HP LaserJet family Service Manual

May 1998 Edition

HP LaserJet Family Quick Reference Service Guide

Volume I

HP LaserJet Family Quick Reference Service Guide

Volume I

Publication number 5021-8943

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.

Contents

1 Control panel messages . . . . . . . . . . . . . . . . . . . . . . . 7

2 Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4 Input/Output (I/O) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

5 Media specifications . . . . . . . . . . . . . . . . . . . . . . . . 107

6 Toner cartridge information . . . . . . . . . . . . . . . . . . 121

7 Printer options and user replaceable parts. . . . . . 131

8 Service parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

9 Summary of service notes and technical tips. . . . 197

10 Image defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

11 Wiring diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

12 Services, support, and training . . . . . . . . . . . . . . . 335

13 Hewlett-Packard LaserJet Companion. . . . . . . . . . 343

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

iii

Ordering Other Manuals

This

HP LaserJet Family Quick Reference Service Guide

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

Service manuals for HP LaserJet products are available from the HP Support Materials Organization (SMO). The Service Parts Order Desk number is:

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

If you are located outside of the U.S., contact your local HP Sales and Service office.

was created

Supported Products

This service guide supports the following printers:

Printer Name Printer Abbreviation

HP LaserJet Companion

(minimal support only) HP LaserJet 6L HP LaserJet 5Si Mopier HP LaserJet 5Si/5Si MX HPLaserJet 5L HP LaserJet 6P/6MP HP LaserJet 5P/5MP HP LaserJet 5/5M/5N HP LaserJet 4V/4MV HP LaserJet 4P/4MP HP LaserJet 4L/4ML HP LaserJet 4+/4M+ HP LaserJet 4/4M HP LaserJet 4Si/4Si MX HP LaserJet IIISi HP LaserJet IIIP HP LaserJet IIP+ HP LaserJet IIP HP LaserJet IIID HP LaserJet III HP LaserJet IID HP LaserJet II HP Classic LaserJet (2686D) HP Classic LaserJet (2686A)

LJ Companion

LJ 6L LJ 5Si Mopier LJ 5Si LJ 5Si MX LJ 5L LJ 6P LJ 6MP LJ 5P LJ 5MP LJ 5 LJ 5M LJ 5N LJ 4V LJ 4MV LJ 4P LJ 4MP LJ 4L LJ 4ML LJ 4+ LJ 4M+ LJ 4 LJ 4M LJ 4Si LJ 4Si MX LJ IIISi LJ IIIP LJ IIP+ LJ IIP LJ IIID LJ III LJ IID LJ II LJ 2686D LJ 2686A

Note

The abbreviation for each printer name is used in the text.

Reference Name Used in this Guide

Model Number Maximum

Pages per Month

Service Manual Part Number

LJ 6L C3990A 6K C3990-99001 5Si Mopier,

LJ5Si MX/5Si*

C3166A/C3167A C4076A/C4077A

100K C4077-99015

LJ 5L C3941A 4K C3990-99001 LJ 6P/6MP*

5P/5MP* LJ 5/5M*/5N C3916A/C3917A/

C3150A/C3155A/ C3980A/C3982A

12K C3980-99001

35K C3916-90984

C3952A LJ 4V/4MV C3141A/C3142A 50K C3141-90929 LJ 4P/4MP* C2005A/C2040A 8K C3980-90956 LJ 4L/4ML* C2003A/C2015A 8K C3980-90956 LJ 4+/4M+* C2037A/C2039A 20K C3916-90984 LJ 4/4M* C2001A/C2021A 20K C3916-90984 LJ 4Si/4SiMX* C2010A/C2011A 75K C2010-90939 LJ IIISi 33491 50K C2010-90939 LJ IIIP 33481 8K 33481-90951 LJ IIP+ C2007A 8K 33481-90951 LJ IIP 33471 6K 33481-90951 LJ IIID 33459 20K 33459-90906 LJ III 33449 16K 33449-90906 LJ IID 33447 16K 33459-90906 LJ II 33440 12K 33449-90906 Classic LJ

2686D 15K 02686-90920 2686D

Classic LJ

2686A - 2686A+ 12K 02686-90920 2686A

*Macintosh

-compatible

Control panel

messages

Overview

This chapter provides information on the display lights on the HP LaserJet 6L, 5L, 6P, 5P, and 4L printers and includes illustrations and detailed error codes for all printers. Error codes are listed as they appear on the printer display. Not all codes are included as many are self-explanatory.

Note

Displays shaded in color represent primary lights. Displays that are not shaded represent secondary lights. T o vie w the secondary lights on the printer, press

[Go]

and

[Reset/Job]Cancel]

simultaneously.

Overview –

LJ 6L, 5L Printer Light-Emitting Diode (LED) Displays

See the legend that follows for a description of the error and the action to remedy it.

STATUS MESSAGES

Error LED is on.

(*Unclearable error)

Error LED is

blinking.

. All LEDs are

blinking.

. Data LED is

blinking.

Error Data Ready

. All LEDs are off.

When all the lights are on, there is a Service error. Press and hold the front panel button to display the LED error code pattern. The code will be shown only while the button is pressed. The following pictures show the possible LED error patterns.

. Error LED is on.

(*Unclearable error)

. Data LED is on.6. All LEDs are on.7. Data and Ready

. Ready LED is on.3. Error and Ready

LEDs are on.

LEDs are blinking.

. Error and Data

LEDs are on.

. Formatter error.

* An unclearable error is not strictly a service message. It will appear without all three lights being displayed first. See item 1 in the following table.

8 – Control panel messages

Legend (6L, 5L Display Lights)

Status Messages

Item Description Recommended Action

1 Paper out

Door open No Electro-photographic (EP)

cartridge

Paper jam 2 Memory error See page 34 3 Incompatible memory card See page 49 4 Manual feed See page 70 5 Sleep mode See page 69

Error and Service Messages

Item Description Recommended Action

1 Unclearable error

Engine error 2 ROM/RAM error See page 50 3 Fuser error See page 44 4 Beam error See page 45 5 Scanner error See page 47 6 Formatter PCA error See page 57 7 Firmware error See page 61 8 Formatter PCA error See page 57

See page 21 See page 18

See page 32 See page 26

See item 1, above See page 39

Note

Before troubleshooting any service error, power cycle the printer to see if the error persists.

LJ 6L, 5L Printer Light-Emitting Diode (LED) Displays –

LJ 6P Printer LED Displays

See the legend that follows for a description of the error and the action to remedy it. If both the error and data lights are lit, simultaneously press [Go] and [Reset/Job[Cancel] to display the Data Error pattern.

LJ 6P Printer LED Displays

STATUS

CONTINUABLE ERRORS

SIMM ERRORS

Tray 1 LED Blinking

Error

Data Ready Tray 1

Tray 2

FATAL ERRORS

Primary Secondary

* To view secondary lights press the buttons simultaneously.

[Go]

and

= Any other combination

[Reset/Job[Cancel]

10 – Control panel messages

Legend (6P Display Lights)

Status Messages

Item Description Recommended Action

1 Paper out (Tray 1) See page 21 2 Paper out (Tray 2) See page 21 3 Printer open

No toner cartridge Paper jam

4 Manual feed See page 70

Continuable Errors

When the ERROR and DATA LEDs are on, press simultaneously. Follow the instructions for the secondary light patterns shown.

Item Description Recommended Action

5 Primary light pattern See note on primary and

5-1 Error 20 (memory overflow) See page 34 5-2 Error 21 (print overrun) See page 35 5-3 Error 22 (I/O error) See page 36 5-4 Error 40 See page 38 5-5 Error 41.1, 41.2, 41.3 See page 40 5-6 Error 68, 68.1 See page 64 5-7 Error 51 (beam detect) See page 45 5-8 Error 52 (scanner malfunction) See page 47 5-9 Error 55 See page 53

See page 18 See page 32 See page 20

and

[Go]

secondary lights, page 13

[Reset]

LJ 6P Printer LED Displays –

SIMM Errors

Remove all SIMMs and power cycle the printer. Retry the operation. Replace the SIMMs one at a time to locate the defective module. Refer to the Service Manual for details.

Item Description Recommended Action

6 Error 53-0 ROM error See note below 7 Error 53-1 RAM error See note below

Fatal Errors

When the DATA, TRAY 2, TRAY 1, and ERR OR LEDs are on, press [Go] and [Reset] simultaneously and follo w the instructions for the secondary light patterns shown.

Item Description Recommended Action

8 Primary light pattern See note on primary and

secondary lights, page 13 8-1 Error 50 fuser See page 44 8-2 Error 57/58 (main motor) See page 54 8-3 Error 61.x (x=1, 2, 3 SIMM) See page 58 8-4 Error 62.x (x=1, 2, 3 SIMM) See page 59 8-5 Error 62.0 See page 58 8-6 Error 63, 64, 64, 65 See pages 59–60 8-7 All other errors See pages 61–72

12 – Control panel messages

LJ 5P Printer LED Displays

See the legend that follows for a description of the error and the action to remedy it. If both the error and data lights are lit, simultaneously press

and

[Go]

STATUS

CONTINUABLE ERRORS

SIMM ERRORS

FATAL ERRORS

to display the Data Error pattern.

[Reset]

LJ 5P Printer LED Displays

Error Tray 1 (MP Tray) Tray 2 (Paper Cassette)

Data Ready

Any Combination

Primary Secondary

* To view secondary lights press [Go] and

[Reset.

LJ 5P Printer LED Displays –

Legend (5P Display Lights)

Status Messages

Item Description Recommended Action

1 Paper out (Tray 1) See page 21 2 Paper out (Tray 2) See page 21 3 Printer open

No toner cartridge Paper jam

Continuable Errors

When the ERROR and DATA LEDs are on, press [Go] and [Reset] simultaneously. Follow the instructions for the secondary light patterns shown.

Item Description Recommended Action

4 Primary light pattern See note on primary and

4-1 Error 20 (memory overflow) See page 34 4-2 Error 21 (print overrun) See page 35 4-3 Error 22 (I/O error) See page 36 4-4 Error 40 See page 38 4-5 Error 41.1, 41.2, 41.3 See page 40 4-6 Error 68, 68.1 See page 64 4-7 Error 51 (beam detect) See page 45 4-8 Error 52 (scanner malfunction) See page 47 4-9 Error 55 See page 53

See page 18 See page 32 See page 20

secondary lights, page 13

14 – Control panel messages

SIMM Errors

Item Description Recommended Action

5 Error 53-0 ROM error See note below 6 Error 53-1 RAM error See note below

Note

Remove all SIMMs and power cycle the printer. Retry the operation. Replace the SIMMs one at a time to locate the defective module. Ref er to the Service Manual for details.

Fatal Errors

When the DATA, TRAY 2, TRAY 1, and ERROR LEDs are on, press and light patterns shown.

Item Description Recommended Action

7 Primary light pattern See note on primary and

7-1 Error 50 fuser See page 44 7-2 Error 57/58 (main motor) See page 54 7-3 Error 61.1/62.1 See page 58 7-4 All other errors See 79 Error, pages 61-71 8 Error 63 service error See page 59

simultaneously. Follow the instructions for the secondary

[Reset]

secondary lights, page 13

[Go]

LJ 5P Printer LED Displays –

LJ 4L Printer LED Displays

Recoverable Errors

For more details, see the page number provided.

Error Paper Data Ready

LED Legend RECOVERABLE ERRORS

Paper Out (See page 23)

(Displayed on single lights)

Printer Open (See page 24)

Paper Jam (See page 26)

21 Print Overrun (See page 35)

Paper LED on steady.

SERVICE ERRORS

Service Error

All 4 LEDs are on. 50 Error/Service

(See page 42)

Ready and Error LEDs are on. 55 Engine (See page 53)

Error LED is on. Ready, Data, and

Error LED on steady. Paper LED is

(Displayed while pressing front panel button)

When all four lights are on, a service error is indicated. Press and hold the front panel button to display the error code. The code will be shown only while the button is pressed. The following pictures show the possible error codes.

NOTE:

If all four lights remain on, yet no error code is displayed when pressing the button, power cycle the printer. If the condition persists, replace the formatter PCA.

51 Loss of Beam Detect (See page 45)

Data and Error LEDs are on. 58 Fan (See page 56

Error LEDs are on.

blinking.

52 Incorrect Scanner Speed (See page 47)

Paper and error LEDs are on.

61.x Formatter (See page 58)

Error LED is off; other LEDs display a pattern.

Error LED is blinking.

53 Accessory Memory Error (See page 49)

Data LED is on.

Blank Display (See page 68

All LEDs are off.

16 – Control panel messages

4L-Specific Error Configurations

Priority of Errors

Each error has a priority in relation to the others. If more than one error condition occurs at the same time, the highest priority error will be displayed. The priority of errors is as follows:

Service Errors

Formatter PCA

RAM

Engine

Scanner

Beam

Fan

6 Recoverable Errors

Door Open/No Toner Cartridge

Paper Jam

Paper Out

Memory Error

Manual Feed

Note

Before troubleshooting any Service error, power cycle the printer to see if the error persists.

LJ 4L Printer LED Displays –

Error Codes

Clear Staple Jam

5Si Mopier

• Clear the jam.

• Check the staple cartridge.

• Check the stapler and cabling.

• Check the stapling unit control’s printed-circuit assembly (PCA).

• Replace the entire stapling unit as required.

Close Printer Cover/Printer Open

All Printers

• The printer door is open.

• Check that the toner cartridge is fully seated and that the covers are

firmly closed.

• The direct current (DC) power supply is defective.

• The DC controller is defective.

• The actuator or tab is missing or broken.

• The paper control printed-circuit assembly (PCA) is defective.

18 – Control panel messages

Install Toner Cartridge/No Cartridge

All Printers

• Reseat or install a new toner cartridge.

• The high voltage contacts are dirty or defective.

• The high voltage power supply is defective.

LJ 5

• The DC Controller is defective.

Install Tray 2

LJ 5

• The lower cassette (Tray 3) is selected and the printer has detected

that the paper cassette (Tray 2) is not installed. – Install or reseat the paper cassette (Tray 2), which is the paper

guide for the lower cassette (Tray 3).

• The paper cassette (PC) is improperly fitted.

– Firmly reseat the PC.

Out of Staples Optional Output X

5Si Mopier

• Replace the staple cartridge.

– If the message continues after the cartridge has been replaced,

check the stapler, top cover assembly, and cabling.

• Check the stapling unit control PCA.

• Replace the entire stapling unit if required.

Error Codes –

Output Operation Condition x.yy

5Si Mopier

x=output device number yy=condition code

For the multibin mailbox: 01 = face-up tray not installed

Note

See also the section on troubleshooting the 2,000-sheet input unit and multibin mailbox/mailbox with stapler.

Remove Paper Jam

LJ 5

• See 13 Paper Jam—all printers

• The rear door is open.

• The cassette paper out sensor flag is broken or missing.

• The 500-sheet lower cassette is not properly adjusted (see service

note C2001A-04). – Adjust the tray, using the instructions in the service note.

• Check the transfer roller to ensure that it is properly seated.

• The input sensor (PS1) or fuser exit sensor (PS3) is bad; or with

jams from the MP tray (Tray 1), the paper end sensor (PS5) is bad.

Staple Limit Reached

5Si Mopier

• Send print jobs of only 20 pages or fewer to the stapler.

20 – Control panel messages

Stapler Align Error

5Si Mopier

• Remove the paper from the stapler and re-send the job.

Stapler Malfunction

5Si Mopier

• Clear the stapler jam and re-send the job.

Stapler Supply Out

5Si Mopier

• Load a new staple cartridge.

Toner Low

5Si, 5

• The toner is uneven in the cartridge.

• The toner cartridge contact points are malfunctioning.

• The high-voltage power supply (HVPS) is defective.

Tray x Empty/x Load/Paper Out

All Printers

• The paper tray is empty or is seated incorrectly.

• The sensor arm is stuck or broken.

• The tray-size sensor is defective or configured incorrectly.

– Verify the tray tabs and switches at the right rear (or right front) of

the tray slot, or configure the tray from the control panel.

– The paper control/sensor PCA is defective.

Error Codes –

Warming Up

5Si, 5

• Separate all accessories.

• Power cycle the printer.

• The formatter PCA is defective.

• The DC controller is defective.

• The power supply is defective.

02 Warming Up (if 3 Minutes)—See also 50 Error

• The Input/Output (I/O) cable is hooked up incorrectly or there is bad

I/O in the computer. – Remove the I/O cables and power cycle the printer.

• There are defective component(s).

– Replace the fusing assembly if it is not warming up the DC

controller, PCA power supply, or formatter PCA.

4Si/IIISi

• The display cable or formatter PCA is defective.

IID, II

• The I/O cable is hooked up incorrectly or there is bad I/O in the

computer. – Remove the I/O cables. Replace the formatter PCA.

2686A/D

• The DC power supply/main motor drive is defective.

22 – Control panel messages

11 Paper Out (MP/PC/UC/LC/EC/LE LO AD)

All Printers

• The paper tray is empty or is seated incorrectly.

• The sensor arm is stuck or broken.

• The tray-size sensing or configuration is defective.

– Verify the tray tabs and switches are at the right rear (or right

front) of the tray slot, or configure the tray from the control panel.

• The paper control/sensor PCA is defective.

• The paper cassette is empty or missing.

• The paper cassette is seated incorrectly.

• The paper out flag PS2 is broken or stuck.

• The DC controller PCA is defective.

• Tray 1 (the MP tray) is empty.

– Add paper to Tray 1; then press

• Tray 2 (the paper cassette) is empty.

– Add paper to the tray if it is on continuously; verify that the

sensor flag movement is not hindered.

to continue.

[Go]

Error Codes –

12 Printer Open

All Printers (Exceptions: 4P, IIIP, IIP Plus, IIP)

• The printer door is open.

– Check that the toner cartridge is fully seated and that the cover is

firmly closed.

• A DC power supply malfunction or DC controller malfunction

occurred.

• Tab is missing on the top cover; replace the tab.

• Check the front Door Open sensor flag sensor; it could be broken or

stuck. – PS402 is located on the small Front Door Unit T erminal PCA, on

the front door under the transfer roller.

• A toner cartridge microswitch malfunction has occurred.

– Check the toner cartridge microswitch (SW501) on the high

voltage PCA.

• A DC controller PCA malfunction has occurred.

4 Plus, 4

• The plunger is missing on the top cover.

• A paper control PCA malfunction has occurred.

4Si, IIISi

• A PS1 malfunction has occurred.

– Check that the PS1 is blocked by the latch flag. Replace the PS1

if it is defective.

• The fuser bulb has burned out.

– Check to see if the fuser bulb turns on. If the fuser bulb does not

turn on, reset SW101 on the AC power supply.

• A DC controller PCA malfunction has occurred.

24 – Control panel messages

12 Open or No EP

• The top cover is open.

• The toner car tridge is not installed.

• There is a defective interlock switch assembly.

• Part of the top door that pushes the plunger down is broken.

• The top door switch (plunger assembly) is broken.

IIIP, IIP Plus, IIP

• The paper path door or top cover is open.

– Close the paper path door or top cover.

• A toner cartridge is not installed or it is not seated.

– Replace or reseat the toner cartridge.

• There is a defective fan, PS4, or PS5.

• The external fuser access door is not closed.

Error Codes –

13 Paper Jam/Remove Paper Jam

All Printers

• The media does not meet HP specifications.

• The paper path is dirty or obstructed.

– Clean the paper path components; ensure that the transfer roller

is seated properly.

• The pickup (or other) rollers and/or the separation pad is worn.

• The paper is the wrong length or the paper size is selected

incorrectly in the software.

• The exit sensor or flag is defective.

• A defective input (paper-out) sensor does not sense that the printer

is out of paper.

• The paper cassettes are not correctly loaded.

• The solenoid operation is bad.

– Verify proper solenoid operation and replace if necessary.

• The gear(s) is bad or not meshing in the drive train.

– Replace the bad gear(s) or check the toner cartridge gears for

damage.

• The main motor or drive circuit is bad.

• The delivery mechanism or the coupler gear to the main drive is

bad.

• The main motor drive circuitry is bad.

• The DC controller is defective.

26 – Control panel messages

5L, 6P, 5P

• If all of the flags move properly and the connectors are seated, but

the error persists, replace the DC controller.

6P, 5P

• There are paper fragments under the oblique rollers (top or front).

– Remove the rollers and the paper fragments.

• The toner cartridge gears are worn or damaged.

• The paper path gears are worn or damaged.

• The DC controller PCA is defective.

• The registration guide is defective.

4P, 4L

• The rear door of the printer is open.

• The flags/sensors are stuck or broken.

• There are paper fragments under the oblique rollers (top or front).

– Remove the rollers and clear out the paper.

• The transfer roller guide is not seated.

4 Plus, 4

• The rear door is open.

• The cassette paper-out sensor flag is broken or missing.

• The 500-sheet lower cassette is improperly adjusted (see service

note C2001A-01A). – Adjust the tray according to the service note instructions.

• The transfer roller is seated improperly.

• There is a bad input sensor (PS1) or fuser exit sensor (PS3); or with

jams from the MP tray (Tray 1), a bad paper-end sensor (PS5).

• The output rollers (service note C2001A-03A) are defective.

Error Codes –

IIID, III, IID, II

• The registration assembly is defective.

• The fuser is defective.

IIID, IID

• The duplex paper path is obstructed or contains worn components.

• The switchback assembly is misadjusted or bent.

III, II

• The sensor cable is defective.

– Replace the fuser to the DC controller cable (RG1-0907-000CN).

2686D/A

• The separation belt is broken.

• The transfer guide assembly is defective.

• The paper pickup clutch is turning more than once.

– Disassemble the clutch and re-grease. NOTE: If one clutch

needs re-greasing, it is likely that they all do.

• The registration shutter is stuck.

• The rear paper guide door is worn.

– Replace the worn paper rollers or readjust the rear door.

• The front paper guide door is worn or misadjusted, preventing paper

from getting to the registration assembly on time. – Readjust the front paper guide door.

28 – Control panel messages

+ 328 hidden pages