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First edition, May 1998
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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
30KC3100-90916/
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.
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.
Provides preventive and troubleshooting techniques for paper and
paper path jams
Note
If you need more detailed information, see the printer service manual.
EN
Overview
1
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
EN
• 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.
1
EN
Pretroubleshooting checklist
3
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
EN
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
1
EN
Control panel messages
5
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
EN
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
1
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.
EN
Control panel messages
7
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
EN
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.
1
Check that the paper-size switch actuators on the tray are not damaged.
2
Check that PS8 is free throughout its entire range of travel and is properly
3
located in its mount.
Check that connector CN802 (on the controller) is fully seated.
4
If the error persists, perform the PS8 Service Mode Test as described
5
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
1
select the Status Test Mode.
Enter the PS8 test address (10) and press
2
With no tray installed, the display will read
3
Open the printer, lift the paper guide, and move the sensor shaft through
4
its range of motion.
The display should change from low to high (
5
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.
6
.
[Enter]
for paper tray empty.
0
to 1) as the photosensor is
0
1
EN
Control panel messages
9
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
EN
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
1
close the side door.
Open the side door and push the interlock mechanism with a flat-
2
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
3
switch linkage is not bent.
Check that the switch connectors are in good repair. Toggle the
4
switches by pressing down on the metal tab over the switches.
If the linkage is not damaged, remove the switch assembly and test
5
it with an ohmmeter.
Replace the assembly if it is defective.
6
1
EN
Control panel messages
11
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
EN
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.
1
EN
Control panel messages
13
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
EN
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.
1
Open the top cover and lower the print drum.
2
Pull the toner collection box out of the drum assembly.
3
Verify that the toner-full flag is moving freely (it should raise up as
4
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
5
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.
1
EN
Control panel messages
15
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
EN
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.
1
If the message persists, remove the suspected developer and
2
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.
3
1
EN
Control panel messages
17
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
EN
Replace the fuser.
6
Replace the control PCA if necessary.
7
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.
1
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
2
connection.
Check that CN101 on the control PCA and CN 254 on top of the
3
developer bias supply are fully seated.
Reseat the collection box and listen for an audible click.
4
If the collection box does not click into place, the leaf spring inside
5
the housing may be defective. Replace the print drum.
Remove the drum and very carefully clean the inside of the sensor,
6
using a cotton swab and isopropyl alcohol.
Re-install the drum.
7
1
EN
Control panel messages
19
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
EN
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.
1
EN
Control panel messages
21
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
EN
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.
1
Check that each of the high voltage contacts on the developer bias
2
assembly is clean and located correctly.
Print several self-tests and look for repetitive defects. Replace the
3
print drum if repetitive defects appear.
Remove the print drum and check its surface for any bright metallic
4
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
5
control PCA.
Try a test print.
6
1
EN
Control panel messages
23
• 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
EN
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