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HP Laserjet 5 Service Manual

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    							6 - 48 Removal and Replacement 
    						
    							7
    Troubleshooting
    Contents
    General Troubleshooting Flowchart .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . . 7-3
    Paper Path and Components .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . . 7-5
    DC Controller Diagram .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . . 7-6
    Printer Error Troubleshooting . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . . 7-7
    Priority of Errors .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . . 7-7
    Printer Status Messages . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . . 7-8
    Service and Error Messages .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-10
    Image Formation Troubleshooting .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-13
    Check the Toner Cartridge . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-13
    Image Defect Examples .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-14
    Troubleshooting Checks .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-21
    Engine Test . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-21
    Half-Self Test Functional Check .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-22
    Drum Rotation Functional Check . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-23
    High-Voltage Power Supply Check .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-24
    Paper Curl .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-26
    Troubleshooting Tools . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-27
    Paper Path Check .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-27
    Repetitive Image Defect Ruler . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-28
    Main Wiring Diagram . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . .  . 7-29
    Troubleshooting 7-1 
    						
    							7-2 Troubleshooting 
    						
    							General Troubleshooting Flowchart
    When the AC power isfirst appliedto the printer:
    ·Both the printer motor and the laser/scanner
    motor rotate for 6 seconds.
    ·All of the LEDs illuminate for one second; the
    “Ready” LED will illuminate after 3 seconds.
    Ifno errormessage is displayed, the Printer Door
    is firmly closed, and the toner cartridge is
    installed, but the motor does NOT rotate when AC
    power is applied to the printer:
    1Verify that AC power is present at the input
    power receptacle and that the power cord is
    firmly inserted into the printer.
    2Verify that FU102 is not open. (See Figure
    7-2.)
    3Verify that motor connector J1 is seated into
    J401 of the DC Controller. (See Figure 7-2.)
    4Verify that the motor is correctly mounted to
    the printer chassis.
    5If all of these conditions are correct, replace
    the DC Controller PCA and/or the motor.
    If the Control Panel is not functional:
    1Verify that the Control Panel connector J9 is
    seated into both the Control Panel and the
    Formatter PCA at J3. (See Figure 7-2.)
    2Verify that the Formatter PCA is firmly seated
    into the DC Controller PCA.
    3Perform an Print Engine Test. (See Figure
    7-4.)
    4If the engine test is successful, replace the
    Control Panel first, then, if necessary, the
    Formatter PCA.
    5If the engine test is not successful, replace the
    DC Controller PCA.
    If the control panel displays an error, refer to the
    appropriate section in this chapter to correct the
    error.
    Continued on following page
    START
    AC Power is
    applied to the printer
    Does the
    Printer Motor
    rotate for about
    6 seconds
    ?
    Is the
    Front Panel
    functional
    ?No
    Yes
    No
    Yes
    Is
    an Error
    displayed
    ?
    NoYes
    7
    Troubleshooting
    Troubleshooting 7-3 
    						
    							General Troubleshooting Flowchart (continued)
    Refer to the section “Image Formation
    Troubleshooting,” later in this chapter.
    If the engine test produces a clear print image, yet
    a Self Test is not generated by initiating the
    Control Panel self-test procedure, replace the
    Formatter PCA.
    Perform an
    Engine Test
    Is the
    Engine Test
    image being printed
    clearly
    ?
    Perform a Front
    Panel Self Test
    Is the
    Self Test image
    being printed
    clearly
    ?No
    Yes
    No
    EXIT
    Yes
    7-4 Troubleshooting 
    						
    							Paper Path and Components
    Paper Path and Components
    PS201PS203PS202 SL1MotorFeed Roller Feed
    Sub
    Roller Pick-up
    Roller
    Paper
    Registration
    SensorPaper
    Out
    Sensor Paper
    Pick-up
    Solenoid
    Photo-
    sensitive
    Drum
    Transfer
    Roller Fuser
    Paper
    Exit Sensor Fusing Unit
    Delivery
    Roller Face-up
    DeliveryDeflector
    Face-down
    Delivery
    Face-down
    Delivery
    RollerManual
    Input
    SlotPaper
    Input
    Bin DC Controller PCA
    PAPER DELIVERY SENSOR signal
    (POSNS)
    MOTOR DRIVE signal
    (MA, /MA, MB, /MB)
    PAPER PICK-UP SENSOR signal
    (PISNS)
    PICK-UP SOLENOID DRIVE signal
    (CPUD)
    PAPER-OUT SENSOR signal
    (PAPERSNS)
    Figure 7-1
    7
    Troubleshooting
    Troubleshooting 7-5 
    						
    							DC Controller Diagram
    DC Controller PCA Components
    J3Control Panel Connector (Formatter
    PCA)J202Paper Registration and Paper-Out
    Photosensors (PS203 and PS202)
    J102Fusing AssemblyJ206Fusing Assembly (thermistor feedback)
    J201Formatter PCA ConnectionJ207Scanner Motor
    J204Paper Pickup Solenoid (SL1)J208Laser Driver/Beam Detect Circuitry
    J301Developer Bias ContactJ209Door Open/No Toner Cartridge
    Photosensor (PS204) (HP LaserJet 5L
    only)
    J302Transfer Roller ContactJ401Motor
    J304Primary Roller ContactFU101
    SW101+12A Vdc Shutoff SwitchFU102110 volt only
    SW201Engine Test Print SwitchINL101Input Power Receptacle
    PS201Fusing Assembly Exit Photosensor
    Figure 7-2
    7-6 Troubleshooting 
    						
    							Printer Error Troubleshooting
    Information regarding printer status is conveyed by two methods:  1) the printer’s
    Control Panel lights and 2) feedback through the bi-directional I/O that displays at
    the PC. The basic method of determining error messages uses patterns of lights on
    the Control Panel LED. Printer messages are categorized into two basic types:
    ·Status Messages
    ·Service and Error Messages
    NoteBefore troubleshooting the printer, cycle the power to the printer to see if the error
    persists.
    Priority of Errors
    Each error has a priority in relation to the others. If there is more than one error
    condition at the same time, the highest priority error will be displayed. The priority
    of errors is:
    1Service Errors
    2Door Open/No Toner Cartridge
    3Paper Jam
    4Paper Out
    5Memory Error
    6Manual Feed
    7
    Troubleshooting
    Troubleshooting 7-7 
    						
    							Printer Status Messages
    The following table lists printer LED messages and their meanings and describes
    recommended actions. For more information on the Front Panel layout, refer to
    “Using the Control Panel” in Chapter 3, “Installation and Configuration.”
    LEDs Description Recommended Action
    Paper Out Error.
    Door Open or No EP Cartridge.
    Paper Jam.Add paper.
    Close the printer door and/or verify that the EP
    cartridge is installed.
    Clear paper jam.
    If you have completed these recommended actions
    and the error persists, see Table 7-3.
    Memory Error. There is either too much
    data or the data is too complex.1. Turn Page Protection on within your software
    application or Windows.
    2. Reduce the complexity of the print job.
    3. Reduce resolution to 300 dpi within your software
    application or Windows.
    4. Add optional memory to the printer.
    5. Make sure Enhanced I/O is on Auto Mode (PCL
    mode) and resend print job. (See Chapter 3, “PCL
    Printer Settings.)
    6. If the Auto-Continue variable is on within PJL, the
    printer will continue printing after 10 seconds.
    7. If the Auto-Continue variable is off within PJL, you
    need to press the Front Panel Button to continue
    printing.
    Incompatible Memory Card. Remove the incompatible memory card and replace it
    with a 1, 2, 4, or 8 Mb, 70 nsec. or faster memory card.
    (See Chapter 8 for memory card part numbers.)
    Manual Feed. The printer is waiting for you
    to add a piece of paper to the single sheet
    input slot.1. Make sure the correct paper is loaded into the
    printer. (See your
    HP LaserJet 5L User’s Manualor theHP LaserJet Printer Family Paper Specifications Guidefor more information.)
    2. Press and release the Front Panel Button.
    3. Turn off manual feed within your software application
    if you do not wish the printer to pause between sheets.
    Table 7-1Printer Status Messages (1 of 2)
    7-8 Troubleshooting 
    						
    							Occasionally you may add paper, close the printer door, add the toner cartridge, and
    clear a paper jam, only to find that the printer still displays an error message. If this
    happens, troubleshoot using Table 7-3 below.
    NoteIf the error appears and persists only after you attempt to print a page, verify that
    the motor is functioning. (See “Printing an Engine Test” later in this chapter.)
    LEDs Description Recommended Action
    Sleep ModeIf the printer’s LEDs remain off:
    1. The printer is in Sleep Mode. Press the Front Panel
    Button or open the EP Door.
    2. Power is not supplied to the printer. Check power
    cord connections and the power source.
    3. Print an engine test to determine if the print engine
    is functional. If the test is successful, replace the
    Formatter PCA.
    4. See the General Troubleshooting Flowchart earlier
    in this chapter.
    Table 7-2Printer Status Messages (Continued 2 of 2)
    This error will persist if any of the three paper movement photosensors (PS201, PS202, and
    PS203) and/or their flags are not functional.
    1. Verify that all three photosensor flags are not blocked and move freely. (See Figure 7-1 to identify
    photosensor flag locations.)
    ·Paper Out Flag (PS202) (See Figure 5-6.)
    ·Paper Registration Flag (PS203) (See Figure 5-6.)
    ·Exit Sensor Flag (PS201) (See Figure 6-18.)
    2. Verify that all connectors are firmly seated. (See Figure 7-2 to identify connector locations on the
    DC controller.)
    ·Door closed/EP Cartridge Photosensor connector (5L only)
    ·Paper-Out and Registration Photosensor Connector (See Figure 5-6.)
    Note: There is no connector for the Exit Photosensor (PS201) since it is located on the DC
    Controller PCA. This flag is located beneath the Fusing Assembly. (Refer to Figure 6-18.)
    If all of the flags move freely and all of the connectors are correctly seated, yet the error persists,
    replace the DC Controller PCA.
    Table 7-3Unclearable Error
    7
    Troubleshooting
    Troubleshooting 7-9 
    						
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