HP 4 Plus Manual
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Combined Service Manual HP LaserJet 4 / 4M (C2001A / C2021A) HP LaserJet 4 Plus / 4M Plus (C2037A / C2039A) HP LaserJet 5 / 5M /5N (C3916A/C3917A/ C3952A)
© Copyright Hewlett-Packard Company 1996 All Rights Reserved. Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws. Publication number C3916-90984 First edition, March 1996 Printed in USAWarranty The information contained in this document is subject to change without notice. Hewlett-Packard makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties or merchantability and fitness for a particular purpose. Hewlett-Packard shall not be liable for errors contained herein or for incidental or consequential damaged in connection with the furnishing, performance, or use of this material.WARNING Electrical Shock Hazard To avoid electrical shock, use only supplied power cords and connect only to properly grounded (3-hole) wall outlets. Hewlett-Packard Company 11311 Chinden Boulevard Boise, Idaho 83714
Conventions This manual uses the following conventions: Unless specifically stated otherwise, information applies to all seven printer models (LaserJet 4/4 Plus/4 M/4 M Plus/5/5 M/5 N). Most procedures are combined for all printers, except where they differ substantially. Color is used to emphasize items which are important to the material under discussion. The names of major printer parts and assemblies are Capitalized. Bold is used for emphasis, particularly in situations where italic type would be confusing. Italic type is used to indicate related documents or emphasis. COMPUTER type indicates text as seen on a computer monitor. DISPLAY\btype indicates text as seen on the printer’s 16 character LCD display panel (LaserJet 4Plus/4MPlus only). [KEYFACE] indicates keys on a computer keyboard or on the printer’s control panel. Examples include [Enter], [On Line] and Go . Note Notes contain important information set off from the text. CAUTIONCaution messages alert you to the possibility of damage to equipment or loss of data. WARNING!Warning messages alert you to the possibility of personal injury. i
Contents 1Product Information Product Family Information . . . . . . . . . . . . . . . 1-2 Identification . . . . . . . . . . . . . . . . . . . . . . . 1-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 1-5 HP LaserJet 4 and 4 Plus . . . . . . . . . . . . . . . . 1-5 Related Documentation . . . . . . . . . . . . . . . . . . 1-7 Safety Information . . . . . . . . . . . . . . . . . . . . . . 1-8 Product and Laser Safety . . . . . . . . . . . . . . . . 1-8 FCC RFI Statement . . . . . . . . . . . . . . . . . . . 1-9 Laser Statement (Sweden/Finland) . . . . . . . . . . 1-10 Toner Safety . . . . . . . . . . . . . . . . . . . . . 1-11 Ozone Statement . . . . . . . . . . . . . . . . . . . . 1-11 Doing Business with HP . . . . . . . . . . . . . . . . . . 1-12 Technical Assistance . . . . . . . . . . . . . . . . . 1-12 HP ASAP 1-800-333-1917 (U.S.) . . . . . . . . . . . . 1-12 HP FIRST . . . . . . . . . . . . . . . . . . . . . . . . 1-12 HP FIRST, U.S. . . . . . . . . . . . . . . . . . . . . . 1-12 HP FIRST, Europe . . . . . . . . . . . . . . . . . . . 1-12 HP AUDIO-TIPS . . . . . . . . . . . . . . . . . . . . 1-13 HP CompuServe Forum . . . . . . . . . . . . . . . . 1-13 Customer Information Centers . . . . . . . . . . . . . 1-13 Customer Support Center (Assist Line) . . . . . . . . 1-13 Printer Drivers . . . . . . . . . . . . . . . . . . . . . 1-13 European Customer Support Center . . . . . . . . . 1-14 Other Areas . . . . . . . . . . . . . . . . . . . . . . . 1-14 2Site Planning and Requirements Site Requirements . . . . . . . . . . . . . . . . . . . . . . 2-1 Printer Space Requirements . . . . . . . . . . . . . . . 2-2 Print Media Specifications . . . . . . . . . . . . . . . . 2-3 Adhesive Labels . . . . . . . . . . . . . . . . . . . . . 2-5 Label Construction . . . . . . . . . . . . . . . . . . . . 2-5 Overhead Transparencies . . . . . . . . . . . . . . . . 2-6 Envelopes . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Envelope Construction . . . . . . . . . . . . . . . . . . 2-7 3Configuration Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Using The Control Panel . . . . . . . . . . . . . . . . . . 3-2 Contents-1
Control Panel Keys . . . . . . . . . . . . . . . . . . . 3-2Reset Menu . . . . . . . . . . . . . . . . . . . . . . . 3-5 Control Panel Menus . . . . . . . . . . . . . . . . . . . 3-6 Printer Features . . . . . . . . . . . . . . . . . . . . . . 3-13 Page Protection (HP LaserJet 4 only) . . . . . . . . . 3-13 Resource Saving (HP LaserJet 4 Plus and 5 only) . . 3-14 I/O Buffering (HP LaserJet 4 Plus and 5 only) . . . . 3-15 EconoMode (HP LaserJet 4 Plus and 5 only) . . . . . 3-16 Resolution Enhancement (REt) . . . . . . . . . . . . 3-16 Memory Enhancement technology (MEt)(HP LaserJet 4 Plus and 5 only) . . . . . . . . . . 3-17 Density . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Network Security . . . . . . . . . . . . . . . . . . . . . 3-18 Remote Control Panel (DOS) . . . . . . . . . . . . . 3-18 HP LaserJet Utility (Macintosh) . . . . . . . . . . . 3-18 HP JetAdmin Utility (Novell Networks) . . . . . . . 3-19 Service Mode . . . . . . . . . . . . . . . . . . . . . . . 3-20 Setting the Page Count . . . . . . . . . . . . . . . . 3-21 Setting the Cold Reset Default . . . . . . . . . . . 3-22 Cold Reset . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Understanding the PCL Self Test Printout . . . . . . 3-24 Changing the Control Panel Display Language . . . . 3-28 Test Print Button . . . . . . . . . . . . . . . . . . . . 3-29 System Configuration . . . . . . . . . . . . . . . . . 3-31 MS-DOS System Configuration . . . . . . . . . . . . 3-31 Parallel DOS Commands . . . . . . . . . . . . . . . 3-31 Serial MS-DOS Commands . . . . . . . . . . . . . . 3-32 Printer I/O Configuration . . . . . . . . . . . . . . . . . 3-33 Parallel Menu . . . . . . . . . . . . . . . . . . . . . 3-33 Advanced Functions . . . . . . . . . . . . . . . . . 3-33 Serial Configuration . . . . . . . . . . . . . . . . . . 3-33 Serial Protocol . . . . . . . . . . . . . . . . . . . . . 3-33 BAUD Rate . . . . . . . . . . . . . . . . . . . . . . . 3-33 Pacing (Handshaking) . . . . . . . . . . . . . . . 3-34 Serial Cable Pin-outs . . . . . . . . . . . . . . . . . . . 3-35 DB-9 RS-232 Serial Connection — HP LaserJet 4 . . 3-35 DB-25 RS-232 Serial Connection — HP LaserJet 4 Plus/5 . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 DB-25 Serial Connection — HP LaserJet 4 . . . . . 3-37 DB-25 RS-232 Serial Connection — HP LaserJet 4 Plus/5 . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 RS-422A Serial Connection (Not available on the HP LaserJet 4 Plus or 5 printers) . . . . . . . . . 3-39 RS-422A Serial Configuration (LaserJet 4 only) . . . 3-39 Modular I/O Configuration . . . . . . . . . . . . . . . . 3-40 Contents-2
Printer Drivers . . . . . . . . . . . . . . . . . . . . . . . 3-41Install Printer Drivers and Utilities . . . . . . . . . 3-41 How to Obtain Printer Drivers . . . . . . . . . . . . . 3-41 DOS Utilities . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Packing the Printer . . . . . . . . . . . . . . . . . . . 3-43 Repackaging Instructions . . . . . . . . . . . . . . 3-43 Packing Checklist . . . . . . . . . . . . . . . . . . . . 3-43 Installing The Optional Lower Cassette . . . . . . . . 3-44 Loading Paper into the Optional Lower Cassette . . 3-45 Envelope Feeder Installation . . . . . . . . . . . . . . . 3-49 LaserJet 4 and 4 Plus . . . . . . . . . . . . . . . . . . 3-50 LaserJet 5 . . . . . . . . . . . . . . . . . . . . . . . . 3-50 SIMM Installation . . . . . . . . . . . . . . . . . . . . . 3-51 Protecting the SIMM Board . . . . . . . . . . . . . . 3-51 Memory Requirements . . . . . . . . . . . . . . . . . 3-53 Accessing the SIMM Slots . . . . . . . . . . . . . . . 3-55 Installing the SIMM Boards . . . . . . . . . . . . . . 3-55 Testing a SIMM Board . . . . . . . . . . . . . . . . . . 3-57 Memory SIMM . . . . . . . . . . . . . . . . . . . . . 3-57 Running a Self Test Printout . . . . . . . . . . . . . . 3-57 Personality SIMM (PostScript) . . . . . . . . . . . . . . . . . . . . . . 3-58 Troubleshooting a SIMM Board . . . . . . . . . . . . . . 3-59 Service / Error Messages . . . . . . . . . . . . . . . . 3-59 4Preventive Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Life Expectancy of Consumables . . . . . . . . . . . . . . 4-2 Service Checkpoints . . . . . . . . . . . . . . . . . . . . . 4-3Cleaning Your Printer . . . . . . . . . . . . . . . . . . 4-4 Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . 4-5 Saving Toner with EconoMode (HP LaserJet 4 Plus and 5 Only) . . . . . . . . . . . . . . . . . . . . 4-6 Storing the Toner Cartridge . . . . . . . . . . . . . . . 4-6 Installing the Toner Cartridge . . . . . . . . . . . . . 4-7 Non-HP Toner Cartridges . . . . . . . . . . . . . . . . 4-9 Clearing the TONER LOW Message . . . . . . . . . 4-10 Periodic Maintenance Procedures . . . . . . . . . . . . 4-11 Removing the MP Tray (Tray 1) Pickup Roller andSeparation Pad . . . . . . . . . . . . . . . . . . . 4-11 Removing the PC (Tray 2) Pickup Roller . . . . . . 4-13 Removing the Lower Cassette (LC) or (Tray 3) Pickup Roller . . . . . . . . . . . . . . . . . . . . 4-14 Removing and Replacing the Transfer Roller . . . . 4-15 Contents-3
Removing the Transfer Roller . . . . . . . . . . . . 4-16 Replacing the Transfer Roller . . . . . . . . . . . . 4-16 5Functional Overview Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 5-1DC Controller System . . . . . . . . . . . . . . . . . . 5-2 DC Controller Loads . . . . . . . . . . . . . . . . . . . 5-3 Serial Data Communication . . . . . . . . . . . . . . . 5-4 Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Photosensors . . . . . . . . . . . . . . . . . . . . . . . 5-6 Microswitches . . . . . . . . . . . . . . . . . . . . . . 5-8 PC (Tray 2) and LC (Tray 3) Tray Size SensingSystem . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Motors . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Paper Jam Detection . . . . . . . . . . . . . . . . . 5-11 Formatter System . . . . . . . . . . . . . . . . . . . . 5-12 I/O Control . . . . . . . . . . . . . . . . . . . . . . . 5-12 Memory Management . . . . . . . . . . . . . . . . . 5-14 Data Processing . . . . . . . . . . . . . . . . . . . . 5-14 PJL Overview . . . . . . . . . . . . . . . . . . . . . 5-15 Image Formation System . . . . . . . . . . . . . . . . . 5-16 Photosensitive Drum . . . . . . . . . . . . . . . . . 5-17 Drum Sensitivity . . . . . . . . . . . . . . . . . . . 5-17 Cleaning Stage . . . . . . . . . . . . . . . . . . . . 5-18 Conditioning Stage . . . . . . . . . . . . . . . . . . 5-19 Writing Stage . . . . . . . . . . . . . . . . . . . . . 5-20 Developing Stage . . . . . . . . . . . . . . . . . . . 5-22 Transferring Stage . . . . . . . . . . . . . . . . . . 5-24 Fusing Stage . . . . . . . . . . . . . . . . . . . . . 5-25 Paper Feed System . . . . . . . . . . . . . . . . . . . 5-26 Printing from the MP Tray (Tray 1) . . . . . . . . . 5-29 Printing from the PC Tray (Tray 2) . . . . . . . . . 5-30 Power System . . . . . . . . . . . . . . . . . . . . . . . 5-31 Basic Sequence of Operation . . . . . . . . . . . . . . 5-33 Standard Printer Operation . . . . . . . . . . . . . 5-33 Timing Diagrams . . . . . . . . . . . . . . . . . . . 5-34 Warmup Period . . . . . . . . . . . . . . . . . . . . 5-37 Standby Period . . . . . . . . . . . . . . . . . . . . 5-37 PowerSave . . . . . . . . . . . . . . . . . . . . . . . 5-37 Initial Rotation Period . . . . . . . . . . . . . . . . 5-38 Print Period . . . . . . . . . . . . . . . . . . . . . . 5-40 Last Rotation Period . . . . . . . . . . . . . . . . . . . 5-42 Contents-4
6Removal and Replacement Required Tools . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Hardware Review . . . . . . . . . . . . . . . . . . . . . . 6-2 Removing the Covers . . . . . . . . . . . . . . . . . . . . 6-4Right Side Cover Removal . . . . . . . . . . . . . . . . 6-4 Top Cover Removal . . . . . . . . . . . . . . . . . . . 6-5 Left Side Cover Removal . . . . . . . . . . . . . . . . . 6-7 Rear Door Removal . . . . . . . . . . . . . . . . . . . . 6-8 Font Door Cover Removal (LJ 5 Right Front Cover Removal) . . . . . . . . . . . . . . . . . . . 6-10 Multi-Purpose (MP) Tray (Tray 1) Door Removal . . . 6-12 Multi-Purpose (MP) Tray (Tray 1) Removal . . . . . . 6-13 Assemblies Removal . . . . . . . . . . . . . . . . . . . . 6-15 Power Supply Removal . . . . . . . . . . . . . . . . . 6-15 Paper Feed Assembly Removal . . . . . . . . . . . . . 6-18 High Voltage Power Supply (HVPS) Removal . . . . . 6-21 Fuser Assembly Removal . . . . . . . . . . . . . . . . 6-22 Control Panel and Overlay Removal . . . . . . . . . . 6-23 Removing the SIMMs Door . . . . . . . . . . . . . . 6-25 Formatter Cage Removal . . . . . . . . . . . . . . . . 6-27 Formatter PCA Removal . . . . . . . . . . . . . . . . 6-29 DC Controller Removal . . . . . . . . . . . . . . . . . 6-33 DC Controller Installation . . . . . . . . . . . . . . . 6-35 Main Motor Assembly Removal . . . . . . . . . . . . 6-37 Gear Assembly Removal . . . . . . . . . . . . . . . . 6-38 Fan Removal . . . . . . . . . . . . . . . . . . . . . . 6-39 Output Assembly Removal . . . . . . . . . . . . . . . 6-41 Paper Exit Sensor (PS3) Removal . . . . . . . . . . . 6-42 Scanner Assembly Removal . . . . . . . . . . . . . . 6-43 Lower Cassette Assemblies . . . . . . . . . . . . . . . . 6-44 Lower Cassette Sensor PCA Removal . . . . . . . . . 6-44 Lower Cassette Pickup Motor Removal . . . . . . . . 6-45 Replacing Fuser Assembly Parts . . . . . . . . . . 6-47 Fuser Assembly Configuration . . . . . . . . . . . . 6-48 Removing the Fuser Roller Heat Lamp . . . . . . . . 6-49 Fuser Assembly Thermoswitch Removal . . . . . . . 6-55 Thermistor Removal . . . . . . . . . . . . . . . . . . 6-56 Paper Control PCA Removal . . . . . . . . . . . . . . 6-59 Sensor PCA Removal . . . . . . . . . . . . . . . . . . 6-60 PS1 and PS2 Sensor Assembly Removal . . . . . . . 6-61 High Voltage Contact Plate (HVCP) and Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . 6-62 Accessing the High Voltage Contact Plate andFeed Guide Assembly . . . . . . . . . . . . . . . . 6-62 Contents-5
Removing the High Voltage Contact Assembly andFeed Guide Assembly . . . . . . . . . . . . . . . . 6-67 Replacing the High Voltage Contact Assembly/Feed Guide Assembly . . . . . . . . . . 6-68 Interconnect PCA Removal . . . . . . . . . . . . . . . 6-69 7Troubleshooting LaserJet 5 Error Map . . . . . . . . . . . . . . . . . . . . 7-A Pre-Troubleshooting Procedures . . . . . . . . . . . . . 7-1 Preliminary Operating Checks . . . . . . . . . . . . . 7-1 Printer Message Troubleshooting . . . . . . . . . . . 7-2 Printer Message Summary Table . . . . . . . . . . . 7-2 Clearable Warnings . . . . . . . . . . . . . . . . . 7-10 Printer Message Troubleshooting Procedures . . . . . . 7-12 Blank Display . . . . . . . . . . . . . . . . . . . . . 7-12 MP/PC/LC (Tray 1/2/3) LOAD Message . . . . . . 7-13 Cassette Size Switches (SW603, SW604, SW605) Functional Check . . . . . . . . . . . . . . . . . . 7-15 Paper Size Sensing Lower Cassette . . . . . . . . . 7-16 PC Empty Sensor (PS2) Functional Check . . . . . . 7-17 PS4 Check (MP Tray Empty Sensor) . . . . . . . . . 7-17 12 Printer Open Message . . . . . . . . . . . . . . . 7-18 SW601 Functional Check . . . . . . . . . . . . . . . 7-19 13 PAPER JAM Message . . . . . . . . . . . . . . . 7-20 PS1 (Input/Registration Sensor) Check . . . . . . . . 7-22 PS3 (Exit Sensor) Check . . . . . . . . . . . . . . . . 7-23 Pickup Motor Functional Test (M2) . . . . . . . . . . 7-23 Lower Cassette Functional Check . . . . . . . . . . 7-24 14 NO EP CART Message . . . . . . . . . . . . . . . 7-25 16 Toner Low Message . . . . . . . . . . . . . . . . 7-25 41.X ERROR Message . . . . . . . . . . . . . . . . 7-27 50 SERVICE Error - Fuser Malfunction . . . . . . . 7-29 51 ERROR Message . . . . . . . . . . . . . . . . . . 7-31 52 ERROR Scanner Malfunction . . . . . . . . . . . 7-32 Laser/Scanner Assembly Functional Checks . . . . . 7-32 57 (or 57.1) SERVICE Message (Main Motor Failure) . . . . . . . . . . . . . . . . . . . . . . . 7-33 Main Motor Functional Checks . . . . . . . . . . . . 7-33 58 (or 57.2) SERVICE (Fan Failure) . . . . . . . . . 7-34 Image Defect Summary . . . . . . . . . . . . . . . . . 7-35 PS5 Check (MP Tray Paper End Sensor) Functional Test . . . . . . . . . . . . . . . . . . . 7-44 Image Formation Troubleshooting . . . . . . . . . . . . 7-49 Half Self-Test Functional Check . . . . . . . . . . . 7-49 Contents-6