Plus M-5 Service Manual Page 1

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

Removing the High Voltage Contact Assembly andFeed Guide Assembly . . . . . . . . . . . . . . . . 6-67Replacing the High Voltage Cont

Cleaning Your PrinterWhen it is time to replace the toner cartridge, perform thecleaning procedures outlined in Figure 4-1.4-4 Preventive Maintenance

Toner Cartridge The toner cartridge in your printer contains the printingmechanism and a supply of toner. Your toner cartridge lifedepends on the am

Saving Toner with EconoMode (HP LaserJet 4Plus and 5 Only)Toner cartridge life can be extended dramatically by using theEconoMode printing feature of

Installing the Toner Cartridge The toner cartridge is empty and must be replaced when thetoner low message cannot be cleared, as described in “Clearin

3 Remove the sealing tape by firmly grasping the tab on theright side of the toner cartridge and pulling it straight out theside of the cartridge. (Se

Non-HP Toner Cartridges While Hewlett-Packard does not prohibit the use of Non-HPtoner cartridges during the warranty period or while under amaintena

Clearing the TONER LOW Message If the 16 TONER LOW message appears in the control panel display,the toner level in the toner cartridge is getting

Periodic Maintenance Procedures Each paper source has a Paper Pickup Roller that should bereplaced when paper no longer feeds reliably. The MP Tray (T

4 Insert a small screwdriver into the indent at the front of theseparation pad and gently lift the pad from its seat (see Figure4-6).5 Discard the use

Removing the PC (Tray 2) Pickup Roller The PC Pickup Roller is underneath the printer (see Figure 4-7).To remove the Pickup Roller:1 Turn OFF and un

Drum Rotation Functional Check . . . . . . . . . . . 7-50High Voltage Power Supply Assembly . . . . . . . . 7-51Interface Trou

Removing the Lower Cassette (LC) or (Tray 3)Pickup Roller If your printer is equipped with the Lower Cassette Assembly,proceed as follows:1 Remove t

Removing and Replacing the Transfer Roller The Transfer Roller is the black sponge-rubber roller locatedinside the printer just to the front of the b

Removing the Transfer Roller 1Turn OFF and unplug the printer.2 Open the printer’s top cover.3 Remove the Toner Cartridge.4 Use the hook inside the

5Functional OverviewIntroductionThis section of the manual presents a functional overview of theprinters. It provides the Service Representative with

DC Controller SystemThe DC Controller PCA is responsible for coordinating allactivities involved in the printing process. The DC Controllerenables the

DC Controller LoadsFigure 5-1 DC Controller LoadsFunctional Overview 5-3

Serial Data Communication The printer communicates with and controls the Paper Feeder,the Lower Cassette Assembly, and the Envelope Feeder thro

Solenoids Solenoids are controlled by the DC Controller. Each solenoiddrives a specific roller (see Table 5-1). The DC Controller outputs+24B VD

Photosensors Photosensors, monitored by the DC Controller, are responsible fordetecting the presence of paper, paper motion, and timing. (SeeTable

Sensor Description PCAPS1 Input/Registration Sensor - detects paper inpickup areaPaper ControlPCA (J605)PS2 PC tray (Tray 2) Paper-out Sensor - detect

Removing the Paper Guide Assembly . . . . . . . . . A-16Removing the Paper Roller . . . . . . . . . . . . . . A-17Removing th

Microswitches All microswitch conditions are monitored by the DC Controllerover serial data lines SLI and SLO. The State Machines on theindivi

PC (Tray 2) and LC (Tray 3) Tray Size SensingSystemTrays inserted into the printer trigger specific microswitches,which define the tray size (see Tabl

Motors The DC Controller controls the Exhaust Fan, the Main Motor,and the Laser/Scanner Motor. The remaining motors andsolenoids are controlled

Paper Jam Detection The Input/Registration Sensor (PS1) and the Paper Exit Sensor(PS3) detect paper moving through the printer. If a paper jam isdetec

Formatter System The formatter is responsible for the following:• Receiving and processing ASCII data from printer interfaces.• Monitoring front pan

Figure 5-5 Formatter PCA—Functional AreasFunctional Overview 5-13

Memory ManagementThe printer uses several different types of memory. This memorycan be divided into two different categories, Read Only Memory(ROM) an

PJL Overview Printer Job Language (PJL) is an integral part of configuration,in addition to the standard Printer Command Language. Withstandard I/O ca

Image Formation SystemLaser printing requires the interaction of several differenttechnologies (such as electronics, optics, andelectro-photographics)

Photosensitive Drum The photosensitive drum is the “heart” of the Image FormationSystem. The special properties of this drum allow an image to beforme

To Print Using the Infrared Port . . . . . . . . . . . . B-36Troubleshooting IR Printing Problems . . . . . . . . B-38Infrared Po

Cleaning Stage During the cleaning stage of the image formation process, thedrum’s surface is physically cleaned, preparing it to hold animage. Durin

Conditioning Stage After the drum is physically cleaned, it must be conditioned. Thisprocess consists of applying a uniform negative charge on thesur

Writing Stage At the writing station, the laser beam is used to discharge thedrum’s negative potential by focusing laser light onto areas of thephoto

At the beginning of each sweep (before the beam reaches thedrum), the beam is reflected off the beam detect mirror. Themomentary pulse of light is sen

Developing Stage The developing station develops the latent electrostatic imageinto a visible image on the drum. The developing unit consists ofa met

The DC bias of the developing cylinder is adjusted to change theforce of attraction between the toner and drum by changing theprint density setting fr

Transferring Stage At the transferring station, the toner image on the drum’s surfaceis transferred to the paper. A positive charge applied to the b

Fusing Stage At the fusing station, the toner is fused into the paper by heatand pressure to produce a permanent image. The paper passesbetween a h

Paper Feed System NoteThe LJ 5 printer designators differ as follows.LJ 4 / 4 Plus Multipurpose (MP) Tray Paper Cassette (PC) Tray Lower Cassette (LC

The Paper Feed Assembly performs horizontal registration of theprint media through the Oblique Rollers. As the print mediapasses through the Oblique R

Contents-10

Figure 5-17 Paper Feed Assembly (Sectional View)Part DescriptionPS1Leading Edge Registration SensorPS2PC Tray (Tray 2) Paper Out SensorPS3Exit SensorP

Printing from the MP Tray (Tray 1) MP tray selection is provided by the Formatter PCA, asconfigured by the operator’s control panel or by a softwareap

Printing from the PC Tray (Tray 2) PC tray selection is provided by the Formatter PCA, asconfigured by the control panel or by software. When the DCC

Power System When the main power switch is turned ON, the AC Power Supplyprovides AC voltage to the DC Power Supply and the fuserassembly heat lamp. T

Figure 5-20 Power System Block Diagram5-32 Functional Overview

Basic Sequence of Operation The Formatter PCA and the DC Controller PCA shareinformation during printer operation. Connector J7 on theformatter and c

6 Each time the formatter receives a synchronized BD signalfrom the DC controller, the formatter sends a VIDEO datastream (VDO) to the DC controller.7

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

This a 2 panel pull-out.Figure 5-22 MP (Tray 1) Timing Diagram—HP LaserJet 4Plus/4M Plus/5/5M/5N5-36 Functional Overview

Warmup Period The Warmup period begins when the printer’s power is turnedON, and ends when the fusing roller temperature reaches 172° C.When the prin

1Product InformationFeatures HP LJ 4 HP LJ 4M HP LJ 4 Plus HP LJ4M PlusModel C2001A C2021A C2037A C2039APrinter Speed 8 ppm 8 ppm 12 ppm 12 ppmResolut

Initial Rotation Period When the DC controller receives a PRINT signal (PRNT) from theformatter, the DC controller allows the fusing roller to beginw

If a failure occurs during this period, the following errors may bedisplayed: 50 SERVICE This error occurs when the fusing roller fails toreach the co

Print Period When the leading edge of the paper activates theinput/registration sensor (PS1), the DC controller forces the laserdiode ON until a BD s

The formatter then sends VDO data to the DC controller. The DCcontroller translates the VDO signal into a VIDEO OUT signal(VDOUT), which modulates the

Last Rotation Period After printing is complete, the Last Rotation period begins,during which residual static charges are eliminated from thephotosen

6Removal and ReplacementThis chapter describes the complete disassembly of the printerfrom the beginning. In every instance, tasks that must beperform

Required ToolsHardware ReviewAll screws used in the printer are Phillips head, which require aPhillips screwdriver. Figure 6-1 shows the difference b

Table 6-2 describes the screws used in the printers, and providesguidelines to help determine where each type of screw is used.The screws can vary in

Removing the Covers Right Side Cover RemovalLJ 4/4 Plus1 Open the Top Cover and release the Right Side Cover bypressing at the points shown in Figure

Top Cover Removal 1 Open the Top Cover.2 Remove the Right Side Cover.3 Open the Rear Door.4 Remove the (3) screws shown in Figure 6-3, callout 1.5 Rel

Product Family InformationThe model HP C2021A is identical to the model HP C2001A froma hardware standpoint, as is the model HP C2039A to the modelHP

7 Disconnect the Control Panel Ribbon Cable and remove thetop cover (see Figure 6-4).Figure 6-4 Control Panel Cable6-6 Removal and Replacement

Left Side Cover Removal 1 Remove the Right Side Cover and the Top Cover.2 Release the 2 latch points on the Left Side Cover (front latchfirst) see Fig

Rear Door Removal1 Remove the PC tray (Tray 2).2 Open the Rear Door. Support the door with one hand.3 Release the door support from the rear of the pr

4 LaserJet 4/5: Flex the Rear Door to release it from its hinges.Press the middle of the door while lifting either side (Figure 6-7a).LaserJet 4 Plus:

Font Door Cover Removal (LJ 5 Right FrontCover Removal)LJ 4/4 Plus1 Remove the Right Side Cover, the Top Cover,and the PC Tray.2 Release the top latc

Figure 6-9 Font Door Cover LatchesRemoval and Replacement 6-11

Multi-Purpose (MP) Tray (Tray 1) Door Removal1 Remove the PC Tray.2 Open the MP Tray door and extend the MP Tray.3 Bend the Door Slides out to release

Multi-Purpose (MP) Tray (Tray 1) Removal1 Remove the Right Side Cover, Top Cover, Left Side Cover, MPTray Door (Tray 1), and the Font Door Cover.2 Rem

4 On the LJ 4+ and LJ 5 you must release the tray tensionspring located at the left side of the tray. Use a pair ofneedlenose pliers to remove the sp

Assemblies RemovalPower Supply Removal1 Remove the Right Side Cover.2 Remove the (3) or (2) screws from the metal cover at the lowerright corner of th

Identification The model number is on a label placed on the outside, rear coverof the printer. The model number (C2001A, C2021A, C2037A orC2039A) i

4 Remove the (2) screws from the bottom frame (see Figure 6-14,callout 1).5 Slide the power supply out the right side of the printer toaccess the powe

6Remove the (2) connectors (6 wire and 3 wire). (See Figure6-15, callout 1.) Squeeze the release tab on the 6-wireconnector. Pull the 3-wire connecto

Paper Feed Assembly Removal1 Remove the Right Side Cover, the MP opening cover, (seeFigure 6-17), the Top Cover and the Left Side Cover, the FontDoor

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

5 Remove the (3) screws from the left side of the printer (seeFigure 6-18, callout 1).6 Remove the Paper Feed Assembly by lifting it and sliding itout

High Voltage Power Supply (HVPS) Removal1 Remove the Toner Cartridge and PC tray.2 Lay the printer on its left side. (Place a cloth under the printert

Fuser Assembly RemovalCautionThe Fuser Assembly may be hot. Allow plenty oftime for the fuser to cool before beginning thefuser removal procedure.1 Op

Control Panel and Overlay Removal1 Remove the Right Side Cover and the Top Cover.2 Turn the Top Cover over and place it on flat surface.3 Release the

5 If you must replace the Control Panel Overlay, release the (2)retaining tabs from the Control Panel and separate theoverlay from the Control Panel (

Removing the SIMMs Door 1 Remove the Right Side Cover.LaserJet 4:2 Remove the (2) screws that hold the SIMMs cover (seeFigure 6-23a, callout 1).3 Open

Figure 1-2 Printer Identification Label for the HP LaserJet4/4M1-4 Product Information

LaserJet 4 Plus/5:2 Remove the (1) screw that holds the SIMMs cover (seeFigure 6-23b, callout 1).3 Swing open the SIMMs cover.Figure 6-23b Opening t

Formatter Cage RemovalNote You may wisht to remove the metal cover (on thelower right side) and the power supply for easieraccess to the Formatter Cag

Figure 6-24b Formatter Cage Screws (Right Side View -LaserJet 4 Plus)Figure 6-24c Formatter Cage Screws (Rear View - LaserJet 4Plus)6-28 Removal and R

Formatter PCA Removal CautionThe Formatter PCA is very sensitive to Electro-static Discharge (ESD) damage. Observe properESD procedures when servicing

LaserJet 4 Formatter PCA:1 Remove any MIO or SIMM modules from the FormatterAssembly.2 Remove the (2) black screws from the side of the FormatterCage

5 Remove the (4) Interface Connector Support Screws from therear of the Formatter Cover. The RS-232 connector is heldwith 5mm hex-head cap screws (see

LaserJet 4 Plus and 5 Formatter PCA1 Remove any MIO or SIMM modules from the FormatterAssembly.2 Remove the MIO Connector Support Bracket (seeFigure 6

DC Controller RemovalNote Note the cable routing before beginning thisdisassembly procedure. Be careful not to damagethe cables during re-assembly.1R

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

DC Controller Installation CautionWhen reinstalling the DC Controller PCA it isextremely important that all cables be properlyrouted. If cables a

Specifications HP LaserJet 4 and 4 PlusDimension HP LaserJet 4/4M(C2001A/C2021A)HP LaserJet 4 PlusHP LaserJet 4M Plus(C2037A/C2039A)Width 16.4 in (416

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

Main Motor Assembly Removal1 Remove the Right Side Cover, Top Cover, and the FormatterCage Assembly.2 Unplug the Main Motor connector from the Main Mo

Gear Assembly Removal 1 Remove the Top Cover, the Right Side Cover, the FuserAssembly, and the Formatter Assembly. 2 Remove the Main Motor Assembly (

Fan RemovalNoteNote the cable routing before beginning thisdisassembly procedure. Be careful not to damagethe cables during re-assembly.1 Remove the

3 Remove the RFI shield (LJ 4 only) by releasing the retainingtab and sliding the shield up (see Figure 6-33, callout 1). 4 Laser Jet 4: Release the (

Output Assembly Removal1 Remove the Right Side Cover, the Top Cover, and the LeftSide Cover.2 Release the grounding strap from the left side of the fr

Paper Exit Sensor (PS3) Removal 1 Remove the Right Cover, Top Cover, and the Output Assembly.2 Disconnect the Sensor Cable.3 Lift the Sensor Retaining

Scanner Assembly Removal1 Remove the Right Side Cover, Top Cover, Left Side Cover, andthe Output Assembly.2 Remove all cables from the Scanner retaini

Lower Cassette AssembliesThe field-replaceable assemblies of the Lower Cassette are:• Lower Cassette Sensor PCA Assembly• Lower Cassette Pickup Motor

Lower Cassette Pickup Motor Removal1 Open the sensor cover and disconnect the center and rearconnectors (see Figure 6-37, callout 2).2 Release the (2)

© CopyrightHewlett-PackardCompany 1996All Rights Reserved.Reproduction, adaptation,or translation withoutprior written permissionis prohibited, except

Status 100/115 V4/4M 4 Plus/4MPlus220/240 V4/4M 4 Plus/4MPlusProduct Rating 6.4 amps 7.8 amps 3.1 amps 4.0 ampsPeak Inrush Current 22 am

5 Lift the motor assembly straight up out of the the LowerCassette Base (see Figure 6-39).NoteNote the ground connector underneath the MotorAssembly.

Replacing Fuser Assembly Parts The following procedures describe the removal and replacementof major Fuser Assembly Components (Fusing Roller, The

Fuser Assembly Configuration Figure 6-40 provides an overview of the orientation of the majorFuser Assembly components. Before beginning the fuserdis

Removing the Fuser Roller Heat Lamp 1 Laser Jet 4 only: Remove the (2) latches that hold the rightside cover. (There is a gear exposed on the right si

3 LaserJet 4: With a screwdriver, release the latches by firstpressing to clear the lower latch, then lifting to release theupper latch (see Figure 6-

(continued on next page)Figure 1-42b Fuser Cover End Latches (LaserJet 4 Plus)Figure 1-42c Fuser Wire Harness Cover Removal (LaserJet 4Plus)6-51 Remo

5 Remove the (1) Heat Lamp lead (thermoswitch screw)(seeFigure 6-43 callout 1). 6 Press the thermoswitch tab towards the paper exit flag torelease th

NoteLaserJet 4 and 5 only: Note the orientation ofthe bushing on the left side of the Fusing Roller. 8 Squeeze the lamp connector to release the slip-

NoteBefore removing the gear cover, note the routingof the wires in the gear cover slots.9 Remove the (2) screws from the right side gear cover (seeFi

Fuser Assembly Thermoswitch Removal NoteSix of the seven latches are accessed from the topof the wire cover. These latches are beneath thefelt pad. Th

Related Documentation The following manuals can be ordered from Hewlett-Packard’sSupport Materials Organization (SMO). The phone number forSMO is (8

Thermistor Removal1 Remove the Wire Harness Cover as shown in Figure 6-47.2 Remove the (2) screws from the thermoswitch connector (seeFigure 6-47, cal

5 Release the (2) springs from the Upper Fusing Frame (seeFigure 6-48a, callout 1).6 Release the tabs that hold the Upper Fusing Frame to theFuser Bod

7 Remove the (1) screw that holds the Thermistor (see Figure6-48b, callout 2).NoteEnsure the thermistor cable is routed correctlywhen assembling the f

Paper Control PCA Removal1 Remove the Right Side, Top, Left Side, and Font Door Covers,then Paper Feed Assembly.2 Disconnect the cables from the senso

Sensor PCA Removal1 Remove the Right, Left, Top, and Font Door covers. You neednot remove the MP Tray. 2 Perform the Paper Control PCA removal procedu

PS1 and PS2 Sensor Assembly RemovalThe PS1 and PS2 sensors are located under the Paper FeedAssembly. 1Remove the Paper Feed Assembly and place it on

High Voltage Contact Plate (HVCP)and Paper Guide Removal This procedure involves removing many subassemblies anddifficult disassembly processes. Be

After removing the Fuser Assembly, remove the contact platefrom the rear of the printer, as follows:1 Remove the (1) screw from the sheet metal Guide

3 Remove the (6) rollers from the High Voltage ContactPlate (see Figure 6-53 callout 1). (continued on next page)Figure 6-53 Paper Guide Rollers6-64 R

4 From the front of the printer, remove the (2) black self-tappingscrews that hold the Inner Cross-member. Remove thecross-member (see Figure 6-54 cal

Safety InformationProduct and Laser Safety HP printers are UL 1950 listed, CSA 22.2 950 certified, andmanufactured in accordance with DIN IEC 950. Th

5 From the left side of the printer, remove the (1) or (2) black,self-tapping screw(s) that holds the Left Toner CartridgeGuide Plate (see Figure 6-55

Removing the High Voltage Contact Assemblyand Feed Guide AssemblyNoteThe following procedures are difficult and thecomponents are damaged easily. The

Replacing the High Voltage ContactAssembly/Feed Guide Assembly The Toner Cartridge Guide Plate and the High Voltage ContactAssembly/Feed Guide Assem

Interconnect PCA Removal The Interconnect PCA is a connector board that connects thePower Supply and the DC Controller with the the FuserAssembly. The

NoteAccess the Interconnect PCA Housing by layingthe printer on the rear of the printer chassis. 4Disconnect the Interconnect Cable connector from th

NoteThe AC Connector has polarity. Note theorientation of the AC Connector before removingit. This is required in order to install theconnector with t

6-72 Removal and Replacement

7LaserJet 5 Error MapThe LaserJet 5/5M/5N printer has error messages that aresimilar to the LaserJet 4/4M/4+/4M+. Use the following table tolook up t

Message on LJ 5/5M/5N RecommendationsINCOMPATIBLE TRAY 3 INSTALLED Indicates that a lower cassette has beeninstalled that is not compatible with theLJ

Message on LJ 5/5M/5N RecommendationsREMOVE PAPER JAM See 13 PAPER JAMREQUESTED LANGUAGE NOT AVAILABLE See W2 INVALID PERSRESETTING ACTIVE I/O See 07

FCC RFI Statement This equipment has been tested and found to comply with thelimits for a Class B digital device, pursuant to Part 15 of the FCCRules.

7-D LaserJet 5 Error Map

7TroubleshootingPre-Troubleshooting Procedures Preliminary Operating Checks Prior to troubleshooting a specific printer problem, you shouldensure th

Printer Message Troubleshooting Printer Message Summary Table Table 7-1 is a list of all status, attendance, error, and servicemessages affecti

Message Symptoms and Recommendations07 RESETRESETTING [xxx]Returns all printer settings to Printing Menu settings, andclears buffered pages, temporary

Message Symptoms and Recommendations18 AUX IO INIT This message is displayed when the MIO (AUX IO) card isin the process of initializing. During initi

Message Symptoms and Recommendations22 ERROR22 SERIAL I/O ERROR22 PARALLEL I/OERROR22 HP MIO ERRORFor serial/Bi-Tronics parallel configuration, the co

NoteRefer to the “Product Family CompatibilityMatrix” in Chapter 1, or for the LaserJet 5,Appendix B to verify correct memory for theprinter.Message S

Message Symptoms and Recommendations55 ERROR55 PRINTER ERRORIndicates a communications problem between the DCController PCA and the Formatter PCA. Pre

Message Symptoms and Recommendations64 SERVICE64 PRINTER ERROR65 SERVICE67 SERVICEThe printer identified an internal service error. If this errorappea

Message Symptoms and RecommendationsFR REMOVE CART An accessory cartridge was installed while the printer wasin an error state. To clear this message,

Laser Statement (Sweden/Finland) LASERTURVALLISUUSLUOKAN 1 LASERLAITEKLASS 1 LASER APPARATHP LaserJet(s) 4/4M, 4 Plus/4M Plus laserkirjoitin on käytt

Clearable Warnings A clearable warning indicates a transient condition in theprinter. The printer continues on line while the message isdisplayed i

Message Displayed MeaningW1 IMAGE ADAPTMEMORY LOW, PAGESIMPLIFIEDThe printer received a graphics print file that was toocomplex to print at the reques

Printer Message TroubleshootingProceduresWhen the following procedures require removing and replacingan assembly or PCA, refer to the applicable secti

MP/PC/LC (Tray 1/2/3) LOAD Message The conditions that result in MP/PC/LC LOAD or (TRAY 1/2/3)messages are: • The absence of any input tray.• The a

Checks ActionIs media present in the tray(s). Install media.Are the proper trays fully inserted in theprinter?Reseat the cassettes. Make sure eachcass

Cassette Size Switches (SW603, SW604, SW605) FunctionalCheck Before beginning this test, remove the Lower Cassette Base andthe Envelope Feeder.

Paper Size Sensing Lower Cassette The operator must set the appropriate paper size for the LowerCassette using a dial which, in turn, activates switc

PC Empty Sensor (PS2) Functional Check 1Power on the printer with the PC tray (Tray 2) empty.2 After the 05 SELF TEST and the 02 WARMING UP cycles, th

12 Printer Open Message The 12 PRINTER OPEN (or CLOSE PRINTER COVER) display tells theoperator to close the printer’s top cover. The DC Controllerdet

SW601 Functional Check 1Open the Top Cover Assembly.2 The message 12 PRINTER OPEN (or CLOSE PRINTER COVER)should appear.3 Close the top cover. The 02

Toner Safety NoteToner may stain clothing. Skin and clothing arebest cleaned by removing as much toner aspossible with a dry tissue, then washing w

13 PAPER JAM Message Paper jams occur when paper fails to arrive at or clear the paperpath sensors in the allotted time. Paper movement is moni

Jam Location Checks and Action RequiredInput Area Jams(Sensed by PS1.)1. Check that the Transfer Roller is fully seated and shows nosign of wear.2. Ch

PS1 (Input/Registration Sensor) Check1Power ON the printer with the top cover open. Wait for the12 PRINTER OPEN (or CLOSE PRINTER COVER) message.2 En

PS3 (Exit Sensor) Check1Open the rear door (cover) of the printer.2 The display should read 13 PAPER JAM (or REMOVE PAPER JAM)immediately after the do

Lower Cassette Functional Check When troubleshooting a Lower Cassette failure, always prove thefailure by removing the Lower Cassette from the prin

14 NO EP CART Message The printer detects the presence of the Toner Cartridge and thelevel of toner present in the cartridge through the condition

124563Figure 7-5 Toner Cartridge ComponentsCallout Assembly1 Toner Low Voltage Contact2 Developer Roller High Voltage Contact 3Developer Roller4Photoc

41.X ERROR Message A 41.X ERROR (misprint) indicates that a temporary malfunctionhas occurred with the print engine (NOT a Formatter error).Occasiona

Error Message Recommended Action41.1 ERRORNoisy Vertical Sync (VS)Reseat all connectors on the DC Controller, the LaserDrive PCA, the Scanner Connecto

50 SERVICE Error - Fuser Malfunction WarningThe Fuser Assembly is HOT. Allow the assemblytime to cool before servicing.The purpose of the fusing syst

Doing Business with HPTechnical Assistance HP ASAP 1-800-333-1917 (U.S.)HP ASAP (Automated Support Access Program) provides freetechnical support inf

NoteThe 50 SERVICE error message can be clearedimmediately by shorting the C202 leads on theHP LaserJet 4/4M (or the C205 leads on the HPLaserJet 4 Pl

51 ERROR Message The 51 ERROR, and the 41.2 ERROR are caused by Beam Detectfailures. If the beam detect signal is lost for more than 2 secondsthe err

52 ERROR Scanner Malfunction The scanner motor is a flat, brushless, DC motor. Motor operationis completely controlled by the DC Controller. The sca

57 (or 57.1) SERVICE Message (Main MotorFailure) The 57 SERVICE indicates that the DC Controller PCA detected ageneral motor failure. The Main Motor

58 (or 57.2) SERVICE (Fan Failure) The 58 SERVICE indicates that the DC Controller detected afailure in the Exhaust Fan (FM1) in the printer or t

Image Defect Summary The quality of the printer’s output is subject to the judgment ofthe user. This section of the manual helps you de

Figure 7-7 Image Defect Summary7-36 Troubleshooting

Figure 7-8 Image Defect SummaryTroubleshooting 7-37

Possible Cause ActionThe HVPS connections are dirty. Clean the HVPS terminals (see Figure7-18 for layout).The HVPS is installed improperly. If theHVPS

Possible Cause ActionPaper. The surface of the paper may betoo smooth for the pickup roller to movethe paper through the paper path.Change paper. Try

HP AUDIO-TIPSHP AUDIO-TIPS, available within HP ASAP, is an interactivevoice response system providing pre-recorded answers to thequestions most frequ

Possible Cause ActionNo toner available for print. Shake/replace the EP Toner Cartridge.Laser shutter may be blocking the beam Ensure that the mechan

For further information on interval dimensions, refer to theRepetitive Defect Ruler, Figure 7-19.Possible Cause ActionToner Cartridge. The circumferen

Possible Cause ActionFuser levers not in place.(All LJ4, some LJ4+, N/A on LJ5)The Fuser Assembly has shipping leversthat must be lowered during the s

Possible Cause ActionLaser/Scanning Assembly or DCController PCA.Replace the Laser/Scanning Assemblyfollowed by the DC Controller PCA, ifnecessary (se

PS5 Check (MP Tray Paper End Sensor) Functional Test 1 Make a test sheet by cutting a notch in the trailing edge of asheet of paper as shown in Figure

Figure 7-9 PS5 Test SheetTroubleshooting 7-45

Possible Cause ActionDirty Primary Charge roller. Change the Toner Cartridge.Bad Toner Cartridge. Replace the Toner Cartridge.Incompatible media. Duri

Possible Cause ActionDefective Toner Cartridge. The TonerCartridge may be internally damaged.Replace the Toner Cartridge.Bad paper lot. The paper mois

Possible Cause ActionDefective laser shutter. Check the laser shutter for free operationwhen inserting the EP Toner Cartridge.EP Cartridge Support dam

Image Formation TroubleshootingHalf Self-Test Functional Check The electro-photographic process can be subdivided into thefollowing stages: • Cleanin

European Customer Support Center The HP European Customer Support Center, located inAmsterdam, Holland, is open from 8:30 am to 6:00 pm centralEuropea

Drum Rotation Functional Check The photoconductive drum, located in the Toner Cartridge, mustrotate for the print process to work. The photoconductiv

High Voltage Power Supply Assembly The High Voltage Power Supply Assembly provides the necessaryvoltages for the printer’s electro-photographic proce

Interface TroubleshootingThis section provides an overview of the printer interfacerequirements. Refer to Chapter 3 for detailed information aboutthe

AUTOEXEC.BAT Standard Configurations Parallel DOS Commands If the previous check did not produce the desired result, ensurethat the AUTOEXEC.BAT fil

Communications ChecksChecks ActionIs your computer configured to theparameters described in theconfiguration instructions?These parameters are require

If the host system and printer still are not communicating, andsteps 1 through 9 have been completed, replace the FormatterPCA and the MIO card, and r

MIO TroubleshootingThe Self Test Printout and explanation shown on the followingpages contain valuable information regarding the current statusof the

Explanation of Self Test Printout1Multiple Environment Information. General informationabout your JetDirect MIO.2 JetDirect Card Status. I/O CARD READ

Figure 7-10 MIO Staus Information on the Self Test Printout7-58 Troubleshooting

Troubleshooting AidsComponent LocationsThe following illustrations help you quickly find the partsdiscussed in this chapter. 123455B5A5CFigure 7-11 Ma

2Site Planning andRequirementsSite RequirementsThe environmental specifications, listed in the Specificationssection of Chapter 1, must be maintained

123456Figure 7-12 Major Assembly and Connector Locations (2 of 3)Number Part1 Laser/Scanner Assembly2 DC Controller PCA3Interconnect PCA Assembly4Pape

1234Figure 7-13 Major Assembly and Connector Locations (3 of 3)Number Part1 Power Supply Assembly2 Envelope Feeder Main Motor (M4)3Lower Cassette Driv

Figure 7-14 Switch Locations Number PartSW101 AC Input ON/OFF Switch (Power Supply Assembly)SW 601 Top Cover Open Sensing SwitchSW602TEST PRINT Switch

Figure 7-15 Optional 500 Sheet Lower CassetteNumber PartSW851Optional 500 Sheet Paper Feeder Paper Tray (Tray 3)Size SwitchesSW852SW853Table 7-35Troub

5VR202J206J203J204 J20561 1811712131J202J2011313J212CP20216TB201CP201J2114110 1J21031J20941312526J213J208J207Figure 7-16 DC Controller PCA Layout—Lase

5J20415 11921J206J205VR2011133117J201J21231J215TB201 6 1J21410 1J21331J2113J21018117J209J208J2073132Figure 7-17 DC Controller PCA Layout —LaserJet 4 P

TB403 TB404TB405TB406VR401J40231J40151ABABTB402TB401Figure 7-18 High Voltage PCA LayoutNumber PartJ401 High Voltage PS Connection To DC Controller PCA

Repetitive Defect Template Repetitive print defects usually are associated with a specificroller within the printer, or the Toner Cartridge. The fol

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

Voltage Test Points The operating voltages of the printer can be verified by:1Listening for the exhaust fan. A rotating fan indicates that the+5 VDC

ConventionsThis manual uses the following conventions:Unless specifically stated otherwise, information applies to allseven printer models (LaserJet 4

Printer Space RequirementsFigure 2-1 Space Requirements2-2 Site Planning and Requirements

7-70 Troubleshooting

8Parts and DiagramsHow To Use the Parts ListsThe figures in this chapter illustrate the major subassembliesand component parts of the HP LaserJet 4/4M

Parts Lists and IllustrationsFigure 8-1a Field-Replaceable Assemblies (1 of 2)8-2 Parts and Diagrams

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

Part # Ref Exchng # Description Fig. #RG5-0454-000CNRG5-0879-130CN1 C2001-69003C2037-69001Fusing Ass’y (100/110V)LaserJet 4 LaserJet 4 Plus/58-10RG5-

Part # Ref Exchng # Description Fig. #C2085BC2085EC3925A13PC Tray (Tray 2) (ltr)LaserJet 4LaserJet 4 PlusLaserJet 58-14C2085CC2085FC3926A13PC Tray (Tr

Figure 8-2 Covers and Panels8-6 Parts and Diagrams

Ref Part # Notes Description 1 RB1-2143-000CNRB1-3558-000CNRB1-7885-000CNLJ4LJ4+LJ5MP Tray Extender2 RB1-2346-000CNRB1-3470-000CNRF5-1644-000CNLJ4LJ4+

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

Ref Part # Notes Description 1 RB1-2330-000CN S Spring, Leaf3 RG5-0458-000CNRG5-0872-000CNLJ4LJ4+Upper Cover Assembly3A RB1-2322-000CNRB1-3474-000CNLJ

Print Media Specifications The complete media specifications are listed in the HP LaserJetFamily Paper Specifications Guide (part no. 5961-0920),

Ref Part # Notes Description 4A C2037-40001C2037-40002C2037-40003C2037-40004C2037-40005C2037-40006C2037-40007C2037-40008C2037-40009C2037-40010C2037-40

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

Ref Part # Notes Description 1 RB1-7895-000CN Tool, Hook2 RB1-7893-000CN S Spring, Leaf3 RG5-2186-000CN Upper Cover Assembly3A RB1-7894-000CN Hinge St

Figure 8-4a Internal Components (1 of 4)Ref Part # Notes Description 1 RB1-2080-000CN Shutter, laser2 RB1-2100-000CNRB1-5730-000CNLJ4/4+LJ5Guide, Cart

7 RB1-2111-030CN Shutter, arm8 RB1-2114-000CN Qty 5 Foot9 RS5-2218-000CN Spring, Compression10 RB1-2122-000CN Shutter Spring, Torsion11 RB1-5732 -000C

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

Ref Part # Notes Description 1 RB1-2112-000CNRB1-3544-000CNLJ4LJ4+/5Exhaust Duct2 RB1-2113-000CNRF5-0748-000CNLJ4LJ4+/5Exhaust Duct Cover3 RB1-2350-00

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

Ref Part # Notes Description1 RS5-8219-000CN S Label2 RB1-2357-000-CNRB1-7897-000CNLJ4/4+LJ5Cover, Connector4 XA9-0584-000CNXA9-0670-000CNLJ4LJ4+/5Scr

Ref Part # Notes Description22 C2002-67901C2038-60004C3919-67901LJ4LJ4+LJ5Formatter PCA22 C2002-69001C2038-69004C3919-69001LJ4LJ4+LJ5Formatter PCA (Ex

Note Printing heavy paper stock (greater than 24 lb.(90 g/m2) from the 500-sheet Lower Cassettespecifically is not supported.Media Size Capacity Weigh

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

Ref Part # Notes Description 1 RB1-2236-000CN Guide, Feeder2 RB1-2253-000CN Roller, Guides (6)3 XA9-0623-000CN Hex Head Screw4 RG5-0468-000CNRG5-2192-

Figure 8-5 Main Switch Assembly8-22 Parts and Diagrams

Ref Part # Notes Description1 RB1-2118-000CNRB1-7906-000CNLJ4/4+LJ5SBase, Switch Mounting2 RB1-2119-000CNRB1-7907-000CNLJ4/4+LJ5SSwitch3 RB1-2345-000C

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

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

Ref Part # Notes DescriptionRG5-0451-000CNRG5-0877-000CNRG5-2195-000CNLJ4LJ4+LJ5Paper Feed AssemblyC2001-69005C2037-69003C3916-69005LJ4LJ4+LJ5Paper Fe

Figure 8-7 MP Tray (Tray 1) Assembly Part # Notes DescriptionRG5-0472-000CNRG5-0888-000CNRG5-2199-000CNLJ4LJ4+LJ5Multi-Purpose Tray AssemblyTray 1 Ass

Figure 8-8 Paper Output AssemblyRef Part # Notes DescriptionRG5-0456-000CNRG5-0886-000CNRG5-2189-000CNLJ4LJ4+LJ5Paper Output Assembly2 RB1-2299-030CN

Figure 8-9 Delivery Sensor AssemblyRef Part # Notes DescriptionRG5-0475-060CN Assembly, Delivery Sensor5 WG8-0291-000CN Photosensor, (PS3)6 RG5-0522-0

Adhesive Labels NotePrinting labels using the Duplex Assembly , the500-sheet Lower Cassette (Tray 3) or the PC tray(Tray 2) specifically is not suppo

Figure 8-10 Fuser Assembly8-30 Parts and Diagrams

Ref Part # Notes DescriptionRG5-0454-000CNRG5-0879-130CNLJ4LJ4+/5Fuser Assembly 110/115VC2001-69003C2037-69001LJ4LJ4+/5Fuser Assembly (Exchange) 110/1

Ref Part # Notes Description20 RS5-0232-000CNRS5-0393-000CNLJ4LJ4+/5SGear, 23T21 RS5-1063-000CNRS5-1097-020CNLJ4LJ4+/5Bushing, Roller22 RS5-1064-000CN

Accessory PartsFigure 8-11 Lower Cassette Base AssemblyParts and Diagrams 8-33

Ref Part # Notes DescriptionC2083A LJ4 LC Base Assembly w/non-Legal CassetteC2083BC2083DC3921ALJ4LJ/4+LJ5LC Base Assembly with Legal UniversalCassette

Figure 8-12 Lower Cassette Drive AssemblyRef Part # Notes Description1 RG5-0481-000CNRG5-1099-000CNRG5-2209-000CNLJ4LJ4+LJ5Drive Assembly, Lower Casse

Figure 8-13 Lower Cassette AssemblyRef Part # Notes Description1 C2084AC2084CLJ4LJ4\4+Universal 500 sheet Lower CassetteTray (non-Legal)1 C2084BC2084

Figure 8-14 Universal CassetteParts and Diagrams 8-37

SIMM Memory Ref Part # Notes DescriptionC2085AC2085DC3924ALJ4LJ4+LJ5250 sheet Universal Tray (Legal, Letter, Exec,A4)C2085BC2085EC3925ALJ4LJ4+LJ5250 s

Miscellaneous Parts and AccessoriesPart # Notes Description92298A Toner CartridgeJ2341AJ2552A (J2552-69001)LJ4LJ4+/5AppleTalk MIO InterfaceJ2550A (J25

Overhead Transparencies NotePrinting overhead transparencies using theDuplex Assembly, the 500-sheet Lower Cassette(Tray 3) or PC tray (Tray 2) specif

Parts ListDescription Part # Fig. # Printer 10-BaseT MIO Interface J2550A (J2550-69001) 5 16 Mbytes C3146A 4+/5 250 Sheet PC Tray (A4) C2085C 8-14 4

Description Part # Fig. # Printer Base, Switch Mounting RB1-2118-000CN 8-5 4/4+ Base, Switch Mounting RB1-7906-000CN 8-5 5 Belt, Timing XF9-0410-000C

Description Part # Fig. # Printer Cable, Paper Feed RG1-0542-020CN 8-11 4/4+/5 Clamp, Plate Release RB1-2284-000CN 8-10 4/4+ Click, Spring RF5-0374-0

Description Part # Fig. # Printer Cover, Upper RF5-0732-000CN 8-3a 4+ Cover, Upper RF5-1643-000CN 8-3b 5 Cover, Wire RF5-0535-000CN 8-10 4 Cover, Wir

Description Part # Fig. # Printer Envelope Feeded (exchange) C2082-69001 4/4+ Envelope Feeded (exchange) C3927-69001 5 Envelope Feeder (new) C2082B 4

Description Part # Fig. # Printer Fuser Assembly (100/115V) C2037-69001 4+/5 Fuser Assembly (220/240V) C2001-69004 4 Fuser Assembly (220/240V) C2037-

Description Part # Fig. # Printer Guide, Lower Separation RB1-2272-000CN 8-10 4 Guide, Lower Separation RB1-3526-000CN 8-10 4+/5 Guide, Paper Entranc

Description Part # Fig. # Printer Inner Cover Assembly RB1-2609-000CN 8-11 4+ Inner Cover Assembly RB1-7978-000CN 5 Inner Cover Assembly RG5-0487-000

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

Description Part # Fig. # Printer Overlay (Czechoslovakian) C3916-40023 8-3b 5 Overlay (Danish) C2001-40008 8-3a 4 Overlay (Danish) C3916-40011 8-3b

Envelope ConstructionThe following table lists the kinds of envelopes you can print inthe MP Tray (Tray 1).See the HP LaserJet Family Paper Specificat

Description Part # Fig. # Printer Overlay (Spanish) C3916-40009 8-3b 5 Overlay (Swedish) C2001-40007 8-3a 4 Overlay (Swedish) C3916-40016 8-3b 5 Over

Description Part # Fig. # Printer Paper Feed Assembly RG5-0451-000CN, 4 Paper Feed Assembly RG5-0451-000CN 8-6 4 Paper Feed Assembly RG5-0877-000CN

Description Part # Fig. # Printer Plate, Grounding RB1-2647-000CN 8-11 4/4+/5 Plate, Length Adjustment RB1-2370-020CN 8-14 4/4+/5 Plate, PCA Holding

Description Part # Fig. # Printer Power Supply (100/110V) RG5-0531-000CN 8-1a 4+/5 Power Supply (100/110V) RG5-0531-000CN 8-1a 4 Power Supply (100/11

Description Part # Fig. # Printer Roller, Lower RB1-3517-030CN 8-10 4+/5 Roller, Lower Delivery RF5-0438-000CN 8-8 4 Roller, Lower Delivery RF5-1077-

Description Part # Fig. # Printer Screw, w/Spring Washer XA9-0584-000CN 8-4c 4 Screw, w/Spring Washer XA9-0670-000CN 8-4c 4+/5 Screw, w/Washer, 2 ea

Description Part # Fig. # Printer Support, Cartridge RB1-2105-030CN 8-4a 4/4+/5 Switch RB1-2119-000CN 8-5 4/4+ Switch RB1-7907-000CN 8-5 5 Thermistor

A Duplexer This Appendix contains a functional overview of the OptionalDuplexer, as well as step-by-step Installation and Removal &Replacement ins

Functional OverviewThe Duplexer consists of two major assemblies; the SwitchbackAssembly that is attached to the back of the printer and theHolding Tr

Duplex PrintingNoteThe bold text and numbers in the followingdescription refer to parts shown in Figure A-2. When the printer is operating in duplex

2-8 Site Planning and Requirements

As the paper moves from the Switchback Assembly, it is pickedup by the rollers that are operated by the Holding Tray InputStepper Motor. The Input Ste

Electrical OverviewThe block diagram in Figure A-3 shows the Duplexer electricalcomponents.AC POWERSUPPLYDUPLEXERCONTROLPCAAC POWERTO PRINTERINPUTAC P

Installing the Optional DuplexerThe optional Duplexer can be installed by the customer. Thereare no fasteners securing the units together. The printe

76524312 312112Figure A-4 Duplexer Installation/RemovalDuplexer A -7

Removal and ReplacementThis section describes the complete disassembly of the Duplexer.Tasks that must be performed before beginning the procedure are

Removing the CoversRemoving the Switchback Covers1Remove the (2) screws shown in Figure A-5, callout 1. 2 Lift the cover off the Switchback Assembly.F

Removing the Side Cover on Power Side1 Open the front door.2 Remove the (1) screw shown in Figure A-6, callout 1.3 Release the (3) latch points with a

Removing the Side Cover on Gear Side1 Remove the (2) screws on top and the (1) screw on the front(see Figure A-7, callout 1).2 Turn the Duplexer on it

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

Removing the Back Cover1 Place the duplexer on a table or bench so that the backoverhangs the edge by a few inches.2 Release the (2) locating pins as

3ConfigurationIntroductionThe Configuration of the printer consists of setting hard and softuser defaults, and setting up the host computer to communi

Removing Internal Duplexer ComponentsRemoving the Fan/Motor/Solenoid/SensorAccess to the electronic components of the switchback assembly iseasy once

Removing the Switchback Paper Guide1 Remove the (1) E-clip from the shaft on the stepper motor sideshown in Figure A-11, callout 1.2 Pull the shaft to

Removing the Paper Guide Assembly1 Remove the (4) screws shown in Figure A-11, callout 2.2 Lift the switchback assembly and clear the wires.3 Remove t

Removing the Paper Roller1 Remove the (1) screw below the Switchback Solenoid Arm onthe gear side as shown in Figure A-13, callout 1.2 Remove the sens

3 Remove the (1) screw shown previously in Figure A-12,callout 2. Remove the upper switchback paper guide byreleasing its latch with a flat screwdrive

5 Remove the (1) E-clip from the gears on the shaft on thePower PCA side shown in Figure A-15, callout 1. 6Rotate the bushings and lift the roller out

Removing the Control PCA 1 Remove the (2) screws shown in Figure A-16, callout 1.2 Remove the cover plate.(continued on next page)Figure A-16 Cover Pl

3 Unplug all connectors from the Control PCA. NoteThe Control PCA connectors are keyed.4 Remove the (4) screws shown in Figure A-17.5 Disconnect the c

Removing the Power PCA1 Remove the (6) cover screws, (4) on the top and (2) on the side.Remove the cover.2 Remove the (4) screws from the Power PCA (s

Removing the Holding Tray Center Paper Guide 1 Remove the Control PCA as described earlier.2 Remove the (2) screws from the plate located on the power

Using The Control Panel(See Appendix B for LaserJet 5 information.)The control panel (see Figure 3-1) consists of eight keys, threeindicator lights, a

Removing the Holding Tray Belt1 Remove all the screws securing the plate (see Figure A-20,callout 1).2 Remove (1) E-clip shown in Figure A-20, callout

6 Remove the (1) one-way gear shown in Figure A-21, callout 1.NoteThe one-way gear must be reassembled correctly.With the gear on the shaft, turn the

Removing the Holding Tray Paper Sensor 1 Release the output holding tray.2 Remove the (2) screws from the stepper motor mount andremove mount. (This

Removing the Switchback Assembly1 Pull out the pin located on the Power PCA side (see FigureA-23, callout 1).2 Release the (1) E-clip on the upper pin

Parts and Diagrams for the DuplexerThe figures in this section illustrate the major subassemblies andcomponent parts of the HP LaserJet 4+/5 Duplexer.

Figure A-24 Duplex External CoversDuplexer A -29

Ref Part # Notes Description1 RA2-2061-000CNRA2-2231-000CNLJ4+LJ5Front Cover2 RA2-2096-000CNRA2-2232-000CNLJ4+LJ5Left Cover3 RA2-2097-000CNRA2-2233-00

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

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

Ref Part # Notes Description1 RA2-2069-000CN LJ4+/5 PCA Shield Plate2RA2-2070-000CNLJ4+/5Static Eliminator sml3 RA2-2072-000CN LJ4+/5 Timing Belt4 RA2

Indicator Mode DescriptionReady On: Ready to print.Flashing: Processing a print job. Do not take off line or switchoff.Off: Not ready; see display for

Ref Part # Notes Description25 RS1-2406-000CN LJ4+/5 Torsion Spring (Qty 3)26RS1-2407-000CNLJ4+/5Torsion Spring27 RS1-2409-000C N LJ4+/5 Tension Sprin

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

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

Ref Part # Notes Description1 RA2-2083-000CN LJ4+/5 Static Eliminator2RA2-2087-000CNLJ4+/5Deflector Linkage3 RA2-2094-000CN LJ4+/5 Upper Feed Guide4 R

Ref Part # Notes Description25 RS1-0591-000CN LJ4+/5 Gear 39T/22T (Qty 2)26RS1-0592-000CNLJ4+/5Gear 29T/54T27 RS1-2408-000CN LJ4+/5 Switchback Tension

BLaserJet 5/5M/5N PrinterThe Combined Service Manual contains information to be usedwith the LaserJet4/4+/4M/4M+/5/5M/5N. In specialcircumstances, th

Product InformationFeatures HP LJ 4+ HP LJ4M+ HPLJ5 HPLJ5M HPLJ5NModel C2037A C2039A C3916A C3917A C3952APrinter Speed 12 ppm 12 ppm 12 ppm 12 ppm 1

Product Family InformationThe model HP C3916A, C3917A, and C3952A are very similarfrom a hardware service standpoint. The models HP C2039A andC3917A p

Accessory Description Work in theLaserJet 4?Work in theLaserJet 4 Plus?Work in theLaserJet 5?C2082A Envelope Feeder Yes No NoC2082B Envelope Feeder

Identification The model number is on a label placed on the outside, rear coverof the printer. The model number (C3916A, C3917A, or C3952A)is found

ii

Key Function[On Line] Switches the printer between ON LINE (communicating with thecomputer or other data source) and OFF LINE (not communicating).For

Specifications HP LaserJet 5 / 5M / 5N Dimension HP LaserJet 5Width 16.4 in (415mm)Depth 15.9 in (403 mm)Height 11.7 in (297 mm)Weight (with toner car

Status 100/115 V 220/240 VRecommendedMinimum CircuitCapacity11.2 amps 5.0 ampsPeak Inrush Current 19-34 amps 17-40amps25% Decay Time 8.7-16.9 ms 1.4-9

Related Documentation The following manuals can be ordered from Hewlett-Packard’sSupport Materials Organization (SMO). The phone number forSMO is (8

Laser Statement (Sweden/Finland) LASERTURVALLISUUSLUOKAN 1 LASERLAITEKLASS 1 LASER APPARATHP LaserJet(s) 5/5M/5N laserkirjoitin on käyttäjän kannalta

Control Panel LayoutThe LaserJet 5 control panel consists of a 16-character scrollingdisplay panel and six keys, three of which have forward andbackwa

Key Explanation Go The Go key replaces the On Line, Form Feed, andContinue keys from previous HP LaserJet printers. The Go key performs five mai

Key Explanation Item Press Item to cycle through the selected menu’s items.Press the > end of the key to move forward through theitems. Press

Control Panel MenusFigure B-3 shows the menus and menu items available with thebasic printer configuration. Not all menu items are discussed inthis s

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

Printing MenuItem Options ExplanationPRINT MENUMAPNo options available When PRINT MENU MAP isdisplayed, press Select to print aconfiguration page an

Reset Menu Use Reset Menu function with caution. It can result in loss ofbuffered page data or printer configuration data. Reset Menu isactivated by h

Item Options ExplanationORIENTATION P*LP stands for portrait (vertical) andL stands for landscape(horizontal) orientation of type onthe page.FORM(5 TO

PCL Fonts MenuItem Options ExplanationPCL FONTLISTNo optionsavailablePress Select to print a list of the PCL fonts. SOURCE INTERNAL*SOFTSLOT NInter

PostScript MenuJob MenuItem Options ExplanationPS FONT LIST No optionsavailablePress Select to print a list of the fonts. While the listis being prin

Configuration MenuItem Options ExplanationTRAY 1 FIRST*CASSETTEWhen set to FIRST, Tray 1 is configured asthe default tray and will be used first durin

Item Options ExplanationAUTOCONTOFF*ONDetermines how the printer reacts to dataerrors and printer errors. When autocontinue is set to OFF, the printe

Memory Configuration MenuItem Options ExplanationI/O BUFFER AUTO*OFFONMemory set aside for I/O buffering isautomatically determined by the printer.No

Parallel MenuSerial MenuItem Options ExplanationHIGH SPEEDYES*NOThe speed at which data is transmitted to the printer.If the default value (YES) resul

Resets MenuNoteThe control panel resets will clear all memory inthe printer, while the Job Cancel feature onlyclears the current job.MenuSelectionPrin

Test MenuItem ExplanationPRINT SELF TEST When PRINT SELF TEST is displayed, press Select to print a self test. PRINT LJ5 DEMO Prints a page that il

Service ModeThe Service Mode should be used only by authorized servicepersonnel. The following can be executed while in the ServiceMode:• Print a Serv

Control Panel MenusFigure 3-2 shows the menus and menu items available with thebasic printer configuration. Not all menu items are discussed inthis se

Setting the Page CountThe page count is stored in the printer’s Non-Volatile Memory(NVRAM). If it is necessary to replace the Formatter PCA, thepage c

Setting the Cold Reset DefaultA Cold Reset procedure returns most user-selectable ControlPanel Menu selections to their factory defaults, including Pa

Skip DemoIf set to TRUE, will disable any test and demo pages containingthe HP logo. This setting should only be used by OEMs notwishing to give user

Programming a Flash SIMMA flash SIMM may be programmed while installed in the printer.To program a flash SIMM.1 Hold down the Menu> , Item< , Va

Changing the Control Panel Display LanguageThe default control panel display language is set for English.Supported languages are: English, French, Ger

NVRAM InitNVRAM Init clears the NVRAM to its initial state. This reset isused when the NVRAM becomes full and the user would like toadd additional pe

Understanding the PCL Self TestPrintoutReference Explanation (Refer to Figure B-4)1 Printer Information lists printer specific statistics. Formatter

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

Infrared CommunicationThe HP LaserJet 5, 5M, and 5N printers are equipped with anInfrared Datalink Association (IrDA) compliant port. The IrDAspecific

System Requirements• Hardware• Both the primary and secondary devices must be equippedwith an IrDA-compliant IR component. Older,non-IrDA-compliant de

Figure 3-2 Control Panel MapConfiguration 3-7

To Print Using the Infrared PortThe C2929A Infrared Transceiver must be plugged into theinfrared (IR) port on your HP LaserJet 5, 5M, or 5N printer,lo

3 Send the print job. The status light on top of the IR pod turnson. (Printing a complex document or using a software printspooler on your PC may dela

If you still have problems printing, make sure you are using anIrDA-compliant device and proper software and have selected theproper port for printing

If all these elements are properly installed and configured, usethe IR test tool to test the IrDA protocol transmission and deviceoperation. This tool

On HP Laser-Jet printers, a self-test page will be initiated by thetest.If the “TEST” LED goes out and the “PASS” LED fails to light,the printer’s IR

Infrared Port Not RespondingSituation SolutionThe connection cannot beestablished or the transmissionseems to be taking longer thanusual.Make sure the

Situation SolutionThe printer prints only part of apage or document.The connection has been brokenduring transmission. If you movethe portable device

Index!12 PRINTER OPEN 7-18 13 PAPER JAM 7-2014 NO EP CART 7-25 16 TONER LOW 4-10, 7-25 21 PRINT OVERRUN 3-53 41.1 ERROR 7-28 41.2 ERROR 7-28, 7-31 41.

defect Ruler 7-67 defect template 7-67 developing station, drum 5-22 DHHS laser safety 1-8 Diagnostics B-28 diagrams, timing 5-34disassembly, fuser 6-

high voltagecontact assembly 6-68 contact plate 6-62 contactor removal 6-62 contactor/paper guide removal 6-62 High Voltage Power Supplyassembly 7-51

Item Options ExplanationCOPIES 1* to 999 Select any number from 1 to999. PAPERENVELOPESLETTER* (110V printers),LEGAL, A4* (220V printers)EXECCOM10* (1

lower cassetteassemblies removal 6-44 assembly 5-4 drive motor (M3) 5-10 functional check 7-24 installing 3-44 paper loading 3-45 pickup motor 7-24 pi

paper feedassembly removal 6-18 paper feed guide removal 6-62 paper feed system 5-1, 5-26 paper jam 7-20 detection 5-11 PS1 7-20 troubleshooting 7-20

PS5check 7-44 MP tray trailing edge sensor 5-7 PS6, lower cassette paper-out sensor5-7 PS7, envelope feeder paper-out sensor5-7 RRAM size 3-24 Random

service checkpoints 4-1, 4-3 Service Mode 3-20, B-25 service/error messages 3-59 setting the cold reset B-27 setting the page count 3-21, B-26 setting

Error messages 7-2 general information 7-1 infrared B-38 Message Summary Table 7-2 messages 7-2 preliminary 7-1 Printer messages 7-2 quick checks 7-1

SN-1 Service Notes

SN-2 Service Notes

SN-3 Service Notes

SN-4 Service Notes

SN-5 Service Notes

Item Options ExplanationFONT SOURCE I*CSMn (1-4)Internal fonts*Cartridge fontsPermanent soft fontsSIMM Module: n=slotnumber. Typefaces stored inone of

SN-6 Service Notes

SN-7 Service Notes

SN-8 Service Notes

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

Item Options ExplanationMP TRAY FIRST*CASSMANUALPaper is selected first.Operates as a PC tray.Operates as a manual feed tray.LOCK NONE*MPPCLCand combi

Item Options ExplanationIO BUFFER AUTO*OFFONMemory is automatically determinedby the printer.No memory is set aside.Size can be manually adjustedIO SI

Item Options ExplanationSERIAL RS-232*RS-422 (HP LJ 4 only)Use the RS-422 when a longer cableis needed.PACING DTR/DSR*XON/XOFFUse if the computer requ

Printer FeaturesSome of the important features of the HP LaserJet 4, 4 Plus, andLaserJet 5 printers are described below.Page Protection (HP LaserJet 4

Contents1 Product InformationProduct Family Information . . . . . . . . . . . . . . . 1-2Identification . . . . . . . . .

Resource Saving (HP LaserJet 4 Plus and 5 only)Resource Saving gives the printer the ability to save certainentities such as permanent soft fonts, mac

I/O Buffering (HP LaserJet 4 Plus and 5 only)I/O buffering allows the user to allocate printer memory to holdthe job while it prints, freeing up the h

EconoMode (HP LaserJet 4 Plus and 5 only)The EconoMode setting uses approximately 50% less toner thanstandard mode printing by reducing dot density. E

Memory Enhancement technology (MEt)(HP LaserJet 4 Plus and 5 only)HP Memory Enhancement technology (MEt) effectively doublesthe printer’s standard mem

Network SecurityThe HP LaserJet 4 Plus and 5 printers allow the SystemAdministrator to lock out other user’s ability to change mostprinter control pan

5 Under the Extras menu, select Set Printer Password. Onthe Printer Security screen, enter the new password (numericvalues can be set from 0 to 65535

Service Mode(Refer to Appendix B for LaserJet 5 information.)The Service Mode should be used only by authorized servicepersonnel. The following can be

Setting the Page Count The page count is stored in the printer’s Non-Volatile Memory(NVRAM). If it is necessary to replace the Formatter PCA, thepage

Setting the Cold Reset Default The default paper size outside of the U.S. is typically A4.Therefore, when replacing Formatters where the desired def

Cold Reset The Cold Reset feature of the printers allows the printer to bereturned instantly to the factory default configuration settings.This featu

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

Understanding the PCL Self TestPrintout (Refer to Appendix B for LaserJet 5 information.)ItemFigure3-3Explanation1 Standard Menu Selections: Shows s

21234567891110Figure 3-3 HP LaserJet 4/4M PCL Self Test Printout Configuration 3-25

ItemFigure 3-4Explanation1 Standard menu selections: Lists selections in the order in which theyappear in the control panel display.2 Optional menus:

Figure 3-4 HP LaserJet 4 Plus/4M Plus PCL Self TestPrintoutConfiguration 3-27

Changing the Control Panel DisplayLanguage The default control panel display language is set for English.Supported languages are: English, French,

Test Print Button The Test Print button access hole is located on the side of theprinter. Press the Test Print button using a tool similar to apaper

Pressing the Test Print button will initiate a 15 ENGINE TEST.This is an engine test only. The Format PCA is bypassed whileprinting this test, althoug

System Configuration MS-DOS System ConfigurationTo communicate properly with the printer, the MS-DOSenvironment requires the addition or modifica

Serial MS-DOS CommandsMost IBM compatible computers default to a parallel printer port.To ensure that information is sent to your serial printer port,

Printer I/O ConfigurationParallel MenuThe default setting for the High Speed Parallel I/O is YES. If it isset to NO, the interface runs at a slower s

Printer Drivers . . . . . . . . . . . . . . . . . . . . . . . 3-41Install Printer Drivers and Utilities . . . . . . .

Pacing (Handshaking) Pacing (or “handshaking”) is a type of communication betweenthe printer and the computer. This is an important item in thepri

Serial Cable Pin-outs The following cable diagrams show the cable pinouts for the mostcommon serial configurations.DB-9 RS-232 Serial Connection — HP

DB-25 RS-232 Serial Connection — HP LaserJet 4 Plus/5If the computer has a serial port with 9 pins, use the C2932A orequivalent cable for the HP Laser

DB-25 Serial Connection — HP LaserJet 4 If the computer has a serial port with 25 pins, use the 17255Dcable or equivalent for the HP LaserJet 4.Figur

DB-25 RS-232 Serial Connection — HP LaserJet 4 Plus/5If the computer has a serial port with 25 pins, use the C2933A orequivalent cable for the HP Lase

RS-422A Serial Connection (Not available on the HPLaserJet 4 Plus or 5 printers)If you are configuring the computer to use an RS-422A serial port,you

Modular I/O ConfigurationThe printers are equipped with a modular I/O slot. A modular I/Ointerface card can be plugged into that slot to increase then

Printer DriversInstall Printer Drivers and Utilities Printer drivers are specialized programs designed to allowspecific software applications to funct

DOS UtilitiesUse the DOS Utilities to install printer drivers for MS-DOSapplications. Printer driver software for some common softwareapplications are

Packing the Printer Repackaging Instructions The printer warranty is for one-year and must be returned to anAuthorized HP service center for servic

Removing the Transfer Roller . . . . . . . . . . . . 4-16Replacing the Transfer Roller . . . . . . . . . . . . 4-165 F

Installing The Optional LowerCassette NotePlease see also the Service Notes section forproper use and adjustment of the lower cassette.These printer

Loading Paper into the Optional Lower Cassette Figure 3-13 Pull the cassette tray straight out of the printer.Figure 3-14 Adjust the cassette for the

Figure 3-15 Slide about 450 sheets of paper into the tray, upagainst the adjustable bracket that sets thepaper length.Figure 3-16 Press down on the st

Figure 3-17 Push down the left corner of the stack until thepaper is secured undered the metal clip.LETTEREXECA4LEGALFigure 3-18 Set the knob on the t

Figure 3-19 Note: cassette MUST be full before adjusting thetension. To adjust the tension, tap the stack of paperseveral times and turn the leftmost

Envelope Feeder InstallationFor complete information about installing the Envelope Feeder,see Envelope Feeder User’s Guide. This guide is provided wit

4 Insert the Envelope Feeder firmly into the printer (see Figure3-22).5 Turn ON the printer.LaserJet 4 and 4 PlusThe envelope size (EE TRAY=) appears

SIMM InstallationSIMM installation is covered in detail in the the printer’s User’sManual and in the kit that accompanies the SIMM. Theinstructions s

Any SIMM board can be installed in any of the four SIMM slots.Because the slots are close together, we recommend installingthem from right to left, st

Memory RequirementsA page’s complexity (rules, graphics, or dense text) may exceedthe printer’s ability to create the image rapidly enough to keeppace

6 Removal and ReplacementRequired Tools . . . . . . . . . . . . . . . . . . . . . . . . 6-2Hardware Review . . . . . .

CautionWhen removing a board from the antistaticpackage, avoid touching the metal traces on theSIMM board.For memory boards, compare the part number o

Accessing the SIMM SlotsPlease refer to Chapter 6, Removal and Replacement, forinstructions on removing the SIMMS door to access the slots.Note that a

3 Hold the SIMM board at a 30-degree angle to the slot andpush the edge of the board evenly and firmly into the slot (seeFigure 3-25 callout (A) ).4 R

Testing a SIMM BoardUse the procedures below to print a self-test page to verify SIMMboard installation. Procedures are given for both memory andPostS

Personality SIMM(PostScript)A personality (printer language) SIMM installation can beverified as outlined below (a PostScript SIMM is used in thisexam

Troubleshooting a SIMM BoardFor more information about the service/error messages below, seeChapter 7, Troubleshooting.Service / Error MessagesOne of

3-60 Configuration

4Preventive Maintenance Introduction The printer requires minimum routine maintenance. Use thischapter for information on:• Service Checkpoints. Thes

Life Expectancy of Consumables Always inspect the components listed in Table 4-1 for wear whenservicing the printer. Replace these components as

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