Instruction/ maintenance manual of the product C4077-90960 EXP Computer
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Copyright© 1997 Hewlett-P ackard Co. Printed in USA 7/97 Manual Part No. C4077-90960 HP LaserJet 5Si Family Printers Service Manual English HP LaserJet 5Si Family Printers Service Manual Printed on a.
Service Manual HP LaserJet 5Si (C3166A) HP LaserJet 5Si MX (C3167A) HP LaserJet 5Si NX (C3950A) HP LaserJet 5Si HM (C3124A) HP LaserJet 5Si Mopier (C4076A/C4077A/C4176A).
© Copyright Hewlett-Packard Company 1997 All Rights Reserved. Reproduction, adapt ation, or translatio n without prior written permis sion is prohibited, exce pt as allowed under t he copyright laws.
Conventions This manual uses the following conventions: The names of major printer parts and assemblies are Capitaliz ed. Color is used to emphasize items which are important to the material under discussion. Bold is used for emphasis, particularly in situations where italic type would be confusing.
Chapter Descriptions 1 Product Information Contains printer features and product overview, tray capacities and sizes, media specifications, service approach, and how to get technical assistance. 2 Site Requirements Contains space and environmental requir ements.
B IO Information Contains basic cabling and configuration information for connecting the printer to supported networks. C Regulatory Information Contains required safety and compliance statements. Subject Index Contains an alphabetical, cross referenced listing of information found in the main body of the manual.
List of Figures Figure 1-1 Sample Model and Serial Number Labels . . . . . . . . . . 1-7 Figure 1-2 HP LaserJet 5Si/5Si MX/NX and Mopier Engine - Front and Right Side View with Tray 1 Open . . . . . . . . . . . 1-14 Figure 1-3 HP LaserJet 5Si Mopier - Front and Right Side View with Tray 1 Open .
Figure 6-3 AC Access Cover . . . . . . . . . . . . . . . . . . . . . . . 6-18 Figure 6-4 Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Figure 6-5 Front Cover (1 of 2) . . . . . . . . . . . . . . . . . . . . . . 6-21 Figure 6-6 Front Cover (2 of 2) .
Figure 6-51 Transfer Roller Assembly . . . . . . . . . . . . . . . . . . 6-64 Figure 6-52 Tray 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-65 Figure 6-53 Tray 4, Back Cover . . . . . . . . . . . . . . . . . . . . . . 6-67 Figure 6-54 Tray 4, Left Cover .
Figure 6-99 Mailbox with Stapler, Stapler Removal . . . . . . . . . . 6-109 Figure 7-1 HP LaserJet 5Si / 5Si MX / 5Si Mopier Troubleshooting Process . . . . . . . . . . . . . . . . . . . 7-4 Figure 7-2 HP LaserJet 5Si / 5Si MX / 5Si Mopier Troubleshooting Process .
Figure 8-3 Printer Internal Components (1 of 4) . . . . . . . . . . . . 8-12 Figure 8-4 Printer Internal Components (2 of 4) . . . . . . . . . . . . 8-14 Figure 8-5 Printer Internal Components (3 of 4) . . . . . . . . . . . . 8-16 Figure 8-6 Printer Internal Components (4 of 4) .
List of T ables Table 1-1 Printer Features . . . . . . . . . . . . . . . . . . . . . . . 1-3 Table 1-2 Tray 1 Media Guidelines . . . . . . . . . . . . . . . . . . . 1-4 Table 1-3 Tray 2 Media Guidelines . . . . . . . . . . . . . . . . . . . 1-5 Table 1-4 Tray 3 Media Guidelines .
Table 7-3 Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Table 7-4 Image Quality . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Table 7-5 Printer Control Panel Messages . . . . . . . . . . . . . . . 7-24 Table 7-6 Blank (White) page .
1 Product Information Chapter Contents Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Paper Capacities and Sizes . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Tray 1 . . . . . . . . . . . . . . . . . . . . . .
Recycling Toner Cartridges . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Related Documentation and Training Media . . . . . . . . . . . . . . . 1-24 Technical Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 HP AUDIO-TIPS .
Printer Features Features LaserJet 5Si (C3166A) LaserJet 5Si MX (C3167A) LaserJet 5Si Mopier (C4076A/C4077A/ C4176A) Print Speed Duplex Speed 24 ppm letter or A4 13 ppm ledger (1 1x17) or A3 15 ppm legal or B4 9.5 ppm letter or A4 6.5 ppm ledger or A3 7.
Paper Capacities and Sizes T ray 1 Media Type (Feed Orientation) Dimensions Weight Capacity Maximum paper size 1 1.7 x 17.7 in (297 x 450 mm) Single-sided: 16-lb bond to 53-lb bond (1 10-lb index); 60.
T ray 2 Note The HP LaserJet 5Si HM (C3124A) supports 16-53 lb bond media from all trays. However, performance in Tray 2 may not be as good with heavier media due to the sharp turn in the paper path. For best performance, Tray 1, 3, or optional Tray 4 are recommended.
T ray 3 T ray 4 (2000 Sheet Input Unit) Media Type (Feed Orientation) Dimensions Weight Capacity Paper , Letter (Landscape) 8.5 x 1 1 in (216 x 279 mm) Single-sided: 16 to 28-lb (60 to 105 g/m 2 ) T wo-sided: 16 to 28-l b bond (60 to 105 g/m 2 ) 500 sheets of 20-lb bond paper (letter and A4 for T rays 2,3, and 4) Paper , ISO A4 (Landscape) 8.
Identification Model and Serial Numbers The model number and serial numbers are listed on identification labels located on the rear of the printer. The model number is alphanumeric, such as C3166A for the HP LaserJet 5Si printer.
Specifications This section contains information on physical and electrical character istics of the printer. For information on the printer site and environmental requirements (such as operating temper ature and humidity, ventilation, etc.) see Chapter 2.
Volts Freq Amps* Watts (typical) Printer 120 V ac ± 10% 100 V ac ± 10% 50/60 Hz ± 2 Hz 50/60 Hz ± 2 Hz 13.5 @ 120v printing = 500 standby = 135 PowerSave Mode LaserJet 5Si =21 LaserJet 5Si MX=24 220 V ac ± 10% 240V ac ± 10% 50 Hz ± 2 Hz 50 Hz ± 2 Hz 6.
Operation position (per ISO 9296) Printer (stand alone) Printer System* Printing L PA dB(A) 54 db 56 db Standby L PA dB(A) 42 db 42 db Bystander 1m (per ISO 9296) Printing L PA dB(A) 50 db 55 db Standby L PA dB(A) 38 db 42 db Sound Power (per ISO 9296) Printing L W AD 6.
Media Selection Guidelines Note More detailed specifications are in the HP LaserJet 5Si and 5Si MX User’s Guide, and the HP LaserJet Printer Family Paper Specification Guide. (See “Related Documentation and Training Media” later in this chapter.
Adhesive Labels Use the following guidelines when selecting labels: Caution Tray 1 is required for printing adhesive labels. Print labels to the Face-Up Bin only. This printer does not support use of labels with any exposed spaces. Do not attempt to print on label sheets after any of the labels have been removed from the sheet.
Storing Print Media Follow these guidelines when stacking and storing print media: • Store paper in its ream wrapper until ready to use. • Re-wrap partially used packages of media before storing. • Stack each carton upright and squarely on top of the other.
Product Overview External V iew of HP LaserJet 5Si/5Si MX/NX and Mopier Engine HP LaserJet 5Si/5Si MX/NX and Mopier Engine - Front and Right Side View with Tray 1 Open 1 Face-Up Bin 2 Control Panel 3 .
External V iew of HP LaserJet 5Si Mopier HP LaserJet 5Si Mopier - Front and Right Side View with Tray 1 Open 1 Left Output Bin 2 Control Panel 3 Top Output Bin 4 Adjustable paper stop 5 Top cover 6 En.
Formatter Assemblies Rear and Left Side View 1 Formatter Printed Circuit Assembly 2 Hard Disk Accessory Location (optional for LJ 5S i/5Si MX/5Si NX and standard for LJ 5Si Mopier and Mopier Engine) 3.
Accessories and Options The accessor ies and optional equipment for the LaserJet 5Si, 5S i MX, and 5Si NX printers are shown in Figure 1-5 and described in Table 1-9.
Accessory/Option Part/Product Number Description T oner Cartridge C3909A Replacement toner cartridge. Stapler Cartridges C3772A 3-pack of staple cartridges.
Hard Disk The Printer Hard Disk accessory is optional for the HP Laser Jet 5Si, 5Si MX, and 5Si NX printers. The hard disk is a standard feature of the HP LaserJet 5Si Mopier and Mopier engine. It can be used to permanently store downloaded fonts and forms in the printer.
If you are a Po stScript langua ge programmer, refer to Adobe’s PostScript Language Reference Manual for information about downloading forms and patterns to the disk. (For the Macintosh environment, refer to the on line help in the HP LaserJet Utility Guide included with the HP LaserJet Utility software.
Service Approach Repair of the printer normally begins with a three-step process: • Step 1: Isolate the problem to the major system, i.e. the host computer, the network and/or server, or the printer system. • Step 2: Determine if the problem is located in the access ories or in the printer engine.
Consumables The printer has two consumables, the toner cartridge and staple cartridges, which may be ordered directly from Hewlett-Packard. Refer to Chapter 8 for ordering information. T oner Cartridge Life The Toner Cartridge (C3909A) is designed to simplify replacement of the major “consumable” parts.
Refilled T oner Cartridges & Non-HP Staple Cartridges While Hewlett-Packard does not prohibit the use of refilled toner cartridges and non-HP staple cartridges during the warranty period or while .
Related Documentation and T raining Media Table 1-11 lists where to order related documentation. See “Order ing Parts” earlier in this chapter for the phone numbers of each organization.
T echnical Assistance HP ASAP (Automated Support Access Program) pr ovides free technical support information 24 hours a day, 7 days a week. The ASAP system includes HP AUDIO-TIPS and HP FIRST, both explained below. The ASAP service requir es a touchtone phone.
HP CompuServe Forum CompuServe members can download a variety of support materials including product data sheets, software application notes, and printer drivers for many popular software applications. Members may also post and reply to questions in an interactive format.
W arranty This warranty entitles you to standard warranty ser vices for your printer and accessories and is available from HP wor ldwide. However, there may be local variations in the level of warranty service. You should c ontact the local HP Service Center to check for the applicable local warr anty in your country or provinc e.
Note The use of non-Hewlett-Packard toner cartridges alone does not affect either your warranty or any maintenance contr act you may have purchased. However, if an HP LaserJet printer failure or damage is found to be attributable directly to the use of a non-HP toner cartridge, HP will not repair the printer free-of-charge.
2 Site Requirements Chapter Contents Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Environmental Requirements . . . . . . . . . . . . . . . . .
2-2 Site Requirements.
Operating Environment The electrical specifications listed in Chapter 1 must be maintained to ensure proper operation of this printer. Cons ider the following points before installing the printer. • Install in a well-ventilated, dust-free area. • Install on a hard, flat and continuous surface, with all four pr inter feet level.
Space Requirements Printer Space Requirements 1 Top view 2 Side view Environmental Requirements Keep the printer within the following environmental conditions for optimum performance. Figure 2-1 Item Operating Storage Temperature 10° to 32.5° C (50° to 90.
3 Operating Overview Chapter Contents Using the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Control Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Indicator Lights . . . . . . . . . . . . . . . . . . . . .
3-2 Operating Overview.
Using the Control Panel Control Panel Layout The control panel consists of a 2-line, 20-character per line display panel, five keys, and three indicator lights. Control Panel Layout Figure 3-1 Key Function [On Line] Switches the state of communication bet ween computer and printer to ON (on line) or OFF (of f line).
Indicator Lights The control panel indicator lights are described in the following table. The column labeled “Do this:” includes an action only when an action is required. When this indicator: Looks like this: It means this: Do this: On Line On Flashing Of f Ready to receive data.
Settings and Defaults The printer makes most printing decisions based on either temporar y settings or factory (permanent) defaults. Note Settings you send from software applications overr ide printer defaults. Temporary Settings are the values set for the cur rent print job by your software application.
Restoring Factory Defaults Caution If possible, print a PCL Configuration Page prior to performing a Cold Reset. This will document current settings for later referenc e.
Menu Item Default Setting DISPLA Y LANGUAGE= ENGLISH P APER DESTINA TION= T OP OUTPUT BIN P APER SIZE= LETTER or A4 P APER TYPE= PLAIN ENVELOPE FEEDER SIZE= COM10 ORIENT A TION= PORTRAIT PERSONALITY= .
Heavy Media Fuser Mode Explanation The LaserJet 5Si HM (Heavy Media) provides users the capability to enhance toner adhesion for heavier media. The fuser mode choices can be made at the printer’s control panel or with PJL commands. Press MENU until you see PRINT QUALITY MENU .
STD PAPER HEAVY PAPER1 HEAVY PAPER2 CARD STOCK1 CARD STOCK2 CARD STOCK3 T ypi cal copy/bond paper , labels, envelopes , and transparenci es. Supports 20-28 lb Bond media. Heavier copy/bond paper , labels. Supports 28-36 lb Bond media. Heavier copy/bond paper , labels.
Control Panel Menus Press [Menus] to cycle through the control panel menus. Each menu is described in a separate table i n this section. Table 3-5 provides a ma p of all the menus and their associated items. Menu items are displayed only if their associated option is installed, or function is activated.
Note Shaded items appear only if the associated option or function is activated. TRAY MENU JOB CONTROL MENU TEST MENU CONFIGURATION MENU PRINT QUALITY MENU See Table 3-6 See Table 3-7 See Table 3-8 Se.
T ray Menu Asterisk ( * ) indi cates printer default. Shaded menu items appear only i f associated option or func tion is acti vated. Tray Menu Items Item Choices Action Required ENV FEEDER TYPE= PLAIN* PREPRINTED LETTERHEAD TRNSPRNCY PREPUNCHED LABELS BOND RECYCLED COLOR CARDSTOCK Press [Item] to display al ternate menu items.
Job Control Menu The items available in the Job Control Menu can also be changed through software applications if an appropriate pr inter driver is installed. Job Control Menu Items Item Choices Action Required CANCEL JOB None Press [Item] to display al ternate menu items.
T est Menu Test Menu items can be selected only from the printer contr ol panel. You cannot change or override them from your softwar e application. See “Testing the Printer” later in this chapter for detailed information about running printer tests and interpreting their r esults.
Configuration Menu This menu contains the items for Personality, Resourc e Saving and Memory setup. Depending on how the printer is configured, any combination of menu items and possible values can appear. Memory configuration items can be selected only from the printer c ontrol panel.
Asterisk ( * ) indi cates printer default. Shaded menu items appear only i f associated option or func tion is acti vated. Configuration Menu Items Item Choices Action Required SERVICE MESSAGE= ON OFF.
Print Quality Menu Asterisk ( * ) indi cates printer default. ** Only wi th HP LaserJet 5Si Heav y Media printers PostScript Menu Asterisk ( * ) indi cates printer default. Shaded menu items appear only i f associated option or func tion is acti vated.
PCL Menu PCL Menu Items Item Choices Action Required SOURCE= INTERNAL * Press [+] to display choi ce. Press [Select] to activate choi ce. NUMBER= 0..52 (0 *) Press [+] to display choi ce. Press [Select] to activate choi ce. PTICH= 0.44..99.99 (10.00 *) Press [+] to display choi ce.
I/O Menu Caution When changing memory configuration (Configuration Menu) or I/O Buffering, the printer will automatically reset. All fonts, macr os, and downloaded data (except what is stored on the optional Disk Acc essory) will be lost. Asterisk ( * ) indi cates printer default.
MIO 1 and 2 Menus Note Items displayed depend upon the MIO card that is installed in the printer. MIO 1 and 2 Menu Items Item Choices Action Required Items display ed depend upon the MIO card that is installed in the pri nter . The actions requi red depend upon the items display ed on the Menu.
Service Mode The Service Mode should be used only by author ized service pers onnel. While in Service Mode, you can: • Verify and set the Page Count and serial number. These are displayed on the PCL Configuration Page. • Set the Cold Reset Paper Size Default.
Service Mode Menu Items Item Choices Actions Required PAGECOUNT= nnnnnnn Displays total number of pages printed by the pri nter . Press [+] to step through values abov e cursor . Press [Select] to activate choi ce. Cursor will move to next di git. Printer will set new number i nto NVRAM after least signi ficant digit is selected.
Setting Page Count, Maintenance Count, and Serial Number The page count, maintenance count, and printer serial numbers ar e stored in Non-Volatile Memory. PAGECOUNT is the total number of images printed by the printer, MAINTCOUNT is the pagecount when the next preventive maintenance should be performed (every 350,000 images), and S.
Setting the Cold Reset Default Paper Size When replacing a Formatter PCA with a default paper size setting of A4, set COLD RESET PAPER= to A4. 1 Enter the Service Mode as previously described in this chapter. 2 Press [Menus] to access the Service Menu.
T esting the Printer PCL Configuration Page When you print a PCL Configuration Page, the printer checks its internal controller and I/O interface, then pr ints two pages, one showing the overall printer configuration (see Figure 3-2), and one showing the current menu settings (see Figure 3-3).
Configuration Page Figure 3-2 PCL Configuration Page 3-26 Operating Overview.
1 Printer Information lists printer s pecific statistics. Serial Number shows the printer serial number . Formatter Number shows the number of the formatter board. Firmware Datecode is an eight-digit date (YYYYMMDD) of the internal code. Processor Revision is the revision number of the firmware processor .
Figure 3-3 PCL Menu Map Page 3-28 Operating Overview.
1 T ray Menu lists the current media types settings, and for T ray 1 or the Envelope Feeder , the media size. 2 Job Control Menu shows the Cancel Job and Form Feed times. 3 T est Menu lists the different available printer tests. 4 PCL Menu lists the PCL font settings used.
Cold Reset Cold reset clears all data from the printer memor y and sets all the defaults (except Service Mode settings) back to the factory settings. Caution Performing a cold reset resets the JetDirect configuration. To avoid making changes to your configuration remove the JetDirect card before performing a cold reset.
4 Maintenance and Adjustments Chapter Contents Cleaning the Printer and Accessories . . . . . . . . . . . . . . . . . . . 4-3 Cleaning the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Cleaning Spilled Toner . . . . . . . . . . . .
4-2 Maintenance and Adjustments.
Cleaning the Printer and Accessories To maintain the print quality and paper performance, thor oughly clean the printer and the paper handling accessories: • Every time you change the toner cartridge. • After printing approximately 15,000 images. • Whenever print quality problems occur.
Cleaning the Printer 1 Before you begin these steps , turn the printer OFF and unplug all cords. 2 Open the top cover of the printer and remove the toner cartridge. WARNING! Avoid touching the adjacent fusing area. It may be HOT. Caution Do not touch the transfer roller (A).
Cleaning Spilled T oner Defective toner cartridges can develop leaks. Also, after a paper jam has occurred, there may be some toner remaining on the rollers and guides inside the printer. The pages that print immediately after the jam may pick up this toner.
Preventative Maintenance The user-conducted preventive maintenance cycle for this printer is every 350,000 images. The part numbers for the preventive maintenance kits are C3971A for the 100V printers, and C3972A for the 220V printers.
T ray 2 and 3 Adjustment Procedure The paper trays are mechanically aligned to the printer chassis at the factory. Perform this procedur e ONLY if a paper tray has been replaced with a tray other than the original factory installed unit, or if the top margin of the image area is off-center more than 0.
Note Refer to Figure 4-2. Each adjustment notch changes the physical position of the tray by 0.5 mm (0.02 in). Moving the lever counter-clockwise moves the tray inward and increases distanc e A. Moving the lever clockwise moves the tray outward and decreas es distance A.
T ray 4 Adjustment Procedure In some cases, the registration from Tray 4 (HCI) causes pr int to start too close to the edge of the paper. This situation is not a typical occurrenc e. In most cases the Tray 4 offset is fine. Although this may or may not be within specification, it is unacceptable to some users.
10 Tighten both screws. 11 Reassemble the vertical transfer unit. 12 Make sure all the cables (vertical transfer unit and paper deck drive assembly) are reconnected. 13 Reinstall left, right, and rear covers to the HCI. Note The locating pin position at the middle could still be unacceptable for some customer’s applications.
5 Functional Overview Chapter Contents Basic Printer Functionality . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Printer Functional Block Diagram . . . . . . . . . . . . . . . . . . 5-4 Power Distribution System . . . . . . . . . . . . . . . .
Printer Input Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 Paper Size Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 Printing from Trays 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . 5-38 Printing from Tray 1 .
Basic Printer Functionality This chapter presents a functional overview of the pr inter and the printing processes. The following topics, functions, and systems are discussed: • Basic Printer Functi.
Printer Functional Block Diagram Figure 5-1 is a functional block diagram of the printer showing the basic paths for signal, control, and media. F unctionalBlockDiagram { { { MediaPath Signal.
Power Distribution System The AC and DC power supply circuits are contained in the Low Voltage Power Supply (LVPS). The high voltages required for image formation ar e generated by the High Voltage Power Supply (HVPS). The Low Voltage Power Supply and Distribution System is illustrated in Figure 5-2.
AC Power Distribution The AC power circuitry supplies AC voltage whenever the power cord is connected, and the power switch is ON. A toner cartridge must be installed and the top access door must be closed before AC voltage is supplied to the DC power circuits or the Fusing Assembly.
High V oltage Power Distribution The High Voltage Power Supply (HVPS, see Figure 5-4) applies a DC biased AC voltage to the primary charging roller and the developing roller, and a programmed DC voltage (depending upon the phase of the printing proc ess) to the Transfer Roller.
Formatter System The Formatter PCA is responsible for the following: • Controlling the PowerSave mode. • Receiving and processing pr int data from the various printer inter faces. • Monitoring Control Panel inputs and relaying printer status information (through the Control Panel and the Bi-Directional I/O).
Note Printer error messages overr ide the PowerSave message. The printer will enter PowerSave mode at the appropriate time, but the error message will continue to be displayed.
DC Controller System The following systems and functions are controlled by the DC Controller PCA: • DC Power Distribution (+5V DC, +12V DC, +24V DC) • Laser and Scanner Drive • Paper Motion Moni.
Engine T est Microswitch The Engine Test Microswitch, located on the DC Controller PCA, is activated manually through the square access hole at the right rear of the printer (see Figure 6-4).
Image Formation System Laser printing requires the interaction of several different technologies (such as electronics, optics, and electrophotographics) to provide a printed page. Each process functions independently and must be coordinated with the other printer processes.
T oner Cartridge The toner cartridge is the “heart” of the Image Formation System. It houses the cleaning, conditioning, and developing steps of the process. The toner cartridge contains the photosensitive drum, primar y charging roller, developing station, toner cavity, and cleaning station.
Drum Cleaning The cleaning blade inside the toner cartridge is in contact with the surface of the drum at all times. As the drum rotates during printing, excess toner is removed from the drum surface and stored in the waste toner receptacle inside the toner cartridge.
Drum Conditioning After the drum is physically cleaned, it is conditioned by applying a uniform negative charge across the surface of the drum with the pr imary charging roller, located in the toner cartridge.
Image W riting During the writing process, a modulated laser diode projects a beam onto a rotating six-sided scanning mirror. As the scanning mirr or rotates, the beam is directed through a set of focusing lenses to a dir ection changing mirror which reflects it through a slot on the top of the toner cartridge, and onto the photosensitive drum.
Image Developing The developing process changes the latent electrostatic image into a visible image by depositing negatively charged toner particles on the exposed areas of the drum. The developing station is located inside the toner cartridge and consists of a metallic cylinder that rotates around a fixed magnetic core.
Image T ransferring and Media Separation During the image transferring process, the toner image on the drum surface is transferred to the media. A positive char ge applied to the back of the media by the transfer roller, causes the negatively char ged toner particles on the drum surface to be attracted to the media.
Image Fusing The Fusing Assembly bonds the toner particles into the media with a heated fusing roller and a soft pressure roller. There ar e two levers on the Fusing Assembly which adjust roller pressure for single sheets (down position), or envelopes (up position).
Paper Paths and Components Printer, Duplex Unit, and Envelope Feeder The components of the printer paper path are illustrated in Figur e 5-14. Figure 5-15 and Table 5-1 illustrate and describe all of the printer sensors, solenoids, clutches, motors, and fans.
Control Device Title Location CL1 Registration Clutch PIU (right side) CL2 Paper Input Unit Feed Clutch PIU (right side) CL3 T ray 1 Feed Clutch T ray 1 Drive Unit Fan 1 Laser/Scanner Fan Under T op C.
Figure 5-15 Printer Sensors, Solenoids, Clutches, Motors, and Fans. 5-22 Functional Overview.
2000-Sheet Input Unit (T ray 4) Components The components of the 2000-Sheet Input Unit paper path are illustrated in Figure 5-16. Figu re 5-17 and Table 5-2 i llu strate and descri be all of its sensors, switches, clutches, and motors.
Control Device Title Location CL31 T rans fer Assembly Clutch T rans fer Assembly CL32 Main Drive Clutch Lower Chassis (behind Back Cover) MT31 Main Motor Lower Chassis (behind Back Cover) PS31 Paper .
Paper Jam Sensor (PS32) Registration Sensor (PS31) Registration Clutch (CL32) Lifter Clutch (CL31) Main Motor (M1) Paper Quantity Switches (SW601, SW602) Paper Size Switches (SW701 - SW704) Power Supp.
2000-Sheet Input Unit Operation All communication and control of the 2000-Sheet Input Unit (and the Multi-Bin Mailbox/Mailbox With Stapler) is through the External Paper Handling (EPH) PCA mounted on the Formatter Assembly. These instructions are sent to the 2000-Sheet Input Unit controller PCA located behind the back cover.
Paper Size SW701 SW702 SW703 SW704 Ledger (portrait) OFF ON OFF OFF A3 (portrait) ON ON OFF OFF B4 (portrait) OFF OFF ON OFF Legal (portrait) OFF ON ON OFF Letter (landscape) OFF ON OFF ON A4 (landsca.
Multi-Bin Mailbox Components The components of the Multi-Bin Mailbox paper path are illustrated in Figure 5-18. Figu re 5-19 and Table 5-5 i llu strate and descri be all of its sensors and motors.
Control Device Title Location M1 Delivery Head Positi on Motor Upper Left Side M2 Flipper Roller Motor Flipper Unit (left end) M3 Delivery Head Roller Motor Delivery Head (left end) M4 Ejector Motor U.
PSFaceUp PSFUFull PSEntry Delivery Head Position Motor (M1) Flipper Roller Motor (M2) Delivery Head Roller Motor (M3) PSExit IRLED PSEject PSBinFull/ Head Position PSBinEmpty PSExit 2 PSBelt Transport.
Multi-Bin Mailbox Operation All communication and control of the Multi-Bin Mailbox (and the 2000-Sheet Input Unit) is through the External Paper Handling (EPH) PCA mounted on the Formatter Assembly. Thes e instructions are sent to the Multi-Bin Mailbox controller PCA located at the bottom of the frame.
trailing edge is sensed by PSFaceUp. The Flipper Roller motor (M3) then reverses and feeds the sheet down between the transport belt and the metallic tape into the delivery head at the accellerated speed of 500 mm per second. There is a magnetic strip on the guide behind the transport belt.
Stapling Unit Components The components of the Stapling Unit paper path are illustrated in Figure 5-20. Figure 5-21 and Table 5 -6 illustrate and describe a ll of its sensors and motors.
Control Device Title Location M1 Stapler DC Motor Stapler Assembly M2 Rack Stepper Motor T op Cover Assembly M3 Slider Stepper Motor T op Cover Assembly M4 Retainer DC Motor Stapling Bed Assembly IR S.
PSSlider NextBin FullSensor PSBinFull M3 M2 STLOut M1 STLSensor SW1 PSRetainer M4 PSRack IRSensor Figure 5-21 Stapler Sensors and Motors 5 Functional Overview Functional .
The major assemblies and subassemblies of the stapler are shown in Table 5-7. Mailbox with Stapler Operation All communication and control of the Mailbox, the 2000-Sheet Input Tray, and the Stapler is through the External Paper Handling Controller (EPH) PCA mounted in the Formatter Assembly.
the left wall of the Stapling Bed. This cycle is repeated until the amount of sheets to be stapled is reached (with a maximum of 20). Stapling Cycle The Sliders move the stack of sheets to the stapling position.
Printer Input Sources Paper Size Switches The paper guides in Trays 2 and 3 operate four levers at the back of the trays which activate the size sensing switches (SW1601 through SW1604) mounted in the printer chassis. Table 5-8 compares paper sizes to switch conditions.
Printing from T ray 1 The presence of paper in Tray 1 is detected by the Tray 1 Paper Present Sensor (PS1301). The lifting plate pressurization solenoid (SL2) is then activated, releasing the plate which applies upward pressure on the paper, causing it to contact the Tray 1 pickup roller.
Paper Jam Detection The PIU Sensor (PS2), the Registration Sensor (PS1), the Fuser Delivery Sensor (PS1403), and the Face-Down Delivery Sensor (PS1402) detect when paper is moving through the printer (see Figure 5-15 for sens or locations). If a paper jam is detected, the DC Controller immediately stops the printing process and causes a 13.
Figure 5-22 General Timing Diagram (1 of 2) for LJ 5Si/5Si MX 5 Functional Overview Functional Overview 5-41.
Figure 5-23 General Timing Diagram (2 of 2) for LJ 5Si/5Si MX 5-42 Functional Overview.
6 Removal and Replacement Chapter Contents Removal and Replacement Strategy . . . . . . . . . . . . . . . . . . . . 6-5 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 User Installable Accessories . . . . . . . . . . .
Formatter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Fusing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Laser/Scanner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Main Gear Assembly .
Motor, Transport Belt and Encoder Assembly . . . . . . . . . . . . 6-96 Paper Bins and Blind Cover . . . . . . . . . . . . . . . . . . . . . . 6-98 PCA, Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99 Strings, Anti-Curl . . . .
6-4 Removal and Replacem ent.
Removal and Replacement Strategy This chapter documents removal and replacement of major ass emblies. Replacement is generally the reverse of removal. Occasionally, directions for difficult or critical replacement procedures ar e included. WARNING! Unplug the power cord from the power outlet before attempting to ser vice the printer.
Required T ools • #2 magnetized Phillips screwdriver (6-inch shaft) • Small flat-blade Screwdriver • Small pair needle-nose pliers • T-15 Torx Driver ( 6-inch shaft) All components in the printer and in the 2000-Sheet Input Unit use Phillips head screws which require a #2 size Phillips screwdriver.
User Installable Accessories Memory and Personality Upgrade Caution SIMM’s and the Formatter PCA can be damaged by small amounts of electrostatic discharge (ESD). Wear an anti-static wrist wrap. 1 With the printer OFF and unplugged, loosen the two captive screws and remove the Formatter PCA.
Disk Drive Note When the disk drive is replaced, all fonts and macros must be re-loaded. 1 The Disk Drive is mounted on the upper front corner of the Formatter PCA under MIO card No. 1 (if installed). 2 With the printer OFF and unplugged, loosen (2) captive screws and remove the Formatter Assembly.
To Reinstall Disk Drive 1 Locate the four disk drive mounting holes on the Formatter Assembly. Remove the drive from the packaging and align with to the mounting holes. 2 Tilt the drive up and insert latch A (nearest the board edge) in the hole, then slide the drive toward the center of the formatter board.
Duplex Unit 1 With the printer turned OFF and unplugged, open the Diverter door on the left side of the printer. 2 Push down the green release lever located at the lower right of the Duplex Unit and slide it straight out of the printer.
Envelope Feeder 1 With the printer turned OFF and unplugged, slide the Envelope Feeder up and out of the printer. 6 Removal and Replacement Removal and Replacement 6-11.
External Paper Handling Controller 1 With the printer turned OFF and the power cable unplugged, disconnect all interface cables from the Formatter Assembly. 2 Loosen (2) captive screws and remove the Formatter Assembly. Remove MIO card No. 2, if installed.
T ray 4 (2000-Sheet Input Unit) 1 With the printer turned OFF and the power cable unplugged, disconnect all interface cables from the Formatter Assembly and from Tray 4. WARNING! The printer weighs approximately 100 pounds. Use at least four people to lift it.
Multi-Bin Mailbox/Mailbox W ith Stapler 1 With the printer turned OFF and unplugged, disconnect the power and interface cables from the Multi-Bin Mailbox/Mailbox With Stapler controller PCA. 2 Carefully slide the Multi-Bin Mailbox/Mailbox With Stapler away from the printer until the locator tabs and the lower guide rail are clear.
Hardware T able Note The screws listed in Table 6-1 are also listed in Chapter 8 with their respective assemblies. Example Reference Description Part Number Usage CH101 S crew , TP , M3X6 (fixed shoul.
CH107 S crew , tapping, pan head, M4X10 XB4-7401-009CN Diverter Assembly , Face-Up Solenoid As sy CH108 S crew , TP , M4X6 XB6-7400-606CN 2000-Sheet Input Unit, general use CH109 S crew , TP , M4X6 XB.
Control Panel 1 While pushing in on the side of the printer (Figure 6-2, callout 1) lift up on the forward edge of the control panel to r elease the plastic retaining tab . 2 Remove the cable from the retainer and unplug the control panel c onnector .
Covers There are five cover assemblies in this pr inter: • AC Access Cover, located at the left rear of the printer. • Back Cover, provides access to the HVPS, DC Controller, LVPS, and Main Motor. • Front Cover, including front access door. • Left Lower Cover, located below the Diverter Access Door.
Back Cover Note The metal back cover and the plastic panel at the right rear are removed as a single unit. The square opening at the upper rear corner on the right side plastic panel is the engine test access. 1 Remove (5) screws, CH102 (Figure 6-4, callout 1).
Front Cover 1 Open all access doors and remove the Duplex Unit if installed. 2 Open front access door and remove (3) screws, CH102 (Figure 6-5, callout 1). 3 Open the Diverter Access Door and release the two plastic r etaining tabs inside the Duplex Unit cavity (Figure 6-6, callout 2).
Front Cover (1 of 2) Front Cover (2 of 2) Figure 6-5 Figure 6-6 6 Removal and Replacement Removal and Replacement 6-21.
Left Lower Cover Caution Be careful not to damage the plastic guides on the inside of the lower left cover. They are part of the Duplex Unit paper path.
T op Cover 1 Remove Control Panel (see Figure 6-2), and rem ove (1) screw, CH102 (Figure 6-8, callout 1). 2 Open the Diverter Assembly access door and remove (1) screw, CH102 (Figure 6-8, callout 2). 3 Open the top cover door and remove (1) screw, CH102 (Figure 6-9, callout 3).
Top Cover (1 of 2) Top Cover (2 of 2) Figure 6-8 Figure 6-9 6-24 Removal and Replacem ent.
Delivery Unit (for Face-Down Bin) 1 Remove the following components: • Formatter Assembly (see Figure 6-24) • AC Access Cover (see Figure 6-3) • Top Cover (see Figure 6-8) • Front Cover (see Figure 6-5) 2 Unplug and re-route the fan cable out of the way (Figure 6-10, callout 1).
Delivery Unit (1 of 2) Delivery Unit (2 of 2) Figure 6-10 Figure 6-11 6-26 Removal and Replacem ent.
Diverter Assembly Caution Support the Diverter Assembly access door during this pr ocedure to prevent damage to the plastic hinge pins. 1 Open the Diverter Assembly access door and releas e the support struts (Figure 6-12, callout 1) by sliding the strut ends forward and downwar d.
Door Assembly , Diverter 1 Open the Diverter access door and release the support struts (Figur e 6-13, callout 1) by sliding the strut ends forward and downward. 2 Rotate the door up to align the flat sides of the right hinge pin with the retaining slot (Figure 6-13, callout 2), and lift upwards to r elease it from the retaining slot.
Door Assembly , Right Lower 1 Remove the back cover assembly (see Figure 6-4). 2 Remove Tray 2 and Tray 3. 3 Open the Right Lower Door and release the lower end of the support strap (Figure 6-14, callout 1). 4 Remove (4) screws, CH102 (Figure 6-15, callout 2).
Right Lower Door Assembly (2 of 3) Right Lower Door Assembly (3 of 3) Figure 6-15 Figure 6-16 6-30 Removal and Replacem ent.
Fan 1, Exhaust (Laser/Scanner) and Housing Fan Housing 1 Remove the toner cartridge. 2 Remove the top cover (see Figure 6-8). 3 Remove and re-route cables away from fan hous ing (Figure 6-17, callout 1).
Fan Motor 1 Unplug the fan cable from the DC Controller PCA. 2 Remove (2) screws, CH101 (Figure 6-18, callout 3), and lift the fan and bracket assembly out of the chassis. 3 Remove (2) screws, CH104 (Figure 6-18, callout 4), to separate the fan motor from the bracket.
Fan 2, Exhaust (L VPS) 1 Remove back cover (see Figure 6-4). 2 Remove the fan cable from the DC Controller PCA (Figur e 6-19, callout 1). 3 Remove (2) screws, CH104 (Figure 6-19, callout 2).
Fan 3, Intake (Formatter) and Housing Fan Motor Note The fan motor (FM3) can be removed without removing the housing assembly. 1 Remove the back cover (see Figure 6-4). 2 Unplug the fan connector (Figure 6-20, callout 1). Caution Do not bend the fan retainer clips upward.
Fan 4, Exhuast (Delivery Unit) 1 Remove the top cover (see Figure 6-8). 2 Unplug the fan cable (Figure 6-21, callout 1). 3 Remove (1) screw, CH101 (Figure 6-21, callout 2), and remove the metal fan shield. 4 Release (4) retainer clips (Figure 6-21, callout 3), and slide the fan forward out of the Delivery Unit Assembly.
Feeder Assembly 1 Open the left access door and remove the Duplex Unit (if installed). 2 Remove the Fuser Assembly (see Figur e 6-25). 3 Open the Top Cover and remove the Toner Cartridge. 4 Remove the Transfer Roller Assembly (s ee Figure 6-51). 5 Remove the Registration Assembly (see Figur e 6-42).
Feeder Assembly (1 of 2) Feeder Assembly (2 of 2) Figure 6-22 Figure 6-23 6 Removal and Replacement Removal and Replacement 6-37.
Formatter Assembly 1 If the Formatter is to be replaced, make sure to note the page count. 2 Loosen the two captive screws (Figure 6-24, callout 1) and slide the Formatter PCA out of the chassis. 3 After installation of a replacement Formatter, be sure to re-enter the serial number, page count, and maintenance count.
Setting Page Count, Maintenance Count, and Serial Number The page count, maintenance count, and printer serial numbers ar e stored in Non-Volatile Memory.
Fusing Assembly 1 Open the Diverter Assembly access door and remove the Duplex Unit if installed. Caution Use the upper levers to release the Fusing Assembly, NOT the lower levers. The lower levers set the pressure rollers inside the Fusing Ass embly for envelope printing (down for single sheets, up for envelopes).
Laser/Scanner Assembly Caution The Laser Scanner diode is extremely sensitive to ESD. 1 Remove the toner cartridge. 2 Remove the top cover (see Figure 6-8). 3 Unplug three cable connectors (Figure 6-26, callout 1). 4 Re-route the cable running across the top of the assembly so that it is out of the way.
Main Gear Assembly 1 Remove the following components in the order listed: • Toner Cartridge • Tray 1 • Tray 2 • Transfer Roller Assembly (see Figur e 6-51) • Back Cover Assembly (see Figure .
Main Gear Assembly (1 of 3) Main Gear Assembly (2 of 3) Figure 6-27 Figure 6-28 6 Removal and Replacement Removal and Replacement 6-43.
Main Gear Assembly (3 of 3) Figure 6-29 6-44 Removal and Replacem ent.
Main Motor Assembly 1 Remove the back cover (see Figure 6-4). 2 Remove the HVPS (see Figure 6-40). 3 Unplug the connector (Figure 6-30, callout 1). Caution Be careful when removing the Main Motor. The steel drive shaft can damage the plastic gears. 4 Remove (4) screws, CH103 (Figure 6-30, callout 2).
Paper Input Unit (PIU) Caution Remove both Tray 2 and Tray 3 to prevent damage to the PIU plastic sensor flags. 1 Remove Tray 2 and Tray 3. 2 Remove the back cover (see Figure 6-4). 3 Remove the Tray 1 Assembly (see Figure 6-52). 4 Remove the Right Lower Door Assembly (see Figur e 6-14).
PCA, DC Controller 1 Remove the Formatter Assembly (see Figur e 6-24). 2 Remove the back cover (see Figure 6-4). 3 Remove the High Voltage Power Supply (see Figure 6-40). 4 Unplug (18) connectors from the PCA (Figure 6-32, callout 1). Note: For the 5Si HM (C3124A), you also need to disconnect the Thermal Control Cable (Figure 6-32, callout 6).
PCA, Output Paper Sensor 1 Remove the following components in the order listed: • Toner Cartridge • Formatter Assembly (see Figure 6-24) • AC Access Cover (see Figure 6-3) • Top Cover (see Fig.
Output Paper Sensor PCA (1 of 4) Output Paper Sensor PCA (2 of 4) Figure 6-33 Figure 6-34 6 Removal and Replacement Removal and Replacement 6-49.
Output Paper Sensor PCA (3 of 4) Output Paper Sensor PCA (4 of 4) Figure 6-35 Figure 6-36 6-50 Removal and Replacem ent.
PCA, Paper Size 1 Remove the following components in the order listed: • Toner Cartridge • Trays 2 and 3 • Back Cover (see Figure 6-4) • LVPS (see Figure 6-41) 2 Unplug the fan cable from the .
Paper Size PCA (2 of 3) Paper Size PCA (3 of 3) Figure 6-38 Figure 6-39 6-52 Removal and Replacem ent.
Power Supply , High V oltage (HVPS) 1 Remove the back cover (see Figure 6-4). 2 Unplug the cable from the LVPS to the DC Controller PCA (Figure 6-40, callout 1), and move it out of the way. 3 Unplug the connector from the bottom of the HVPS (Figure 6-40, callout 2).
Power Supply , Low V oltage (L VPS) 1 Remove the Formatter Assembly (see Figur e 6-24). 2 Remove the back cover (see Figure 6-4). 3 Remove Fan 3 and its Housing Assembly (s ee Figure 6-20). 4 Unplug (3) LVPS connectors (Figure 6-41, callout 1). 5 Unplug the LVPS fan (FM1) cable from the DC Controller (Figur e 6-41, callout 2).
Registration Assembly 1 Open the top cover door and remove the toner cartridge. 2 Remove the Transfer Roller Assembly (s ee Figure 6-51). 3 Remove the Main Gear Train Shield. Release the retainer clip (Figure 6-43, callout 1) and lift the forward end up.
Registration Assembly (1 of 3) Registration Assembly (2 of 3) Figure 6-43 Figure 6-42 6-56 Removal and Replacem ent.
Registration Assembly (3 of 3) Figure 6-44 6 Removal and Replacement Removal and Replacement 6-57.
Roller and Separation Pad, T ray 1 Feed Roller 1 Open Tray 1 door and remove the plastic shield. 2 Pinch retainer tabs together (Figure 6-45, callout 1) and slide the roller to the left, off of the shaft.
Separation Pad Open Tray 1 door and remove the Feed Roller Insert a flat bladed screwdriver into the slot (Figure 6-46, callout 2) and carefully pry the separation pad upwards out of its retaining notches. To Reinstall: Make sure the metal edge of the Separation pad faces forward.
Rollers: T ray 2 & 3, Pickup, Feed, and Separation Note There are three rollers for each tr ay: The Pickup Roller, the Feed Roller, and the Separation Roller. The Feed and Separation Rollers are interchangeable with each other and between trays. The Pickup Rollers are interchangeable between trays.
Sensor , Paper Input Unit (PS2) 1 Remove the following components in the order listed: • Toner Cartridge • Trays 2 and 3 • Transfer Roller (see Figure 6-51) • Registration Assembly (see Figure.
Sensor , Registration (PS1) 1 Remove the following components in the order listed: • Toner Cartridge • Trays 2 and 3 • Transfer Roller (see Figure 6-51) • Registration Assembly (see Figure 6-4.
Solenoid Assembly , SL3 (Face-Up) 1 Remove the top cover (see Figure 6-8). 2 Remove the Delivery Unit (see Figure 6-10). 3 Remove (1) self-tapping screw, CH107 (Figure 6-50, callout 1). Caution Be careful not to damage the plastic arm when removing the assembly.
T ransfer Roller Assembly Caution Handle the Transfer Roller from the ends only. Do not touch the surface of the Transfer Roller. Skin oils will affect its electrical characteristics, resulting in poor image transfer. 1 Open the top cover door and remove the toner cartridge.
T ray 1 Assembly 1 Remove the front cover (see Figure 6-5) and the back c over (see Figure 6-4). 2 Open the top cover and remove the toner cartridge. 3 Open the right lower door.
T ray 2/3 Assemblies Note The paper trays are mechanically aligned to the printer chassis at the factory. If you are replacing Tray 2 or Tray 3 with a tr ay other than the original factory installed unit, you may have to adjust the new tray. For details, refer to the Tray 2 and 3 Adjustment Procedure in Chapter 4.
T ray 4 (2000-Sheet Input Unit) Back Cover 1 Remove (4) screws, CH108 (Figure 6-53, callout 1), and pull cover back from the chassis. To Reinstall: 1 Make sure the tab on the left lower corner is inserted in its alignment slot. 2 Insert the star lockwasher under the lower right screw.
Left Cover 1 Remove (2) screws, CH108 (Figure 6-54, callout 1). 2 Pull out on the top of the cover and lift up on the right side of the cover to clear the retaining tabs along the bottom edge. 3 Pull out on cover at the lower left corner (Figure 6-54, callout 2) to release the plastic retainer tab and lift the cover off.
Right Cover 1 Remove the Transfer Assembly (see Figur e 6-64). 2 Remove (2) screws, CH109 (Figure 6-55, callout 1). 3 Release plastic retaining tab (Figur e 6-55, callout 2). 4 Carefully pull out on the top of the cover while lifting it upward to clear the retaining tabs along the inside bottom of the cover.
Main Drive Assembly 1 Remove the Transfer Assembly (see Figur e 6-64). 2 Remove the back cover (see Figure 6-53) and the right cover (see Figure 6-55). 3 Unplug (2) connectors (Figure 6-56, callout 1). 4 Remove (4) screws, CH108 (Figure 6-56, callout 2) and pull the assembly straight out of the chassis.
Paper T ray 1 Remove all unused paper from the tray. 2 Remove the Transfer Assembly (see Figur e 6-64). 3 Remove the left cover (see Figure 6-54) and the right cover (see Figur e 6-55). 4 Remove (1) screw, CH108 (Figure 6-57, callout 1) and the metal retaining tab from each side of the chassis.
PCA, Controller 1 Remove the back cover (see Figure 6-53) and the left cover (see Figur e 6-54). 2 Unplug (8) connectors from the PCA (Figure 6-58, callout 1). 3 Remove (2) screws, CH108 (Figure 6-58, callout 2). 4 Release (2) plastic retaining posts (Figure 6-58, callout 3), and pull the PCA free of the chassis.
Pickup Assembly 1 Open the paper tray to the stops. 2 Remove the Transfer Assembly (see Figur e 6-64). 3 Remove the right cover (see Figure 6-55) and the Back Cover (see Figure 6-53). 4 Unplug (1) connector (Figure 6-59, callout 1) from the fr ont of the Pickup Assembly.
Pickup Assembly Photosensors There are three photos ensors on the Pickup Assembly: • one to sense that the Transfer Ass embly is closed (Figure 6-60, callout 1). • one to sense that the tray has raised the paper to the proper height (Figure 6-60, callout 2).
Power Supply 1 Remove the back cover (see Figure 6-53) and the left cover (see Figur e 6-54). 2 Unplug the connector from the Power Supply (Figure 6-61, callout 1). 3 Remove (2) screws, CH108 (Figure 6-61, callout 2). 4 Lift the Power Supply up to clear the locating tabs underneath, and slide it to the left to free it from the chassis.
Rollers: Pickup, Feed, and Separation There are three rollers in this ass embly. The upper forward roller is the Pickup Roller, the upper rear roller is the Feed Roller, and the lower roller is the Separation Roller. The Feed and Separation Rollers are interchangeable with each other and between Trays 2 and 3 and 4.
Switch Assembly , Paper Quantity 1 Remove the back cover (see Figure 6-53). 2 Open the paper tray and pull it out to the stops. 3 Unplug the connector (Figure 6-63, callout 1) from the Contr oller PCA and free the cable. 4 Remove (1) screw, CH108 (Figure 6-63, callout 2), and remove the metal retaining spring (Figur e 6-63, callout 3).
Switch Assembly , Lifter Sensing 1 Lift the printer clear of the HCI and place it on a smooth, stur dy surface. 2 Remove the top cover (2 screws). 3 Remove the back cover (4 screws, Figure 8-7, reference 5). 4 Disconnect the outside cables (connector with two cables) to r elease Microswitch Assembly fr om the back top of the frame.
Tray 4, Transfer Assembly Figure 6-64 6 Removal and Replacement Removal and Replacement 6-79.
Multi-Bin Mailbox/Mailbox W ith Stapler Covers The procedure for r emoving the left and right covers is the same. 1 Using a small flat-blade screwdriver, release (3) retaining tabs (Figur e 6-65, callout 1) along the rear edge of the cover and rotate the cover clear of the frame.
Delivery Head Assembly 1 Remove the left cover (see Figure 6-65). 2 Remove all paper bins and the blind cover (see Figure 6-86) or the stapling unit (see Figure 6-91).
Multi-Bin Mailbox/Mailbox with Stapler, Delivery Head Mounting Screws Multi-Bin Mailbox/Mailbox with Stapler, Delivery Head Pulley Detail Figure 6-67 Figure 6-68 6-82 Removal and Replacem ent.
Flipper Assembly 1 Remove all paper bins and the blind cover (see Figure 6-86). 2 Remove the Left and Right Covers (see Figure 6-65). 3 Remove the Delivery Head Position Motor (see Figure 6-82). 4 Remove the Jam Access Door (see Figures 6-74 thr ough 6-76).
Multi-Bin Mailbox/Mailbox with Stapler, Flipper Assembly Mounting Screws Multi-Bin Mailbox/Mailbox with Stapler, Flipper Assembly Ground Wire Figure 6-70 Figure 6-71 6-84 Removal and Replacem ent.
Input Paper Guide 1 Remove the paper bins and the blind cover (see Figure 6-86). 2 Open the Jam Access Door and disconnect the ground wir e from the bottom of the Flipper Roller Motor (Figure 6-71, callout 3). 3 From the rear of the unit, release the Paper Guide retaining tabs (Figure 6-72, callout 1).
Interlock Switch 1 Remove the left cover (see Figure 6-65). 2 Disconnect (2) wires from the Inter lock Switch (Figure 6-73, callout 1). 3 Press the retainer tabs together (Figure 6-73, callout 2) to releas e the switch and remove it from the rear of the unit.
Jam Access Door Assembly 1 Remove the left and right covers (see Figure 6-65). 2 Remove the Delivery Head Position Motor (see Figure 6-82). 3 Remove all paper bins and the blind cover (see Figure 6-86). 4 Release the upper end of the Metallic Tape (see Figure 6-79).
Multi-Bin Mailb ox/Mailbox with Stapler, Ja m Access Door Springs Multi-Bin Mailb ox/Mailbox with Stapler, Ja m Access Door E-Clip Note Figure 6-76 with callout 3 is on the following page.
Multi-Bin Mailbox/Mailbox with Stapler, Jam Access Door String Connection Figure 6-76 6 Removal and Replacement Removal and Replacement 6-89.
Lower Elevator Pulley Assemblies 1 Remove all paper bins and the blind cover (see Figure 6-86). 2 From the front of the unit, disc onnect (2) tension springs (Figure 6-77, callout 1). 3 From the back of the unit, release (2) lower pulley assemblies by pushing down on the assembly, and then pushing it forward (Figur e 6-78, callout 2).
Multi-Bin Mailb ox/Mailbox with Stapler, Elevato r Pulley Tension Spring Multi-Bin Mailb ox/Mailbox with Stapler, Pulle y Housing Release Figure 6-77 Figure 6-78 6 Removal and Replacement Removal and .
Metallic T ape and Housing Assembly 1 Remove all of the paper bins, and the blind cover (see Figure 6-86). 2 Lower the Delivery Head to the bottom of the frame. 3 Release the tape retainer by pushing the tab (see Figure 6-79, callout 1). 4 Carefully rewind the tape into its housing.
Multi-Bin Mailbox/Mailbox with Stapler, Metallic Tape Retaining Pin Multi-Bin Mailbox/Mailbox with Stapler, Metallic Tape Release Note Figure 6-81 with callout 3 is on the following page.
Multi-Bin Mailbox/Mailbox with Stapler, Metallic Tape Housing Figure 6-81 6-94 Removal and Replacem ent.
Motor , Delivery Head Position 1 Remove the left cover (see Figure 6-65). 2 Unplug the cable connector (Figure 6-82, callout 1). 3 Remove (2) screws, CH112 (Figure 6-82, callout 2), slide the motor downward to release it from the fr ame, and lift it straight out of the frame.
Motor , T ransport Belt and Encoder Assembly 1 Remove the left cover (see Figure 6-65). 2 Remove all paper bins and the blind cover (see Figure 6-86). 3 Remove the Controller PCA (see Figure 6-87). 4 Remove (2) screws, CH112, from the motor assembly (Figure 6-83, callout 1).
Multi-Bin Mailb ox/Mailbox with Stapler, Tr ansport Be lt Drive Gear Multi-Bin Mailbox/Mailbox with Stapler, Transport Belt Encoder Figure 6-84 Figure 6-85 6 Removal and Replacement Removal and Replac.
Paper Bins and Blind Cover The procedure for r emoving the paper bins and the blind cover is the same. Each bin rests in its labeled slot. 1 Remove the paper bins and the blind cover from the top down. 2 Lift up on the outer edge of the bin (or blind cover) to clear the retaining notch, and pull it forward out of the frame (Figur e 6-86).
PCA, Controller 1 Remove all paper bins and the blind cover (see Figure 6-86). 2 Lay the Multi-Bin Mailbox/Mailbox With Stapler over onto its right side. 3 Remove (1) grounding screw, CH112 (Figure 6-87, callout 1), and four self-tapping screws, CH113 (Figure 6-87, callout 2).
Strings, Anti-Curl The Anti-Curl Strings are attached to the Jam Acc ess Door Assembly at the top of the frame, routed through small pulleys at the back of the Delivery Head Assembly, and then around pulleys near the bottom of the fram e, where they are attached to tension springs.
Multi-Bin Mailbox/Mailbox with Stapler, Anti-Curl String Upper Connection Multi-Bin Mailbox/Mailbox with Stapler, Anti-Curl String Middle Connection Figure 6-89 Figure 6-90 6 Removal and Replacement R.
Stapling Unit Assembly The Stapling Unit Assembly is mounted in the Mailbox with Stapler, replacing the three top output bins. 1 Turn OFF the printer. 2 Make sure the Delivery Head Assembly is not in the stapler area. It should be in the bottom portion of the mailbox.
Back Plate 1 Remove the Stapling Unit Assembly (see Figure 6-91). 2 Remove the Scan Bar by carefully pressing the tab on the scan bar backwards and downwards through the hole of the Stapling Bed (see Figure 6-92) with a flat-tip screwdriver, then lift the bar.
Figure 6-93 6-104 Removal and Replacement.
Stapling Unit Controller PCA 1 Remove the Stapling Unit Assembly (see Figure 6-91). 2 Remove the Back Plate (see Figure 6-92). 3 Remove (2) screws located on the right side of the Stapling Unit, holding the PCA board (see Figure 6-94, callout 1). 4 Unplug the cables that are connected to the PCA.
Figure 6-95 Figure 6-96 6-106 Removal and Replacement.
T op Cover Assembly 1 Remove the Stapling Unit Assembly (see Figure 6-91). 2 Open the Top Cover Assembly and remove the Back Plate (see Figur e 6-92). 3 Unplug the ground and signal cables from the right side of the Stapling Unit Controller board, being careful to keep them in the cable holder.
Stapling Bed Assembly 1 Remove the Stapling Unit Assembly (see Figure 6-91). 2 Remove the Back Plate (see Figure 6-92). 3 Remove the Stapler Unit Controller PCA (see Figure 6-94).
Hinges 1 Remove the Stapling Unit Assembly (see Figure 6-91). 2 Remove the Top Cover Assembly (see Figur e 6-97). 3 Remove the Stapling Bed Assembly (see Figure 6-98). 4 Release the brushes bar from the retaining notches and lift upwards. 5 Remove (2) screws joining each hinge to the housing (see Figure 6-99, callout 1).
6-110 Removal and Replacement.
7 T roubleshooting Chapter Contents Troubleshooting Process . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Power-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Overview . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77 Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77 General Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . 7-80 Miscellaneous Problems and Solutions .
T roubleshooting Process The troubleshooting process is a systematic approach that addr esses the major problems first and then other problems as you identify the causes for printer malfunctions and errors. The Troubleshooting Process, Figure 7-1, on the following two pages, illustrates the major steps for troubleshooting the printing system.
Figure 7-1 HP LaserJet 5Si / 5Si MX / 5Si Mopier Troubleshooting Process 7-4 Troubleshooting.
Figure 7-2 HP LaserJet 5Si / 5Si MX / 5Si Mopier Troubleshooting Process 7 Troubleshooting Troubleshooting 7-5.
Power -On Overview It is important to have the printer’s Control Panel functional as soon as possible in the troubleshooting process so that the printer’s diagnostics can assist in locating printer err ors. Problem Action 1. Is AC power avai lable at the printer ’ s power receptacle? V erify .
Fan Location and Airflow Note When the printer is in PowerSave mode, the fans are off. Fan Number Fan Name Fan Location 1 Laser/Scanner fan Exhaust air fl ows from the back of the printer , on the left-hand side of the fus ing assembly . 2 Low-voltage Power Supply Lower right-hand c orner of the printer .
Engine T est The engine test verifies that the print engine is functioning correctly. The Formatter PCA is completely bypassed during an engine test. This test is very useful for isolating printer problems.
Display Overview Use the printer’s Control Panel to access the error log to troubleshoot the printer. With the printer’s test menu, you can access the printer’s error log to display more information about the current error. The er ror log retains the printer’s last 50 error messages.
Configuration Use the configuration pages to verify the proper installation of accessories, options, and personalities. When you print the configuration pages, the printer checks its internal controller and I/O interface, then pr ints two pages. One shows the overall printer configuration, and the other one shows the current menu settings.
Device Action if installed and not detected Duplex Unit Power-off, reseat, veri fy connector is not broken, then replace duplex cabl e and/or duplex unit and power-on.
Configuration Page Illustration and Key Configuration Page Example The default S/N is AAXXYY99999. To set the correct S/N, refer to the SERVICE MODE procedure in Chapter 3 of this manual. The three most recent error log messages display here. All the paper handling devices that are physically present should be lis ted in this section.
Menu Page Example Menu Page Example Figure 7-6 7 Troubleshooting Troubleshooting 7-13.
Communications Link (C-Link) Cables Communications Link (C-Link)Cables, Supported Daisy Chain Connections All C-Link cables have a single dot molded into the device output connector cable end, and two dots molded into the device input connector cable end.
Image Quality When you are working with customers, obtain a print sample before you begin troubleshooting their printer. Ask the customer to explain the quality they expect from the printer. The print sample will also help clarify the customer’s explanation.
Check the T oner Cartridge Image formation defects are often the result of toner cartridge problems. If there is any doubt, always replace the toner cartridge before troubleshooting image defects. Use the following check list to ensure that the toner cartridge is still operable.
Error Log Use the error log to diagnose and tr oubleshoot printer err ors and intermittent failures. Also, you can use "Show Error Log" under "Display and Evaluate the Error Log" discussed earlier in this chapter. Print and Evaluate the Error Log The printer’s internal error log stores the last 50 errors and can be printed.
Whenever a 13.xx appears on the Control Panel, a good practice is to clear all the paper from the printer, take the printer offline, and print the er ror log. If you cannot print the error log, you can still display it on the display panel. Write the error next to the last error logged.
Communication Ask the customer to run a print job from the host system. If the print job is successful, proceed to the following step, “Ver ification.” V erify Communication Print the PCL configuration page and study the HP MIO block. The MIO block will appear on the bottom portion of the configuration page.
• The "Novell Status" block should state the Novell printer server name to which the printer is connected. If the node name reads "NPIxxxxxx" (xxxxxx=last six digits of the MIO’s LAN address), the MIO card has not been configured for a Novell server.
V erification Paper Path T est Using the error trend information from Step 5 (Er ror Log), you may verify a specific printer paper path with the paper path test. You must first set the desired paper destination in the configuration menu and then select the paper path test.
Paper Path Test Source and Output Selection Customer Print Job Ask the customer to send a print job from the problem sour ce(s) to the problem destination(s). Try to recreate the paper jam err ors by having the customer do typical print jobs and the type of print job that has been causing the paper jams.
Reference Control Panel Messages and Errors Printer messages displayed on the control panel provide five categor ies of information. Each message category is assigned a priority. If more than one condition occurs at the same time, the highest priority message is displayed.
Error Log T able Message Error Log Category/ Message Description Recommended Action ACCESS DENIED Status After an attempt to select a loc ked-out function, this message displays for approximately 2 seconds. The JetAdmin Admini strator controls the control panel lockout feature.
Clearing Staple Jams Scanbar and MBM Interlock Switch (SW1). 1 and 2 - Scanbar gaps. 3 - Multi-Bin Mailbox Interlock Switch Figure 7-11 Figure 7-12 "Home" position gap.
Message Error Log Category/ Message Description Recommended Action ENGINE TEST Status This message di splays after the engine test button is pressed and i ndicates that the engine test is in process. If the tes t fails, an error or attendance message displ ays.
High-Voltage Power Supply Contacts 1. Primary Charging Roller Connector 2. Toner Registration/Toner Sensor 3. Developing Roller Bias Connector 4. Drum Ground Connector Figure 7-13 7 Troubleshooting Tr.
Message Error Log Category/ Message Description Recommended Action HP MIO 2 NOT READY Status The lower MIO card is not ready . One of two situations may oc cur .
Message Error Log Category/ Message Description Recommended Action LOAD TRA Y X or LOAD ENV FEEDER <media type> <paper s ize> Attendance Required The printer recei ved a request for a media type and size that is not c urrently installed in the printer .
Message Error Log Category/ Message Description Recommended Action OUTPUT OPERA TION CONDITION x.yy Attendance Required An external output dev ice has a conditi on that needs to be corrected before pri nting can resume.
Message Error Log Category/ Message Description Recommended Action PROCESSING JOB FROM TRA Y x Status The printer is processing data from the acti ve I/O channel. Some data is printed and some data cannot be printed, suc h as downloading fonts or macros.
Message Error Log Category/ Message Description Recommended Action ST APLER LIMIT REACHED Attendance Required The stapler has reached its maxi mum of 20 sheets to be stapl ed. Remove the 20 sheets from the bin. The printer will automati cal l y continue and stapl e the remaining pages separately .
Tray 2 (1) and Tray 3 (2) Paper Out Flags Vertical Transfer Door Closed Sensor (PS35) (1.) PS35 Vertical Transfe r Door Switch (2.) Drive Gear (3.) Vert ical Transfer Door Registrat ion Sensor Flag PS31 (4.
Message Error Log Category/ Message Description Recommended Action TRA Y 4 EMPTY Status T ray 4 is empty or not lifting. Under normal operating conditions , when T ray 4 is closed the paper stack lifts until the paper is directl y beneath T ray 4’ s feed rol lers .
Message Error Log Category/ Message Description Recommended Action W ARMING UP Status The Fuser is warming up and the printer is not ready . It may be necessary to display the error log to determine if more i nformation is available to assist y ou in troubleshooting.
Sensor Flag Locations Along the Paper Path Figure 7-16 PS31 Tray 4, Transfer Door Re gistration Phot sensor PS32 Tray 4, Transfer Door Pape r Jam Photosensor PS2 Paper Input Unit Pape r Jam Photosensor PS1 Registration As sembly Photosensor PS1403 Fusing Exit Photosens or PS1402 Face Down Delive ry Paper Jam Photosensor.
General Paper Path T roubleshooting Paper jams occur in the printer when paper does not either reach or clear a photosensor along the printer’s paper path in a specific amount of time. If a paper jam occurs, a " 13.xx PAPER JAM " message is displayed on the printer’s Control Panel.
Message Error Log Category/ Message Description Recommended Action 13.0 P APER JAM CLEAR PRINTER Attendance Required Paper is jammed s omewhere in the paper path, or a sensor flag may be stuck, causing a false paper jam warning. The jam was detected immediatel y after a power cycle.
Message Error Log Category/ Message Description Recommended Action 13.x P APER JAM (Continued) 13.0 13.1 13.2 13.3 13.4 13.5 13.6 13.0n.00 13.0n.01 13.0n.02 13.0n.03 13.0n.04 13.0n.05 13.0n.06 Printer Engine Specific Paper Jams 0 = Non Specific paper jam.
Message Error Log Category/ Message Description Recommended Action 13.x P APER JAM (Continued) 13.7 13.8 13.9 13.9n 13.10 13.0n.07 13.0n.08 13.0n.09 13.
Message Error Log Category/ Message Description Recommended Action 13.x P APER JAM (Continued) 13.13 13.14 13.10.03 through 13.13.03 Stapler Assembly Error s 13 = FUSER ACCORDION JAM 14 = PRINTER COUL.
Message Error Log Category/ Message Description Recommended Action 13.1 1 P APER JAM Error Message 13.27.1 1 A paper jam occurred at the V ertical T ransfer Assembly . Paper did not reach exit sensor (PS32) on time (see Figure 7-14). See all recommendations listed for Error Log Message 13.
Flipper Assembly a nd Paper Sensor Flags (Multi- Bin Mailbox) 1. PS Face Up 2. PS Face Up Full 3. PS Entry Se nsor Paper Sensor Exit 1. PSExit1 - Detect s paper entering head as sembly.
Message Error Log Category/ Message Description Recommended Action 13.1 1 P APER JAM Error Message 13.59.1 1 A paper jam occurred at V ertical T ransfer Assembly exit or after openi ng the V ertical T ransfer Assembly . Paper in PS32 (see Figure 7-14) at power-on (flush routi ne not implemented at power-on).
Mailbox Motor and Encoder Disk (callout 1) Stapler Unit 1. Offset Pusher 2. Exit Flap 3. Registratio n Pusher 4. Slider Arms Figure 7-19 Figure 7-20 7 Troubleshooting Troubleshooting 7-45.
Message Error Log Category/ Message Description Recommended Action 13.12 P APER JAM Error Message 13.03.32 A paper jam occurred along the T ransport Belt. When the paper ’ s final destination i s either the stapler or one of the mai lboxes, paper moves from the Flipper Assembl y to the T ransport Belt.
Message Error Log Category/ Message Description Recommended Action 13.12 P APER JAM Error Message 13.07.72 A paper jam occurred in the input guide. The input guide is l ocated at theentry and accepts paper from the printer . It guides the paper into the Flipper Assembly on the Multi -Bin Mailbox (refer to Figure 7-17).
Message Error Log Category/ Message Description Recommended Action 13.12 P APER JAM Error Message 13.12.03 A slider jam occurred. The slider arms are stuck or something i s interfering with thei r movement (refer to Figure 7-20). T wo slider arms hold the rear edge of the paper stac k in position during the stapl ing proc es s.
Message Error Log Category/ Message Description Recommended Action 21 PRINT OVERRUN DA T A LOST Error Message The data (dense tex t, rules, raster or vector graphics) sent to the printer was too complex.
Message Error Log Category/ Message Description Recommended Action 31.1.1 DISK NOT INITIALIZED Error Message 31.01.01 An optional disk ac cessory is not properly initialized. If the proper initi alization command is sent to the di sk, the message may be removed.
Message Error Log Category/ Message Description Recommended Action 51.x ERROR CYCLE POWER Service Message 51.01.00 A laser subsystem problem ex ists. x = 1: Beam detect mal function x = 2: Laser mal function Press [Select] to resume operation.
Message Error Log Category/ Message Description Recommended Action 55.xx ERROR PRESS SELECT KEY Service Message 55.xx.00 A printer command error occurred, which indicates a problem between the Formatter PCA and the print engine.
Message Error Log Category/ Message Description Recommended Action 58.x PRINTER ERROR CYCLE POWER Service Message 58.01.00 58.02.00 58.03.00 58.04.00 The tray lifter malfunctioned. The tray lifter mechanisms l ift the paper stack in eac h tray until the paper is loc ated directly beneath the feed rollers.
Message Error Log Category/ Message Description Recommended Action 62.x PRINTER ERROR CYCLE POWER Service Message 62.0x.00 The printer encountered a problem when accessing an internal memory (CRC error). x = device 0 = Formatter 1-4 = SIMM Module Cycle power .
Message Error Log Category/ Message Description Recommended Action 66.1.1 DEVICE ERROR CYCLE POWER Service Message 66.01.01 Feed Motor malfunction. The 2000-Sheet Input Feeder Main Drive Motor provides all "drive" capabilities for feedi ng paper in T ray 4.
Message Error Log Category/ Message Description Recommended Action 66.2.1 DEVICE ERROR CYCLE POWER Service Message 66.02.01 Home reference is not found. During the power-on sequence, the Multi -Bin Mailbox and the delivery head travel the length of the mailbox veri fying that all the bins and the stapler are installed.
Delivery Head Exit Roller 1. Exit Roller. 2. Guide Fingers. Multi-Bin M a ilb ox Figure 7-21 Figure 7-22 7 Troubleshooting Troubleshooting 7-57.
Message Error Log Category/ Message Description Recommended Action 66.2.3 DEVICE ERROR CYCLE POWER Error Message 66.02.03 Delivery Head rollers are not sliding. One or more fingers on the delivery roller mechanism in the mai lbox’ s Delivery Head Assembly is out of position.
Message Error Log Category/ Message Description Recommended Action 66.2.14 DEVICE ERROR CYCLE POWER Error Message 66.02.14 Multi-Bin Mailbox C-Link is not responding. Cycle power . Print the PCL configuration pages . Note which installed devices are NOT pres ent on the configuration pages (refer to Figure 7-5).
Tray 4 Cavity 1. Paper Quantity Swit ches 2. Lifter Safety Switch (SW31) 3. Paper Surface Sens or Flag (SW34) 4. Tray 4 Paper Out Flag (SW33) Tray 4 Lift Cables Figure 7-23 Figure 7-24 7-60 Troublesho.
Message Error Log Category/ Message Description Recommended Action 68 NVRAM FULL CHECK CONFIGURA TION Service Message The non-vol atile memory (NVRAM) is full. Press [Select] . The printer will go of fline. Remove MIO card and perform a COLD RESET . The printer displays the message REST ORING F ACTOR Y SETTINGS.
Message Error Log Category/ Message Description Recommended Action 79 SERVICE (x xxx) CALL SER VICE Catastrophic System Message An unrecoverable fi rmware error occurred. The numbers (xxxx) followi ng the error indicate the specifi c error . Record the error message including the number in parentheses (XXXX), then press SELECT .
Image Formation T roubleshooting Check the T oner Cartridge Image formation defects are often the result of toner cartridge problems. If there is any doubt, always replace the toner cartridge before troubleshooting image defects. Use the following check list to ensure that the toner cartridge is still operable.
Image Quality T ables Possible Cause Recommended Action OCCASIONAL BLANK P AGES: 1. Software Configuration. Make sure the application software is not sending incorrec t page length requests, or extra page eject commands . 2. Network Configuration. Some s haring devices on networks may generate a blank page as a separator .
Possible Cause Recommended Action 1. Defective toner cartri dge. Replace the toner cartridge. 2. Light is l eaking into the printer . Ensure all covers are in place. 3. High voltage c ontact springs are di rty or defective. The high vol tage contac ts are mounted on the High V oltage Power Supply PCA and protrude into the toner cartridge cavity .
Possible Cause Recommended Action 1. T oner supply is low . Shake the cartridge gently to redi stribute the toner , or replace the cartridge. 2. Print Density i s set incorrec tly . Change to a darker setting and retry printi ng. 3. EconoMode is on. Ec onoMode saves toner by reducing the dot density .
Possible Cause Recommended Action 1. Single sheet of paper defec tive. T ry reprinting the job. 2. Paper does not meet specs. The paper moisture content, conduc tivity , or surface fini sh may not work correc tly with the electrophotographic proc ess.
Possible Cause Recommended Action 1. Paper does not meet specs. The moisture content, conductivity , or surface finish of the media being printed may not work correctly with the electrophotographic process. T ry a dif ferent paper lot or other media (see HP LaserJet Printer Fami ly Paper Specifications Guide ).
Possible Cause Recommended Action 1. T oner cartridge is damaged. If the defect repeats at any of the followi ng intervals and in the direction of paper mov ement, it is assoc iated with a component ins ide the toner cartridge.
Possible Cause Recommended Action 1. Paper surface too rough. T oner migrates to low spots, leav ing higher areas void. T urn EconoMode OFF . Use paper with correct finish (smoothnes s) (see HP LaserJet Printer Family Paper Specific ations Guide ). 2.
Possible Cause Recommended Action 1. Paper is loaded i ncorrectly . If the paper is not installed flus h into the paper tray , a skewing problem will resul t. Remove paper from the tray and instal l paper correctly . Position the paper guide correctly for the paper size being used.
Possible Cause Recommended Action 1. Page too complex. The printer can not create the image fast enough to keep pac e with the print engine. Set Page Protect to ON or AUT O. 2. Not enough memory . The page is too complex for standard printer memory . Add printer memory .
Figure 7-25 Repetitive Defect Ruler 7 Troubleshooting 7-73.
Image System T roubleshooting Half Self Test Functional Check The electrophotographic process can be subdivided into the following stages: • Cleaning (removing excess toner from drum sur face) • C.
Drum Rotation Functional Check The photosensitive drum, located in the toner cartridge, must rotate for the print process to work. The photosens itive drum receives its drive from the Main Drive assembly. To verify whether the drum is rotating: 1 Open the top cover.
High-Voltage Power Supply Check The High-Voltage Power Supply PCA provides the necessary voltages for the electrophotographic processes. A method for verifying the high-voltage system is given below: Toner cartridge connection points Visually inspect the four connection points on the inside right end of the toner cartridge.
T roubleshooting Checks Paper Jams Paper jams occur most often when: • Paper trays are not correctly loaded. Make sur e the paper is loaded with the arrow pointing UP in Tray 1, and DOWN in Trays 2, 3, and 4. • The print media does not meet the specifications listed in the HP LaserJet Printer Family Paper Specifications Guide .
Figure 7-27 shows the possible locations for most of the paper jams. Paper Path Jam Locations 1. T oner cartridge area 6. Front Door 2. T ray 1 pick-up roller and feed area 7. T ray 2 and T ray 3 3. Right door 8. Fusing Assembly Area 4. T ray 4 transfer door 9.
Clearing Paper Jams Note: Open and close all printer covers to clear the paper jam message. After removing a sheet of paper, you may need to check other areas to ensure that all paper has been removed.
General T roubleshooting Information Miscellaneous Problems and Solutions The following lists symtoms and typical solutions to those problems. Abnormal noises are evident; grinding or chattering when main motor energized . From EP Area: 1 Replace Toner Cartridge.
Excessive Image Skew 1 Remove and reseat paper fences (fr ont fence in paper trays). 2 Image Skew Specifications: • 1 mm over 260 mm length • First line to leading edge 5.0 +/- 2.5 mm • Text Stretching 1% simplex 1.5% duplex • Envelope Skew 6.
Print Voids on pages after coming out of POWER SAVE mode. Turn POWER SAVE off (POWER SAVE is an item under the CONFIGURATION MENU) and retry. Jams when printing envelopes, transparencies, or labels to MultiBin Mailbox or Stapler . MultiBin Mailbox does not support these media.
Wrinkling Envelopes 1 Place Fusing Levers in UP position and retr y envelopes. 2 Try new media. Verify Envelopes are within specifications. See LaserJet Family Paper Specifications Guide . Poor Fusing 1 Verify Fusing Levers are in the down position for cut sheet paper.
If the paper path test works, it may be a software or user related issue. Perform the following steps: 1 Define the media types which are loaded in each paper tray. This can be done from either JetAdmin or the front contr ol panel of the printer. From JetAdmin • Select the Trays tab.
Caution Do not make changes to the driver unless the application does not provide this option. Print job settings selected through your application always override settings made through theprinter driver. Printer settings made in the application or print driver always override the cor responding setting made on the printer Control Panel.
Diagrams This section contains the following diagrams: • Printer Sensors and Switches • Printer Motor, Clutches, and Solenoids • DC Controller Inputs and Outputs (5 sheets) • Main Wiring Diagr.
Figure 7-28 Printer Sensors and Switches (Print Engine Only) 7 Troubleshooting Troubleshooting 7-87.
Figure 7-29 Printer Motor, Clutches, and Sol enoids 7-88 Troubleshooting.
Figure 7-30 DC Controller Inputs and Output s (1 of 5) 7 Troubleshooting Troubleshooting 7-89.
Figure 7-31 DC Controller Inputs and Output s (2 of 5) 7-90 Troubleshooting.
Figure 7-32 DC Controller Inputs and Output s (3 of 5) 7 Troubleshooting Troubleshooting 7-91.
Figure 7-33 DC Controller Inputs and Output s (4 of 5) 7-92 Troubleshooting.
Figure 7-34 DC Controller Inputs and Output s (5 of 5) 7 Troubleshooting Troubleshooting 7-93.
Figure 7-35 Printer Main Wiri ng Diagram 7-94 Troubleshooting.
Figure 7-36 2000-Sheet Input Unit Controller PCA Inputs 7 Troubleshooting Troubleshooting 7-95.
Figure 7-37 2000-Sheet Input Unit Controller PCA Outputs 7-96 Troubleshooting.
Figure 7-38 2000-Sheet Input Unit Main Wiring Diagram 7 Troubleshooting Troubleshooting 7-97.
1 2 3 4 5 6 7 8 9 10 Vcc Vcc Vcc 1 2 3 1 2 3 4 1 2 1 2 3 4 5 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 0 98765432 1 previous device connector (in) CLINK next device connector (out) CLINK power supply connector (o.
Figure 7-40 Stapling Unit Controll er PCA Main Wiring Diagram 7 Troubleshooting Troubleshooting 7-99.
7-100 Troubleshooting.
8 Parts and Diagrams Chapter Contents How to Use the Part Lists and Diagrams . . . . . . . . . . . . . . . . . 8-3 Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Accessories and Supplies . . . . . . . . . . . . . . . . . .
8-2 Parts and Diagrams.
How to Use the Part Lists and Diagrams The figures in this chapter illustrate the major subassemblies in the printer and their component parts. A table (material list) follows each exploded assembly diagram.
Accessories and Supplies The accessories, supplies, and parts listed in Chapter 1 and in the following pages are available through your local authorized HP dealer. To find a dealer near you (or if your dealer is temporarily out of stock), call the HP Customer Information Center (800) 752-0900 (U.
Illustrations and Parts Lists The following illustrations and their assorted parts tables list the field replaceable components for this printer. Where applic able, the exchange part number is listed immediately following the original equipment part numbers.
Figure 8-1a LJ 5Si Family Printer and Paper Handling Components 8-6 Parts and Diagrams.
Figure 8-1b LJ 5Si Mopier Family and Paper Handling Components 8 Parts and Diagrams Parts and Diagrams 8-7.
Ref Description/Product Number Part Number Exchange /Service Number QTY 01 Formatter Assembly C3168-67905 01A Formatter Assembly , Exchange C3168-69005 (ex.) 01 Formatter Assembly , Heavy Media C3125-60001 (serv .) 02 PostScript SIMM/C3169A C3169-69001 (ex.
Ref Description/Product Number Part Number Exchange /Service Number QTY not shown C-Link Cable Assembly 178 cm (HCI to MBM) C3764-70000 not shown C-Link Cable Assembly 61 cm (Engi ne to HCI) C3763-700.
Figure 8-2 Printer Covers and Doors 8-10 Parts and Diagrams.
Ref Description Part Number QTY 01 Left Access Door RB1-6667-000CN 1 02 Left Access Door Struts RF5-1440-000CN 2 03 Hinge Pl ate RB1-6507-000CN 1 04 Label, Operation (Spec ial Order) RS5-8596-000CN 1 .
Figure 8-3 Printer Internal Components (1 of 4) 8-12 Parts and Diagrams.
Ref Description Part Number QTY 01 T ransfer Guide Bushi ng RB1-6441-000CN 2 02 T ransfer Guide RF5-1394-000CN 1 03 T ransfer Roller RF5-1412-000CN 1 05 Damper Holder (Front) RB1-6461-000CN 1 06 Dampe.
Figure 8-4 Printer Internal Components (2 of 4) 8-14 Parts and Diagrams.
Fig Ref Description Part Qty 8-04 A Di verter Assembly RG9-1150-000CN 8-04A 11 Diverter Drive Assembly RF5-1441-000CN 1 8-04A 16 20T Gear RS5-0758-000CN 1 8-04A 18 Conductive Bushing RS5-1 101-000CN 1.
Figure 8-5 Printer Internal Components (3 of 4) 8-16 Parts and Diagrams.
* LaserJet 5Si HM (C3124A) onl y. Ref Description Part Number QTY 06 Laser / Scanner As sembly RG5-1895-000CN 1 06A Laser / Scanner Assembly , Exchange C3166-69006 16 Fan 1 RH7-1266-000CN 1 18 Cable A.
Figure 8-6 Printer Internal Components (4 of 4) 8-18 Parts and Diagrams.
Ref Description Part Number QTY 02 Fuser Cable 1 RG5-1849-000CN 1 03 Fuser Cable 2 RG5-1850-000CN 1 04A Low V oltage Power Supply , 1 10-120V RG5-1876-000CN 1 04B Low V oltage Power Supply , Universal.
Figure 8-7 2000-Sheet Input Unit Internal Components 8-20 Parts and Diagrams.
Ref Description Part Number QTY 01 2000-Sheet Input T ray Assembly RG5-2155-000CN 1 02 Front Cover RF5-1632-000CN 1 03 Right Cover RB1-7832-000CN 1 04 Left Cover RB1-7833-000CN 1 05 Back Cover RB1-783.
Figure 8-8 2000-Sheet Input Unit Internal Components 8-22 Parts and Diagrams.
Ref Description Part Number QTY 01 Paper Deck PCA RG5-4198-000CN 1 02 Paper Sensor PCA RG5-2225-000CN 1 03 Paper Size PCA RG5-2226-000CN 1 04 Adjus table T ip Feet RBI-7684-000CN 4 26 DC Power Supply .
Figure 8-9 Multi-Bin Mailbox/Mailbox with Stapler Components (1 of 3) 8-24 Parts and Diagrams.
Ref Description Part Number QTY 01 T op Cover C3764-60555 1 02 Spacer , plastic C3764-60524 1 03 Right Cover C3764-60553 1 04 Power Supply Assembly 0950-2927 1 05 Attachment Beam Assembly C3764-67906 .
Figure 8-10 Multi-Bin Mailbox/Mailbox with Stapler Components (2 of 3) 8-26 Parts and Diagrams.
Ref Description Part Number QTY 01 Flipper Assembl y (no cable) C3764-60501 1 02 Mounting Shaft (Hex ) C3764-60516 1 03 Jam Acces s Door Assembly C3764-60514 1 04 Spring, l eft, jam access door C3764-.
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Ref Description Part Number QTY 01 Left Cover C3764-60554 1 02 Delivery Head Pos ition Motor C3764-60507 1 03 Cable, Delivery Head Position Motor to Controller PCA C3764-60547 1 04 Cable Holder , Roun.
1 2 3 4 Figure 8-12 Stapling Unit Internal Components 8-30 Parts and Diagrams.
Ref Description Part Number Qty Stapling Unit As sembly C3766-60500 1 Exchange Stapling Unit C3766-69500 1 1T op Cover Assembl y C3766-60501 1 2 Stapling Bed Assembl y C3766-60503 1 3 Stapling Unit Co.
8-32 Parts and Diagrams.
A Parts Index Parts Index A-1.
Alphabetical Parts Index Description Product/Part No. Fig. Ref. 2000-Sheet Input Unit (T ray 4) C3763A 8-01 07 2000-Sheet Input T ray Assembly RG5-2155-000CN 8-07 01 3 W ay Power Adapter C4077-60102 8.
Description Product/Part No. Fig. Ref. Cable Assembly RG5-1924-000CN 8-02 22 Cable Holder , Edge C3764-60566 8-11 06 Cable Holder , Flat C3764-60513 8-11 07 Cable Holder , Round Gasket C3764-60565 8-1.
Description Product/Part No. Fig. Ref. Diverter Assembly RG9-1 150-000CN 8-02 30 Diverter Drive Assembl y RF5-1441-000CN 8-04A 11 Duplex Unit C3762A 8-01 10 Duplex Unit, Heav y Media C4178-69001 8-01 .
Description Product/Part No. Fig. Ref. Front Door Latch XZ9-0379-000CN 8-02 10 Front Panel ( Control Panel Di splay) RG5-2433-000CN 8-02 19 Fuse, L VPS, 1 10-120V VD5-0056-301CN 8-06 05 Fuse, L VPS, U.
Description Product/Part No. Fig. Ref. Laser / Scanner Assembly RG5-1895-000CN 8-05 06 Laser / Scaner Assembl y , Exchange C3166-69006 8-05 06A Left Access Door RB1-6667-000CN 8-02 01 Left Access Door.
Description Product/Part No. Fig. Ref. Overlay , Swedish C3166-40007 not shown Overlay , Danish C3166-40008 not shown Overlay , Finnish C3166-40009 not shown Overlay , Dutch C3166-40010 not shown Over.
Description Product/Part No. Fig. Ref. Pickup Roller RF5-1427-000CN 8-04E 21 Pickup Roller RF5-1427-000CN 8-07 53 PIU PCA RG5-1860-000CN 8-04E 103 Plate Guard RB1-6522-000CN 8-02 25 Plate Shield RF5-1.
Description Product/Part No. Fig. Ref. Screw , TP , M3X6 (fixed shoulder) XA9-0267-000CN 8-03 CH101 Screw , TP , M3X6 (fixed shoulder) XA9-0267-000CN 8-05 CH101 Screw , TP , M3X6 (fixed shoulder) XA9-.
Description Product/Part No. Fig. Ref. T orque Limiter RB1-6588-000CN 8-04E 10 T orque Limiter RB1-6588-000CN 8-07 54 T ransfer Guide RF5-1394-000CN 8-03 02 T ransfer Guide Bushing RB1-6441-000CN 8-03.
Numerical Parts Index Part No. Descr iption Fig. Ref. 0950-2927 Power Supply Assembly 8-09 04 C2009-00006 MIO Coverplate 8-01 14 C2930A T ray 3 8-01 09 C2931A T ray 2 8-01 08 C2965-40001 420 MB Disk L.
Part No. Descr iption Fig. Ref. C3764-60505 Face Up Bin 8-09 11 C3764-60507 Delivery Head Position Motor 8-11 02 C3764-60513 Cable Holder , Flat 8-11 07 C3764-60514 Jam Access Door As sembly 8-10 03 C.
Part No. Descr iption Fig. Ref. C3764-60564 Pulley , small 8-10 14 C3764-60565 Cable Holder , Round Gasket 8-11 04 C3764-60566 Cable Holder , Edge 8-11 06 C3764-67900 Kit, Metallic T ape/Housing 8-10 .
Part No. Descr iption Fig. Ref. C3766-69500 Exchange Stapling Unit 8-12 not shown C3766-69500 Stapling Unit Exchange 8-09 12 C3766-69515 Exchange Mailbox: 5 Bin for Stapler 8-01 12 C3766-69515 Exchang.
Part No. Descr iption Fig. Ref. RB1-6558-000CN Sensor Arm Spri ng 8-04E 49 RB1-6588-000CN T orque Limiter 8-04E 10 RB1-6588-000CN T orque Limiter 8-07 54 RB1-6614-000CN Fuser Flag 8-04C 36 RB1-6615-00.
Part No. Descr iption Fig. Ref. RF5-1623-000CN Adjustable Size Pl ate: Front 8-07 69 RF5-1632-000CN Front Cover 8-07 02 RG5-1833-040CN Registration Assembl y 8-03 24 RG5-1834-000CN Feeder Assembly 8-0.
Part No. Descr iption Fig. Ref. RG5-1924-000CN Cable Assembly 8-05 18 RG5-1925-000CN Scanner Motor Cable 8-05 19 RG5-1926-000CN BD Cable 8-05 20 RG5-1927- 000CN ILS Cable 8-05 21 RG5-1928-000CN Regist.
Part No. Descr iption Fig. Ref. RS5-1207-020CN Bushing, Pl astic 8-07 65 RS5-2463-000CN Compression Spring, Front 8-04D 14 RS5-2466-000CN Compression Spring, Rear 8-04D 16 RS5-2490-000CN T ension Spri.
B I/O Information IEEE 1284 Parallel Cable Information The IEEE 1284 parallel interface is compatible with Centronics parallel interfaces. To take advantage of its enhanced capabilities such as bi-dir.
Parallel Cable Pin Configuration For best results, use the C2951A cable, or equivalent. Caution Ensure that all power and interface cables on the printer and host c omputer are properly gr ounded in compliance with local codes.
Connecting to LocalT alk Networks The printer does not come with a LocalTalk network cable. Use a standard LocalTalk network cable and connector kit, such as the HP LocalTalk Network Cable Kit, part number 92215N. You will need one connector kit for each printer on the network, and another for each Mac intosh computer on the network.
Connecting to the MIDDLE of a LocalT alk Network Connecting to the MIDDLE of a LocalTalk Network (1 of 2) 1 Disconnect the printer from its power sourc e. Insert the new connector box cable into the LocalTalk port of the printer. 2 Insert one end of the new cable into the connector box.
Connecting to a Network. The printer supports up to four different cables: IEEE 1284 parallel, (Figure B-5, callout 1), BNC (ThinLAN) (Figure B-5, callout 2), 10Base-T (RJ-45) (Figure B-5, callout 3), and DIN-8 (LocalTalk) (F igure B-5, callout 4).
DIN-8 (LocalTalk) Interface Plug the end of the DIN-8 cable into the LocalTalk port on the HP JetDirect card. Note If you are using only the LocalTalk port, 18 MIO NOT READY will appear every time you turn on the printer. This message will automatically disappear after 5 minutes.
Configuring Novell NetWare Frame Type Parameters. Normally selecting a NetWare frame type is not required. The HP JetDirect card automatically selects a NetWare frame type, and only when this selection is incorrect do you have to set the NetWare fram e type through the HP LaserJet 5Si MX c ontrol panel.
Configuring TCP/IP Parameters The HP JetAdmin utility for UNIX (sold separately) may be used to configure TCP/IP parameters. If you do not have the HP JetAdmin utility for UNIX, or you are using a UNI.
Configuring Apple EtherTalk Phase Parameter To configure EtherTalk parameters: 1 If you do not want to configure the phase parameter, Press [On Line] . 2 Press [Item] . CFG ETALK=NO * appears. 3 Press [+] . CFG ETALK=YES appears. 4 Press [Select] . CFG ETALK=YES * appears.
Disable Network Protocols (Optional). 1 Press [On Line] to take the printer offline. 2 Press [Menu] repeatedly until MIO MENU appears. 3 Press [Item] . CFG NETWORK=NO * appears. 4 Press [+] . CFG NETWORK=YES * appears. 5 Press [Select] . CFG NETWORK YES * appears.
C Regulatory Information Laser Safety (U.S.A.) The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration implemented regulations for laser products manufactured since August 1, 1976. Compliance is mandator y for products marketed in the United States.
Laser Statement (Finland) The following applies to printer operation and servicing in Finland. LASERTURVALLISUUS LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT HP LaserJet(s) 5Si, 5S i MX, and 5Si Mopier laserkirjoitin on käyttäjän kannalta turvallinen luokan 1 laserlaite.
T oner Safety Note In case of toner spills, skin and clothing are best cleaned by rem oving as much toner as possible with a dry tissue, then washing with cold water.
FCC Regulations This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reas onable protection against harmful interferenc e in a residential installation.
DECLARATION OF CONFORMITY according to ISO/IEC Guide 22 and EN 45014 Manufacturer ’ s Name: Hewlett-Packard Company Manufacturer ’ s Address: 1 131 1 Chinden Boulevard Boise, Idaho 83714-1021, USA.
C-6 Regulatory Information.
Index ! 2000-sheet input unit components 5-23 operation 5-26 see "tray 4 " 6-67 A ac access cover 6-19 ac power distrib ution 5-6 accessories user installa ble 6-7 accessories and options 1-.
FIRST) 1-25 features 1- 3 control panel 1-3 feed roller tray 1 6-58 tray 2 6-60 tray 3 6-60 feeder assembly 6-37 fonts internal 1-3 formatter a ssembly 6-39 formatter sy stem 5-8 front cover 6- 21 fun.
overhead transparency specifications 1-12 overvoltage protection 5-6 P page count setting 3-21, 6-40 verification 3-19 page usage, monthly 1-3 paper capacities 1-4 paper curl 7-85 paper input unit sen.
rollers tray 1 6-58 tray 2 6-60 tray 3 6-60 S saving menu selections 3-8 scanner drive 5-10 scanner motor 5-1 1 scanner/laser assembly 6-42 screwd rivers 6-6 screws descriptions 6-16 Select, key 3-3 s.
Copyright© 1997 Hewlett-P ackard Co. Printed in USA 7/97 Manual Part No. C4077-90960 HP LaserJet 5Si Family Printers Service Manual English HP LaserJet 5Si Family Printers Service Manual Printed on a.
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