HP CLJ 4500, CLJ family Service Manual

October 1998 Edition

HP Color LaserJet Family Quick Reference Service Guide

October 1998 Edition

Publication number 5040-9071

First edition, October 1998

Warranty

The information contained in this document is subject to change without notice.

Hewlett-Packard makes no warranty of any kind with respect to this information. HEWLETT-PACKARD SPECIFICALLY DISCLAIMS THE IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Hewlett-Packard shall not be liable for any direct, indirect, incidental, consequential, or other damage alleged in connection with the furnishing or use of this information.

Trademark credits

Adobe™ and PostScript

™

are registered trademarks of Adobe Systems, Inc., which may be registered in certain jurisdictions.

Microsoft

is a U.S. registered

trademark of Microsoft Corporation.

MS-DOS

is a U.S. registered

trademark of Microsoft Corporation.

UNIX

is a registered trademark in the United States and other countries, licensed exclusively through X/Open Company Limited.

Hewlett-Packard Company 11311 Chinden Boulevard Boise, Idaho 83714 U.S.A.

1 Troubleshooting control panel messages. . . . . . . . . . . . . 1

2 Service tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4 Input/Output (I/O) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5 Media specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6 Toner cartridge information . . . . . . . . . . . . . . . . . . . . . . 83

7 Printer options and consumables. . . . . . . . . . . . . . . . . . 95

8 Printer parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

9 Image quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

10 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

11 Services and support resources . . . . . . . . . . . . . . . . . 157

A Acronyms and abbreviations . . . . . . . . . . . . . . . . . . . . 169

Index

iii

Ordering other manuals

This

HP Color LaserJet Family Quick Reference Service Guide

been created to help the HP LaserJet service engineer quickly troubleshoot common printer problems. While this reference is intended to provide information the service engineer will need f or on-site r epair of HP LaserJet color products, it is not intended to replace the service manual for any HP LaserJet color product. For detailed information about the HP LaserJet color products described in this guide, see the user guide or service manual for that product.

Service manuals for HP LaserJet products are available from Hewlett-Packard. The phone number for the Service Parts Order Desk is:

(800) 227-8164 (U.S. only)

If you are located outside of the U.S., contact your local HP Sales and Service Office. See “Services and support resources” on page 157.

has

Supported products

Name used in this guide

HP Color LaserJet 4500/4500 N/ 4500 DN

Note

This guide will be updated as the service needs change, as new products are introduced, or as information becomes available.

Model number

C4084A/C4089A/ C4094A

Maximum pages per month

35 K C4084-90958

Service manual part number

Troubleshooting

control panel messages

Overview

This chapter provides a list of control panel messages for the HP Color LaserJet printers. Alphabetical messages are listed first, followed by numerical messages. Control panel messages that are self-explanatory are not included. See the service manual for more detailed information.

Following the control panel messages are suggestions for troubleshooting paper path problems.

Overview

Pre-troubleshooting checklist

WARNING!

Always unplug the printer before servicing. Current is present in the DC power supply whenever the printer is plugged in.

Note

The customer is responsible for ensuring that the maintenance units are in good condition.

Before troubleshooting any specific printer problem, check the following:

• Has the printer been maintained on a regular basis?

• Are all of the maintenance units within their rated life?

• Is the customer using media as specified in Chapter 5, “Media

specifications” and the

Guide

• Is the media stored correctly and within environmental limits?

• Is the printer installed on a solid, level surface?

• Has the line voltage been chec ked to ma ke sure that it does not v ary

more than 20% from the nominal rated v alue specifi ed on the po w errating label?

– Large motors used near the printer can cause temporary voltage

changes.

• Is the operating environment within the parameters listed in the

printer service manual?

• Is the printer protected from substances such as office cleaning

materials and the ammonia gas that is produced by diazo copiers?

• Is the printer protected from direct sunlight?

HP LaserJet Family Paper Specification

2 Chapter 1 Troubleshooting control panel messages

CAUTION

Using non-HP components, such as toner, may cause permanent damage to the printer.

• Have all non-HP components (toner, typeface DIMMs, memory

boards, and MIO cards) been removed from the printer?

• Has the printer hardware or software configuration changed?

Or could the problem be associated with any specific software? – Contact the Customer Care Center for software-related problems

(see Chapter 11, “Services and support resources”).

• Could the problem be related to network configuration changes?

– Remove the printer from the network and make sure that the

failure is associated with the printer before beginning troubleshooting.

Pre-troubleshooting checklist

Control panel messages

Alphabetical messages

Access denied, menus locked

This message is displayed for approximately 5 seconds when a user has attempted to select a menu value while the printer control panel locking is enabled.

• See the system administrator for access to the printer control panel.

Bad duplexer connection

The duplex-printing accessory is not correctly installed.

1 Check the duplex-printing accessory power cord. 2 Turn the printer off, and then turn the printer on. 3 If the error continues, verify that the duplex-printing accessory is

correctly installed.

4 If the error persists, replace the duplexer.

Calibration executing

The printer is executing an internal color calibration. This process should take approximately 90 seconds.

• No action is required.

4 Chapter 1 Troubleshooting control panel messages

Canceling job

The printer is canceling the current print job. Incoming data for the current job will be discarded.

• No action is required.

Cannot duplex check rear bin

alternates with

Cannot duplex check paper

The printer cannot duplex because the rear output bin is open or the media is not supported by the duplex-printing accessory.

Close the rear output bin.

Verify that the media is supported by the duplex-printing accessory.

Checking printer

The printer is performing an internal test. This process should take approximately 30 seconds. The message is displayed during the initiation of the engine test. When finished, the printer goes online.

• No action is required

Clearing paper from printer

The printer has jammed or was turned on and media was detected in the paper path. The printer is attempting to clear these pages.

• No action is required.

Control panel messages

Close middle front drawer

The drawer that holds the intermediate transfer belt (ITB) is open. Switch SW1 indicates the drawer is open. When the drawer is closed, a plastic protrusion on the lower left corner of the drawer pivots an arm allowing SW1 to toggle to the open position.

1 Close the middle front drawer. 2 If the message persists, remove the printer’s left-side cover and

inspect the mechanical linkage that closes SW1.

3 Refer to the wiring diagram to verify the wiring; the two-wire

connector should be firmly seated to SW1 and the wiring harness should be firmly seated to connector J1003 of the DC controller PCB.

4 If the message persists, use an ohmmeter to verify the functionality

of SW1.

6 Chapter 1 Troubleshooting control panel messages

Close upper rear door

Switch SW5 monitors the closing of the printer’s upper rear door (this door allows you to access the fusing assembly). When the fusing door is closed, a tab on the rear door pushes a door switch actuator that runs along the left side of the printer and closes SW5.

WARNING!

High voltages occur during operation. Closing the rear door and the upper and middle front draw ers closes SW4 and SW5, enabling +24B Vdc. When either drawer or the rear door is open +24B Vdc is disabled. This safety f eature protects the operator from high v oltages.

Close the upper rear door.

If the message persists, remove the printer’s left-side cover and

inspect the mechanical linkage of SW5 and the lever. Refer to the wiring diagram and verify that all connections (J103 of

the DC controller PCB and SW5) are firmly seated. Verify that both the front upper and middle drawers are firmly closed;

closing these drawers also closes SW4.

Close top cover

SW2 indicates if the printer’s toner cartr i dge access door is closed. When the toner cartridge door is closed a lever is pushed down. This in turn rotates a pivot forward, opening the top cover switch (SW2).

Close the top cover.

If the message persists, remove the printer’s top cover and verify all

mechanical linkages associated with SW2. Verify that the connector on J1003 of the DC controller PCB is firmly

seated.

Control panel messages

Close upper front drawer

The drawer that holds the imagi ng drum is open. Swi tch SW3 i ndicates that the drawer is open. When the drawer is closed a plastic protrusion on the lower left corner of the drawer pivots an arm that allows SW3 to toggle to the open position.

Note

Closing the drawer also closes SW4 (the front dr a wer s witch). Whe n SW4 is open +24B Vdc is disabled. This safety feature protects the operator from any high voltages when the upper or middle front drawers are open.

1 Open the drawer and firmly push the drawer closed using one hand

in the middle of the drawer.

2 If the message persists, remove the printer’s left-side cover and

inspect the mechanical linkage that closes SW3.

3 Refer to the wiring diagram (chapter 10) and verify the wiring; the

two-wire connector should be firmly seated to SW3 and the wiring harness should be firmly seated to connector J1003 of the DC controller PCB.

4 If message persists, use an ohmmeter to verify the functionality of

SW3.

Cold reset

The cold reset power-up sequence has been entered.

• Most printer variables will reset to their factory default values.

8 Chapter 1 Troubleshooting control panel messages

Continuous page, press cancel job

The printer configuration page is being printed continuously.

• Press

ANCEL JOB

printing and return the printer to the

to terminate continuous configuration page

state.

READY

Density sensor out of range

alternates with

Clean density sensor

A density sensor out of range error was detected during a color calibration.

• The density sensor may be dirty. Inspect and clean the sensor. See

“Cleaning the toner density sensor” in the service manual.

Data received

The printer has received and processed data and is waiting for a form feed.

• Load the appropriate media to continue the print job.

Diagnostics mode

The extended diagnostics power-up key sequence has been entered. Refer to the diagnostics procedures provided in the service manual.

• No action is required.

Drum error replace drum kit

An error has been detected with a component of the print drum kit.

• Replace the print drum kit.

Control panel messages

Drum life low replace drum kit

Approximately 80% of the drum’s life has been consumed.

• Drum replacement will be required in the near future.

Drum life out replace drum kit

The imaging drum has reached the end of its expected life.

• Replace the print drum kit.

Duplexer error check duplexer

An error has occurred in the duplex-printing accessory.

• Verify that the duplex-printing accessory is correctly installed and

plugged in.

EIO x initializing yyy

alternates with

Do not power off

The EIO device in slot “x” is initializing. The yyy value will increment every 10 seconds during this process.

• No action is required.

EIO x not functional

The EIO slot specified does not have a card installed or is not functional.

• No action is required.

10 Chapter 1 Troubleshooting control panel messages

Event log empty

SHOW EVENT LOG

event log has no entries.

• No action is required.

was selected from the Information menu, but the

Fuser life low replace kit

Approximately 95% of the fuser’s life has been consumed.

• Fuser replacement will be required in the near future. Continue

printing, or replace the fuser kit.

Fuser life out replace kit

The fuser has reached the end of its expected life.

• Replace the fuser kit.

Install drum kit

The drum kit is not installed or is incorrectly installed.

• Verify that the drum kit is correctly installed.

Install Tray 2

The printer cannot print until media is loaded into Tray 2. The paper path for Tray 3 passes through Tray 2.

• Insert T ray 2 into the printer so that printing from Tray 3 can begin or

continue.

Control panel messages

Memory full stored data lost

The printer has no available memory. The current job may not print correctly. Some downloaded fonts may have been deleted.

• Try printing simplified pages. If this does not resolve the problem,

add printer memory.

Memory settings changed

The I/O buffering settings w ere ch anged by the printer because there is not enough memory available to use the previous settings.

• No action is required. However, adding printer memory can prevent

this from occurring.

Memory shortage job cleared

The available memory was not enough to continue printing. The remainder of the job was canceled.

• Adding printer memory can prevent this from occurring.

Memory shortage page simplified

The printer’s adaptive data compression had to resort to lossy compression to fit raster graphics in the available memory. This has caused a data loss in the raster output.

• Reduce the complexity of the page to improve the print quality.

Note

Adding memory will not correct this problem.

12 Chapter 1 Troubleshooting control panel messages

No job to cancel

ANCEL JOB

cancel. The printer automatically returns to the

• No action is required.

was pressed but there is no active job or buffered data to

READY

state.

Page cannot print now

alternates with

Retry when printing stops

An internal page has been requested while the printer is printing an incoming job. Interrupting the job to print the internal page would corrupt the job’s environment and potentially cause the job to finish printing incorrectly after the internal page is completed. Consequently, internal pages are not permitted to interrupt jobs and can only be printed when the printer is idle.

• Retry print job after printer has completed current job.

Page simplified

The printer’s adaptive data compression had to resort to lossy compression to fit raster graphics in the available memory. This has caused a data loss in the raster output.

• Reduce the complexity of the page to improve the print quality.

Note

Adding memory will not correct this problem.

Control panel messages

Page too complex to print

alternates with

Press Go to continue

The page could not be printed.

Note

Reducing the complexity of the page could allow it to print successfully. Adding memory will not correct this problem.

• Press GO to continue printing the current page (with noticeably poor

results on this page).

• Press C

ANCEL JOB

to terminate the entire job.

Press Go to print

alternates with

Press Select to change toner

The top cover was opened and closed when the printer was not in the toner cartridge replacement mode.

• Press G

replacement menu.

to resume printing or press S

to enter the toner

ELECT

Printer language not available

The printer received a request for a new language (personality) that does not exist in the printer.

• No action is required.

14 Chapter 1 Troubleshooting control panel messages

Reinstall transfer belt

This message occurs if you do not have the intermediate transfer belt installed in the printer or if the home positions (marks on the ITB) are not detected by sensor PS5.

Note

The intermediate transfer belt must be rotating before PS5 is able to detect the “home position” marks on the ITB. Both the ITB and the imaging drum are driven by the drum motor (M4).

Check SW1 for correct operation and make sure the cables are

connected. Verify that the ITB is installed in the printer.

If the ITB is installed and seated properly, verify that PS5 is not

damaged. PS5 is located on the ITB assembly. If the sensor appears damaged, replace the entire ITB assembly.

Clean PS5.

Verify all wiring within the ITB drawer. Note the connection on the

ITB assembly (located on the front, lower, left-hand corner of the assembly). When the drawer is closed the connector “mates” with a receptacle connector on the drawer. V erify that the connector and al l wiring are in good condition.

Verify that the drum motor (M4) is rotating both the imaging drum

and the ITB. If necessary use a light felt marker and identify a spot (outside the imaging area) on the edge of the imagin g drum. Turn on the printer, then open the drawer to see if the mark has moved.

If the imaging drum is not rotating, verify that the imaging drum

connector is firmly seated into the J204 connector of the developing PCB.

Control panel messages

Remove paper top output bin

The top output bin holds 200 sheets of paper . Sensor PS9 along with its sensor flag detects the height of the output paper stack.

1 Verify that PS9 moves freely and its movement is not blocked. 2 Verify that PS9 is free of dust and debris (the printer’s top cover

must be removed to access the sensor).

3 Verify that all connectors are firmly seated. Refer to the wiring

diagram in chapter 10.

Note

For more information, see the service manual for the printer.

Resetting memory

The printer is executing a memory reset. The printer returns to the

READY

state upon completion of this process.

• No action is required.

Resetting values finished

The color calibration density values have been reset to their default values.

• No action is required.

Select language

The language selection power-up k e y sequence h as been entere d. The printer will prompt the user to select a new control panel display language once it has completed its initialization process.

• Select a new language when prompted.

16 Chapter 1 Troubleshooting control panel messages

Service mode

The service mode powerup key sequence has been entered. The printer will remain in service mode until

• Press

to exit the service mode.

is pressed.

Toner CMYK low

The toner cartridge specified is low on toner.

• Printing will continue until a

change the toner cartridge now, press

TONER OUT

message appears. To

ELECT

Toner CMYK low

alternates with

Press Select to change toner

The toner cartridge specified is low on toner and must be replaced.

• Press

Toner CMYK out

to enter the toner replacement menu.

ELECT

alternates with

Press Select to change toner

The toner cartridge specified is out of toner.

• If the

TONER OUT

OVERRIDE

• Press

ELECT

resume printing without changing the cartridge.

setting in the Configuration menu is set to

, press

to resume printing.

to enter the toner replacement menu. Press

Control panel messages

Toner position [color] = [state]

Indicates the current state of a particular toner cartridge. This message is displayed when S is displayed.

• If necessary, replace the specified toner cartridge.

is pressed while a

ELECT

TONER LOW/OUT

message

Transfer kit low replace kit

The transfer kit is near the end of its expected life.

• Although printing can continue, the transfer kit should be replaced

for optimum printer operation.

Transfer kit out replace kit

The transfer kit has reached the end of its expected life.

• Replace the transfer kit.

Tray x empty [type] [size]

The specified tray is empty b ut the cu rrent job doe s not requ ire this tr ay to complete the job.

• No action is required. However, to avoid this message in the future,

load the proper media type and size into the tray.

Tray x load [type] [size]

The specified media type and size need to be loa ded into the requested tray.

• Load the specified media type and size into the requested tray.

Press G on different media.

18 Chapter 1 Troubleshooting control panel messages

to override this request and cause the page to be printed

Tray x size [size]

Media has been loaded into Tray 1. The most recently configured size will be displayed with an asterisk next to it.

• Use

• Press

and

ALUE

for the currently displayed size. Press

ELECT

to view all possible sizes.

ALUE

to clear the

message.

Tray x type [type]

Media has been loaded into Tray 1. The most recently configured type will be displayed with an asterisk next to it.

• Use

• Press

and

ALUE

for the currently displayed type. Press

ELECT

to view all possible sizes.

ALUE

to clear the

message.

Waste toner full replace drum kit

Waste toner full sensor PS13 detects a waste toner full condition. Light receiver and light pipe arrangement along with a window in the drum assembly look for a waste fill condition. Verify that the sensors and light pipes are not blocked.

Replace the drum kit.

Check the sensor, and if it is defective, replace it.

Control panel messages

Numerical messages

13.xx Paper jam

xx = Description:

0 = Jam in input feed area 1 = Jam in fusing area 2 = Jam in fusing area 3 = Jam in duplex reversing unit 4 = Jam in duplex feed unit 5 = Jam in duplex paper feed area 6 = Jam in duplex paper feed area 7 = Jam in paper feed area 8 = Door open jam

9 = Irregular paper jam in paper path 10 = Paper in the paper path is too short 11 = Paper in the paper path is too long

13.xx Paper jam

alternates with

Check all rear door

Media is jammed in the rear paper path or rear duplexing area. 1 Open the rear duplex cover (if installed) and remove any jammed

media.

2 Open the upper rear door and remove any jammed media.

13.xx Paper jam

alternates with

Check middle front doors

Media is jammed in the transfer belt area or media is not picking.

• Open the middle front drawer and remove any jammed media.

• Watch the pick roller to ensure it is turning.

20 Chapter 1 Troubleshooting control panel messages

13.xx Paper jam

alternates with

Check front duplex drawer

Media is jammed in the front duplexing area.

• Open the front duplex drawer and remove any jammed media.

13.1 Paper jam

alternates with

Check in rear of drawer

A jam has occurred inside the middle front drawer area.

• Open the middle front drawer and carefully inspect for and remove

any jammed media.

13.1 Paper jam open middle front drawer

with

Check in rear of drawer

A jam has occurred inside the middle front drawer area. The jam may be located in the fuser area or between the transfer area and the fuser.

Open the middle front drawer and carefully inspect for any media.

Be sure to inspect the fusing area. You may need to access the

fusing area through the rear door. Remove any jammed media.

20 Insufficient memory

alternates with

alternates

Press Go to continue

More data has been received from the computer than fits in the printer’s internal memory.

To continue printing, press

the printer’s internal memory is printed. To cancel the job, press

Add more memory to resolve the problem.

. Only the amount of data that fits in

ANCEL JOB

Control panel messages

22 EIO x buffer overflow

alternates with

Press Go to continue

The EIO buffer for the EIO card in slot “x” has overflowed du ring a b usy state.

• The current data in the print buffer will be lost.

• Press GO to resume printing and then resend the job.

22 Parallel IO buffer overflow

alternates with

Press Go to continue

This message indicates that the parallel buffer has overflowed.

• The current data in the print buffer will be lost.

• Press G

40 EIO x data error

to resume printing and then resend the job.

alternates with

Press Go to continue

A connection with the card in the specified slot has been broken. 1 Check that all cables are connected to the EIO ports and that the

EIO board is seated properly.

2 If possible, print to another network printer to verify that the network

is working properly.

Note

All data in the print buffer will be lost.

41.3 Unexpected paper size

alternates with

Check paper in Tray x

A tray is configured for a specific paper size, but the sheet loaded is a different size. This error often occurs when the printer is multifeeding.

• Load the tray with the requested size media.

22 Chapter 1 Troubleshooting control panel messages

41.5 Unexpected paper type

alternates with

Check paper in Tray x

A tray is configured for a specific media type, but the printer detects that a different media type is loaded. The most common cause for this error is a paper jam at the registration plate (under the ITB) where the customer does not remove the paper. The engine tries to check the OHT sensor and receives an error.

Verify that the correct media is loaded in the input tray and that the

printer control panel is configured correctly. Clean the detection windows of OHT sensors 1 and 2.

49 Error xxxx cycle power

This message indicates that a critical firmware error has occurred. An invalid command or data was sent to the formatter causing the processor to stop. This is the last action taken by the processor. The most likely cause of this error is invalid data or a bad command sent to the printer. A poor quality parallel cable, connection, or homegrown application has been known to cause this error.

Verify that all cables are connected.

Turn the printer off and on to reset the printer.

Cancel all print jobs then resend. Try to isolate any offending print

job. If the formatter pan assembly or DC controller was removed, make

sure the ribbon cable between the DC controller and the interconnect PCB is connected.

Control panel messages

50.x Fuser error

The fusing assembly contains two heating bulbs, two thermo-switches, and two thermistors. AC power is provided to the fusing assembly via the DC power supply, which is controlled by the DC controller PCB. The thermistors monitor the temperature of the fusing assembly and provide feedback to the DC controller PCB to regulate the fusing temperature. The two thermo-switches are wired in series with the fusing b ulbs . The y “open” if the temperature exceeds 240° C (464° F).

x = Description:

1 = Low temperature error 2 = Fuser warm-up service 3 = High fuser temperature 4 = Faulty fuser 5 = Fuser voltage mismatch (verify that you have NOT installed a

110V fuser in a 220V printer or vice-versa) 6 = Fuser heater cutoff 7 = Fuser motor malfunction (see recommended action for 50.7

Fuser error).

Note

A visual check to determine if the fusing assembly is functional can be made by defeating the rear door interlock switch. To do so, press in on the white plastic button abo ve the left-rear corner of the fan while turning the printer on. If the fusing bulbs and thermoswitches are good, you should observe light from the lower fusing bulb as the printer warms up.

1 Turn the printer off and on to reset the printer. If the error persists,

try re-installing the fusing assembly. If the error continues to persist, proceed to step 2.

24 Chapter 1 Troubleshooting control panel messages

+ 156 hidden pages

HP CLJ 4500, CLJ family Service Manual

Contents

Ordering other manuals

Supported products

Overview

Pre-troubleshooting checklist

Control panel messages

Alphabetical messages

Numerical messages