tray (Tray 1) Paper Out Sensor MP Tray (Tray 1) Paper End Sensor Cassette (Tray 2) Pickup Roller Clutch Solenoid MP (Tray 1) Tray Pickup Roller Clutch Solenoid 5-28 Functional Overview...

  • Page 141: Printing From The Mp Tray (tray 1)

    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).

  • Page 142: Printing From The Pc Tray (tray 2)

    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°...

  • Page 143: Power System

    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.

  • Page 144

    Figure 5-20 Power System Block Diagram 5-32 Functional Overview...

  • Page 145: Basic Sequence Of Operation, Standard Printer Operation

    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.

  • Page 146: Timing Diagrams

    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. 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.

  • Page 147

    This a 2 panel pull-out. Figure 5-21 MP Tray Timing Diagram—HP LaserJet 4/4M Functional Overview 5-35...

  • Page 148

    This a 2 panel pull-out. Figure 5-22 MP (Tray 1) Timing Diagram—HP LaserJet 4 Plus/4M Plus/5/5M/5N 5-36 Functional Overview...

  • Page 149: Warmup Period, Standby Period, Powersave

    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.

  • Page 150: Initial Rotation Period

    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).

  • Page 151

    If a failure occurs during this period, the following errors may be displayed: This error occurs when the fusing roller fails to 50 SERVICE reach the correct temperature in the required time (see “50 SERVICE”) in Chapter 7). This error occurs when the BD signal is not 51 ERROR received by the DC controller, (see “51 ERROR BEAM DETECT)”...

  • Page 152: Print Period

    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 DC controller translates the VDO data into a VIDEO OUT signal (VDOUT), which modulates the laser diode ON and OFF, creating intermittent bursts of laser light which reflect off the scanner...

  • Page 153

    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.

  • Page 154: Last Rotation Period

    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.

  • Page 155: Removal And Replacement

    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.

  • Page 156: Required Tools, Hardware Review

    Required Tools Table 6-1 Required Tools TOOL #2 Magnetized Phillips Screwdriver (6-inch shaft) Small Needle Nose Pliers Small Flat-head Screwdriver (6-inch shaft) 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.

  • Page 157

    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.

  • Page 158: Removing The Covers, Right Side Cover Removal

    Removing the Covers Right Side Cover Removal Figure 6-2 Right Side Cover Release Points LJ 4/4 Plus Open the Top Cover and release the Right Side Cover by pressing at the points shown in Figure 6-2. Fold the cover away from the printer to release the bottom supports and lift the door off of the printer frame.

  • Page 159: Top Cover Removal

    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.) Carefully lift the top cover to access the Control Panel cable.

  • Page 160

    Figure 6-4 Control Panel Cable Disconnect the Control Panel Ribbon Cable and remove the top cover (see Figure 6-4). 6-6 Removal and Replacement...

  • Page 161: Left Side Cover Removal

    Left Side Cover Removal Figure 6-5 Left Side Cover Latches Remove the Right Side Cover and the Top Cover. 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.

  • Page 162: Rear Door Removal

    Rear Door Removal Figure 6-6 Releasing the Door Support Remove the PC tray (Tray 2). Open the Rear Door. Support the door with one hand. Release the door support from the rear of the printer frame as follows: (see Figure 6-6) Using needle-nose pliers, squeeze the tabs on the end of the retaining strap.

  • Page 163

    Figure 6-7a Releasing the Door Hinge (LaserJet 4/5) 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).

  • Page 164: Font Door Cover Removal (lj 5 Right Front Cover Removal)

    Font Door Cover Removal (LJ 5 Right Front Cover Removal) Figure 6-8 Font Door Removal (LaserJet 4 shown) LJ 4/4 Plus Remove the Right Side Cover, the Top Cover,and the PC Tray. Release the top latch (see Figure 6-8, callout 1). 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).

  • Page 165

    Figure 6-9 Font Door Cover Latches Removal and Replacement 6-11...

  • Page 166: Multi-purpose (mp) Tray (tray 1) Door Removal

    Multi-Purpose (MP) Tray (Tray 1) Door Removal Figure 6-10 Removing the MP Tray Door Remove the PC Tray. Open the MP Tray door and extend the MP Tray. Bend the Door Slides out to release the tray from the door slides (see Figure 6-10).

  • Page 167: Multi-purpose (mp) Tray (tray 1) Removal

    Multi-Purpose (MP) Tray (Tray 1) Removal Figure 6-11 Remove the Crossmember Bracket Remove the Right Side Cover, Top Cover, Left Side Cover, MP Tray Door (Tray 1), and the Font Door Cover. Remove the PC Tray (Tray 2). Remove the (2) screws in the Cross-member Bracket as shown in Figure 6-11, callout 1.

  • Page 168

    Figure 6-12 Rotate the Tray Down to Release the Hinge from its Slots 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. Rotate the tray down until it slides off its slotted hinges (about 120°)(see Figure 6-12).

  • Page 169: Assemblies Removal, Power Supply Removal

    Assemblies Removal Power Supply Removal Figure 6-13a Remove the Sheet Metal Plate (LaserJet 4) Remove the Right Side Cover. 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.

  • Page 170

    Figure 6-13b Remove the Sheet Metal Plate (LaserJet 4 Plus/5) Figure 6-14 Power Supply Screws Remove the (2) screws from the bottom frame (see Figure 6-14, callout 1). Slide the power supply out the right side of the printer to access the power supply connectors.

  • Page 171

    Figure 6-15 6-wire and 3-wire Connectors for the Power Supply 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. Remove the power supply. N o t e When replacing the power supply, be sure to use the screws with the star washers to ensure proper...

  • Page 172: Paper Feed Assembly Removal

    Paper Feed Assembly Removal Figure 6-16 Paper Feed Assembly Screws and Connectors 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.

  • Page 173

    Figure 6-17 MP Tray Opening Cover (continued on next page) Removal and Replacement 6-19...

  • Page 174

    Figure 6-18 Paper Feed Assembly Screws (numbered) Remove the (3) screws from the left side of the printer (see Figure 6-18, callout 1). Remove the Paper Feed Assembly by lifting it and sliding it out the front of the printer. Replace the screws in order as shown.

  • Page 175: High Voltage Power Supply (hvps) Removal

    High Voltage Power Supply (HVPS) Removal Figure 6-19 HVPS Screws (2) and Latches (2) (Bottom View) Remove the Toner Cartridge and PC tray. Lay the printer on its left side. (Place a cloth under the printer to prevent marking the cover.) Remove the (2) screws that hold the HVPS in place (see Figure 6-19, callout 1).

  • Page 176: Fuser Assembly Removal

    Fuser Assembly Removal Figure 6-20 Fuser Assembly Screws C a u t i o n The Fuser Assembly may be hot. Allow plenty of time for the fuser to cool before beginning the fuser removal procedure. Open the rear door. Remove the (2) screws that hold the Fuser to the printer frame (see Figure 6-20, callout 1).

  • Page 177: Control Panel And Overlay Removal

    Control Panel and Overlay Removal Figure 6-21 Control Panel Latches Remove the Right Side Cover and the Top Cover. Turn the Top Cover over and place it on flat surface. Release the (3) latches that contain the Control Panel (see Figure 6-21, callout 1).

  • Page 178

    Figure 6-22 Changing the Control Panel Overlay 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). Squeeze the sides of the Control Panel Overlay to release the (2) tabs (see Figure 6-22, callout 1).

  • Page 179: Removing The Simms Door

    Removing the SIMMs Door Figure 6-23a Removing the SIMMs Door (LaserJet 4) Remove the Right Side Cover. LaserJet 4: Remove the (2) screws that hold the SIMMs cover (see Figure 6-23a, callout 1). Open the SIMMs cover, lift the door slightly to remove the door from the hinge.

  • Page 180

    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. 6-26 Removal and Replacement...

  • Page 181: Formatter Cage Removal

    Formatter Cage Removal Figure 6-24a Formatter Cage Screws (Right Side View - LaserJet 4 and 5) N o t e 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. Remove the Right Side Cover and the Top Cover.

  • Page 182

    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...

  • Page 183: Formatter Pca Removal

    Formatter PCA Removal The Formatter PCA is very sensitive to Electro- C a u t i o n static Discharge (ESD) damage. Observe proper ESD procedures when servicing the printer. Before removing the old Formatter PCA, print a N o t e 05 SELF TEST to check the current printer page count, if possible.

  • Page 184

    LaserJet 4 Formatter PCA: Remove any MIO or SIMM modules from the Formatter Assembly. Remove the (2) black screws from the side of the Formatter Cage (see Figure 6-25a, callout 1). Remove the MIO Connector Support Bracket (see Figure 6-25a, callout 2). Remove the (2) Formatter PCA mounting screws (see Figure 6-25a callout 3).

  • Page 185

    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.

  • Page 186

    LaserJet 4 Plus and 5 Formatter PCA Remove any MIO or SIMM modules from the Formatter Assembly. Remove the MIO Connector Support Bracket (see Figure 6-25a, callout 2). Remove the (4) I/O screws (see Figure 6-26 callout 1). Remove the (2) Formatter PCA mounting screws (see Figure 6-26 callout 2).

  • Page 187: Dc Controller Removal

    DC Controller Removal Figure 1-27a DC Controller Connectors/Retaining Clips (LaserJet 4) N o t e 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.

  • Page 188

    Figure 1-27b DC Controller Connectors/Retaining Clips (LaserJet 4 Plus/5) 6-34 Removal and Replacement...

  • Page 189: Dc Controller Installation

    DC Controller Installation C a u t i o n 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.

  • Page 190

    Figure 1-28 Leading Edge Registration Adjustment Dimensions Figure 1-29 VR202 Settings (LaserJet 4 shown) 6-36 Removal and Replacement...

  • Page 191: Main Motor Assembly Removal

    Main Motor Assembly Removal Figure 1-30 Main Motor Assembly Remove the Right Side Cover, Top Cover, and the Formatter Cage Assembly. Unplug the Main Motor connector from the Main Motor Assembly (see Figure 6-30, callout 1). Remove the (4) Main Motor screws (see Figure 6-30, callout 2). Remove the Main Motor.

  • Page 192: Gear Assembly Removal

    Gear Assembly Removal Remove the Top Cover, the Right Side Cover, the Fuser Assembly, and the Formatter Assembly. Remove the Main Motor Assembly (see Figure 6-30). Remove the (2) screws that hold the Gear Assembly (see Figure 6-31 callout 1). Slide the Gear Assembly from the rear of the printer.

  • Page 193: Fan Removal

    Fan Removal Figure 1-32 Fan Connector N o t e Note the cable routing before beginning this disassembly procedure. Be careful not to damage the cables during re-assembly. Remove the Right Side Cover, the Top Cover, and the Formatter Cage Assembly. Unplug the fan connector (J209 on the LaserJet 4, J211 on the LaserJet 4+/5).

  • Page 194

    Figure 1-33 Exhaust Fan Removal (Laser Jet 4 shown) Remove the RFI shield (LJ 4 only) by releasing the retaining tab and sliding the shield up (see Figure 6-33, callout 1). 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).

  • Page 195: Output Assembly Removal

    Output Assembly Removal Figure 1-34 Output Assembly Removal Remove the Right Side Cover, the Top Cover, and the Left Side Cover. Release the grounding strap from the left side of the frame. 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.

  • Page 196: Paper Exit Sensor (ps3) Removal

    Paper Exit Sensor (PS3) Removal Figure 1-35 Exit Sensor Remove the Right Cover, Top Cover, and the Output Assembly. Disconnect the Sensor Cable. Lift the Sensor Retaining Latch and slide the sensor forward (see Figure 6-35). Remove the Paper Exit Sensor. 6-42 Removal and Replacement...

  • Page 197: Scanner Assembly Removal

    Scanner Assembly Removal Figure 1-36 Scanner Assembly Removal Remove the Right Side Cover, Top Cover, Left Side Cover, and the Output Assembly. Remove all cables from the Scanner retaining clips. Remove the (3) connectors (see Figure 6-36, callout 2). N o t e Be careful not to flex the Laser PCA when removing or installing the cables.

  • Page 198: Lower Cassette Assemblies, Lower Cassette Sensor Pca Removal

    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 Release the Sensor PCA cover latches (see Figure 6-37 callout 1). Cut the tie-wrap and remove the (3) sensor connectors (see Figure 6-37 callout 2).

  • Page 199: Lower Cassette Pickup Motor Removal

    Lower Cassette Pickup Motor Removal Figure 1-38 Lower Cassette Upper Front Cover Open the sensor cover and disconnect the center and rear connectors (see Figure 6-37, callout 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).

  • Page 200

    Figure 1-39 Lower Cassette Motor Lift the motor assembly straight up out of the the Lower Cassette Base (see Figure 6-39). N o t e Note the ground connector underneath the Motor Assembly. Be careful not to damage this connector during reassembly. 6-46 Removal and Replacement...

  • Page 201: Replacing Fuser Assembly Parts

    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. C a u t i o n Handle the Heater Bulb by the ceramic ends.

  • Page 202: Fuser Assembly Configuration

    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). Figure 1-40 Fuser Assembly Table 1-1 Fuser Assembly Configuration...

  • Page 203: Removing The Fuser Roller Heat Lamp

    Removing the Fuser Roller Heat Lamp Figure 1-41 Fuser End Cap Removal (LaserJet 4 only) 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.) 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...

  • Page 204

    Figure 1-42 Fuser Wire Harness Cover Removal (LaserJet 4) 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.

  • Page 205

    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...

  • Page 206

    Figure 1-43 Left Side Fuser Cover Remove the (1) Heat Lamp lead (thermoswitch screw)(see Figure 6-43 callout 1). 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). LaserJet 4: Remove the cable retainer from the fuser frame, and free the heat lamp lead from the cable retainer.

  • Page 207

    Figure 1-44 Gear Side Heat Lamp Connector N o t e LaserJet 4 and 5 only: Note the orientation of the bushing on the left side of the Fusing Roller. 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).

  • Page 208

    Figure 1-45 Fuser Gear Cap Removal N o t e Before removing the gear cover, note the routing of the wires in the gear cover slots. 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.

  • Page 209: Fuser Assembly Thermoswitch Removal

    Fuser Assembly Thermoswitch Removal N o t e 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.

  • Page 210: Thermistor Removal

    Thermistor Removal Figure 1-47 Thermistor Connector Remove the Wire Harness Cover as shown in Figure 6-47. Remove the (2) screws from the thermoswitch connector (see Figure 6-47, callout 1). Release the thermoswitch latch from the paper sensor flag side of the Fuser Assembly (behind the side cover, see Figure 6-47, callout 2).

  • Page 211

    Figure 1-48a Upper Fuser Frame Removal (LaserJet 4) Release the (2) springs from the Upper Fusing Frame (see Figure 6-48a, callout 1). 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).

  • Page 212

    Remove the (1) screw that holds the Thermistor (see Figure 6-48b, callout 2). Ensure the thermistor cable is routed correctly N o t e when assembling the fuser (see Figure 6-47). Figure 1-48b Upper Fuser Frame Removal (LaserJet 4 Plus) 6-58 Removal and Replacement...

  • Page 213: Paper Control Pca Removal

    Paper Control PCA Removal Figure 1-49 Paper Control PCA Retaining Screws and Latches Remove the Right Side, Top, Left Side, and Font Door Covers, then Paper Feed Assembly. Disconnect the cables from the sensors (see Figure 6-49, callout 1). Remove the (2) self-tapping screws from the Paper Control PCA (see Figure 6-49, callout 2).

  • Page 214: Sensor Pca Removal

    Sensor PCA Removal Figure 6-50 Sensor PCA Removal Remove the Right, Left, Top, and Font Door covers. You need not remove the MP Tray. Perform the Paper Control PCA removal procedure, as shown in the preceding section. Disconnect the connectors for SL1, SL2, and M2 from the left end of the Sensor PCA.

  • Page 215: Ps1 And Ps2 Sensor Assembly Removal

    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. Remove the Paper Feed Assembly and place it on a flat surface, with the MP Tray side down. You need not remove the MP Tray from the Paper N o t e Feed Assembly.

  • Page 216: High Voltage Contact Plate (hvcp) And Paper Guide Removal

    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.

  • Page 217

    After removing the Fuser Assembly, remove the contact plate from the rear of the printer, as follows: Remove the (1) screw from the sheet metal Guide Plate Cover. (This screw is behind the Fuser Assembly, see Figure 6-52, callout 1). Remove the Guide Plate Cover by freeing the front edge, lifting upward, and sliding the cover out the rear of the printer.

  • Page 218

    Figure 6-53 Paper Guide Rollers Remove the (6) rollers from the High Voltage Contact Plate (see Figure 6-53 callout 1). (continued on next page) 6-64 Removal and Replacement...

  • Page 219

    Figure 6-54 Cross Member Screws 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). (continued on next page) 6-65 Removal and Replacement...

  • Page 220

    Figure 6-55 Left Toner Cartridge Guide Plate Screw 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). Release the guide plate latch (see Figure 6-55, callout 2). Remove the Laser Shutter Pivot Pin from its seat in the Left Toner Cartridge Guide Plate (see Figure 6-55, callout 3).

  • Page 221: Feed Guide Assembly

    Removing the High Voltage Contact Assembly and Feed Guide Assembly N o t e 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.

  • Page 222: Replacing The High Voltage Contact Assembly/feed Guide Assembly

    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. Set the contact assembly over its mounting holes.

  • Page 223: Interconnect Pca Removal

    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.

  • Page 224

    N o t e 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 Disconnect the Interconnect Cable connector from the DC Controller (J210 on LJ4, J213 on LJ4+/5). Remove the cable from its retainer.

  • Page 225

    N o t e 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). Release the AC Connector from the sheet metal with needle-nose pliers.

  • Page 226

    6-72 Removal and Replacement...

  • Page 227

    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 , look up the recommendation for that error in the Printer Message Troubleshooting section (Tables 7-1 and 7-2).

  • Page 228

    Message on LJ 5/5M/5N Recommendations Indicates that a lower cassette has been installed that is not compatible with the LJ5. Press to clear the error. The tray will not appear in any control panel or PJL messages. (powerup only) See W4/7 JOB 300/[page protect size] This message is displayed whenever the device is in the process of flushing the pipeline so it can go offline or into the...

  • Page 229

    Message on LJ 5/5M/5N Recommendations 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. x=Tray 1 or Envelope Feeder LaserJet 5 Error Map 7-C...

  • Page 230

    7-D LaserJet 5 Error Map...

  • Page 231: Preliminary Operating Checks

    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.

  • Page 232: Printer Message Troubleshooting, Printer Message Summary Table

    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.

  • Page 233: Troubleshooting

    Table 7-1 Printer Messages (continued) Message Symptoms and Recommendations Returns all printer settings to Printing Menu settings, and clears buffered pages, temporary soft fonts, and macros. Wait for the printer to display the message. See the Reset Menu section in Chapter 3 for more details. Printer is initializing non-volatile RAM.

  • Page 234

    Table 7-1 Printer Messages (continued) Message Symptoms and Recommendations This message is displayed when the MIO ( ) 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.

  • Page 235

    Table 7-1 Printer Messages (continued) Message 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.

  • Page 236

    Table 7-1 Printer Messages (continued) Message Symptoms and Recommendations An error occurred during configuration and validation of SIMM memory: X Hardware Type: 0:ROM 1:RAM 2:Flash Y Hardware Device: 0: Internal Memory 1: SIMM Slot 1 2: SIMM Slot 2 3: SIMM Slot 3 4: SIMM Slot 4 ZZ Error Number: 0: Unsupported Memory...

  • Page 237

    Table 7-1 Printer Messages (continued) Message 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.

  • Page 238

    Table 7-1 Printer Messages (continued) Message 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. The printer detected an error in the nonvolatile memory (NVRAM).

  • Page 239

    Table 7-1 Printer Messages (continued) Message Symptoms and Recommendations 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. This message is displayed when there is a request for a manually fed envelope.

  • Page 240: Clearable Warnings

    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 . 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.

  • Page 241

    Table 7-2 Clearable Warning Messages Message Displayed 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.

  • Page 242: Printer Message Troubleshooting Procedures, Blank Display

    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 Action Is the power on? Check the ON/OFF switch and verify the power is plugged in.

  • Page 243: Mp/pc/lc (tray 1/2/3) Load Message

    MP/PC/LC (Tray 1/2/3) LOAD Message The conditions that result in or ( 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.

  • Page 244

    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 Reseat the cassettes. Make sure each printer? cassette is fully seated into the printer. Ensure that the Universal Paper tray selector knob setting matches the installed paper.

  • Page 245: Cassette Size Switches (sw603, Sw604, Sw605 Functional Check

    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.

  • Page 246: Paper Size Sensing Lower Cassette

    Table 7-5 Switch Logic for Cassette Size Cassette Cassette Size Sensing Switch SW603/851 SW604/852 SW605/853 Upper Middle Lower Legal Letter Executive No Cassette 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.

  • Page 247: Pc Empty Sensor (ps2) Functional Check, Ps4 Check (mp Tray Empty Sensor)

    PC Empty Sensor (PS2) Functional Check Power on the printer with the PC tray (Tray 2) empty. After the and the cycles, the ) or message appears. Add paper to the PC tray and re-install the tray. The display should read , then message persists, replace PS2.

  • Page 248: Printer Open Message

    12 Printer Open Message ) 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.

  • Page 249: Sw601 Functional Check

    SW601 Functional Check Open the Top Cover Assembly. The message should appear. Close the top cover. The message should appear. 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).

  • Page 250: Paper Jam Message

    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). PS1, the Input/Registration Sensor, located in the Paper Feed Assembly.

  • Page 251

    Table 7-7 Paper Jam Troubleshooting Checklist Jam Location Checks and Action Required Input Area Jams 1. Check that the Transfer Roller is fully seated and shows no (Sensed by PS1.) sign of wear. 2. Check that the Toner Cartridge is fully seated. 3.

  • Page 252: Ps1 (input/registration Sensor) Check

    PS1 (Input/Registration Sensor) Check Power ON the printer with the top cover open. Wait for the ) message. Engage PS1 by taping it down. For the LaserJet 5, install the toner cartridge. Close the top cover. The message should display. After the fuser warms up, the main motor should turn on.

  • Page 253: Ps3 (exit Sensor) Check, Pickup Motor Functional Test (m2)

    PS3 (Exit Sensor) Check Open the rear door (cover) of the printer. The display should read immediately after the door is opened. Close the rear cover. The display should change from If the message does not appear, check that the rear door is not damaged, and the the door closes and latches properly.

  • Page 254: Lower Cassette Functional Check

    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.

  • Page 255: No Ep Cart Message, Toner Low Message

    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).

  • Page 256

    Figure 7-5 Toner Cartridge Components Table 7-8 Toner Cartridge Components Callout Assembly Toner Low Voltage Contact Developer Roller High Voltage Contact Developer Roller Photoconductive Drum Charge Roller High Voltage Contact Charge Roller 7-26 Troubleshooting...

  • Page 257: X Error Message

    41.X ERROR Message (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 messages indicate a problem requiring attention. is usually accompanied by a blank, or partially [Continue] (or Go) key re-prints the printed page.

  • Page 258

    Table 7-9 41.X ERROR Checks Error Message Recommended Action Reseat all connectors on the DC Controller, the Laser Noisy Vertical Sync (VS) Drive PCA, the Scanner Connector and the Beam Detect Connector. Reseat all connectors on the DC Controller. Also check the Beam Detect (BD) Laser Scanning Assembly connections.

  • Page 259: Service Error - Fuser Malfunction

    50 SERVICE Error - Fuser Malfunction The Fuser Assembly is HOT. Allow the assembly W a r n i n g 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.

  • Page 260

    Table 7-10 50 SERVICE Fuser Malfunction Checks Checks Action Is the Fuser Assembly correctly Reseat the Fuser Assembly. Allow seated? adequate time for the error message to clear (10 minutes) and turn the printer Is the Fuser Bulb/ Thermoswitch open? The fuser bulb and thermoswitch are wired in series.

  • Page 261: Error Message

    Figure 7-6 Fuser Assembly Connector 51 ERROR Message , and the are caused by Beam Detect failures. If the beam detect signal is lost for more than 2 seconds the error is posted as a . The can be cleared [Continue] (or Go).

  • Page 262: Error Scanner Malfunction, Laser/scanner Assembly Functional Checks

    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.

  • Page 263: Or 57.1) Service Message (main Motor Failure), Main Motor Functional Checks

    57 (or 57.1) SERVICE Message (Main Motor Failure) 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.

  • Page 264: Or 57.2) Service (fan Failure)

    58 (or 57.2) SERVICE (Fan Failure) 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. Check that the fan is mounted correctly in its shroud. Check that the fan blades are not blocked.

  • Page 265: Image Defect Summary

    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.

  • Page 266

    Figure 7-7 Image Defect Summary 7-36 Troubleshooting...

  • Page 267

    Figure 7-8 Image Defect Summary Troubleshooting 7-37...

  • Page 268

    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 Remove the HVPS, and check the HVPS has been removed and replaced, connectors for damage.

  • Page 269

    Table 7-14 Faulty Registration Possible Cause Action Paper. The surface of the paper may be Change paper. Try a brand of paper too smooth for the pickup roller to move known to be good. the paper through the paper path. Worn Pickup Roller and Separation Pad.

  • Page 270

    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.

  • Page 271

    Table 7-19 Repetitive Defects Possible Cause Action Toner Cartridge. The circumference of Replace the Toner Cartridge. 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.

  • Page 272

    Table 7-20 Smeared Print/Improper Fusing Possible Cause Action Fuser levers not in place. The Fuser Assembly has shipping levers (All LJ4, some LJ4+, N/A on LJ5) that must be lowered during the setup process. See Chapter 3 for instruction on how to lower the fusing levers.

  • Page 273

    Table 7-22 Black Pages with Horizontal White Strips Possible Cause Action Laser/Scanning Assembly or DC Replace the Laser/Scanning Assembly Controller PCA. followed by the DC Controller PCA, if necessary (see Figure 7-12 for locations). Table 7-23 Image Skew Possible Cause Action Input/Registration Sensor (PS1).

  • Page 274: Ps5 Check (mp Tray Paper End Sensor Functional Test

    Table 7-24 Improperly Sized Image Possible Cause Action PC tray Microswitches. The paper tray Perform the “Cassette Size Switches microswitches indicate the paper size of (SW603, SW604, SW605) Functional the installed tray. This information is used Check” on page 7-15. Ensure that the to format the print image to the size of correct envelope size is selected if the paper installed in the tray.

  • Page 275

    Figure 7-9 PS5 Test Sheet Troubleshooting 7-45...

  • Page 276

    EP Cartridge, between the laser shutter opening and the fuser stop plate. Bad transparencies. Transparencies Use Hewlett-Packard-approved exhibit this problem if they are not transparencies (refer to the HP LaserJet designed for proper toner adhesion.

  • Page 277

    Table 7-27 Background Scatter Possible Cause Action Defective Toner Cartridge. The Toner Replace the Toner Cartridge. Cartridge may be internally damaged. Bad paper lot. The paper moisture Try a different paper lot (see the HP content, conductivity, or surface finish LaserJet Family Paper Specifications may be incompatible with the Guide) for paper specifications.

  • Page 278

    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, Refer to item 4 in Figure 8-4a. Guide improperly positioned, or missing. must be installed properly above the EP Cartridge, between the laser shutter opening and the fuser stop plate.

  • Page 279: Image Formation Troubleshooting, Half Self-test Functional Check

    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.

  • Page 280: Drum Rotation Functional Check

    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: Open the printer’s Top Cover Assembly. Remove the Toner Cartridge.

  • Page 281: High Voltage Power Supply Assembly

    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).

  • Page 282: Interface Troubleshooting, Communications Check, Test Message

    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. The CSC telephone number is: (208) 323-2551.

  • Page 283: Autoexec.bat Standard Configurations, Parallel Dos Commands, Serial Ms-dos Commands

    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 N o t e This example assumes that you are using parallel printer port LPT1.

  • Page 284: Communications Checks

    Communications Checks Table 7-30 Communications Checks Checks Action Is your computer configured to the These parameters are required to parameters described in the communicate with the printer. Verify your configuration instructions? 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.

  • Page 285

    C a u t i o n with mechanical switch-box products without proper surge protection. These devices generate high transient voltages that cause permanent damage to the Formatter PCA. This circumstance is not covered by the Hewlett-Packard warranty. Troubleshooting 7-55...

  • Page 286: Mio Troubleshooting, Troubleshooting Hints

    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.

  • Page 287: Explanation Of Self Test Printout

    Explanation of Self Test Printout Multiple Environment Information. General information about your JetDirect MIO. 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. Network Statistics.

  • Page 288

    Figure 7-10 MIO Staus Information on the Self Test Printout 7-58 Troubleshooting...

  • Page 289: Troubleshooting Aids, Component Locations

    Troubleshooting Aids Component Locations The following illustrations help you quickly find the parts discussed in this chapter. Figure 7-11 Major Assembly and Connector Locations Table 7-31 Number Part Number Part Fuser Assembly Paper Feed Assembly Cooling Fan Paper Control PCA DC Controller PCA Sensor PCA Main Motor Assembly...

  • Page 290

    Figure 7-12 Major Assembly and Connector Locations (2 of 3) Table 7-32 Number Part Laser/Scanner Assembly DC Controller PCA Interconnect PCA Assembly Paper Control PCA High Voltage Power Supply PCA Exit Sensor Assembly 7-60 Troubleshooting...

  • Page 291

    Figure 7-13 Major Assembly and Connector Locations (3 of 3) Table 7-33 Number Part Power Supply Assembly Envelope Feeder Main Motor (M4) Lower Cassette Drive PCA Lower Cassette Main Motor (M3) Troubleshooting 7-61...

  • Page 292

    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 PC (Tray 2) Tray Size Switches SW604 SW605 7-62 Troubleshooting...

  • Page 293

    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...

  • Page 294

    VR202 J206 J203 J207 J208 J204 J205 J202 J213 J209 J201 CP202 J210 TB201 J211 J212 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...

  • Page 295

    VR201 J205 J204 J207 J206 J209 J208 J210 J211 J215 J201 J212 J214 J213 TB201 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...

  • Page 296

    TB401 TB402 TB403 TB404 VR401 TB405 J402 TB406 J401 Figure 7-18 High Voltage PCA Layout Table 7-38 Number Part J401 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...

  • Page 297: Repetitive Defect Template

    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.

  • Page 298

    Figure 7-20 Main Wiring Diagram (LJ 4+/5 only) 7-68 Troubleshooting...

  • Page 299: Voltage Test Points, Measuring The Dc Voltage Levels

    Voltage Test Points The operating voltages of the printer can be verified by: 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.) Listen for the Main Motor.

  • Page 300

    7-70 Troubleshooting...

  • Page 301: How To Use The Parts Lists

    Part numbers with no indicator in the Notes column are stocked and can be ordered through Hewlett-Packard’s Support Materials Organization (SMO). Parts marked with an S in the Notes column are special order parts which can be ordered through SMO but may have an eight-week lead time.

  • Page 302: Parts Lists And Illustrations

    Parts Lists and Illustrations Figure 8-1a Field-Replaceable Assemblies (1 of 2) 8-2 Parts and Diagrams...

  • Page 303

    Figure 8-1b Field-Replaceable Assemblies ( 2 of 2) Parts and Diagrams 8-3...

  • Page 304

    Table 8-1 Field-Replaceable Assemblies Part # Exchng # Description Fig. # Fusing Ass’y (100/110V) 8-10 RG5-0454-000CN C2001-69003 LaserJet 4 RG5-0879-130CN C2037-69001 LaserJet 4 Plus/5 Fusing Ass’y (220/240V) 8-10 RG5-0455-000CN C2001-69004 LaserJet 4 RG5-0880-130CN C2037-69002 LaserJet 4 Plus/5 Main Motor 8-4b RH7-1151-000CN LaserJet 4 RH7-1169-000CN...

  • Page 305

    Table 8-1 Field-Replaceable Assemblies (continued) Part # Exchng # Description Fig. # PC Tray (Tray 2) (ltr) 8-14 C2085B LaserJet 4 C2085E LaserJet 4 Plus C3925A LaserJet 5 PC Tray (Tray 2) (A4) 8-14 C2085C LaserJet 4 C2085F LaserJet 4 Plus C3926A LaserJet 5 Power Supply (100/120V)

  • Page 306

    Figure 8-2 Covers and Panels 8-6 Parts and Diagrams...

  • Page 307: Parts And Diagrams

    Table 8-2 Covers and Panels Part # Notes Description RB1-2143-000CN MP Tray Extender RB1-3558-000CN LJ4+ RB1-7885-000CN RB1-2346-000CN Right Cover RB1-3470-000CN LJ4+ RF5-1644-000CN RB1-2347-000CN Left Cover RB1-3471-000CN LJ4+ RB1-7881-000CN RF5-0533-000CN Rear Door Assembly RF5-0733-000CN LJ4+ RF5-1645-000CN RB1-2354-000CN Rear Door Support Strap RB1-2335-000CN LJ4/4+ Rear Door Latch...

  • Page 308

    Figure 8-3a Top Cover Assembly for LaserJet 4/4+ 8-8 Parts and Diagrams...

  • Page 309

    Table 8-3a Top Cover Assembly Part # Notes Description RB1-2330-000CN Spring, Leaf RG5-0458-000CN Upper Cover Assembly RG5-0872-000CN LJ4+ 3A RB1-2322-000CN Top Cover Door RB1-3474-000CN LJ4+ 3B RB1-2323-000CN Hinge, Bracket 3C RB1-2324-000CN 2 ea. Hinge, Pin 3D RB1-2329-000CN Hinge, Arm RB1-3473-000CN LJ4+ 3E RB1-2364-000CN Hinge, Bracket...

  • Page 310

    Part # Notes Description 4A C2037-40001 LJ4+ English C2037-40002 French C2037-40003 German C2037-40004 Italian C2037-40005 Spanish C2037-40006 Norwegian C2037-40007 Swedish C2037-40008 Danish C2037-40009 Finnish C2037-40010 Dutch C2037-40011 Polish C2037-40012 Turkish C2037-40013 Portugese C2037-40014 European English RG5-0478-000CN Display Ass’y (W/O overlay) RG5-1076-000CN LJ4+ RB1-2260-000CN...

  • Page 311

    Figure 8-3b Top Cover Assembly for LaserJet 5 Parts and Diagrams 8-11...

  • Page 312

    Table 8-3b Top Cover Assembly Part # Notes Description RB1-7895-000CN Tool, Hook RB1-7893-000CN Spring, Leaf 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) RG5-2238-000CN Display Ass’y (W/O overlay) RB1-7887-000CN Display Cover (part of item 3) Part Numbers...

  • Page 313

    Figure 8-4a Internal Components (1 of 4) Table 8-4a Internal Components (Section 2) Part # Notes Description RB1-2080-000CN Shutter, laser RB1-2100-000CN LJ4/4+ Guide, Cartridge RB1-5730-000CN RB1-2101-020CN Guide, Cartridge RB1-2105-030CN Support, Cartridge RB1-2106-000CN Plate, grounding RB1-2107-000CN LJ4/4+ Guide, Cassette, Left RB1-7913-000CN Parts and Diagrams 8-13...

  • Page 314

    RB1-2111-030CN Shutter, arm RB1-2114-000CN Qty 5 Foot RS5-2218-000CN Spring, Compression RB1-2122-000CN Shutter Spring, Torsion RB1-5732 -000CN Spring, Torsion RB1-2141-000CN LJ4/4+ Cover, Inner RB1-7888-000CN RB1-2353-000CN LJ4/4+ Holding Plate RF5-1648-000CN 13A RB1-7901-000CN Mount, Tray 1 Door (not shown-part of 13) RB1-2358-000CN LJ4/4+ Spring, Switch RB1-2966-000CN RF5-0363-000CN...

  • Page 315

    Figure 8-4b Internal Components (2 of 4) Parts and Diagrams 8-15...

  • Page 316

    Table 8-4b lnternal Components (Section 2) Part # Notes Description RB1-2112-000CN Exhaust Duct RB1-3544-000CN LJ4+/5 RB1-2113-000CN Exhaust Duct Cover RF5-0748-000CN LJ4+/5 RB1-2350-000CN Exhaust Fan Cover RB1-3547-000CN LJ4+/5 RB1-2352-000CN LJ4/4+ RB1-7896-000CN RF5-0470-000CN Mount, DC Controller RF5-0743-000CN LJ4+ RF5-1653-000CN RG5-0511-000CN DC Controller PCA RG5-0966-030CN LJ4+/5 C2001-69002...

  • Page 317

    Figure 8-4c Internal Components (3 of 4) Parts and Diagrams 8-17...

  • Page 318

    Table 8-4c Internal Components (Section 3) Part # Notes Description RS5-8219-000CN Label RB1-2357-000-CN LJ4/4+ Cover, Connector RB1-7897-000CN XA9-0584-000CN Screw, w/ spring washer XA9-0670-000CN LJ4+/5 XA9-0574-000CN Screw, 5mm hex head RF5-0471-000CN Plate, Shield RF5-0746-000CN LJ4+ RF5-1647-000CN RF5-0355-000CN Panel, I/O RB1-2312-000CN Sheet RB1-2313-000CN Sheet RB1-2341-000CN...

  • Page 319

    Part # Notes Description C2002-67901 Formatter PCA C2038-60004 LJ4+ C3919-67901 C2002-69001 Formatter PCA (Exchange) C2038-69004 LJ4+ C3919-69001 RB1-3494-000CN LJ4+ Plate, Reinforcement RB1-7892-000CN Parts and Diagrams 8-19...

  • Page 320

    Figure 8-4d Internal Components (4 of 4) 8-20 Parts and Diagrams...

  • Page 321

    Table 8-4d Internal Components (Section 4) Part # Notes Description RB1-2236-000CN Guide, Feeder RB1-2253-000CN Roller, Guides (6) XA9-0623-000CN Hex Head Screw RG5-0468-000CN LJ4/4+ Transfer Block Ass’y RG5-2192-000CN RB1-2251-000CN Block, Connecting RG5-0521-000CN Cable, D.C. Controller /Interconnect PCA RG5-0979-000CN LJ4+/5 RG5-0515-000CN Connector PCA Ass’y RG5-0513-000CN High Voltage PCA RG5-0969-040CN...

  • Page 322

    Figure 8-5 Main Switch Assembly 8-22 Parts and Diagrams...

  • Page 323

    Table 8-5 Main Switch Assembly Part # Notes Description RB1-2118-000CN LJ4/4+ Base, Switch Mounting RB1-7906-000CN RB1-2119-000CN LJ4/4+ Switch RB1-7907-000CN RB1-2345-000CN Cover (LJ4/4+ only) RG5-0524-000CN J201/ Cable, Paper Control PCA/ J601 DC Controller RG5-0530-000CN J603/ Cable, Lower Feed Assembly J135 Parts and Diagrams 8-23...

  • Page 324

    Figure 8-6a Paper Feed Assembly (1 of 2) 8-24 Parts and Diagrams...

  • Page 325

    Figure 8-6b Paper Feed Assembly (2 of 2) Parts and Diagrams 8-25...

  • Page 326

    Table 8-6 Paper Feed Assembly Part # Notes Description RG5-0451-000CN Paper Feed Assembly RG5-0877-000CN LJ4+ RG5-2195-000CN C2001-69005 Paper Feed Ass’y (exchng) C2037-69003 LJ4+ C3916-69005 RB1-2126-000CN Roller, Pickup, PC Tray RB1-3477-000CN LJ4+ RB1-7911-000CN Roller, Pickup, Tray 2 RB1-2127-000CN LJ4/4+ Roller, MP Tray Pickup RB1-2205-000CN Roller, Tray 1 Pickup RB1-2138-000CN...

  • Page 327

    Figure 8-7 MP Tray (Tray 1) Assembly Table 8-7 MP Tray (Tray 1) Assembly Part # Notes Description RG5-0472-000CN Multi-Purpose Tray Assembly RG5-0888-000CN LJ4+ RG5-2199-000CN Tray 1 Assembly Parts and Diagrams 8-27...

  • Page 328

    Figure 8-8 Paper Output Assembly Table 8-8 Paper Output Assembly Part # Notes Description RG5-0456-000CN Paper Output Assembly RG5-0886-000CN LJ4+ RG5-2189-000CN RB1-2299-030CN 4 ea. Rollers, Delivery RB1-2302-000CN 4 ea. Spring, Roller RF5-0425-040CN 4 ea. Holder, Roller RS5-2185-000CN Spring, Compression RS5-2267-000CN LJ4+/5 4 ea.

  • Page 329

    Figure 8-9 Delivery Sensor Assembly Table 8-9 Delivery Sensor Assembly Part # Notes Description RG5-0475-060CN Assembly, Delivery Sensor WG8-0291-000CN Photosensor, (PS3) RG5-0522-000CN Cable, Delivery Sensor RG5-0980-000CN LJ4+/5 Parts and Diagrams 8-29...

  • Page 330

    Figure 8-10 Fuser Assembly 8-30 Parts and Diagrams...

  • Page 331

    Table 8-10 Fuser Assembly Part # Notes Description RG5-0454-000CN Fuser Assembly 110/115V RG5-0879-130CN LJ4+/5 C2001-69003 Fuser Assembly (Exchange) 110/115V C2037-69001 LJ4+/5 RG5-0455-000CN Fuser Assembly 220/240V RG5-0880-130CN LJ4+/5 C2001-69004 Fuser Assembly (Exchange) 220/240V C2037-69002 LJ4+/5 RA1-7584-000CN Ring, Roller (2 ea.) RB1-0253-000CN LJ4+/5 RB1-2287-000CN Washer, Grounding (LJ4 only)

  • Page 332

    Part # Notes Description RS5-0232-000CN Gear, 23T RS5-0393-000CN LJ4+/5 RS5-1063-000CN Bushing, Roller RS5-1097-020CN LJ4+/5 RS5-1064-000CN Bushing, Roller RS5-1098-000CN LJ4+/5 RS5-1065-000CN Bushing, Lower Roller (2) RS5-1099-000CN LJ4+/5 RS5-2168-000CN Spring, Compression (2) RS5-2265-020CN LJ4+/5 RS5-2180-000CN Spring, Tension RB1-2286-000CN Spring, Guide RH7-7045-000CN Thermistor RH7-7054-000CN LJ4+/5 RH7-4046-000CN...

  • Page 333: Accessory Parts

    Accessory Parts Figure 8-11 Lower Cassette Base Assembly Parts and Diagrams 8-33...

  • Page 334

    Table 8-11 Lower Cassette Base Assembly Part # Notes Description C2083A LC Base Assembly w/non-Legal Cassette C2083B LC Base Assembly with Legal Universal C2083D LJ/4+ Cassette C3921A Tray 3 RB1-2606-000CN LJ4/4+ Cover, Front RB1-7977-000CN RB1-2628-000CN Cover RB1-2647-000CN Plate, Grounding RF5-0374-000CN Click, Spring RF5-0375-000CN Shaft...

  • Page 335

    Figure 8-12 Lower Cassette Drive Assembly Table 8-12 Lower Cassette Drive Assembly Part # Notes Description RG5-0481-000CN Drive Assembly, Lower Cassette RG5-1099-000CN LJ4+ RG5-2209-000CN Drive Assembly, Tray 3 RB1-2627-020CN Weight RB1-2632-000CN Roller, Pickup RB1-2650-000CN LJ4+ RB1-7983-000CN Parts and Diagrams 8-35...

  • Page 336

    Figure 8-13 Lower Cassette Assembly Table 8-13 Lower Cassette Assembly Part # Notes Description C2084A Universal 500 sheet Lower Cassette C2084C LJ4\4+ Tray (non-Legal) C2084B Universal 500 sheet Lower Cassette C2084D LJ4/4+ Tray (Legal) C3923A RB1-2645-000CN LJ4/4+ Cover, Rear Cassette RB1-8009-000CN RF5-0446-000CN LJ4/4+...

  • Page 337

    Figure 8-14 Universal Cassette Parts and Diagrams 8-37...

  • Page 338: Simm Memory

    Table 8-14 Universal Cassette Part # Notes Description C2085A 250 sheet Universal Tray (Legal, Letter, Exec, C2085D LJ4+ C3924A C2085B 250 sheet PC Tray (letter) C2085E LJ4+ C3925A C2085C 250 sheet PC Tray (A4) C2085F LJ4+ C3926A RB1-2370-020CN Plate, Length Adjustment (part of tray assy) RF5-0430-000CN Plate (part of tray assy) RB1-2391-000CN...

  • Page 339: Miscellaneous Parts And Accessories

    Miscellaneous Parts and Accessories Table 8-16 Miscellaneous Parts and Accessories Part # Notes Description 92298A Toner Cartridge J2341A AppleTalk MIO Interface J2552A (J2552-69001) LJ4+/5 J2550A (J2550-69001) 10-BaseT MIO Interface C2082B LJ4/4+ Envelope Feeder (new) C3927A C2082-69001 LJ4/4+ Envelope Feeder (exchange) C3927-69001 C2809A LJ4+/5...

  • Page 340: Parts List

    Parts List Table 8-17 Alphanumeric Parts List Description Part # Fig. # Printer 10-BaseT MIO Interface J2550A (J2550-69001) 16 Mbytes C3146A 4+/5 250 Sheet PC Tray (A4) C2085C 8-14 250 Sheet PC Tray (A4) C2085F 8-14 250 Sheet PC Tray (A4) C3926A 8-14 250 Sheet PC Tray (letter)

  • Page 341

    Description Part # Fig. # Printer Base, Switch Mounting RB1-2118-000CN 4/4+ Base, Switch Mounting RB1-7906-000CN Belt, Timing XF9-0410-000CN 4/4+/5 Block, Connecting RB1-2251-000CN 8-4d 4/4+/5 Brush, cleaning RB1-2260-000CN 8-3a 4/4+ Bushing, Lower Roller (2) RS5-1065-000CN 8-10 Bushing, Lower Roller (2) RS5-1099-000CN 8-10 4+/5 Bushing, Roller...

  • Page 342

    Description Part # Fig. # Printer Cable, Paper Feed RG1-0542-020CN 8-11 4/4+/5 Clamp, Plate Release RB1-2284-000CN 8-10 4/4+ Click, Spring RF5-0374-000CN 8-11 4/4+/5 Click, Tray 1 Door (Qty 2) RB1-7902-000CN 8-4a Connector PCA Assembly RG5-0515-000CN 8-4d 4/4+/5 Cover RB1-2270-000CN 8-10 Cover RB1-2345-000CN 4/4+...

  • Page 343

    Description Part # Fig. # Printer Cover, Upper RF5-0732-000CN 8-3a Cover, Upper RF5-1643-000CN 8-3b Cover, Wire RF5-0535-000CN 8-10 Cover, Wire RF5-0738-000CN 8-10 4+/5 DC Controller PCA C2001-69002 8-1b DC Controller PCA C2001-69002 8-4b DC Controller PCA C2037-69004 8-1b 4+/5 DC Controller PCA C2037-69004 8-4b 4+/5...

  • Page 344

    Description Part # Fig. # Printer Envelope Feeded (exchange) C2082-69001 4/4+ Envelope Feeded (exchange) C3927-69001 Envelope Feeder (new) C2082B 4/4+ Envelope Feeder (new) C3827A Exhaust Duct RB1-2112-000CN 8-4b Exhaust Duct RB1-3544-000CN 8-4b 4+/5 Exhaust Duct Cover RB1-2113-000CN 8-4b Exhaust Duct Cover RF5-0748-000CN 8-4b 4+/5...

  • Page 345

    Description Part # Fig. # Printer Fuser Assembly (100/115V) C2037-69001 4+/5 Fuser Assembly (220/240V) C2001-69004 Fuser Assembly (220/240V) C2037-69002 4+/5 Fuser Assembly (220/240V) RG5-0455-000CN Fuser Assembly (220/240V) RG5-0880-130CN 4+/5 Fusing Assembly (100/110V) C2001-69003 8-10 Fusing Assembly (100/110V) C2037-69001 8-10 4+/5 Fusing Assembly (100/110V) RG5-0454-000CN 8-10...

  • Page 346

    Description Part # Fig. # Printer Guide, Lower Separation RB1-2272-000CN 8-10 Guide, Lower Separation RB1-3526-000CN 8-10 4+/5 Guide, Paper Entrance RB1-2265-000CN 8-10 Guide, Paper Entrance RB1-3518-000CN 8-10 4+/5 Guide, Separation RF5-0536-000CN 8-10 Guide, Separation RF5-0744-000CN 8-10 4+/5 Heater, Halogen (100/115V) RH7-4046-000CN 8-10 Heater, Halogen (100/115V)

  • Page 347

    Description Part # Fig. # Printer Inner Cover Assembly RB1-2609-000CN 8-11 Inner Cover Assembly RB1-7978-000CN Inner Cover Assembly RG5-0487-000CN 8-11 Label RS5-8219-000CN 8-4c 4/4+/5 Label 110/115V RS5-8205-000CN 4/4+/5 Label 220/240V RS5-8916-000CN 4/4+/5 Laser/Scanner Assembly C2001-69006 8-1b Laser/Scanner Assembly C2001-69006 8-4a Laser/Scanner Assembly C2037-69008 8-1b...

  • Page 348

    Description Part # Fig. # Printer Lower Cassette Tray, Univ. 500 sheet C2084A 8-13 Lower Cassette Tray, Univ. 500 sheet C2084C 8-13 4+/5 Lower Cassette Tray, Univ. 500 sheet C2084B 8-13 Legal Lower Cassette Tray, Univ. 500 sheet C2084D 8-13 4+/5 Legal Lower Cassette Tray, Univ.

  • Page 349

    Description Part # Fig. # Printer Overlay (Czechoslovakian) C3916-40023 8-3b Overlay (Danish) C2001-40008 8-3a Overlay (Danish) C3916-40011 8-3b Overlay (Dutch) C2001-40010 8-3a Overlay (Dutch) C3916-40013 8-3b Overlay (English) C2001-40001 8-3a Overlay (English) C3916-40005 8-3b Overlay (English) RB1-2359-000CN 8-3a Overlay (English) RB1-3476-000CN 8-3a 4/4+...

  • Page 350

    Description Part # Fig. # Printer Overlay (Spanish) C3916-40009 8-3b Overlay (Swedish) C2001-40007 8-3a Overlay (Swedish) C3916-40016 8-3b Overlay (Thai) C3916-40025 8-3b Overlay (Traditional Chinese) C3916-40017 8-3b Overlay (Turkish) C2001-40012 8-3a Overlay (Turkish) C3916-40020 8-3b Overlay, Danish C2037-40008 8-3a Overlay, Dutch C2037-40010 8-3a Overlay, English...

  • Page 351

    Description Part # Fig. # Printer Paper Feed Assembly RG5-0451-000CN, Paper Feed Assembly RG5-0451-000CN Paper Feed Assembly RG5-0877-000CN Paper Feed Assembly RG5-0877-000CN Paper Feed Assembly RG5-2195-000CN Paper Feed Assembly RG5-2195-000CN Paper Output Assembly RG5-0456-000CN Paper Output Assembly RG5-0456-000CN Paper Output Assembly RG5-0886-000CN Paper Output Assembly RG5-0886-000CN...

  • Page 352

    Description Part # Fig. # Printer Plate, Grounding RB1-2647-000CN 8-11 4/4+/5 Plate, Length Adjustment RB1-2370-020CN 8-14 4/4+/5 Plate, PCA Holding RB1-2365-000CN 8-4c Plate, PCA Holding RB1-3493-000CN 8-4c 4+/5 Plate, Pressure RB1-7917-000CN 8-4a Plate, Pressure RB1-7918-000CN 8-4a Plate, Pressure RF5-0365-000CN 8-4a 4/4+ Plate, Pressure RF5-0366-000CN...

  • Page 353

    Description Part # Fig. # Printer Power Supply (100/110V) RG5-0531-000CN 8-1a 4+/5 Power Supply (100/110V) RG5-0531-000CN 8-1a Power Supply (100/110V) RG5-2499-000CN 8-1a Power Supply (100/110V) RG6-2499-000CN 8-1a 4+/5 Power Supply (220/240V) C2001-69008 8-1a Power Supply (220/240V) C2037-69007 8-1a Power Supply (220/240V) RG5-0553-000CN 8-1a Power Supply (220/240V)

  • Page 354

    Description Part # Fig. # Printer Roller, Lower RB1-3517-030CN 8-10 4+/5 Roller, Lower Delivery RF5-0438-000CN Roller, Lower Delivery RF5-1077-030CN 4+/5 Roller, MP Tray Pickup RB1-2127-000CN 8-6b 4/4+ Roller, MP Tray Pickup RB1-2205-000CN 8-6b Roller, Pickup RB1-2126-000CN 8-6b Roller, Pickup RB1-2632-000CN 8-12 Roller, Pickup RB1-2650-000CN...

  • Page 355

    Description Part # Fig. # Printer Screw, w/Spring Washer XA9-0584-000CN 8-4c 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. FA9-1449-000CN 8-4b Sensor PCA RG5-0514-000CN 8-6b 4/4+/5 Shaft RF5-0375-000CN 8-11 4/4+/5 Sheet RB1-2312-000CN 8-4c 4/4+/5...

  • Page 356

    Description Part # Fig. # Printer Support, Cartridge RB1-2105-030CN 8-4a 4/4+/5 Switch RB1-2119-000CN 4/4+ Switch RB1-7907-000CN Thermistor RH7-7045-000CN 8-10 Thermistor RH7-7054-000CN 8-10 4/4+ Thermoswitch Assembly RG5-0474-000CN 8-10 Thermoswitch Assembly RG5-0881-000CN 8-10 4+/5 Toner Cartridge 92298A Tool, hook RB1-7895-000CN 8-3b Top Cover Door RB1-2322-000CN 8-3a Top Cover Door...

  • Page 357

    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.

  • Page 358: Functional Overview

    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.) SWITCHBACK ASSEMBLY OUTPUT TRAY MP TRAY PC TRAY HOLDING TRAY DUPLEXER OPTIONAL...

  • Page 359: Duplex Printing, Switchback Assembly, Holding Tray

    Duplex Printing The bold text and numbers in the following N o t e 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.

  • Page 360

    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.

  • Page 361: Electrical Overview

    Electrical Overview The block diagram in Figure A-3 shows the Duplexer electrical components. AC POWER TO PRINTER AC POWER SWITCHBACK SUPPLY INPUT SOLENOID AC POWER SWITCHBACK STEPPER MOTOR DUPLEXER CONTROL HOLDING TRAY STEPPER MOTOR SWITCHBACK PAPER SENSOR TO PRINTER DC CONTROLLER HOLDING TRAY PAPER SENSOR Figure A-3...

  • Page 362: Installing The Optional Duplexer

    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.

  • Page 363

    Figure A-4 Duplexer Installation/Removal Duplexer A -7...

  • Page 364: Removal And Replacement, Required Tools

    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.

  • Page 365: Removing The Switchback Covers, Removing The Covers

    Removing the Covers Removing the Switchback Covers Figure A-5 Switchback Cover Remove the (2) screws shown in Figure A-5, callout 1. Lift the cover off the Switchback Assembly. Duplexer A -9...

  • Page 366: Removing The Side Cover On Power Side

    Removing the Side Cover on Power Side Figure A-6 Side Cover Open the front door. Remove the (1) screw shown in Figure A-6, callout 1. Release the (3) latch points with a flat screwdriver and rotate the cover downward (see Figure A-6, callout 2). A -10 Duplexer...

  • Page 367: Removing The Side Cover On Gear Side

    Removing the Side Cover on Gear Side Figure A-7 Side Cover on Gear Side Remove the (2) screws on top and the (1) screw on the front (see Figure A-7, callout 1). Turn the Duplexer on its side to access the latch location on the underside.

  • Page 368

    Figure A-8 Latch Location on Underside of Duplexer A -12 Duplexer...

  • Page 369: Removing The Back Cover, Removing The Front Cover

    Removing the Back Cover Figure A-9 Back Cover Place the duplexer on a table or bench so that the back overhangs the edge by a few inches. Release the (2) locating pins as shown in Figure A-9. 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.

  • Page 370: Removing Internal Duplexer Components, Removing The Fan/motor/solenoid/sensor

    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).

  • Page 371: Removing The Switchback Paper Guide

    Removing the Switchback Paper Guide Figure A-11 Switchback Paper Guide Remove the (1) E-clip from the shaft on the stepper motor side shown in Figure A-11, callout 1. Pull the shaft toward the left and out of its track. Rotate the shaft 90 degrees to remove it from the metal paper guide solenoid arm.

  • Page 372: Removing The Paper Guide Assembly

    Removing the Paper Guide Assembly Figure A-12 Wire Routing and Upper Switchback Guide Screw Remove the (4) screws shown in Figure A-11, callout 2. Lift the switchback assembly and clear the wires. Remove the assembly. When re-assembling, verify proper wire routing N o t e : as shown in Figure A-12, callout 1.

  • Page 373: Removing The Paper Roller

    Removing the Paper Roller Figure A-13 Solenoid Arm Remove the (1) screw below the Switchback Solenoid Arm on the gear side as shown in Figure A-13, callout 1. Remove the sensor, squeezing the tabs on the underside of the sensor (see Figure A-13, callout 2). (continued on next page) Duplexer A -17...

  • Page 374

    Figure A-14 Upper Paper Guide Sheet Metal 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. Remove the (4) screws on top of the sheet metal part of the upper paper guide shown in Figure A-14, callout 1.

  • Page 375

    Figure A-15 Gears on Paper Roller Remove the (1) E-clip from the gears on the shaft on the Power PCA side shown in Figure A-15, callout 1. Rotate the bushings and lift the roller out. Duplexer A -19...

  • Page 376: Removing The Control Pca

    Removing the Control PCA Figure A-16 Cover Plate Remove the (2) screws shown in Figure A-16, callout 1. Remove the cover plate. (continued on next page) A -20 Duplexer...

  • Page 377

    Figure A-17 Control PCA Unplug all connectors from the Control PCA. N o t e The Control PCA connectors are keyed. Remove the (4) screws shown in Figure A-17. Disconnect the connector from the power supply. Remove the PCA. Duplexer A -21...

  • Page 378: Removing The Power Pca

    Removing the Power PCA Figure A-18 Power PCA Remove the (6) cover screws, (4) on the top and (2) on the side. Remove the cover. Remove the (4) screws from the Power PCA (see Figure A-18, callout 1). Unplug the connector (see Figure A-18, callout 2). Lift the Power PCA out of the duplexer.

  • Page 379: Removing The Holding Tray Center Paper Guide

    Removing the Holding Tray Center Paper Guide Figure A-19 Plate on Power PCA Side of Duplexer Remove the Control PCA as described earlier. Remove the (2) screws from the plate located on the power PCA side of the duplexer (see Figure A-19, callout 1). Lift off the guide.

  • Page 380: Removing The Holding Tray Belt

    Removing the Holding Tray Belt Figure A-20 Holding Tray Belt Cover Plate Remove all the screws securing the plate (see Figure A-20, callout 1). Remove (1) E-clip shown in Figure A-20, callout 2. Remove the bushing underneath the E-clip. Release (2) latch points shown in Figure A-20, callout 3. N o t e : The (2) washers on the gear beside the bushing are now loose.

  • Page 381

    Figure A-21 Holding Tray Gears and Belt Remove the (1) one-way gear shown in Figure A-21, callout 1. N o t e 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.

  • Page 382: Removing The Holding Tray Paper Sensor

    Removing the Holding Tray Paper Sensor Figure A-22 Holding Tray Paper Sensor Release the output holding tray. Remove the (2) screws from the stepper motor mount and remove mount. (This provides access to the paper sensor latches.) Squeeze the (2) latch points of the paper sensor to release (see Figure A-22).

  • Page 383: Removing The Switchback Assembly

    Removing the Switchback Assembly Figure A-23 Switchback Assembly Hinge Pins Pull out the pin located on the Power PCA side (see Figure A-23, callout 1). Release the (1) E-clip on the upper pin near the retaining arm (see Figure A-23, callout 2). Pull the retaining arm off the pin.

  • Page 384: Parts And Diagrams For The Duplexer

    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. N o t e Not all duplexer parts are orderable. The parts listed are the only orderable parts.

  • Page 385

    Figure A-24 Duplex External Covers Duplexer A -29...

  • Page 386

    Table A-24 Duplex External Covers Part # Notes Description RA2-2061-000CN LJ4+ Front Cover RA2-2231-000CN RA2-2096-000CN LJ4+ Left Cover RA2-2232-000CN RA2-2097-000CN LJ4+ Right Cover RA2-2233-000CN RA2-2098-000CN LJ4+ Rear Lower Cover RA2-2237-000CN RG1-3508-000CN LJ4+ Rear Cover Assembly RG1-3570-000CN RA2-2100-000CN LJ4+ Latch LJ4+ RS1-2413-000CN Compression Spring RS5-2571-000CN...

  • Page 387

    Figure A-25a Duplex Feeder Assembly (1 of 2) Duplexer A -31...

  • Page 388

    Figure A-25b Duplex Feeder Assembly (2 of 2) A -32 Duplexer...

  • Page 389

    Table A-25 Duplex Feed Assembly Part # Notes Description RA2-2069-000CN LJ4+/5 PCA Shield Plate RA2-2070-000CN LJ4+/5 Static Eliminator sml RA2-2072-000CN LJ4+/5 Timing Belt RA2-2076-000CN LJ4+/5 Sensor Arm RA2-2078-000CN LJ4+/5 Rod Crank RA2-2079-000CN LJ4+/5 Front Cover Rod RA2-2081-000CN LJ4+/5 Hold Tray Rear Guide RA2-2082-000CN LJ4+/5 Hold Tray Front Guide...

  • Page 390

    Part # Notes Description RS1-2406-000CN LJ4+/5 Torsion Spring (Qty 3) RS1-2407-000CN LJ4+/5 Torsion Spring RS1-2409-000C N LJ4+/5 Tension Spring RS1-7010-000CN LJ4+/5 Shaft WG8-5210-000CN LJ4+/5 Photo Interrupter RG1-3501-000CN LJ4+ Duplex Control PCA RG1-3582-000CN RF1-3817-00017 Duplex Roller Holder A -34 Duplexer...

  • Page 391

    Figure A-26a Duplex Switchback Assembly (1 of 2) Duplexer A -35...

  • Page 392

    Figure A-26b Duplex Switchback Assembly (2 of 2) A -36 Duplexer...

  • Page 393

    Table A-26 Duplex Switchback Assembly Part # Notes Description RA2-2083-000CN LJ4+/5 Static Eliminator RA2-2087-000CN LJ4+/5 Deflector Linkage RA2-2094-000CN LJ4+/5 Upper Feed Guide RA2-2095-000CN LJ4+/5 Lower Feed Guide RA2-2112-000CN LJ4+/5 Cable Cover RA2-2116-000CN LJ4+/5 Stepped Screw 3 By 6.9 (Qty 2) RA2-2119-000CN LJ4+/5 Paper Deflector RF1-3806-000CN...

  • Page 394

    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...

  • Page 395

    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.

  • Page 396: Product Information

    Product Information Table B-1 Printer Features Features HP LJ 4+ HP LJ4M+ HPLJ5 HPLJ5M HPLJ5N Model C2037A C2039A C3916A C3917A C3952A Printer Speed 12 ppm 12 ppm 12 ppm 12 ppm 12 ppm Resolution 300/600 dpi 300/600 dpi 300/600 dpi 300/600 dpi 300/600 dpi Expandable I/O...

  • Page 397

    Features HP LJ 4+ HP LJ4M+ HPLJ5 HPLJ5M HPLJ5N Interfaces Serial (9 pin) Serial (9 pin) Serial (9 pin) Serial (9 pin) Serial (9 pin) Parallel Parallel Parallel Parallel Parallel Local Talk Local Talk Local Talk 10-baseT Ethernet Ethernet Serial Infrared*** Serial Infrared*** Serial Infrared*** MIO Slots...

  • Page 398

    Table B-2 Product Family Compatibility Matrix Accessory Description Work in the Work in the Work in the LaserJet 4? LaserJet 4 Plus? LaserJet 5? C2082A Envelope Feeder C2082B Envelope Feeder C3927A Envelope Feeder C2083A Optional 500 Sheet Feeder Assembly C2083D Optional 500 Sheet Feeder Assembly C3921A...

  • Page 399

    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.

  • Page 400

    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. (16.8 kg) Table B-4 Power Specifications Volts Freq...

  • Page 401: Electrical Specifications, Environmental Specifications

    Table B-6 Electrical Specifications Status 100/115 V 220/240 V Recommended 11.2 amps 5.0 amps Minimum Circuit Capacity 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...

  • Page 402

    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. Table B-7 Printer Documentation HP LaserJet 5/5M/5N Part Number Documents—Description Getting Started Guide for the HP LaserJet C3917-90901 5/5M/5N Printer HP LaserJet 5/5M/5N User’s Manual...

  • Page 403

    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.

  • Page 404: Control Panel Layout, Control Panel Keys

    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.

  • Page 405

    Table B-8 Control Panel Keys Explanation key replaces the On Line, Form Feed, and Continue keys from previous HP LaserJet printers. The 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.

  • Page 406

    Explanation Item Item Press 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.

  • Page 407: To Change A Control Panel Setting, Control Panel Menus

    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.

  • Page 408

    Figure B-3 Control Panel Menu Map B-14 LaserJet 5/5M/5N Printer...

  • Page 409: Printing Menu

    Printing Menu TableB-10 Printing Menu Items Item Options Explanation PRINT MENU No options available When PRINT MENU MAP is Select displayed, press to print a configuration page and a menu map. The message PRINTING CONFIGURATION PAGE is displayed. PWRSAVE OFF, PWRSAVE stands for PowerSave.

  • Page 410

    Item Options Explanation ORIENTATION P stands for portrait (vertical) and L stands for landscape (horizontal) orientation of type on the page. FORM 60* (110V printers) Sets vertical spacing, from 5 to (5 TO 128 LINES) 64* (220V printers) 128 lines, for default paper size. Press - Value + once to change setting...

  • Page 411: Pcl Fonts Menu

    PCL Fonts Menu Table B-11 PCL Fonts Menu Items Item Options Explanation Select PCL FONT No options Press to print a list of the PCL fonts. LIST available SOURCE INTERNAL* Internal fonts* SOFT Permanent soft fonts SLOT N SIMM Module: n=slot number. Typefaces stored in one of the four ROM SIMM slots (SLOT=slot 1, for example).

  • Page 412: Postscript Menu, Job Menu

    PostScript Menu Table B-12 PostScript Menu Items Item Options Explanation Select PS FONT LIST No options Press to print a list of the fonts. While the list available is being printed, the message PRINTING FONT LIST is displayed. PRT PS ERRS OFF* PRT PS ERRS stands for PRINT POSTSCRIPT ERRORS.

  • Page 413: Configuration Menu

    Configuration Menu Table B-14 Configuration Menu Items Item Options Explanation TRAY 1 FIRST* 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.

  • Page 414

    Item Options Explanation AUTO OFF* Determines how the printer reacts to data CONT errors and printer errors. When auto continue is set to OFF, the printer displays an error message and goes off line until you press 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.

  • Page 415: Memory Configuration Menu

    Memory Configuration Menu Table B-15 Memory Configuration Menu Items Item Options Explanation I/O BUFFER AUTO* Memory set aside for I/O buffering is automatically determined by the printer. No memory is set aside for I/O buffers. Size can be manually adjusted. I/O SIZE 10K and up When IO BUFFER is set to ON, this item appears in...

  • Page 416: Parallel Menu, Serial Menu

    Parallel Menu Table B-16 Parallel Menu Items Item Options Explanation HIGH SPEED 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. YES* Sets the parallel interface to run at a higher data rate Sets the parallel interface to run at a slower speed.

  • Page 417: Resets Menu

    Resets Menu Table B-18 Resets Menu Items Menu Printer Response Explanation Selection Select MEMORY Press to perform a MEMORY RESET. This CLEARING MEMORY RESET will clear the printer buffer and return all printing environment parameters to those values set in the Control Panel menus. Select FACTORY Press...

  • Page 418: Test Menu

    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.

  • Page 419

    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).

  • Page 420

    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: Enter the Service Mode as described previously.

  • Page 421

    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.

  • Page 422: Skip Demo, Big Data, Diagnostics

    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.

  • Page 423: Programming A Flash Simm

    Programming a Flash SIMM A flash SIMM may be programmed while installed in the printer. To program a flash SIMM. Menu> Item< Value+ Select Hold down the , and keys while powering on the printer. The printer will display “PROGRAM SLOT 4”. To change the slot number, press Value+/-.

  • Page 424

    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. Switch OFF the printer.

  • Page 425: Nvram Init

    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.

  • Page 426

    Understanding the PCL Self Test Printout Table B-20 Self Test Printout Items for the HP LaserJet 5 Reference 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 427

    Figure B-4 HP LaserJet 5 PCL Self Test Printout LaserJet 5/5M/5N Printer B-33...

  • Page 428: Infrared Communication

    The primary protocol software is the responsibility of the host supplier. It is not provided by Hewlett-Packard with the printer. IrDA host (or primary device) communications can be obtained either via an internal IR port or an external IR accessory. Several manufacturers offer complete accessory upgrades for both host and peripheral devices.

  • Page 429: System Requirements

    primary device secondary secondary Application ASCII Data device device ASCII to Windows Formatter Raster Data System ASCII Standard Windows I/O Buffer Ptr DVR Data Buffer LJ Printer Driver (SW) IR Redirector IRLMP Unpacks Data IRLMP (Software) IR Driver Packetizes IRLAP Checks Packets Data (SW or FW) IRLAP...

  • Page 430: To Print Using The Infrared Port

    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).

  • Page 431

    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.

  • Page 432: Troubleshooting Ir Printing Problems

    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. The IrDA standard for infrared communications N o t e represents an emerging technology. Older non-IrDA-compliant portable devices may not be compatible with your HP LaserJet 5/5M/5N printer.

  • Page 433

    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.

  • Page 434

    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: Place the test tool on a table in front of the PC’s IR port.

  • Page 435: Infrared Port Not Responding

    Infrared Port Not Responding Table B-21 Solutions for Infrared Not Responding Situation Solution The connection cannot be Make sure the device you are established or the transmission using is IrDA-compliant; look for seems to be taking longer than an IrDA symbol on the device or usual.

  • Page 436

    Situation Solution The printer prints only part of a The connection has been broken page or document. 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.

  • Page 437

    Index check MP tray empty sensor 7-17 12 PRINTER OPEN 7-18 sw601 7-19 13 PAPER JAM 7-20 checkpoints, service 4-3 14 NO EP CART 7-25 CIC (Customer Information Centers) 16 TONER LOW 4-10, 7-25 1-13 21 PRINT OVERRUN 3-53 cleaning brush uses 4-16 41.1 ERROR 7-28 cleaning station, drum 5-18 41.2 ERROR 7-28, 7-31...

  • Page 438

    defect Ruler 7-67 defect template 7-67 checks 7-34 developing station, drum 5-22 failure 7-34 DHHS laser safety 1-8 motor signals 5-10 Diagnostics B-28 removal 6-39 diagrams, timing 5-34 faulty registration 7-39 disassembly, fuser 6-47 fax information service (HP FIRST) display language, changing 3-28, B-30 1-12 distorted print 7-35, 7-42 feed guide assembly 6-62...

  • Page 439

    high voltage the toner cartridge 4-7 contact assembly 6-68 the transfer roller 4-16 contact plate 6-62 INSUFFICIENT MEMORY 7-B contactor removal 6-62 insufficient memory messages 7-10 contactor/paper guide removal 6-62 interconnect PCA removal 6-69 High Voltage Power Supply interface troubleshooting 7-52 assembly 7-51 interfaces checks 7-51...

  • Page 440

    lower cassette MODE statement 7-53 assemblies removal 6-44 model number 1-3, B-5 assembly 5-4 motor locations 7-61 drive motor (M3) 5-10 MP Door Removal 6-12 functional check 7-24 MP pick-up roller clutch solenoid installing 3-44 (SL2) 5-5 paper loading 3-45 MP rollers, PM 4-3 pickup motor 7-24 MP tray...

  • Page 441

    paper feed port assembly removal 6-18 infrared B-35 paper feed guide removal 6-62 PostScript 3-58 paper feed system 5-1, 5-26 postscript menu B-18 paper jam 7-20 power supply removal 6-15 detection 5-11 power system 5-1, 5-31 PS1 7-20 POWERSAVE ON 7-B troubleshooting 7-20 pre-troubleshooting procedures 7-1 paper motion 5-2...

  • Page 442

    RESETTING ACTIVE I/O 7-C check 7-44 RESETTING ALL I/O 7-C MP tray trailing edge sensor 5-7 Resolution Enhancement (REt) 3-16 PS6, lower cassette paper-out sensor Resolution Enhancement technology status 3-26 PS7, envelope feeder paper-out sensor Resource Saving 3-14 status 3-26 RESTORING FACTORY SETTINGS returning the printer 3-43 RFI statement 1-9...

  • Page 443

    service checkpoints 4-1, 4-3 sw851, lower cassette size switch 5-8 Service Mode 3-20, B-25 sw852, lower cassette size switch 5-8 service/error messages 3-59 sw853, lower cassette size switch 5-8 setting the cold reset B-27 switch locations 7-62 setting the page count 3-21, B-26 switch settings, paper tray 5-9 setting up the envelope feeder 3-50 system...

  • Page 444

    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 unpacking the printer 3-43 user maintenance 4-2 variable, customization 3-22 version number 3-26 vertical dark streaks 7-35, 7-46 vertical sync late (41.4) 7-28 vertical white streaks 7-35, 7-40...

  • Page 445

    SN-1 Service Notes...

  • Page 446

    SN-2 Service Notes...

  • Page 447

    SN-3 Service Notes...

  • Page 448

    SN-4 Service Notes...

  • Page 449

    SN-5 Service Notes...

  • Page 450

    SN-6 Service Notes...

  • Page 451

    SN-7 Service Notes...

  • Page 452

    SN-8 Service Notes...

  • Page 453

    © Copyright 1996 Hewlett-Packard Company Printed in USA 3/96 Manual Part No. C3916-90984 *C3916-90984* *C3916-90984* C3916-90984...

This manual also for:

Laserjet 5m

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