HP laserjet 5, laserjet 5m schematic

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May 1998 Edition

HP Color LaserJet and HP Color Laser Jet 5/5M Printer Quick Reference Service Guide

HP Color LaserJet and HP Color LaserJet 5/5M Printer Quick Reference Service Guide

Publication number 5041-9258

First edition, May 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 trademark of Microsoft Corporation.

MS-DOS trademark of Microsoft Corporation.

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

is a U.S. registered

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

Ordering other manuals

This

HP Color LaserJet and HP Color LaserJet 5/5M Printer Quick

Reference Service Guide

service engineer quickly troubleshoot common printer problems. While this reference is intended to pr ovide information the service engineer will need for on-site repair 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 “Training and support resources” in chapter 9.

has been created to help the HP LaserJet

Supported products

Name used in this guide

HP Color LaserJet/ HP Color LaserJet 5/5M

Model number

C3100A C3961A/C3962A/

Maximum pages per month

30K C3100-90916/

Service manual part number

C3961-90955

Note

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

iii

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

2 Cleaning and maintenance. . . . . . . . . . . . . . . . . . . . . . . 73

3 Service Mode and diagnostics . . . . . . . . . . . . . . . . . . . . 85

4 Media specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

5 Printer options and replaceable parts. . . . . . . . . . . . . . 121

6 Parts and part locations . . . . . . . . . . . . . . . . . . . . . . . . 125

7 Image quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

8 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

9 Training and support resources . . . . . . . . . . . . . . . . . . 205

A Acronyms and abbreviations. . . . . . . . . . . . . . . . . . . . . 213

Troubleshooting

control panel messages

Overview

This chapter contains the following sections:

Pretroubleshooting checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Contains a list of questions to address bef ore troubleshootin g printer problems

Basic troubleshooting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Includes a flowchart that provides help in solving printer hardware problems

Control panel messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Provides a list of control panel messages along with solutions. Alphabetical messages are listed first, followed by numerical messages. Self-explanatory messages are not included.

Aids to troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Provides tools to help isolate the cause of many printer failures, including troubleshooting by part swapping and a self-test printout

Troubleshooting paper feed problems. . . . . . . . . . . . . . . . . . . . . . 68

Provides preventive and troubleshooting techniques for paper and paper path jams

Note

If you need more detailed information, see the printer service manual.

Overview

Pretroubleshooting checklist

WARNING!

Always unplug the printer before servicing. Current is present in the main body cooling fan (M4), the noise filter board (Color LaserJet only), the AC driver board (Color LaserJet only), and the DC power supply whenever the printer is plugged in.

Before troubleshooting any specific printer problem, check the following:

• Has the printer been maintained on a regular basis (as described in

Chapter 2, “Cleaning and maintenance”)? – Note the location of spilled or accumulated toner before

troubleshooting. Toner contamination may be an indication of another problem.

Note

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

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

• Is the customer using media as specified in Chapter 4, “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 specified on the po w er rating 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?

HP LaserJet Family Paper Specification

2 Chapter 1 – Troubleshooting control panel messages

• Is the printer protected from direct sunlight?

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

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

CAUTION

Using non-HP components, such as toner, may cause permanent damage to 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 9, “Training 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.

Pretroubleshooting checklist

Basic troubleshooting process

The troubleshooting flowchart shown below highlights the process that most quickly solves printer hardware problems. During its power-on sequence, the printer verifies that its components are operating correctly. If the printer fails to turn on correctly, use the steps shown in the flowchart to troubleshoot the failure.

Note

User-accessible parts are blue-coded in the Color LaserJet and purple-coded in the Color LaserJet 5/5M.

Troubleshooting flowchart

4 Chapter 1 – Troubleshooting control panel messages

Control panel messages

Alphabetical messages

Blank display

• Remove the cover over the display and look in the upper right-hand

corner of the vacuum florescent display (VFD). The dot should be dark. If it is white, the vacuum in the display has been lost. Replace the front panel.

• Turn off the printer. Then unplug and plug in the printer before

turning the printer on again.

• Check the 5 VDC on Fuse 1 on the control PCA, as shown in

“Voltage checks” in the printer service manual. The 5 VDC may be missing.

• Reseat the display connections.

• Reseat the formatter.

• Check the fuses and connectors and listen for running fans and

motors when turning the printer on. – If no fans or motors are running, there is no AC voltage to the

unit.

• Check the voltage at the test connector.

• Replace the formatter.

Config language

• Do not interrupt this installation sequence.

• This message is displayed when pressing and holding

turning the printer on. When the power-on self-test is completed, the display language menu is available for configuration. This message is not localized.

[Enter]

while

Control panel messages

Drum inst./drum number = xxx

• This message indicates that the printer has detected a new drum

and is waiting for the user to enter the number that is printed on the bar-code label on the front of the drum. Press the [+] and [-] keys to enter this information. The number xxx is a whole number between 1 and 127.

Note

The drum number (or drum ID) should match the number shown on the self-test printout. (See “Understanding the self-test printout” on page 64.)

Note

If the incorrect number was entered when the

number = xxx

message appeared, it can be corrected now.

Drum inst./drum

Error log

• To display this message, press and hold [Form Feed] while

power-cycling the printer.

• When the power-on self-test is completed, the error log is available

to use. See Chapter 7 in the printer service manual for instructions on entering the Error Log Mode. This message is not localized.

Extended diagnostics

• Use extended diagnostics to test the printer when formatter,

memory (DRAM only), and MIO-related errors persist. The extended diagnostics test exercises the ability of the f ormatter to communicate across the MIO and with the memory. To perform the extended diagnostics tests, see “Extended diagnostics” on page 110.

6 Chapter 1 – Troubleshooting control panel messages

FE font cart err/cycle power

Color LaserJet only

• The font cartridge was removed while the printer was online.

– This error occurs whether or not the cartridge was being

accessed.

– Power cycle the printer to clear this error.

Initializing NVRAM

• This message occurs when NVRAM must be initialized because one

or more values are incorrect.

• After the initialization is complete, the printer self-test message

appears.

Note

This message should only appear when the printer is turned on. It should never appear during normal printer operation.

Installing new developer

Note

Do not interrupt this installation sequence.

• The new developer sequence has started.

– The installation sequence lasts about 3 minutes for the black

developer and 9 minutes for the color developer.

No fonts top/bottom/both font cartridge

Color LaserJet only

• The printer is not reading some (or all) of the indicated cartridges.

– To clear this error, reinsert the specified font cartridge and press

[Online]

• If the message persists, the indicated cartridge is bad and should be

replaced.

Control panel messages

Please verify drum number = xxx

• Re-enter the drum number for verification.

– Press the [+] and [-] keys to change the displayed number. If the

incorrect number was entered when the Drum inst. drum number + xxx message appeared, it can be corrected now.

– This verifies that the correct number was entered.

Reinsert top/bottom/both font cartridge

Color LaserJet only

• Any or all of the font cartridges were removed while the printer was

offline and contained buffered data.

• Clear this error by reinserting the specified cartridge(s) and pressing

[Online].

Service Mode

• Service Mode is used to test printer functions by issuing commands

to the control PCA through the control panel. For more information on this display panel message, see “Accessing Service Mode” on page 87.

8 Chapter 1 – Troubleshooting control panel messages

Numerical messages

11.x Front tray empty

• The paper tray is not installed, or the tray is empty.

– Load paper. – Check the paper-size detect board. – Check that the switch actuators (on the tray) are not damaged.

11.4 Front tray empty

• The paper-out photosensor (PS8) senses an empty tray.

• If paper is in the tray, the sensor arm could be stuck or broken.

Troubleshoot PS8 as follows:

Remove the paper tray and open the top cover.

Check that the paper-size switch actuators on the tray are not damaged.

Check that PS8 is free throughout its entire range of travel and is properly

located in its mount. Check that connector CN802 (on the controller) is fully seated.

If the error persists, perform the PS8 Service Mode Test as described

below.

PS8 Service Mode test

• PS8, the paper-out photosensor, can be tested in Service Mode as

follows:

Enter Service Mode (see “Accessing Service Mode” on page 87) and

select the Status Test Mode. Enter the PS8 test address (10) and press

With no tray installed, the display will read

Open the printer, lift the paper guide, and move the sensor shaft through

its range of motion. The display should change from low to high (

activated. If it does not change, check that the PS8 connector on the highvoltage power supply (HVPS) is fully seated, as shown in the figure below. (The connectors are on the back of the HVPS.)

Replace the photosensor.

[Enter]

for paper tray empty.

to 1) as the photosensor is

Control panel messages

Photosensor PS8 connections on HVPS (HVPS inverted)

11.X Rear tray empty

• Check that the rear feed unit (RFU) is installed and that it has paper

in it.

• Remove the RFU and check that the connector is not damaged.

• Remove and reseat the RFU if paper is present.

Note

Do not remove or install the RFU when the power is on. The printer only checks for the prese nce of the RFU when the printer is turned on.

10 Chapter 1 – Troubleshooting control panel messages

12 Close top or side door

• The printer’s top or side door is open or the door sensor has failed.

– Close the top or side door or replace the door sensor.

• One of the two interlock switch es (MS2 or MS3) m ay be defective . If

the following test proves that the switches are defective, replace the interlock switch assembly as shown in Chapter 6 of the printer service manual.

Note

Power cycle the printer and re-close both doors to confirm the message before troubleshooting.

Test the interlock switch

WARNING!

Do not inhibit the free movement of the interlock switch. If this mechanism is blocke d, voltage ma y be present when the top cove r is open.

Open and close the top cover. If the message remains, open and

close the side door. Open the side door and push the interlock mechanism with a flat-

blade screwdriver (see “Testing the interlock switches” on page 7-21 of the service manual), while running test 41 from Service Mode (see Chapter 3).

If the message persists, remove the top cover and check that the

switch linkage is not bent. Check that the switch connectors are in good repair. Toggle the

switches by pressing down on the metal tab over the switches. If the linkage is not damaged, remove the switch assembly and test

it with an ohmmeter. Replace the assembly if it is defective.

Control panel messages

13.1 Clear drum winding jam

Note

The locations of all sensors are identified on page 139.

• Paper is detected in the out of limit area of the print drum. The

drum-winding jam sensor indicates that paper is beginning to wrap around the print drum. – Turn the paper stack over end-to-end. – Check that the paper meets HP paper specifications for the

printer. – Check that media is not being re-fed into the printer. – Check that the drum-wrap sensor is not blocked by opening the

side door and checking for paper wrapped around the drum.

• If no paper is seen, calibrate the drum-winding jam sensor by

entering into Service Mode (see “Accessing Service Mode” on page 87“) and running test 47.

• See “Troubleshooting paper feed problems” on page 68.

13.2 Clear output jam

Note

The locations of all sensors are identified on page 139.

• Print media is jammed in the exit assembly because it failed to clear

the exit sensor (PS1) in the allotted time. – Check that the sensor flag moves freely and that the sensor is

free of paper dust.

– Check that media is not in the sensor when the printer is turned

on.

– Te st th e operation of the sensors by entering Service Mode (see

“Accessing Service Mode” on page 87“) and running test 22.

• See “Troubleshooting paper feed problems” on page 68.

12 Chapter 1 – Troubleshooting control panel messages

13.4 Clear front tray input jam

Note

The locations of all sensors are identified on page 139.

• The printer detects a paper jam in the front tray area.

– Clear the front tray area.

• The paper failed to arrive at PS7 within the allotted time after SL1

(the paper feed solenoid) was engaged. – Inspect the input an d registrati on area f or media . Transparencies

can be especially difficult to see.

– Test the operation of the sensors by entering Service Mode (see

“Accessing Service Mode” on page 87“) and running test 20.

• See “Troubleshooting paper feed problems” on page 68.

13.5 Clear fuser jam (CLJ)

13.5 Clear paper jam (CLJ5)

• Paper did not arrive at PS1 (exit sensor) in the allotted time. (See

the diagram on page 141 for the location of PS1.) – Check that PS1 is free throughout its entire range of travel and

that media is not at the sensor when the printer is turned on. – Check for paper dust in the sensor. – Chec k to see if me dia has cleared the reg istra tion pl ate. If media

is present, check the operation of the registration plate solenoid

by running test 25 from the status and test section of the printer

service manual.

• Check to see if the transfer assembly is installed correctly.

• Test the interlock switch. (For instructions, see the section called “To

test the interlock switch” under erro r message 12 on page 11.)

• See “Troubleshooting paper feed problems” on page 68.

Control panel messages

13.6 Clear rear tray input jam

• The printer detects paper in the rear input area.

– Clear the RFU.

• The sensor (PS4) did not activate within the allotted time after M7

started. (See the diagram on page 142 for the location of PS4.) – Repair the sensor. – Check that PS4 is not blocked.

• Sensor PS4, the RFU paper sensor, failed to detect paper media

within the allotted time. – Check that the sensor is not stuck. – Check if media has been picked from the tray.

• Verify that the RFU is properly adjusted for the loaded media.

• See “Troubleshooting paper feed problems” on page 68.

13.7 Clear rear tray paper jam

Note

The locations of all sensors are identified on page 140.

• The printer detects a paper jam at the rear input area. This message

indicates that the paper was picked, but did not arrive at the registration area (PS7), in the allotted time. – Clear the jam and check the paper feed rollers. – Check that sensor PS4 is not defective and that it is free

throughout its travel.

• See “Troubleshooting paper feed problems” on page 68.

13.8 Clear paper jam

• Paper is jammed in the paper registration area.

– Open the printer and remove the jammed paper.

• Paper may be on PS7 when the printer is turned on. (See the

diagram on page 141 for the location of PS7.) – Check that PS7 is free.

• See “Troubleshooting paper feed problems” on page 68.

14 Chapter 1 – Troubleshooting control panel messages

13.8 Internal paper jam during warm-up

• Media was detected in the printer during warm up.

– Open the top cover and clear any media found inside the printer. – If no media is found in the printer, check all sensors by running

the tests described under error messages 13.1, 13.2, 13.4, and 13.5.

• Verify that all paper path sensors are not blocked and that the

detection flags are free throughout their travel.

• See “Troubleshooting paper feed problems” on page 68.

14.5 Replace collection box

16.5 Replace collection box

• Remove the toner collection box from the OPC drum assembly and

inspect the flexible diaphragm (in the top surface of the collection box). – If the diaphragm has been pushed above the collection box

surface by accumulated toner, the box is full. In this case, the collection box must be replaced. Do not attempt to push the diaphragm down to correct this condition.

• The excess toner collection box is monitored by PS3. (See the

diagram on page 141 for the location of PS3.) Perform the sensor checks below to isolate the problem.

Toner collection box full sensor tests

Power cycle the printer.

Open the top cover and lower the print drum.

Pull the toner collection box out of the drum assembly.

Verify that the toner-full flag is moving freely (it should raise up as

you are pulling the toner collection box out of the assembly and drop down once the collection box is remo ved).

Check to see if the toner collection box is full. If the toner collection

box is full, the diaphragm will be pushed out. If it is pushed out, then the collection box is full and needs to be replaced.

Control panel messages

CAUTION

Do not try to continue using the toner collection box by pushing the diaphragm down.

6 Check that the PS3 sensor is fully seated, clean, and connected

properly. (See the diagram on page 141 for the location of PS3.)

If these tests are not effective, perform the PS3 Service Mode test described below.

Note

If the collection box is overfilled, the printer may need a thorough cleaning. In addition, the excess toner auger (inside the print drum) may be compacted or broken. The print drum may have to be replaced.

PS3 Service Mode test

Note

The PS3 sensor flag is not accessible to toggle by hand. You must have an empty collection box to perform this test.

1 P o wer cycle the printer and enter the Service Mode (see “Accessing

Service Mode” in Chapter 3.)

2 Select the status and test Mode of the Service menu. 3 Enter the PS3 test address (55), and press [Enter]. 4 Install the empty collection box. If the display is high (1), the sensor

is stuck or defective.

5 If the display is low (0), pull out the collection box about an inch to

make the sensor flag rise. If the displa y does not change from 0 to 1, the sensor flag is stuck or brok en or the sensor (PS3) is disl odged or defective .

6 Check connector CN904 on the toner sensor PCA (Color LaserJet

only).

16 Chapter 1 – Troubleshooting control panel messages

14.6 Replace coating kit

• If this message does not clear when the coating pad kit is replaced,

the fusible link in the coating pad may not be contacting the leaf spring in the fusing assembly or a coating kit with a blown fuse has been installed. – Reseat the coating pad.

Color LaserJet only

• If a new style fusing assembly with a purple handle has been

installed, then the fusible-link contacts are not making proper electrical contact with the contact fusing spring assembly. – Reseat the cleaning roller.

CAUTION

The printer should continue to print when returned online. The fuser and main drive may be damag ed if the oil pad and cleaning roller are not replaced as soon as possible.

16.5 Replace collection box

• See “14.5 Replace collection box.”

17.1 Install developer

17.2 Install developer

• The printer failed to detect either the black developer (for the 17.1

message) or the color developer (for the 17.2 message). – If the developer is not installed, install it.

Power cycle the printer.

If the message persists, remove the suspected developer and

inspect the blade connectors that insert into the toner sensor PCA. Check that they are clean and straight. Also check the toner sensor PCA connectors.

Re-install the developer.

Control panel messages

Ton er sensor PCA connections (circled) 4 Check all the connectors on the toner sensor PCA. Ensure that they

are all fully seated.

5 Check the wiring behind the power supply drawer for nicks or cuts

that may cause the signal line to short to ground. Reseat the connectors if any are suspect.

6 Replace the toner sensor PCA if necessary. 7 If steps 1 through 6 do not resolve the problem, replace the

developer.

17.4 Install fuser

• The fuser is not installed, or the printer failed to detect the fuser.

1 Power cycle the printer. 2 If the message persists, remove and reseat the fuser. 3 Check that the fuser connectors are not damaged (no bent or

broken pins).

4 Check that nothing prevents the fuser from fully seating into its plug. 5 Check the connector (CN105) at the control PCA.

18 Chapter 1 – Troubleshooting control panel messages

Replace the fuser.

Replace the control PCA if necessary.

17.6 Install collection box

• The toner collection box or the print drum is not installed or is not

detected. The switches that post this message are inside the print drum cartridge and cannot be tested directly.

Power cycle the printer to clear the message.

With the printer turned off and unplugged, inspect the print drum connector (see the figure under “17.8 Reinstall drum”). Ensure that the connections are not bent and that both the male and female ends are in good repair and clean.

Ensure that nothing inhibits the print drum from fully seating into the

connection. Check that CN101 on the control PCA and CN 254 on top of the

developer bias supply are fully seated. Reseat the collection box and listen for an audible click.

If the collection box does not click into place, the leaf spring inside

the housing may be defective. Replace the print drum. Remove the drum and very carefully clean the inside of the sensor,

using a cotton swab and isopropyl alcohol. Re-install the drum.

Control panel messages

17.7 Remove drum cover

• The protective shipping cover for the print drum has not been

removed. – Remove the drum cover (see the printer service manual for

instructions) or clear the drum wrap sensor.

• If the error persists, perform the status and test checks (see the

printer service manual) to test the drum wrap sensor.

• If the error still persists, perform the drum reflectance calibration

(Service Mode status and test address 47). Also see the procedures for the 66.1 Jam sensor service message.

17.8 Reinstall drum

• This message indicates that the drum-winding sensor output is

abnormal during printing (see 66.1 Jam sensor error message).

• A jam sensor could be broken or defective, or a connection could be

loose.

1 Remove the print drum and inspect both sides of the connector as

shown in the “Print drum connector” figure below.

2 Re-install the print drum. Check that nothing prevents the print drum

from being fully seated into the printer.

Note

If the drum assembly is for a Color LaserJet 5/5M (the assembly will be purple-coded), you will need to make sure the corona cleaning lever on the drum is fully seated to the right.

3 Power cycle the printer. 4 Run test 47 in Service Mode (see Chapter3 for information on

accessing Service Mode).

5 Replace the drum cartridge assembly.

20 Chapter 1 – Troubleshooting control panel messages

Print drum connector (circled).

17.9 Reinstall fuser

• The fuser did not warm up correctly.

– Reseat the fuser.

• The fuser connection is not stable.

WARNING!

The fuser is HOT. Turn off the printer to allow the fuser to cool for at least 30 minutes before beginning this procedure.

– Power cycle the printer to clear the message.

• If the message persists:

– Remove the fuser. Check that all the connectors are strai ght an d

clean.

– Reseat the fuser, being certain that all the connectors make

contact.

• If the message persists, replace the fuser.

Control panel messages

18.1 Clean transfer corona wire

• The paper-charging brush or the bias roller in the transfer assembly

is arcing. – Power cycle the printer. – Clean the transfer corona wire (see Chapter 2, “Cleaning and

maintenance”).

– Check connector CN701 on the control PCA and connector

CN702 on the HVPS. – Replace the transfer assembly and try another test print. – Replace the HVPS.

18.2 Reinstall drum

• The printer sensed a high-voltage leak in the print drum neutralizing

corona. – Power cycle the printer to clear this error. – Remove and reinstall the print drum. Try a test print. – Check connector CN731 on the control PCA and connector

CN730 on the HVPS.

– Check the neutralizing corona contact for damage or

contamination. (see the “Neutralizing corona contacts” figure

below.) – Replace the print drum. – Replace the HVPS.

• The neutralizing corona may have arced.

– Clean the printer.

22 Chapter 1 – Troubleshooting control panel messages

Neutralizing corona contacts (circled)

18.3 Reinsert developers

• The printer detected a high-voltage leak in the de v elo per bias po wer

supply. (Although this is a developer bias fault, the print drum is often the root cause of this failure.)

• The developer is not turning.

Remove each developer and check their pin contacts.

Check that each of the high voltage contacts on the developer bias

assembly is clean and located correctly. Print several self-tests and look for repetitive defects. Replace the

print drum if repetitive defects appear. Remove the print drum and check its surface for any bright metallic

spots, dents, or def ects that may indicate an arcing point (anywhere in the green area). Replace the print drum if any defects are found.

Check CN601 on the developer bias supply and CN600 on the

control PCA. Try a test print.

Control panel messages

• If the message persists, replace the print drum f ollo w e d b y the color

developer and the black developer if necessary.

7 Replace the developer bias power supply.

18.4 Clean transfer corona

• There is a high-voltage leak in the transf er belt, print drum, or HVPS.

– Power cycle the printer.

Note

If the problem will not repeat dependably , print transparencies in color. Transparencies print at a slower speed with a higher transf er current.

• Clean the transfer corona (see Chapter 2, “Cleaning and

maintenance”).

• Check that the print drum contacts are clean.

• Remove the transfer belt assembly and print a test page.

• If a 13.x Paper jam message appears when printing without the

transfer assembly installed, the high-voltage leak is associated with the transfer assembly. – Check the transfer assembly contacts for proper alignment,

corrosion, etc. before replacing them.

• If the error persists, reseat the print drum. Then replace the print

drum followed by the HVPS if necessary.

24 Chapter 1 – Troubleshooting control panel messages

18.5 Reinsert developers

18.6 Reinsert developers

Note

18.5 Reinsert developers is for black developers.

18.6 Reinsert developers is for color developers.

Note

Do not replace devel opers until the actual cause h as been identified. Replace the developers only if they are proven defective.

• The printer does not sense the changing output from the toner

concentration sensor that occurs with normal toner mo vement within the developers. – The developer is not selected. – The developer drive gears are not engaging the developer. – The developer drive gears do not rotate. – The developer is not rotating.

• Reinsert the developer.

Note

If new developers are installed in the printer, toner compaction may cause the toner concentration sensor to give an abnormal reading. Remove the new dev eloper , shake it as described in Chapter 4 of the printer service manual, and reinstall.

• Perform the following procedure to troubleshoot the 18.5 and 18.6

message:

Remove the developers and check that the drive and gears are not worn

and that no teeth are missing. Remove the developer assemblies and print drum. Move the top cover up

and down. Check that the developer drive gears extend and retract and are free throughout their travel. With the top cover partially closed, press each developer drive gear and check that each has firm spring pressure.

Rotate the gears on each developer assembly by hand (this requires some

force). Check that they all hav e similar resistance. If the gears will not turn, replace the developer.

Shake the developer as shown in chapter 4 of the service manual. Toner

may be compacted inside the developer.

Control panel messages

Examine the connectors on the developer and the toner sensor PCA for

damaged pins or connectors. If symptoms still persist, follow the procedures listed below.

Service Mode tests

• Use Service Mode to check that the developers are rotating. This

test is especially useful because the status Mode displays the toner concentration value while the developer augers rotate. To perform this test, follow the steps below.

CAUTION

Do not perform this test with the RFU installed. Performing this test with the RFU installed and the toner hopper cover removed will damage the toner feed augers.

1 Enter Service Mode (see “Accessing Service Mode” in Chapter 3). 2 From the Status and Test Mode, select address 08. 3 Select subtest 0 for the 18.5 message, or address 1, 2, or 3 for the

18.6 message. Once selected, press [Online] to start the test. When the test starts, the control panel displays the toner concentration value for the selected developer. If the developer drive gear rotates, the toner concentration sensor value displayed on the control panel should fluctuate slightly.

4 If the gears do not rotate, check the developer rotation as follows:

A Remove the RFU, if installed. B Remove the toner hopper cover. C Run the Service Mode test again. D Watch the developer drive gears at the rear of the printer. They

should turn when the test is started. Make sure you are looking at the developer drive gear and the developer gear during this test. (The black drive gear is the most difficult to see.)

E If the gears do not rotate, perform the mechanism alignment

checks.

5 If the gears rotate and the toner conce ntration sensor valu e does not

fluctuate, check the electrical connections between the developer and the control PCA.

26 Chapter 1 – Troubleshooting control panel messages

If the electrical connections are OK, replace the toner sensor PCA.

If the message persists, replace the developer.

Mechanism alignment checks

• Misalignment between the developer drive assembly, the toner

hopper assembly, and the printer frame may cause 18.5 and 18.6 errors. Check the f ollowing items for a lignment when troub leshooting this error.

Remove the developer and check to see if the developer casing is

bent. To do so, follow these instructions:

Place the developer on a flat surface with the back of the

developer toward you. Push the developer forward inside the casing.

If the developers do not mov e f or ward un til the bias contact p in is

against the casing on the left side, the casing is bent. Replace the developer assembly.

The printer frame has detents that position the developer drive

assembly correctly on the printer frame. Ensure that the assembly is properly seated on these detents. Improper seating will misalign the developer drive assembly with the developers and the toner hopper assembly . If misa ligned, loosen the screw s, align the de ve loper drive assembly on the detents, and then tighten the screws.

The developer drive assembly aligns with the toner hopper

assembly through an alignment pin located on the developer drive assembly. Check that the alignment pin is straight and that the toner hopper is fully seated. If the alignment pin is bent, replace the developer drive assembly.

If the alignment pin is not damaged, remove the screws that hold the

toner hopper in place, and then:

Slide the toner hopper towards the left side of the printer (to the

right when viewed from the rear of the printer).

Control panel messages

B Check the gear cluster on the toner hopper for bent sheet metal.

If the toner hopper select shaft is out of its bushing or if the b u shing is not mounted correctly in the sheet metal, the sheet metal may be bent. If the gear cluster is damaged, replace the toner hopper assembly.

C Check to see if the activation arms for the toner hopper lockout

fingers are against the select cams. If the arms are on the cams, check the toner hopper lock solenoid (SL6), located on the left side of the toner hopper, for binding and correct operation.

D If the toner hopper assembly is functioning correctly, slide the

assembly back into position. Align it with the developer drive assembly being careful not to damage the gear cluster. Reinstall the toner hopper screws.

19.x User maintenance

• A printer consumable has exceeded its maximum life . Press [Online]

to continue. The printer will continue to print, but print quality will degrade until the indicated consumable is replaced.

CAUTION

The main drive gears could become damaged if the fuse r is allo w ed to remain past its maximum life in the printer.

• If the indicated consumable has been replaced:

Reseat the consumable.

Check both sides of the connector for bent pins.

Power cycle the printer.

Verify that the fuse for the consumable is not blown. The drum,

developers, transfer, fuser, and coating kit are fused. If the fuse is blown when a new consumable is installed in the printer, the consumable will not be detected as a “new” part.

Note

Do not return a consumable to stock once the fuse is blown.

Try another of the indicated consumables.

Check the self-test print for any value that is inconsistent with the

perceived actual cumulative usage. If a value is suspect, investigate the possibility of a NVRAM problem. If necessary, contact your local response center.

28 Chapter 1 – Troubleshooting control panel messages

20 Memory overflow

• More data has been received from the host than fits in internal

memory. – Press

printer memory is printed.

• If the message persists, install more memory.

to continue printing. Only the data that fits in

[Online]

21 Memory out

• The printer has run out of memory. Imaging the current job cannot

continue until the engine clears memory. – Press

• If this error persists, install additional memory.

to clear memory. This results in data loss.

[Online]

22 I/O config error

• The computer is not obeying the pacing mechanism of the MIO link.

This causes the printer’s receiving buffer to overflow during a busy state.

23 MIO not ready

• The MIO card cannot accept data.

– Print the self-test page for more information. – The MIO card could be defective.

• If the message persists, reseat the MIO card and ensure it is

properly connected to the network. If necessary, replace the MIO card.

Control panel messages

24 Busy moving toner

• The printer is adding toner to the developers. If this message is

displayed frequently, check for faint print. If several pages of heavy toner coverage are being printed, this message may not indicate an error. If the message persists, the toner feed auger may not be turning or a toner sensor may be defective.

1 Power cycle the printer. 2 Check the toner level in the toner hopper assembly by manually

opening each hopper. If any of the hoppers are completely empty, the toner sensor for the empty hopper may be defective. Use the Service Mode status and test (address 01) to test the toner level sensors.

Note

The toner sensors on the hoppers are piezo -electric. When the toner falls below the level of the sensor, the sensor output is audible. However, the high-pitched sound may be out of hearing range for some people.

3 If the hoppers have enough toner to cover the sensor, and the

message persists, check the toner hopper auger operation as follows:

A Remove the RFU. B Manually open the hoppers and watch the paddles while printing

the demo page.

C If the paddles turn, the problem is in the hopper augers . Replace

the toner hopper assembly.

D If the paddles do not turn, print the demo page 10 times. Watch

that the toner hopper supply shaft rotates, that the hopper select shaft engages the hopper clutch, and that the toner supply augers turn.

E If the toner supply shaft does not rotate, perform the toner supply

solenoid test as described below.

30 Chapter 1 – Troubleshooting control panel messages

Toner supply solenoid test

Test the toner supply solenoid (SL3) and supply augers as follows:

Enter the Service Mode (see “Accessing Service Mode” in

Chapter 3) and select test address 52. Remove the RFU and the back cover. Listen for the solenoid to

actuate.

30 PostScript error xx

• The printer encountered a PostScript error indicated by XX.

– Press

to continue. The current job is canceled.

[Online]

Note

For PostScript errors, look at the program that is being sent, rather than at the printer unless every Po stScript file comes up with the same error.

30 PostScript error 00

• An attempt was made to add an item to a dictionary that is full. This

may be a driver incompatibility problem. – Select a different PostScript driver and resend the print job.

30 PostScript error 01

• An attempt was made to place too many dictionaries on the

dictionary stack. This may be a driver incompatibility problem. – Select a different PostScript driver and resend the print job.

30 PostScript error 02

• An attempt was made to remove more dictionaries from the

dictionary stack than were available. This may be a driver incompatibility problem. – Select a different PostScript driver and resend the print job.

Control panel messages

30 PostScript error 03

• The execution stack is too large. Procedure invocation is nested

deeper than PostScript allows. This may be a driver incompatibility problem. – Select a different PostScript driver and resend the print job.

30 PostScript error 04

• An attempt was made to access an array, dictionary, file, or string

object incorrectly.

30 PostScript error 05

• An incorrect exit was executed.

30 PostScript error 06

• An incorrect access string specification to the file operator occurred.

30 PostScript error 07

• The operand to make font or set font is not a well formed font

dictionary.

30 PostScript error 08

• An incorrect restore was attempted.

30 PostScript error 09

• An error occurred during the execution of one or more of the file

operators.

30 PostScript error 10

• A PostScript implementation limit was exceeded.

32 Chapter 1 – Troubleshooting control panel messages

30 PostScript error 11

• An operator requiring a current point was exceeded while the

current path was empty.

30 PostScript error 12

• A numeric operand’s value is out of range.

30 PostScript error 13

• An attempt was made to push too many objects on the operand

stack.

30 PostScript error 14

• An attempt was made to pop an item from an empty operand stack.

30 PostScript error 15

• The PostScript scanner encountered text that does not conform to

the PostScript syntax rules.

30 PostScript error 16

• The PostScript interpreter timed out waiting for the user to manually

feed paper, waiting for data from the computer, or because a job took too long to complete.

30 PostScript error 17

• An operand was encountered that is not the correct type, such as a

number when a string is required.

30 PostScript error 18

• A name was encountered that cannot be found since it was

previously undefined.

Control panel messages

30 PostScript error 19

• A file identified by a name string operand of the file or run operators

cannot be found or opened.

30 PostScript error 20

• An overflow, underflow, or meaningless result of a numeric

calculation (such as division by zero) occurred.

30 PostScript error 21

• A clear-to-mark or count-to-mark operator could not find the

required mark on the stack.

30 PostScript error 22

• An operator object was executed for which the interpreter has no

built in action.

30 PostScript error 23

• An error occurred in virtual memory.

30 PostScript error 24

• The systemdict quit operator was executed causing the PostScript

interpreter to re-initialize virtual memory. All non-persistent information was lost.

30 PostScript error 25

• A PostScript firmware failure occurred. This is associated with

normal error handling and not with hardware.

30 PostScript error 26

• A “setpagedevice” request cannot be satisfied.

34 Chapter 1 – Troubleshooting control panel messages

30 PostScript error 27

• An external interrupt request was received by the PostScript

interpreter.

30 PostScript error 28

• A named resource sought by the findresource operator does not

exist.

40 I/O data error

• A data error has occurred while receiving data from the computer.

Press the printer and computer.

to continue printing. Check the connection between

[Online]

48 Invalid job/aborting job

• The printer does not recognize the language it is being switched to.

– This message remains in the display until it receives a valid

language.

50.x Fuser service

• The printer senses that the fuser temperature is incorrect for the

application. The voltage read at the upper fusing roller thermistor momentarily exceeded the limit. Leave the printer on for 20 minutes (this gives the internal clock time to count do wn and rese t) and th en power cycle the printer to clear this message. This message can also be reset by going into the service Mode, register adjust, and setting address 47 to 00. If the message persists:

• Check that the fuser connector is in good repair (no bent or broken

pins).

• Open and close both doors during the warm-up period. If the

message appears immediately, replace the fuser.

• Make certain the fuser can be fully seated into the printer and that

toner has not accumulated around the fuser area.

Control panel messages

• Check the connectors on the fuser, and check the connectors in the

printer that interface with these fuser connectors.

• Check connector CN105. CN105 is labeled on the control PCA.

(See the main wiring diagram in Chapter 8).

• Replace the fusing assembly.

50.1 Fuser service error

• The fuser temperature is too high for the application.

– Leav e the pow er on f or 20 minutes while the printer counts down,

then power cycle the printer to clear this error or use address 47 in the register adjust section of the Service Mode to reset this message.

– Check the fuser connections.

50.2 Fuser service error

• The fuser temperature is too low for the application.

– Leav e the pow er on f or 20 minutes while the printer counts down,

then power cycle the printer to clear this error or use address 47 in the register adjust section of the Service Mode to reset this message.

– Check the fuser connections.

50.3 Fuser service error

• The fuser temperature sensor is open.

– Leav e the pow er on f or 20 minutes while the printer counts down,

then power cycle the printer to clear this error or use address 47 in the register adjust section of the Service Mode to reset this message.

– Check the fuser connections.

36 Chapter 1 – Troubleshooting control panel messages

50.4 Fuser service error

• There is a fuser temperature error caused by erratic sensor values.

– Leave the power on for 20 minutes, and then power cycle the

printer to clear this error or use address 47 in the register adjust section of the Service Mode to reset this message.

52.1 Engine NVRAM error

• This error indicates a fail ure to read the N VRAM on the control PCA.

To troubleshoot this problem: Power cycle the printer.

If for some reason the NVRAM was remov ed from its soc k et, ensure

that there are no bent pins and that they are all in their correct position.

If the error persists, contact your local response center for

assistance in evaluating NVRAM viability.

52.2 Engine NVRAM error

• A developer with a blown fuse is being installed into a new printer.

• The NVRAM data could be corrupt.

– The printer checks an address in NVRAM for the status of the

engine. If the status returned is new, then the printer checks the developers to see if the fuses are ne w (clo sed). If the fuses ha ve been blown, then the fuses are blown on the developers use an ohmmeter across pins 5 and 6 on the color developer, and pins 4 and 6 on the black developer (see the main wiring diagram in Chapter 8). (Pin 1 is at the bottom of each connector.) If either developer has a blown fuse, replace the developer.

• If the printer is new, replace the developer. If the printer is not new,

troubleshoot as 52.1 Engine NVRAM error.

52.2 error

is displayed. To check if the

Control panel messages

53 Laser error

• The printer has detected a laser diode error.

– Power cycle the printer.

• If the error persists, reseat connectors CN300 and CN101. (See

Chapter 8, “Wiring diagrams” for the locations of these connectors.)

• If the connectors are in good repair, replace the laser scanner

assembly.

53 Laser error/service

• The laser signal is unstable.

1 Press [Online] to continue. 2 Power cycle the printer. 3 Open, then close the side door. 4 Check the side door interlock.

54.x Engine error/service error

The engine reported one of five types of failures or errors as listed below. Try to clear the errors by pressing [Online]. If the message persists, perform the appropriate procedure described below for the applicable 54 error message.

54.1 Engine error/service

• The scanner motor (M6) did not reach the correct speed in the

allotted time. – Power cycle the printer.

• If the motor spins up and the error persists, perform the following

procedure.

1 Check CN104 and CN350 on the optics assembly. 2 Inspect the wires behind the power supply drawer for nicks or cuts

on the insulation.

3 Measure the 24V DC.

38 Chapter 1 – Troubleshooting control panel messages

Replace the laser scanner assembly.

Replace the control PCA.

54.2 Engine error/service

• The printer detected an error in the 24V DC supply.

– Power cycle the printer to clear the error.

• If the error persists, check the 24V DC line.

– If the 24V DC voltage is missing, replace the DC power supply.

Note

The actual measured voltage should be approximately 22V DC.

• A defective or misaligned interlock switch can also cause this error.

– Use a screwdriver to push the interlock mechanism in the

direction shown in the printer service manual, page 7-21, Figure 7-4.

• If the message clears, adjust the tab on the side door which

operates the interlock mechanism.

• If the message persists, turn off the printer and check the interlock

mechanism, connectors, and cabling.

• Check fuse F5 on the DC power supply and fuse F2 on the control

PCA.

54.3 Engine error/service

Note

Do not replace any dev elopers until the cause of the error is identi fied. Replacing developers without identifying the cause of the error will only mask the problem and could lead to an other service call from the customer.

• A toner concentration error occurs when the toner concentration

sensor reading is at a minimum or maximum value. This error can be caused by: – a defective toner concentration sensor – failure of the toner hopper sensor or toner supply mechanism – too much or too little toner in the developer

Control panel messages

– a defective toner sensor PCA – incorrect NVRAM values. Incorrect NVRAM values can be

caused by:

not installing the correct NVRAM on the control PCA

•

installing the NVRAM incorrectly

•

a defective NVRAM

•

installing a used devel o pe r.

•

Incorrect NVRAM values usually cause too much toner to be delivered to the developer. Failure of the toner hopper sensor or toner supply mechanism is usually associated with not enough ton er being delivered to the developer. To determine the cause of this error follow the steps below:

1 Power cycle the printer. 2 Run se v eral self-test pa ges to see if the e rror returns. You should be

able to print at least one self-test page before the 54.3 error message reappears.

3 If the error returns, look at the self-test page and check for faded or

bold colors.

4 If a color looks fa ded, the problem will most lik ely be associated with

a defective toner hopp er sensor or the toner supply mechanism. If any color looks bold, then too much toner may have been added to a developer.

5 To identify which developer is reporting the error, run the toner

concentration test shown below. A value of 127 or 63 on the front panel is an indicator for the developer reporting the error.

6 See “Faint print” on page 157 for the procedure to troubleshoot a

problem with faded print.

7 If a color looks bold on the self-test page, the problem can be

caused by one of the following: – an incorrect NVRAM value

– the wrong NVRAM was installed on the control PCA – a developer, which is not the most recent one to be initialized by

the printer, has been installed

40 Chapter 1 – Troubleshooting control panel messages

• The NVRAM values correspond to the last developer that was

initialized in the printer. Even if the developer currently installed was initialized in the printer, if it was not the last de veloper initialized, the NVRAM values are not correct.

If the wrong developer was installed, reinstall the correct developer.

If the wrong NVRAM was installed, reinstall the correct NVRAM.

If the correct NVRAM or the correct developer(s) is not available, a

new developer(s) must be initialized in the printer. For other NVRAM associated problems, contact your local response

center.

Toner concentration test

Note

The toner concentration test is useful whenever the printed page displays characteristics of having either low toner concentration or high toner concentration. The procedures to correct low and high toner concentration are discussed later in this chapter.

Print a self-test page and note the relative humidity reading.

Power cycle the printer and enter the Service MODE (see

“Accessing Service Mode” in Chapter 3). Select the Register Adjust function of the Service Mode (see Chapter 3 for instructions on the register adjust function) to obtain the data values contained in the NVRAM addresses listed below.

NVRAM addresses

Color Black Yellow Magenta Cyan

Address Data

Example: Page

count

30 29 28 33 32 31 36 35 34 39 38 37

AA00BB16CC23AA00BB08CC28AA00BB08CC28AA00BB08CC

AABBCC AABBCC AABBCC AABBCC

Control panel messages

3 Press the [Form Feed] and [Reset] keys to select the desired

NVRAM address. When the desired NVRAM address is displayed, press [Enter] to display the value held at that address. For example, if the displayed NVRAM address is 29 and the value held at that address is 18, then the display will read:

Current Value 029 ReadOnly 18

Record the address and the value it contains. To clear this display and toggle back to

Enter Address xxx

, press [Enter] again. Repeat this procedure until the NVRAM values for all of the addresses in the “NVRAM addresses” table ha ve been obtained and recorded.

4 The current cumulative page counts for each of the developers can

now be constructed from the data you have obtained. See the following e x amples:

Examples

Address: 30=00, Address 29-16 and Address 28-23. The black page count is

001623. Address 33=00. Address 32=08 and Address 31=28. The yellow page count is

000828. Address 36=00. Address 35=08 and Address 34=28. The magenta page

count is 000828. Address 39=00. Address 38=08 and Address 37=15. The cyan page count

000815.

Note

Do not use the black and color page counts from the self-test page (these counts indicate the total cumulative page counts for the printer , which are usually different than the page counts for the developers).

5 Power cycle the printer and enter Service Mode again. Select the

status and test function from the Engine Service Status/Test Mode.

6 Follow the Status and Test Mode flow charts (pages 88 and 90 until

you come to the

Enter Address AB

several times to increment to AB = 08 (see the toner concentration values table on page 43).This sets the system to select test number 08 (developer rotation).

display. Press [Form Feed]

42 Chapter 1 – Troubleshooting control panel messages

Press

[Enter]

to display:

Enter Subset # 08 0

Enter the value of the subset # that is appro priate for the developer; select the number from the target toner concentration table below.

Press

[Enter]

to display:

Online to Start AB x YYY

When values of YYY will be displayed. After allo wing the rotation/update to run for at least 30 seconds, record the displayed. While the rotation/update is in progress, the following message displays:

is pressed, the developer will rotate and updated

[Online]

value that is being

YYY

Reset to Cancel AB x YYY

Make sure to record the displayed developer. Press

Use the following table to convert the number displayed on the

control panel to the actual concentration value.

to end the rotation/update.

[Reset]

value for the appropriate

YYY

Toner concentration values

Displayed value (

Less than 64 Same as displayed value 64 or larger 64 minus the displayed value

Using the Internal Humidity reading from the self-test page and the

page count for the developer (from NVRAM), locate the target toner concentration value for each developer from the target toner concentration table.

If the toner concentration value (derived from step 10) is more than

12 points lower than the target value, then the toner concentration in the developer is too low. If the toner concentration value is more than 12 points higher than the target value, then the toner concentration value is too high. Try the following techniques for correcting low or high toner concentration problems.

) Actual toner concentration value

YYY

Control panel messages

Correcting toner concentration levels

Low toner level

Effective resolution of a low toner concentration problem r equires correction of the root cause. Here are some likely causes:

• Poor distribution of the toner mix in the developer cartridge at the

time of its initial use in the printer. – It is possib le that shipment or stor age of the de veloper resulte d in

some toner/carrier segregation. This can result in erroneous calibration of the toner-concentration sensor when the new developer is initialized in the printer. Toner/carrier segregation can result in toner-rich compaction in the concentration-sensor zone. This presents a worst-case condition f or sensor cali bration error. Properly shaking new developer before initialization, as prescribed in the installation instructions and in the user guide f or the printer will usually prevent this condition. Correcting an improper initialization is not practical. If print quality is noticeably deficient, replace the developer.

• Use of a replacement developer that has not been properly

initialized in this printer. – This can cause a toner concentration error. Short-term use of a

previously initialized developer for troubleshooting is acceptable, but the original (properly initialized) developer should be reinstalled after troubleshooting is completed ; otherwise, install a new developer.

• Compaction of toner in the replenishment mechanism (auger

assembly or feed-in port). – This can result in toner depletion.

• Empty auger tubes.

– If service efforts have resulted in replacing the toner hopper

assembly, the toner auger tubes may not have been filled. To correct this problem:

Use Test 19 in Service Mode to unlock the hoppers.

Fill the hoppers with toner, if necessary.

Manually rotate (downwards) the large white gear on the side of each

hopper to fill the auger tubes. Do this while holding the auger tube shutter open at the developer end of the auger tube with something in place to catch any toner that escapes, such as a tissue or index card.

44 Chapter 1 – Troubleshooting control panel messages

• Incomplete toner fill in the auger tubes.

– Ensure a complete toner fill in the auger tube associated with

any developer (which has been revealed by the Toner Concentration Test). This can be accomplished in the manner described above (step 3).

• Incomplete toner concentration test.

– After completing any corrective action(s) for low toner

concentration, such as described above, run the Toner Concentration Test again. Remember, it takes some time for the replenished toner to be uniformly distributed through the developer; the test should be allowed to run for at least 30 seconds before making the front panel reading ( resulting return to normal toner concentration on its own during regular operation. If it “errors out” or if the displayed value is greater than 100, manually feed toner (step 3, above) and repeat the Toner Concentration Test. Failure to improve toner concentration values with these measures may indicate failure of the toner concentration detection circuitry or the toner replenishment mechanisms. Installation of a new developer may appear to correct the problem, but if the detection system, replenishment system, or both are malfunctioning, the problem can return.

value is in the range 000 to 100, the printer will

YYY

value). If the

YYY

High toner level

• Recovering from this toner condition is not as easy as recovering

from a low toner level. It is important that the root problem for this condition has been clearly identified; otherwise, the problem will be masked for only a short time and the original problem will eventually occur again.

Print a solid fill page for the color generating the error. Continue to

print this page until the error no longer appears. If far too much toner is in the developer, the developer will need to

be replaced.

Control panel messages

Target toner concentration

Developer

count

>0 4 4 3 3 2 2 2 1 2 0 >40 8 8 6 6 4 4 4 2 4 0 >80 12 12 9 9 6 6 6 3 6 0

>120 15 15 11 11 8 8 8 4 8 0 >160 18 18 13 14 9 9 9 5 9 0 >230 21 21 15 16 11 10 11 6 11 0 >310 24 24 17 18 12 12 12 6 12 0 >400 27 27 19 20 14 13 14 7 14 0 >500 30 30 22 23 16 14 16 8 16 0 >650 33 33 24 25 17 16 17 9 17 0

>800 36 36 26 27 19 17 19 9 19 0 >1000 39 39 28 29 20 19 20 10 20 0 >1250 42 42 30 32 22 20 22 11 22 0 >1500 45 45 32 34 23 22 23 12 23 0 >1750 48 48 35 36 25 23 25 12 25 0 >2000 50 50 38 36 26 24 26 11 26 0 >2750 47 47 34 35 24 23 24 10 24 0 >3500 44 44 32 33 23 21 23 9 23 0 >4250 41 41 30 31 21 20 21 8 21 0 >5000 38 38 27 29 20 18 20 6 20 0 >5750 35 35 25 26 18 17 18 4 18 -2 >6500 32 32 23 24 17 15 17 2 17 -4

20% or less 20-29% 30-39% 40-59% >60%

M C

Relative humidity

M C

46 Chapter 1 – Troubleshooting control panel messages

Target toner concentration (continued)

Developer

count

>7000 28 28 20 21 16 13 16 0 16 -6 >7500 28 28 20 18 15 12 15 -2 15 -8 >8000 28 28 20 18 15 10 14 -4 14 -10 >8500 28 28 20 18 15 8 13 -6 13 -12 >9000 28 28 20 18 15 8 12 -6 12 -14

>9500 28 28 20 18 15 8 11 -6 11 -16 >10000 28 28 20 18 15 8 10 -6 10 -18 >14000 28 28 20 18 15 8 9 -6 9 -20

20% or less 20-29% 30-39% 40-59% >60%

M C

Relative humidity

M C

54.4 Engine error/service

• A pressure cam home position sensor (PS2) error has occurred.

The pressure cam did not sense the home position with in 4 seconds after the initial rotation of the pressure cam. – Power cycle the printer.

54.4 Cam home position sensor

M C

• The cam sensor (PS2) did not detect home position. This message

can also occur with general printer disassembly involving the control PCA or the developer bias supply. – Since PS2 is located on the back of the developer bias supply,

make sure it is reconnected if the developer bias supply was removed. (See page 139 for the location of PS2.)

– Make sure that the connector (CN802) on the control PCA is fully

seated.

Control panel messages

• Other symptoms include the following:

– complete or partially blank pages – smeared vertical line on the front of the page – smeared toner image on the back of the page

Note

This message might appear as a result of the drive gears being installed incorrectly causing a loss of cam timing. Follow the cam timing procedure in Chapter 6 of the printer service manual to correct the cam timing problem.

• To troubleshoot the 54.4 message:

1 Open the top cov er and locate the tab that activ ates the A C interlock

switch. The tab is located to the right and belo w th e black dev el oper and is part of the developer drive assembly. If the tab is bent, bend the tab until it is aligned with the plunger.

2 If the tab is stra ight, turn the printer on while chec king the 24V DC at

the test connector, which is located on the rear of the printer.

Note

The actual measured voltage will be approximately 22V DC.

3 If no voltage is present, check the interlock switches on the left side

of the printer and verify that they are working correctly. Replace the switch mechanism if defective.

4 If the switch mechanism is oka y and the v oltage does not reach 22V

when the printer is turned on, replace the DC power supply.

5 If the DC voltage is OK, remove the right-side cover and watch the

AC motor (M2) to see if it turns as you turn on the printer.

6 If M2 does not turn, turn off the printer and unplug the power cord.

Disconnect the connector to M2 and connect a voltmeter.

WARNING!

With the printer turned on, there is 120/240V AC at this connector . Do not cross the leads of your meter or touch them with your hand. Doing so will cause damage to the printer or result in electrical shock.

7 Plug the power cord into the printer and turn the printer on. Watch to

see if the AC voltage is supplied.

48 Chapter 1 – Troubleshooting control panel messages

If power is available replace M2.

If no power is available, replace the AC power supply in the Color

LaserJet or the DC power supply in the Color LaserJet 5/5M. If the power supply does not solve the problem, follow the

procedures for the cam service Mode test to verify that the sensor is operating correctly.

Run test 53 in service Mode to verify that the solenoid is operating.

You should be able to hear when the solenoid turns on or off. Replace the solenoid if defective. A good solenoid should have a resistance value of approximately 56 ohms.

If the solenoid is okay when the resistance is measured and

everything else noted above has been checked, replace the control PCA.

Cam Service Mode test

Enter the status and test section of the Service Mode (see

“Accessing Service Mode” in Chapter 3). Select address 51.

Open the top cover, remove the print drum, and release the cam

solenoid (SL4), as shown in the figure below. Turn the gear train slowly, and watch the control panel display. The

status display will change from 000 to 001 when the cam home sensor is activated.

If the home sensor reading does not change, check the following:

• The developer bias supply is fully seated.

• The cam home sensor is mounted in the printe r frame correctly.

• The sensor connector is in good repair.

• If all of the above are okay, replace the sensor PS2. (See page 141

for the location of PS2.)

• When checking the cam home solenoid, run a demo page. With the

top cover removed, check that the solenoid releases. If it does not, replace solenoid (SL4) and its clutch, and then check th e cam timing as shown in Chapter 6 of the printer service manual.

Control panel messages

Releasing the pressure cam home solenoid

54.5 Engine error/service

• A developer home position sensor (PS6) error has occurred. The

developing switch position sensor did not detect the home position within 4 seconds after the initial motion of the pressure cam.

54.5 Developer home position sensor

• The printer failed to detect the developer cam home position within

4 seconds after the initial rotation of the pressure cam.

• The sensor (PS6) is defective. (See page 141 for the location of

PS6.)

Note

If this message occurs after general printer disassembly around the control PCA, the sensor PS6 may be disconnected. See chapter 5 under “Sensors” in the printer service manual to locate PS6, and check that it is plugged in both at the sensor and at the control PCA (CN802).

50 Chapter 1 – Troubleshooting control panel messages

54.5 Service Mode test

Select the Service Mode Status and test address 51 and check that

the developer drive motor rotates. If the developer drive motor (M2) does not rotate, check the

connectors. If the connectors are proper and M2 still does not rotate, replace M2.

If the developer d rive mo tor rotates , use the status Mode test (50) to

test the developer home sensor. (It may be necessary to turn the gear train by hand to activ ate this sensor .) The displa y changes from 00 to 01 when the sensor is activated.

If the sensor does not activate, check that the sensor is properly

connected at both ends. If the connections are correct and the sensor is properly mounted,

replace the sensor, PS6.

55.X Engine CMD error

• All 55.X messages indicate that the formatter and the control PCA

have failed in some aspect of their communication. When troubleshooting this message: – Reseat the formatter into its connector and perform a test print. – If the message persists, remove the formatter, and check that

none of the formatter connector pins are bent or broken. (This is not a probable cause if the control PCA or formatter have never been removed.)

– Check the 5V fuse on the control PCA. If the fuse is blown,

attempt to determine why the fuse blew, then correct the condition.

– If the message persists, replace the formatter, followed by the

control PCA if necessary.

Control panel messages

56 Laser index service

• The printer failed to register the beam detect pulse, or the beam

detect pulse is missing.

1 Power cycle the printer to clear this error. 2 Check the wiring harness behind the power supply drawer for nicks

and cuts.

3 Wrap with insulation tape to prevent the wires from grounding. 4 If the error persists, replace the laser scanner assembly, followed by

the control PCA if necessary.

5 Reseat all the connectors to the laser scanner assembly.

• The laser index pulse is absent.

– Open and then close the side door and power cycle the printer.

57 Fan motor service error

• There is a cooling fan error.

– One of the cooling fans is not connected. – One of the cooling fans is defective.

• Either the main body fan, formatter cooling fan, DC power supply

fan, or fuser cooling fan is not running or is running at an incorrect speed. – Power cycle the printer to clear this error. If the error persists:

Reseat all fan connectors on the relay board.

•

Ensure that the wiring harness is in good condition, and that the wires

•

are fully seated into the connector. Check that nothing inhibits the fan rotation.

•

Replace the defective fan assembly.

•

Note

The formatter cooling fan and DC power supply fan are only for the Color LaserJet.

52 Chapter 1 – Troubleshooting control panel messages

59 Manual feed service error

• The RFU was removed or installed while the power was on.

– Power cycle the printer to clear this error.

59 Alternate feed service

• The RFU was installed or removed while the printer was turned on.

– Power cycle the printer to clear this error.

CAUTION

Installing or removing the rear feed unit with the printer turned on ma y damage the electronics within the unit.

• If the message persists after power cycling, replace the RFU.

• Check the blade connectors on the RFU and inspect their matching

connectors on the printer. Check that the pins are straight and that none of the connectors are damaged. If the printer has been disassembled, ensure that none of the wires are damaged (pinched).

60.X SIMM error/SIMM service error

Note

The 60.X through 63.X Service errors occur only during the poweron sequence.

• The firmware detects a bad CRC (cyclical redundancy check) in a

SIMM. (The bad SIMM is indicated by the X.) The printer completes its power-on sequence without initializing (and therefore using) the defective SIMM, but uses all base RAM and usable SIMMs. The

60.X message appears in the display when the power-on sequence is complete. Full memory capability is not available.

• Multiple ROMs (such as two PostScript ROMs o r tw o Epso n ROMs)

have been installed. Troubleshoot this message as follows:

Power cycle the printer to clear this error.

If the error persists, reseat the indicated SIMM and try to print.

Replace the indicated SIMM.

Control panel messages

– If the SIMM is detected when the printer is turned on, the bad

SIMM can be ignored.

Replace the formatter.

61.X SIMM compatibility

• The size or speed of the SIMM that is installed is incompatible with

the formatter. If this SIMM is detected when the printer is turned on, the printer does not use the incompatible SIMM, but uses all base RAM as well as usable SIMMs. The 61.X message appears in the display when the power-on sequence is complete. Full memory capability is not available. Troubleshoot this message as follows:

Power cycle the printer to clear this error.

If the message persists, reseat the indicated SIMM and try to print.

Finally, if the message persists, replace the indicated SIMM with a

compatible SIMM.

62.x Internal ROM service

• A checksum error has occurred in the ROM. The X indicates which

ROM generated the error. If x=0, the error is in the code ROMs. If x=1, the error is in the lower 4M ROMs. If x=2, the error is in the upper 4M ROMs. Power cycle the printer to clear this error. If the error persists, replace the formatter. The individual ROMs are not replaceable.

Note

Indicate the failure Mode on the return slip when exchanging the formatter PCA.

62 Internal ROM service error

• This message indicates an error in the internal ROM.

– Power cycle the printer to clear this error.

• If the error persists, replace the formatter.

54 Chapter 1 – Troubleshooting control panel messages

63.0 DRAM service error

• This message indicates the printer detected an error in the base

DRAM. – Power cycle the printer to clear this error. – If the error persists, replace the formatter PCA.

• When this error message is displayed, pressing any control panel

key displays more information about this error

Note

Indicate the failure Mode on the return slip when exchanging the formatter PCA.

63.X SIMM error

• This message indicates a faulty SIMM expansion memory module.

• If the error occurs when the printer is turned on, press

• If this error occurs after the printer is turned on, unplug the printer

and remove the defective SIMMs as indicated by the control panel display.

[Continue]

Note

When a SIMM expansion card is removed, the printer can continue to operate, but may not be able to print all jobs that require greater memory. The printer still uses the base memory plus all the installed SIMMs.

64.X DMA timeout service error

• The printer has detected a video direct access error. Power cycle

the printer to clear this error. If the error persists:

Run the job that caused the error, then wait about 3 minutes for the

timeout to repeat. If the error message reappears, run a self-test, and wait another three

minutes. If the message persists, reseat, then replace the formatter PCA, followed by the control PCA, if necessary.

If no error appeared after running the job, run the error log to see the

occurrence rate.

Control panel messages

If the error occurs frequently:

– Reseat, then replace the formatter. – Check the 5V DC line for noise. – Check the 5V DC voltage at the control PCA. – Replace the control PCA, if necessary.

• The printer detected a video DMA error.

– Power cycle the printer to clear the error.

• If the error persists, run the extended diagnostic test to determine

the cause. See “Extended diagnostics” on page 110.

66.1 Jam sensor service error

Drum reflectance calibration procedure

• The printer must initially and periodically calibrate the electronics

against the value of print drum reflectance. The sensor on the jam detect PCA senses media wrapping on the drum and the value of print drum reflectance. The print drum reflectance changes over time. False jams may occur if the print drum reflectance is not recalibrated. This message occurs when the printer calibrates the print drum reflectance during new drum installation, or during the course of normal, periodic print drum recalibration. To troubleshoot this error:

1 Power cycle the printer and enter the Service Mode (See

Chapter 3).

2 Enter test code 47 and press [Enter]. The printer will begin the drum

calibration process.

3 If the message persists after p erforming the drum reflectance

calibration, the drum reflectance is out of specification. This may be caused by a faulty yellow developer. Ensure that a solid yellow strip is being deposited on the drum during the calibration process.To do so, interrupt the calibration process by opening the cover while the printer is turned on to inspect the yellow calibration strip on the drum.

4 Clean the drum-wrap sensor as described below. 5 Replace the print drum.

56 Chapter 1 – Troubleshooting control panel messages

• An abnormal drum-wrap value was detected while the sensor was

being calibrated. – Clear this error by reinstalling the drum, or power-cycling the

printer.

Cleaning the drum wrap sensor

• The drum-wrap sensor may be cleaned if necessary. Perform this

task only if the printer has become dirty from a neglect of periodic maintenance.

CAUTION

Be careful not to damage the print drum. To prevent scratching, place the print drum on the cleaning cloth provided in the collection kit. Also , do not blow on the print drum.

Remove the print drum from the printer and place it on the cleaning

cloth provided in the collection kit. Place a sheet of paper between the print dr um and the sensor.

Remove the screw located at the top of the print drum.

Remove the print drum neutralizing corona housing.

Release the sensor board from its retainers, being careful not to

damage the print drum. Ensure that connectors CN970 and CN971 are fully seated.

Use the toner cloth provided in the toner collection box kit to clean

the sensor.

Note

Run the reflectance calibration service Mode status and test (address

47) procedure after cleaning the drum-wrap sensor.

Control panel messages

68 NVRAM error

• A recoverable error has been detected in the formatter NVRAM.

– Press [Online] to clear the error, then verify the control panel

settings. One or more of the control panel settings may have been reset to the factory defaults during error recovery.

• Run the extended diagnostics test before replacing any

components. See “Extended diagnostics” on page 110.

• Replace the formatter if the error occurs whenever the printer is

turned on.

68 NVRAM service error

• A general formatter NVRAM failure has occurred.

– Power cycle the printer to clear the error.

• If the error persists, run the extended diagnostic tests to determine

the cause. See “Extended diagnostics” on page 110.

• This message refers to the formatter NVRAM, not the NVRAM chip

on the DC controller board.

68 Cold reset

• All of the control panel values have been reset to their factory

defaults. If this message appears whenever the printer is turned on, part of the formatter NVRAM is defective. – Check that the [Online] ke y is not stuck. If the [Online] key is okay ,

replace the formatter.

– Run the extended diagnostics tests before replacing any

components. See “Extended diagnostics” on page110.

– If the message persists, replace the formatter.

58 Chapter 1 – Troubleshooting control panel messages

79 Service error

• If this error is associated with a specific job, there could be a defect

in the software code that created the job. – Run a self-test to check that the error is not generated by the

printer. If the error is isolated to the user’s print job, ref er the user to the software manufacturer.

• An unrecoverable error occurred in the formatter PCA firmware.

– Run the e xten ded diagno stic tests to get more information about

this message. Then, power cycle the printer to clear this error.

• Replace the formatter if the error persists.

– Be sure to include the failure code which accompanied the

message on the control panel when returning the formatter.

Note

It is extremely rare that a formatter causes a 79 Service error.

80 Service

• This error indicates that an unrecoverable MIO error has occurred.

The XXX meaning is listed in the technical reference manual that came with the MIO card. – Power cycle the printer to clear this error. – If the error persists, replace the MIO card.

Note

Run the extended diagnostic tests before replacing any components. See “Extended diagnostics” on page 110. Be sure to put the entire error code (including the numbers in parenthe ses) on the retu rn slip when returning the MIO card. Also, be sure to include the failure code which accompanied the message on the control panel when returning the MIO card.

Control panel messages

89 Service

• An unrecoverable error occurred in the PostScript SIMM.

– Power cycle the printer to clear this error.

• Run the extended diagnostic tests before replacing any

components. See “Extended diagnostics” on page 110.

• If the message persists, replace the PostScript SIMM.

– Be sure to include the failure code which accompanied the

message on the control panel when returning the PostScript SIMM.

60 Chapter 1 – Troubleshooting control panel messages

Aids to troubleshooting

Troubleshooting by swapping parts

The printer records the age of most of the user-replaceable maintenance units. All new maintenance units (except the toner collection kit) have fusible links. When a new maintenance unit is installed, the printer senses its fusible link and blows the fuse. The control PCA resets the counter for the maintenance unit to zero. When the developers or print drum are replaced, the control PCA restarts the page-dependent firmware algorithms which control the printer operating point. Also, when the print drum is replaced, the drum-winding sensor is calibrated.

The fusible links and the associated firmware algorithms affect service and troubleshooting strategy as follows:

• The maintenance units cannot be removed and used as a new unit

in another printer.

• If a new maintenance unit is installed, the control PCA resets its

counters and determines the optimum operating point for the installed unit. If another unit with no fusible link (such as a print drum or developer from another printer) is installed, the operating point will not be correct. The correct operating point is especially critical for the print drum and developers.

Swapping parts

The following procedures use maintenance units known to be in good working condition to help troubleshoot maintenance units problems. Ensure that the original (or a new) maintenance unit is installed after performing each procedure. Donot leave a test unit installed.

Aids to troubleshooting

Print drum

A test print drum, which has the fusible link already blown, can be installed to verify failures such as repetitive print defects. Do not print more than 50 pages with the test drum. The test print drum may cause

13.1 CLEAR DRUM WINDING JAM errors. If this occurs, use the Service Mode status and test address 47 to calibrate the drum-winding sensor. It is necessary to recalibrate this sensor when installing the original drum. If the print defect is confirmed and a new print drum is installed, the drum-winding calibration process is automaticall y perf ormed as part of the installation algorithm. Do not leave the test print drum installed after troubleshooting.

Developer

A test developer in which the fu sible link h as already blo wn can be used to troubleshoot print problems such as white lines. Do not print more than 50 pages with the test developer. If the print defect is shown to be unrelated to the developer, be sure to reinstall the original developer. If the defect is related to the original developer, use the installation procedures shown in Chapter 4 of the service manual to install the new developer. Do not leave the test developer installed after troubleshooting.

Transfer belt, fuser, and coating kit

Test units in which the fusible link has already blown can be installed briefly to verify print defects. Do not print more than 200 pages with these units. If a print defect is not verified, reinstall the original unit. If a defect is verified, replace the defective unit as described in Chapter 4 of the service manual. Do not leave the test components installed after troubleshooting.

62 Chapter 1 – Troubleshooting control panel messages

Voltage checks

The illustration below shows the most readily accessible voltage test points of the printer.

18 10

26 19

+5V

Pin #22 Pin #8 Pin #20

PGND

+24V

Voltage test points

CAUTION

Be careful not to damage the printer when inserting test probes in the connector.

Note

The actual voltage measured for 24V will be approximately 22V.

Aids to troubleshooting

Understanding the self-test printout

PCL self-test page (Color LaserJet)

(See the table on page 67 for a description of the numbered elements.)

64 Chapter 1 – Troubleshooting control panel messages

PostScript self-test page (Color LaserJet 5/5M)

(See the table on page 67 for a description of the numbered elements.)

Understanding the self-test printout

7 8

PCL self-test page (Color LaserJet 5/5M)

(See the table on page 67 for a description of the numbered elements.)

66 Chapter 1 – Troubleshooting control panel messages

Self-test page elements

Printing menu:

Config menu:

Parallel menu:

the same as the MIO configuration. The advanced functions feature enables the bidirectional I/O.

Consumable life:

the printer maintenance units. use this section when performing printer maintenance, and when deciding how to troubleshoot specific printer failures. The consumable counters show how many of each maintenance units have been installed in the printer throughout its life.

MIO configuration:

Installed memory and page count:

the printer, and the page count. Black pages and color pages are listed separately. Add the numbers to get the total page count.

Serial number and firmware datecode:

when replacing the formatter PCA. If possible, run the self-test page before replacing the formatter. The firmware datecode is used by HP to identify the printer’s program level.

Options:

components.

Print test pattern:

drum for random defects.

REt setting:

current REt setting. Use the lines to adjust the REt setting such that the horizontal and vertical lines match. Inaccurate REt settings cause horizontal and vertical bands in the lines.

Color bars:

are enabled.

Internal humidity:

the internal humidly sensor.

Shows the configuration of the print menu.

Lists the current printer configuration.

Lists the configuration for the parallel I/O port. This is not

Lists the percent of the maximum life used b y each of

Shows the configuration of the MIO.

Displays the memory recognized by

The serial number is used

Shows the installed and recognized optional printer

(displayed on PCL self-test page only) Tests the print

(displayed on Color LaserJet self-test page only) Shows the

Demonstrates that each of the primary and process colors

Shows the humidity inside of the printer as read by

Understanding the self-test printout

Troubleshooting paper feed problems

Paper problems

Paper problems can be difficult to detect. The following series of steps will help isolate paper-induced problems versus printer problems:

• Isolate a paper path.

• Isolate a brand of paper.

• Isolate a type of paper.

• Evaluate paper-use practices.

• Evaluate environmental conditions.

Here are some simple tips:

• Turn the paper over and print on the other side. Doing so often

corrects excess paper curl.

• Rotate the paper 180° (end-to-end) to f e ed a different leading edge.

This can help correct multi-sheet feeding problems.

Paper jams

When troubleshooting paper jams, r emember that jams are posted as a result of timing errors. That is, paper fails to arrive at (or fails to clear) the paper path sensor in the allotted time. The paper path timing is set by the control PCA. Stuck or defective sensors will cause the paper path timing to post a jam message when the printer is turned on, as will scraps of paper caught in the paper path. See the figure on page 69 to locate the paper path sensors. The paper jam message code identifies the sensor which failed to change state within the required time.

Note

Check that the paper path sensors are free throughout their full r ange of travel. All interlock switches must be operational in order for the printer to clear paper jam messages.

68 Chapter 1 – Troubleshooting control panel messages

Paper path sensors

1 Manual feed sensor (RFU) 5 PS8 paper out sensor (main tray) 2 Paper-out sensor (RFU autofeed) 6 Drum wrap sensor board 3 RFU paper in path sensor 7 PS1 paper exit sensor 4 PS7 paper registration sensor

• Check that the transfer corona cleaner is pushed all the way to the

right. Paper jams occur when this knob is out of place.

• Clean the printer. Toner and paper dust in the paper path inhibit free

movement of media through the printer and block the sensors.

• Vary the input and output selections of the printer to de termine if the

problem is associated with a particular area of the printer.

• Worn separation pads on the paper tray cause last page multifeeds.

Check the condition of the pickup rollers and separation pads when troubleshooting multifeeds. Bent separation tabs cause misfeeds and multifeeds. Replace the tray if necessary.

Troubleshooting paper feed problems

• Defective paper tray switches may cause paper jams by indicating

the wrong size paper to the formatter.

• Scraps of paper left in the paper path may cause intermittent pa per

jams. Always check that the paper path is clear when cleaning the printer and when clearing paper jams. Also, remove the fuser and carefully check it for jammed paper.

• If the optional RFU is installed, check that the paper is loaded

correctly. Check that the correct paper size is selected and that the paper is not slumped.

• Curl on the trailing edge of transparencies is caused by improper

face-up output bin position. Make sure the face-up output bin is pulled out all the way. It tilts up slightly when in its proper position.

Reduce curl of black-only transparencies by printing to the face-up output bin and by keeping the transparencies in a presentation sleeve.

CAUTION

Duplexing (printing on both sides of the page) is not supported and could damage the printer. Duplexing causes paper jams at the

input and exit areas.

70 Chapter 1 – Troubleshooting control panel messages

Multifeeds from the front input tray

• Check that the media meets the specifications f or this printer . Rou gh

paper and lightweight media multi-feed more frequently.

• Ensure that the media is not sticking together in the paper stack.

• Check the condition of the media. Look for damaged paper or

ragged edges.

• Check the paper stack tabs in the paper tray (see Figure 7-17 on

page 7-68 in the service manual). Replace the paper tray if the tabs are bent or burred.

• Check the paper-size adjustment lever to ensure it is snug against

the media without pinching.

• Check that the media is fully under the paper stack tabs. Do not

overload the paper tray. The paper tray can hold approximately 250 sheets of 20-pound paper (a 1-inch stack).

Troubleshooting paper feed problems

Feed problems from the rear feed unit (RFU)

• Check that the media meets the specifications for this printer.

• Check that the RFU is not overloaded. The RFU can hold 250

sheets of 20-pound paper (a 1-inch stack).

• Check the paper-size adjustment for the rear input tray and the

manual feed input. – The guides should be snug against the media without pinching.

– The paper adjustment knob for the rear input tray should be set

for the correct media before the media is loaded. If necessary, fine adjustments can be made after the media is in the tray.

• Check that media is not slumped forward in the rear input tray. The

top cover or the rear tray must be fully opened when loading media.

• Check that the media is neatly stacked in the rear input tray.

• When manually feeding, push the media slightly into the pickup

roller nip, especially when using legal and tabloid size paper.

• The pickup rollers should be cleaned with a cloth moistened with

isopropyl alcohol.

72 Chapter 1 – Troubleshooting control panel messages

Cleaning and

Overview

This chapter gives information on cleaning and maintaining the printer, and on identifying consumables.

maintenance

Overview

Cleaning locations and tool

The following illustration shows the areas of the printer that require periodic cleaning and the location of the provided laser optics cleaning tool.

Areas that require periodic cleaning

1 Toner hopper area 4 Laser optics cleaning tool 2 Laser optics glass 5 Transfer corona wire 3 Drum corona wire *

* New style drum (C3967A) only.

74 Chapter 2 – Cleaning and maintenance

Regular maintenance procedures

Overall print quality largely depends on keeping critical components of the printer clean. Some of the more sensitive printer components need to be cleaned regularly (approximately every 2,000 pages) to ensure the highest possible print quality. Use the procedure that follows to clean these three components:

• optics glass

• drum corona

• transfer corona

CAUTION

Remove all jewelry and watches before continuing. The drum can be easily scratched, causing damage. Do not expose the print drum to direct light for extended periods. Exposure to light can permanently damage the drum.

Press the top cover release button (1) and open the top cover (2).

Regular maintenance procedures

2 Pull the drum lock lever at the left edge of the drum toward you.

Lower the drum until it is horizontal.

CAUTION

Be careful not to contaminate the cleaning tool pad with the oil from your hands or other contaminants.

3 Locate the laser optics cleaning tool.

4 Insert the cleaning tool above the drum with the padded portion

down and towards the glass, and with the cupped portion against the chrome rod (1). Press the pad on the cleaning tool firmly against

76 Chapter 2 – Cleaning and maintenance

the right end of the optics glass. Slide the cleaning tool to the left side of the printer, and then slide it back to the right. Repeat several times, then return the cleaning tool to its storage place.

Find the drum cleaning handle located toward the back-right corner

of the main drum.

Slide the cleaning handle slowly and smoothly to the left end of the

drum and completely back to the right home position. (This

Regular maintenance procedures

procedure should take approximately 3-5 seconds.) Repeat as necessary.

7 Raise the drum until it locks into place.

Note

The drum corona cleaning handle is only on the new style drum (C3967A).

CAUTION

Before closing the printer, be sure that the drum corona cleaning handle and transfer corona cleaning knob are reseated in the full-right position.

8 Locate the transfer corona cleaning knob located between the

transfer belt and the fuser on the right side of the printer.

CAUTION

Do not touch the transfer be lt surface. Oil fr om your hands and debris can reduce the life span of the belt and affect print quality.

9 Slide the cleaning knob slowly and smoothly to the left end of the

drum and completely back to the right home position. (This procedure should take approximately 3-5 seconds.) Repeat as necessary.

78 Chapter 2 – Cleaning and maintenance

When you add toner, clean the toner reservoir area. Add toner only

when prompted by a control panel message.

• Push the optional rear feed unit away from the printer. Then open the toner reservoir cover and use the cover to hold the rear feed unit away from the printer.

• With the cleaning cloth from the toner collection kit, wipe off any dust or toner on the area between the individual toner doors.

CAUTION

Do not drop excess toner into the manual feed area. Toner in the manual feed area can result in manual feed problems.

• Close the toner reservoir cover.

• Return the optional rear feed unit to its upright position against the back of the printer.

Regular maintenance procedures

Replacement of maintenance units

The printer prompts you from the control panel when it is time to replace a maintenance unit. The following table lists the approximate time intervals for replacing maintenance units. For proper printer operation, use only HP maintenance units. (See Chapter 8 in the service manual.)

Approximate replacement intervals

Unit Printer message Page count** Time period*

Toner TONER OUT [CMYK] ADD [color] 2200 pages 1 to 2 months Toner collection

box filter Coating pad,

cleaning roller Coating roller,

cleaning roller Black

developer Color developer 19.2 COLOR DEVEL. USER

Transfer belt 19.5 TRANS BELT USER

Fuser 19.4 FUSER USER

Print drum 19.3 DRUM USER

* This time period assumes you are printing 2,000 pages per month. If your print quantities

differ, adjust the time period accordingly. ** Approximate page count based on 5% coverage of individual toner colors *** HP Color LaserJet printer **** HP Color LaserJet 5/5M printer ***** The page count for the drum increments once for every standard black and white or

monochrome page and twice for each multiple color page, legal, tabloid, or A3-size page.

14.5 REPLACE COLLECTION KIT Varies with toner

14.6 REPLACE (CLJ)*** COATING PAD KIT

14.6 Replace Coating Kit (CLJ5/5M)****

19.1 BLACK DEVEL. USER MAINTENANCE

MAINTENANCE

usage. Varies with toner

usage. Varies with

transparency usage 40,000 pages 15 months

40,000 pages 15 months

60,000 pages 30 months

80,000 pages 40 months

60,000 pages***** 30 months

4 to 6 months

80 Chapter 2 – Cleaning and maintenance

Identifying consumables

The following illustration shows the location of the consumables.

Consumable locations (CLJ 5/5M)

Color developer

Print drum

Toner collection

box *

* The toner collection box and ozone filter are included in the collection kit. ** The cleaning roller and coating roller are included in the coating kit.

Coating roller**

Ozone filter**

Cleaning roller

Fuser

Transfer belt

Black developer

Identifying consumables

Note

Do not install an old-style coating pad kit into a new style fuser. See the “Supplies compatibility” table on page 83.

Note

All original maintenance items for the HP Color LaserJet printer have blue handles and tabs that indicate user access or lift points. With the exception of the toner area, the maintenance items in the HPColor LaserJet 5/5M printer should have purple handles and tabs.

82 Chapter 2 – Cleaning and maintenance

Supplies compatibility

The following supplies for the HPColor LaserJet 5/5M printers are fully backward-compatible with the HP Color LaserJet printer. However, the original set of HP Color LaserJet printer supplies should not be used in HP Color LaserJet 5/5M printers.

HP Color LaserJet and HP Color LaserJet 5/5M

Product number

Toner Supplies

C3105A Black toner bottle full compatibility • • C3102A Cyan toner bottle full compatibility • • C3103A Yellow toner bottle full compatibility • • C3104A Magenta toner bottle full compatibility • • C3120A Toner collection kit full compatibility • • C3106A Coating pad kit compatible with C3911A

C3964A Coating kit* compatible with C3969A

Imaging Units

C3107A Black developer HP Color LaserJet

C3965A Black developer* full compatibility • • C3108A Color developer HP Color LaserJet

C3966A Color developer* full compatibility • • C3109A Print drum HP Color LaserJet

C3967A Print drum full compatibility • • C3110A Transfer assembly HP Color LaserJet

C3968A Transfer assembly* full compatibility • • C31111

Opt. 110 or 220A

C3969A

Opt 110 or 220

* Products in

Product name Comment Compatible with

fuser unit only

compatibility ONLY

printers.

Fuser 110 = 110V Opt. 220 = 220V)

Fuser*

(Opt 110 = 110V Opt 220 = 220V)

bold-faced type

HP Color LaserJet compatibility ONLY

full compatibility • •

are new supplies introduced with the HP Color LaserJet 5/5M

HP Color LaserJet

HP Color

LaserJet 5/5M

•

••

•

Supplies compatibility

84 Chapter 2 – Cleaning and maintenance

Service Mode and

Overview

Service Mode allows service personnel to verify and manipulate internal printer settings and diagnostics. Service Mode should be used only by authorized service personnel.

diagnostics

Overview

Service Mode menu

Service Mode is used to test printer functions by issuing commands to the control board through the control panel. The menu items are:

• Register adjust allows the service engineer to change the factory-

set NVRAM values that control the placement of the image on the page. In this mode, detailed developer counter information is also available for troubleshooting toner concentration problems. Enter this mode as shown in the “Keystroke sequence to enter Service Mode” on page 87 and “Keystroke sequence to enter Register Adjust Mode” on page 90. See the “Register adjust addresses” table on page 91.

input

• Status requests indicates the state of an

Generally, this test applies to sensor requests and switches. These commands have a control panel indication (or digital value, either high or low) of the state of the selected input. Inputs that can be checked with the Service Mode are listed in the “Status and test address” table on page 94.

• Operation commands control the output of the control board to the

selected component. (Motors and developers are examples of selectable components.) The command addresses are listed in the “Status and test address” on page 94. Issuing an output command starts the function shown in the output list.

Note

Some outputs will stop automatically after a preset time.

• Subtests of the operation command are used for components with

multiple assemblies, functions, or modes. These subtests are identified by a subtest number. Subtest numbers allow the operator to select a particular item when several selections are possible. The subtest numbers are listed in the table on page 97.

to the control board.

86 Chapter 3 – Service Mode and diagnostics

Accessing Service Mode

Turn off the printer.

Press and hold

while turning the printer on. Continue holding the keys until all the control panel lights are illuminated and the control panel display is blank.

Press

The display will flash self-test and boot cycle.

[Item]

[Online], [Form Feed]

, and then press

SERVICE MODE

, and

[Enter]

. Allow the printer to complete its

(simultaneously)

[Item]

get

Keystroke sequence to enter Service Mode

Service Mode menu

Service Mode flow chart

88 Chapter 3 – Service Mode and diagnostics

Register Adjust Mode

The Register Adjust Mode allows the service engineer access to the NVRAM address. Changing the value of this address allows the paper registration to be adjusted. This mode also provides detailed developer counter information that is needed for troubleshooting toner concentration.

Note

This mode does not affect the operation of solenoids or sensors. Use the Status and T est Mode on page 92 to monitor and test the solenoids and sensors.

Accessing the Register Adjust Mode

Enter Service Mode as described in the previous section.

Repeatedly press

Press

Use

digits until the desired address is displayed. Press

Use

desired value. Press

If the address is invalid or appears as read-only, press

select a new address. Power cycle the printer to continue normal operation.

to display

[Item]

to activate the Register Adjust Mode.

[Enter]

[Online], [Form Feed]

to obtain the address value.

[Enter]

[Form Feed]

to save the new value.

[Enter]

to display

[Menu]

, and

and

[Reset]

ENGINE SERVICE

to increment the address

[Reset]

to change the address value to the

[Enter]

Keystroke sequence to enter Register Adjust Mode

90 Chapter 3 – Service Mode and diagnostics

Register Adjust Mode addresses

This table lists the accessible addresses in the control NVRAM.

Address Initial

* These are read-only values. ** This register can be reset to 00 to clear 50.X Fuser errors without waiting for the fuser error

*** Default values

value

28 00* Black developing unit counter (10s & 1s digit). Range = 00-99 29 00* Black developing unit counter (1000s & 100s digit). Range= 00-99 30 00* Black developing unit counter (100,000s & 10,000s digit. Range=00-99 31 00* Yellow developing unit counter (10s & 1s digit). Range = 00-99 32 00* Yellow developing unit counter (1000s & 100s digit). Range= 00-99 33 00* Yellow developing unit counter (100000s & 10000s digit). Range = 00-99 34 00* Magenta developing unit counter (10s & 1s digit). Range = 00-99 35 00* Magenta developing unit counter (1000s & 100s digit). Range = 00-99 36 00* Magenta developing unit counter (100000s & 10000s digit).

37 00* Cyan developing unit counter (10s & 1s digit). Range = 00-99 38 00* Cyan developing unit counter (1000s & 100s digit). Range = 00-99 39 00* Cyan developing unit counter (100000s & 10000s digit). Range = 00-99 47 00** Fuser error code (00 - 01) 74 48*** Leading edge margin adjustment for RFU auto-feed. Range = 35-65 75 43*** Side margin (start of scan) adjustment for RFU auto-feed.

76 48*** Leading edge margin adjustment for manual feed. Range = 35-65 77 43*** Side margin (start of scan) adjustment for manual feed.Range = 01-99 78 48*** Leading edge margin adjustment for main tray. Range = 35-65 79 43*** Side margin (start of scan) adjustment for main tray. Range = 01-99

timeout.

Range = 00-99

Range = 01-99

Function

Status and Test Mode

Selecting the status and test addresses

The Status and Test Mode allows the service engineer access to individual printer components. Access the Status and Test Mode from the Service Mode menu. Enter Service Mode as shown on page 87 and then complete the following steps:

1 Repeatedly press [Menu] to display

selection is

2 Press [Item] to select the Status and Test Mode. 3 Press [Enter] to activate the Status and Test Mode. 4 Use [Online] and [Form Feed] to increment the address digits until

the desired address is displayed.

ENGINE SERVICE

. The first

92 Chapter 3 – Service Mode and diagnostics

Press

If necessary, input the subtest number by pressing

desired subtest number is displayed. When

The number on the right is the status value for the address that was entered in step 5. This value is updated once every second.

Press

for the address entered in step 5. Press

to activate the displayed address.

[Enter]

ONLINE TO START

to cancel the Status Mode.

[Reset]

to activate the Test Mode. The printer starts the test

[Online]

to cancel the Test Mode.

[Reset]

is displayed, the printer is in Status Mode.

[Online]

until the

Status and test addresses

The addresses listed in the “Status and test address” table on page 94 select the function shown in the status column or enable the test listed in the test column. Status shows the state of the switch, sensor , or other component that the control board responds to. Subtest numbers also apply to some of the tests (such as developer tests). Subtest numbers select a particular subtest (such as black developer) when more than one function is possible. Subtest numbers are listed separately on page

97.

Note

Status and test codes are not coded together and therefore may not match. Many status outputs and test functions share an address. For instance, when address 20 is entered, the display shows the status of the registration sensor. Pressing solenoid.

activates the paper-feed

[Online]

Status and Test Mode

Status and test address

Address Status Test

01 Toner leve l detection. Shows logic of the

08 Toner concentration sensor signal for the

10 Paper empty (main tray). Indicates the state

13 Rear input empty sensor (RFU).

14 Paper empty sensor (RFU manual feed).

15 Paper size signal (tray). Indicates the

16 Paper size signal (RFU). Indicates the state

19* Unlocks all toner hoppers

20* Registration sensor signal. (PS7) Indicates

21 Rear feed unit paper-in-path sensor. Detects

22 Paper exit sensor signal, indicates the logic

25* Turns on the registration solenoid

* This address has an automatic shut-off to protect the component from extended use.

toner level detect sensor for the selected color. 1=toner present, 0=toner empty

selected color. The initial value is 63. Starting the test displays the current concentration offset value.

of the paper-out sensor (PS8). 1=paper present, 0=paper empty

1=paper empty, 0=paper present

1=paper not present, 0=paper present

detected tray size: lgl=0, ledger (tabloid)=1, Ltr=2, Exec=4, A3=5, A4=6, No tray=7

of the RFU paper size sensor: 1=A4, 2=exec, 3=ltr.

the state of the registration sensor. 1=paper detected, 0=paper not detected

media in the RFU.

states of the paper exit sensor. (PS1) 1=paper not detected, 0=paper detected

Rotates the developing unit for the selected color. You should hear the developer rotate when this test is run.

Turns on the paper tray solenoid (SL1)

(SL2)

94 Chapter 3 – Service Mode and diagnostics

HP laserjet 5, laserjet 5m schematic

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Overview

Pretroubleshooting checklist

Basic troubleshooting process

Control panel messages

Alphabetical messages

Numerical messages

Aids to troubleshooting

Troubleshooting by swapping parts

Voltage checks

Understanding the self-test printout

Self-test page elements

Troubleshooting paper feed problems

Paper problems

Paper jams

Multifeeds from the front input tray

Feed problems from the rear feed unit (RFU)

Overview

Cleaning locations and tool

Regular maintenance procedures

Replacement of maintenance units

Identifying consumables

Supplies compatibility

Overview

Service Mode menu

Accessing Service Mode

Register Adjust Mode

Accessing the Register Adjust Mode

Register Adjust Mode addresses

Status and Test Mode

Status and test addresses