Grizzsm LJ4100_SM LJ4100 SM

User Manual: LJ4100_SM

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Contents
Figures
Tables
Printer description
Service approach
Printer operation
Printer maintenance
Theory of operation
Removing and replacing parts
Troubleshooting
Parts and diagrams
Index
- Numerics
- A
- B
- C
- D
- E
- F
- G
- H
- I
- J
- K
- L
- M
- N
- O
- P
- Q
- R
- S
- T
- U
- V
- W

service manual

hp LaserJet 4100

HP LaserJet 4100 Series Printer

Service Manual _____________

Hewlett-Packard Company

11311 Chinden Boulevard

Boise, Idaho 83714 U.S.A.

Company

Reproduction, adaptation, or

translation without prior written

permission is prohibited, except

as allowed under the copyright

laws.

Publication number

C8049-90920

First edition, April 2001

Warranty

The information contained in this

document is subject to change

without notice.

Hewlett-Packard makes no

warranty of any kind with respect

to this information.

HEWLETT-PACKARD

SPECIFICALLY DISCLAIMS

THE IMPLIED WARRANTY OF

MERCHANTABILITY AND

FITNESS FOR A PARTICULAR

PURPOSE.

Hewlett-Packard shall not be

liable for any direct, indirect,

incidental, consequential, or

other damage alleged in

connection with the furnishing or

use of this information.

Trademark Credits

ENERGY STAR® is a U.S.

registered mark of the United

States Environmental Protection

Agency.

Microsoft® is a U.S. registered

trademark of Microsoft Corp.

MS-DOS® is a U.S. registered

trademark of Microsoft Corp.

Netscape™ is a U.S. trademark of

Netscape Communications

Corporation.

PostScript™ is a trademark of

Adobe Systems Incorporated

that may be registered in certain

jurisdictions.

TrueType™ is a U.S. trademark of

Apple Computer, Inc.

Contents 3

Contents

1 Printer description

Printer features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Product compatibility matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Model and serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Environmental requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Print media specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Supported types of print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Types of print media to avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Weight equivalence table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Adhesive labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Overhead transparencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Envelopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Card stock and heavy paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Toner safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Laser safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Regulatory information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

2 Service approach

Service approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Parts and supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Ordering information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Printer documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

HP direct ordering for genuine HP parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Exchange program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

World Wide Web. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

HP service parts information compact disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

HP support assistant compact disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Toner cartridge information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Warranty statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Printer warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Limited warranty for toner cartridge life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

3 Printer operation

Using the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Control panel layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Control panel lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Control panel keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Settings and defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Control panel menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Quick copy jobs menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Private/stored jobs menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Information menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Paper-handling menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Printing menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Print quality menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

4Contents EN

Configuration menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

I/O menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

EIO menu (networked printers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Resets menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Page count. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Maintenance count. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Maintenance interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Serial number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Cold reset paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Clear event log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Top margin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Tray 1 left margin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Trays 2 and 3 left margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Testing the printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Engine test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Resetting the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Cold reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Clearing NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Initialization of NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Initialization of the hard disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

MS-DOS system configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Parallel DOS commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4 Printer maintenance

Cleaning the printer and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Using the printer cleaning page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Using the auto-cleaning page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Cleaning spilled toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Performing printer maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Reset maintenance count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Expected life of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

5 Theory of operation

Power supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

AC/DC power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Overcurrent/overvoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Fuser over-temperature protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

High-voltage power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Toner-cartridge detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Cartridge memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Engine controller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Engine controller board inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Laser/scanner drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Paper-motion monitoring and control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Solenoids, sensors, clutches, and switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Engine test print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Formatter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

PowerSave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Resolution Enhancement technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

EconoMode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Input/output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Printer memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

EN Contents 5

DIMM slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

PJL overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

PML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Image formation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Toner cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Photosensitive drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

Writing the image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Developing the image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

Transferring the image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Image fusing/variable fusing temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

Paper feed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

Clutches and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

Printing from tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

Printing from tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

Printing from the optional 500-sheet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

Envelope feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Duplexer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

Other controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

Environmental detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

Basic sequence of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

6 Removing and replacing parts

Removal and replacement strategy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136

Other helpful tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136

Removing covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Rear right side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Left side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Front right side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144

Rear cover/rear output bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Removing internal assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

Firmware DIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150

Formatter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

Output delivery assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152

Laser/scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

Cartridge memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

Main motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158

Transfer roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159

Tray 1 pickup roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160

Tray 1 pickup assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161

Right side toner cartridge guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164

Registration assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165

Paper feed assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167

Printer drive assembly (gear train) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169

Delivery drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170

Separating the engine module from the paper-feed module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171

Engine controller board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173

Paper-feed guide assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176

Removing tray assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177

Paper-feed rollers for trays 2, 3, and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177

6Contents EN

Separation rollers for trays 2, 3, and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Tray 2 paper-feed module disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Tray 3 and 4 paper-feed module disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

7 Troubleshooting

Troubleshooting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Troubleshooting flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Troubleshooting flowchart (continued). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Troubleshooting the printing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Preliminary operating checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Power on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Engine test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Printer messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

General paper-path troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Information pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Image quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Image system troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Reference diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Locations of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Engine controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

Paper-size detection switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Motors and fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

PCAs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Sensors, switches, and thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Solenoids and clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

8 Parts and diagrams

How to use the parts lists and diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Accessories and supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Common screws and replacement cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Illustrations and parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Alphabetical parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Numerical parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

Index

Contents 7

Figures

Figure 1. Sample label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Figure 2. Top view, HP LaserJet 4100/4100N/4100TN/4100DTN printer . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Figure 3. Side view, HP LaserJet 4100/4100N printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Figure 4. Side view, HP LaserJet 4100TN/4100DTN printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Figure 5. Control panel layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Figure 6. Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Figure 7. Location of the transfer roller – Do Not Touch! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Figure 8. Low-voltage power supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Figure 9. Engine controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Figure 10. Cartridge memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Figure 11. Engine controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Figure 12. Engine controller board I/O (1 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Figure 13. Engine controller board I/O (2 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Figure 14. Engine controller board I/O (3 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Figure 15. Engine controller board I/O (4 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Figure 16. Engine controller board I/O (5 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Figure 17. Main motor control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

Figure 18. Image formation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Figure 19. Toner cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Figure 20. Photosensitive drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

Figure 21. Cleaning the drum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

Figure 22. Primary charging roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Figure 23. Writing the image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Figure 24. Developing the image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

Figure 25. Transferring the image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Figure 26. Image fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

Figure 27. Fusing temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

Figure 28. Paper feed subsystem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

Figure 29. Paper path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Figure 30. Tray 1 pickup timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

Figure 31. Tray 1 pickup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

Figure 32. Tray 2 pickup timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

Figure 33. Skew correction at registration assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

Figure 34. Multiple-feed prevention mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

Figure 35. Paper-feeder driver I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

Figure 36. Paper feed pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

Figure 37. Paper path for the duplexer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

Figure 38. Timing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

Figure 39. Comparing Phillips and Posidriv screwdrivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136

Figure 40. Removing the rear right side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Figure 41. Removing the control panel overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Figure 42. Removing the control panel board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

Figure 43. Disconnecting the toner cartridge drive arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Figure 44. Removing the top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

Figure 45. Releasing tabs to lift the top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

Figure 46. Removing the left side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Figure 47. Removing the front right side cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144

Figure 48. Removing the rear cover/rear output bin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

Figure 49. Removing tray 1 from the front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Figure 50. Removing the tray 1 sensor arm cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Figure 51. Detail of the tray 1 sensor arm cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

Figure 52. Detail of hinge spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

8Figures EN

Figure 53. Unlocking the fuser assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Figure 54. Installing a firmware DIMM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Figure 55. Removing the formatter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Figure 56. Removing the output delivery assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Figure 57. Left end of output delivery assembly (brass arm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Figure 58. Right end of output delivery assembly (white tab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Figure 59. Removing the laser/scanner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Figure 60. Removing the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Figure 61. Detail of the plastic fan clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Figure 62. Removing the main motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Figure 63. Removing the transfer roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Figure 64. Removing the pickup roller (shown with envelope entrance cover removed) . . . . . . . . . . . . . . . . 160

Figure 65. Installation of tray 1 pickup roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Figure 66. Removing the gear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Figure 67. Removing the tray 1 pickup assembly—right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Figure 68. Removing the tray 1 pickup assembly—left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Figure 69. Removing the tray 1 pickup assembly—front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Figure 70. Removing the right side toner cartridge guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Figure 71. Removing the registration assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Figure 72. Detail of screws for the registration assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Figure 73. Unplugging the connector to the paper feed assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Figure 74. Removing the upper screws from the paper feed assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Figure 75. Detail of clutch orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Figure 76. Removing the printer drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Figure 77. Removing the delivery drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Figure 78. Unplugging the connector to the paper-feed module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Figure 79. Separating the engine from the paper-feed module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Figure 80. Removing the engine controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Figure 81. Removing the engine controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Figure 82. Location of VR501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Figure 83. Adjusting the top margin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Figure 84. Removing the paper feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Figure 85. Removing the separation roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Figure 86. Removing the tray 2 paper-feeder plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Figure 87. Removing the paper-feeder plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Figure 88. Detail of clutch release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Figure 89. Detail of spring and lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Figure 90. Location of spring and lever (the paper feeder is inverted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Figure 91. Troubleshooting flowchart (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Figure 92. Troubleshooting flowchart, continued. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Figure 93. Location of the engine test button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Figure 94. Sample event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Figure 95. Sample menu map (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Figure 96. Sample menu map (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Figure 97. Sample configuration page (HP LaserJet 4100 series printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Figure 98. Repetitive print defect ruler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

Figure 99. Components of the paper pickup and feed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Figure 100. Components of the optional paper feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Figure 101. Components of the optional duplexer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Figure 102. Components of the fusing and delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Figure 103. Components of the optional envelope feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Figure 104. Paper sensors and the paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Figure 105. Engine controller board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

Figure 106. Paper-size detection switches (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Figure 107. Paper-size detection switches (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Figure 108. Location of motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Figure 109. Connectors (1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Figure 110. Connectors (2 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Figure 111. Connectors (3 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

EN Figures 9

Figure 112. Location of PCAs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261

Figure 113. Location of sensors, switches, and thermistors (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263

Figure 114. Location of sensors, switches, and thermistor (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264

Figure 115. Location of solenoids and clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266

Figure 116. Pickup timing for tray 2 (and lower trays) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268

Figure 117. Pickup timing for tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268

Figure 118. Assembly location diagram (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274

Figure 119. Assembly location diagram (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275

Figure 120. External covers and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277

Figure 121. Top cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278

Figure 122. Internal components (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280

Figure 123. Internal components (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282

Figure 124. Internal components (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284

Figure 125. Internal components (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .286

Figure 126. Engine controller board assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288

Figure 127. Delivery drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289

Figure 128. Printer drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290

Figure 129. Tray 2 paper pickup guide assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291

Figure 130. Tray 1 pickup assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292

Figure 131. Paper feed guide assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294

Figure 132. Delivery assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295

Figure 133. Fuser assembly (1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296

Figure 134. Fuser assembly (2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297

Figure 135. Internal components of optional 500-sheet feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298

Figure 136. Paper pickup guide assembly of optional 500-sheet feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300

Figure 137. 500-sheet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302

Figure 138. Envelope feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303

Figure 139. Internal components of duplexer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304

10 Figures EN

Contents 11

Tables

Table 1. Printer features for the HP LaserJet 4100 series printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Table 2. Product compatibility matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Table 3. Electrical specifications for the HP LaserJet 4100 series printers . . . . . . . . . . . . . . . . . . . . . . . . . .21

Table 4. Printer and toner cartridge environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Table 5. Operating sound power or pressure (Per ISO 9296). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Table 6. Print media specifications, tray 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Table 7. Print media specifications, trays 2, 3, and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Table 8. Print media specifications, optional envelope feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Table 9. Print media specifications, optional duplexer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Table 10. Weight equivalence table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Table 11. Adhesive labels specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Table 12. Overhead transparencies specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Table 13. Envelope specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Table 14. Paper specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Table 15. Printer documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Table 16. Control panel lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Table 17. Control panel keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Table 18. Settings and defaults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Table 19. Quick copy jobs menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Table 20. Private/stored jobs menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Table 21. Information menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Table 22. Paper handling menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Table 23. Printing menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Table 24. Print quality menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Table 25. Configuration menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Table 26. I/O menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Table 27. EIO menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Table 28. Resets menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Table 29. Changing the page count (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Table 30. Cleaning the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Table 31. Maintenance kit part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Table 32. Life of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Table 33. Printer timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

Table 34. Screws used in the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Table 35. Major steps for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184

Table 36. Power on defect or blank display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188

Table 37. Printer messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194

Table 38. Mopy disk error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218

Table 39. General paper-path troubleshooting questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220

Table 40. Image quality checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228

Table 41. Weights of toner cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228

Table 42. Image defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231

Table 43. High voltage system checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245

Table 44. Components of the paper pickup and feed system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247

Table 45. Paper sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252

Table 46. Engine controller board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254

Table 47. Paper-size detection switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256

Table 48. Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257

Table 49. Location of PCAs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262

Table 50. Sensors, switches, and thermistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264

Table 51. Solenoids and clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267

Table 52. Accessories and supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271

12 Tables EN

Table 53. Screws used in the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Table 54. Replaceable cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Table 55. Assemblies (listed alphabetically) and their part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Table 56. External covers and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Table 57. Top cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

Table 58. Internal components (1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Table 59. Internal components (2 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Table 60. Internal components (3 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Table 61. Internal components (4 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Table 62. Engine controller board assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

Table 63. Delivery drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Table 64. Printer drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

Table 65. Paper pickup guide assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Table 66. Tray 1 pickup assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

Table 67. Paper feed assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

Table 68. Delivery assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Table 69. Fuser assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Table 70. Internal components of optional 500-sheet feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

Table 71. Paper pickup guide assembly, optional 500-sheet feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Table 72. 500-sheet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Table 73. Envelope feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

Table 74. Internal components of duplexer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

Table 75. Alphabetical parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Table 76. Numerical parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

Chapter 1 Printer description 13

1Printer description

Chapter contents

Printer features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Product compatibility matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Site requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Environmental requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Print media specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Supported types of print media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Types of print media to avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Weight equivalence table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Adhesive labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Overhead transparencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Envelopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Card stock and heavy paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Toner safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Laser safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Regulatory information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

14 Printer description EN

Printer features

Table 1. Printer features for the HP LaserJet 4100 series printers

Models HP LaserJet 4100 (C8049A):

!25 pages per minute (ppm) for letter-size paper, and 24

ppm for A4-size paper

!16 megabytes (MB) random-access memory (RAM)

!600-sheets input capacity

HP LaserJet 4100N (C8050A):

Base unit plus the following:

!16 MB RAM (32 MB total)

!10/100BaseT card

HP LaserJet 4100TN (C8051A):

Base unit plus the following:

!16 MB RAM (32 MB total)

!10/100BaseT card

!One 500-sheet feeder (1100-sheet input capacity)

HP LaserJet 4100DTN (C8052A):

Base unit plus the following:

!16 MB RAM (32 MB total)

!10/100BaseT card

!One 500-sheet feeder (1100-sheet input capacity)

!Duplex printing accessory

Accessories !Stackable 500-sheet feeder with XY size capability

!Duplex printing accessory

!75-sheet envelope feeder

!4, 8, 16, 32, 64, and 128 MB dual inline memory

modules (DIMMs)

!2 and 4 MB flash DIMMs

!LocalTalk/Universal Serial Bus (USB)/Serial and Token

Ring EIO cards

!Infrared adapter

!Enhanced input/output (EIO) hard disk drive

!HP Print to Mail (not available in all regions)

Speed !25 ppm for letter-size paper, and 24 ppm for A4-size

paper

!RIP ONCE (rasterized image processing) capability

with 16 MB or hard-disk options for faster production

!First page out = 12 seconds

!250 MHz RISC processor

EN Chapter 1 Printer description 15

Resolution The printer prints true 1200 dpi and supports the following:

!HP ProRes 1200 at full engine speed (PCL6 and PS)—

produces 1200-dpi printing for the best quality of

graphic images

!HP FastRes 1200 (PCL6 only)—produces emulated

1200-dpi print quality for fast, high-quality printing of

business text and graphics

!600 dpi with PCL5e and PS

!300 dpi with PCL5e and HP PostScriptTM Level 3

emulation (PS)

Typefaces/fonts 110 Scalable TrueTypeTM (80 built-in, 30 with HP

FontSmart, all PCL and PS accessible)

Memory Standard Memory:

!HP LaserJet 4100: 16 MB synchronous dynamic

random access memory (SDRAM) standard (installed

on a DIMM)

!HP LaserJet 4100N/4100TN/4100DTN: 32 MB SDRAM

standard (installed on a DIMM)

Optional Memory:

!4, 8, 16, 32, 64, and 128 MB SDRAM DIMM

!Expandable memory (up to 256 MB) using three DIMM

slots

Mass storage options !2 and 4 MB flash DIMMs

!2 gigabyte (GB) or larger EIO hard disk

Interface !Bidirectional (IEEE-1284-compliant) parallel interface

!Paper-handling connector (PHC)

!10/100Base-TX Fast Ethernet (4100N/4100TN/

4100DTN)

Optional networking !Enhanced input/output (EIO)—HP JetDirect EIO

internal print server network cards

!Token Ring (EIO) network cards

!Fast Ethernet (10/100Base-TX single RJ-45 port)

!HP JetDirect Connectivity card (EIO) for USB, Serial,

LocalTalk

Expansion slots !Three 100-pin DIMM slots

!Two EI O sl ot s

Table 1. Printer features for the HP LaserJet 4100 series printers (continued)

16 Printer description EN

Paper trays 100-sheet tray 1

!Standard and custom sizes: from 76 by 127 mm (3 by 5

inches) to 216 by 356 mm (8.5 by 14 inches)

500-sheet tray 2

!Letter: 216 by 279 mm (8.5 by 11 inches)

!A4: 210 by 297 mm (8.3 by 11.7 inches)

!Executive: 191 by 267 mm (7.3 by 10.5 inches)

!Legal: 216 by 356 mm (8.5 by 14 inches)

!B5 (JIS): 182 by 257 mm (7.2 by 10 inches)

!A5: 148 by 210 mm (5.8 by 8.2 inches)

!Custom sizes: from 148 by 210 mm (5.8 by 8.2 in) to

216 by 356 mm (8.5 by 14 in)

500-sheet tray 3 (HP LaserJet 4100TN/4100DTN)

!Letter: 216 by 279 mm (8.5 by 11 inches)

!A4: 210 by 297 mm (8.3 by 11.7 inches)

!Executive: 191 by 267 mm (7.3 by 10.5 inches)

!Legal: 216 by 356 mm (8.5 by 14 inches)

!B5 (JIS): 182 by 257 mm (7.2 by 10 inches)

!A5: 148 by 210 mm (5.8 by 8.2 inches)

!Custom sizes: from 148 by 210 mm (5.8 by 8.2 in) to

216 by 356 mm (8.5 by 14 in)

Optional 500-sheet tray

!Letter: 216 by 279 mm (8.5 by 11 inches)

!A4: 210 by 297 mm (8.3 by 11.7 inches)

!Executive: 191 by 267 mm (7.3 by 10.5 inches)

!Legal: 216 by 356 mm (8.5 by 14 inches)

!B5 (JIS): 182 by 257 mm (7.2 by 10 inches)

!A5: 148 by 210 mm (5.8 by 8.2 inches)

!Custom sizes: from 148 by 210 mm (5.8 by 8.2 in) to

216 by 356 mm (8.5 by 14 in)

Paper path Straight-through paper path available.

Output capacity !250-sheet top output bin (with bin-full sensor)

!50-sheet rear output bin

Input capacity !HP LaserJet 4100 and 4100N: hold 600 sheets of

paper.

!HP LaserJet 4100TN and 4100DTN: hold 1,100 sheets

of paper.

!Expandable to hold up to 1,600 sheets of paper with

optional 500-sheet tray(s); also holds envelopes.

Media handling options !Duplexer

!Envelope feeder (up to 75 envelopes)

!500-sheet tray

!HP Print to Mail (not available in all regions)

Media weights See page 25 through page 27.

Table 1. Printer features for the HP LaserJet 4100 series printers (continued)

EN Chapter 1 Printer description 17

HP genuine toner

cartridge

!No-shake cartridge design.

!HP UltraPrecise toner for crisp, sharp output.

!Supplies status page—provides information about the

toner gauge, page count, and paper sizes used in the

printer.

Printer languages !HP PCL6

!HP PCL5e

!PostScript 3 emulation

!Automatic language switching

Duty cycle Up to 150,000 pages per month.

Expanded support

capabilities Embedded Web server provides remote access and status

information.

Table 1. Printer features for the HP LaserJet 4100 series printers (continued)

18 Printer description EN

Product compatibility matrix

Table 2. Product compatibility matrix

HP LaserJet printer series:

Product Part number 4000 4050 4100

Envelope feeder C4122A

C8053A

Duplex printing accessory (duplexer) C4123A

C8054A

Toner cartridges

6,000 pages

10,000 pages

6,000 pages

10,000 pages

C4127A

C4127X

C8061A

C8061X

Paper trays

500-sheet paper feeder and tray

500-sheet replacement tray

500-sheet standard replacement tray

250-sheet standard replacement tray

C4124A

C8055A

C4125A

C8056A

C3122A

C4126A

1. A5 size is detected as

custom size.

2. A5 size is detected as

custom size; larger custom

sizes might be detected as

A5 size.

3. Supports only letter, A4,

and legal sizes.

EN Chapter 1 Printer description 19

Memory

4 MB extended data out (EDO) DIMM

8 MB EDO DIMM

16 MB EDO DIMM

4 MB SDRAM DIMM

8 MB SDRAM DIMM

16 MB SDRAM DIMM

24 MB SDRAM DIMM

32 MB SDRAM DIMM

64 MB SDRAM DIMM

128 MB SDRAM DIMM

2 MB flash DIMM

4 MB flash DIMM

C4135A

C4136A

C4137A

C4140A

C4141A

C7842A

C4142A

C7843A

C7844A

C4143A

C7845A

C3913A

C7846A

C9121A

C4286A

C4287A

Font DIMMs

Traditional Chinese font DIMM (8 MB

Asian read-only memory [ROM])

Simplified Chinese font DIMM (8 MB

Asian ROM)

Korean font DIMM (8 MB Asian ROM)

C4292A

C4293A

D4838A

Jet Direct EIO cards

Ethernet RJ-45 only

Ethernet RJ-45 and BNC, LocalTalk

Token Ri ng

10/100Base-TX

USB, LocalTalk, and Serial

J3110A

J3111A

J4167A

J4169A

J4135A

Fast infrared receiver (FIR) pod C4103A !!

EIO hard disk C2985B !!!

Preventive maintenance kits, user

installable (consumable)

110 V kit

220 V kit

110 V kit

220 V kit

C7851A

C7852A

C8057A

C8058A

Table 2. Product compatibility matrix

HP LaserJet printer series:

Product Part number 4000 4050 4100

20 Printer description EN

Identification

Model and serial numbers

The model number and printer serial number are listed on an identification label located under the

top cover on the right side of the printer. The model number is alphanumeric, such as C8049A for the

HP LaserJet 4100 printer.

The serial number contains information about the country of origin, the revision level, the production

code, and production number of the printer. An example of a serial number is USBB123456.

The label also contains power rating and regulatory information as shown in figure 1.

Figure 1. Sample label

EN Chapter 1 Printer description 21

Site requirements

The following environmental specifications must be maintained to ensure the correct operation of the

printer. Consider the following points before installing the printer:

!Install in a well-ventilated, dust-free area.

!Install on a hard, flat, continuous surface, with all four printer feet level. Do not install on carpet or

other soft surfaces.

!Ensure adequate power is supplied. Printer power requirements are listed in table 3.

Uninterruptable power supplies (UPSs) are not recommended.

!Install where temperature and humidity are stable, away from water sources, humidifiers, air

conditioners, refrigerators, or other major appliances. See table 4 for temperature and humidity

ranges.

!Install away from direct sunlight, open flames, or ammonia fumes. If the printer is placed near a

window, make sure the window has a curtain or blind to block direct sunlight.

!Install with enough space around the printer for access and ventilation.

!Install away from the direct flow of exhaust from air ventilation systems.

Table 3. Electrical specifications for the HP LaserJet 4100 series printers

Volts Frequency Circuit Capacity Watts (W) (typical)

100-127 VAC±10% 50/60 Hz ± 3 Hz Minimum

recommended =

10 amps

printing = 450 W

standby = 19 W

PowerSave on = 18 W

(EPA ENERGY STAR ®)

220-240 VAC±10% 50/60 Hz ± 3 Hz Minimum

recommended =

5 amps

printing = 450 W

standby = 19 W

PowerSave on = 18 W

(EPA ENERGY STAR ®)

22 Printer description EN

Installation requirements

Install the printer with enough space around it to open trays and bins, install toner, and perform

maintenance. If the duplexer is installed, the printer needs 101 mm (4 inches) of ventilation space on

the left side (fan side) and rear of the printer.

Figure 2. Top view, HP LaserJet 4100/4100N/4100TN/4100DTN printer with trays and rear output bin

open

Figure 3. Side view, HP LaserJet 4100/4100N printer

1043 mm (41.1 inches)

390 mm

(15.4 inches)

345 mm

(13.6 inches) with

top cover closed

475 mm

(18.7 inches) with

top cover open

EN Chapter 1 Printer description 23

Figure 4. Side view, HP LaserJet 4100TN/4100DTN printer

Printer weight (without toner cartridge)

!HP LaserJet 4100/4100N printers: 18 kg (39 lb)

!HP LaserJet 4100TN printer: 25 kg (55 lb)

!HP LaserJet 4100DTN printer: 28 kg (62 lb)

465 mm

(18.3 inches) with top

cover closed

595 mm

(23.4 inches) with

top cover open

24 Printer description EN

Environmental requirements

Note Testing per International Standards Organization (ISO) 9296/7779

Table 4. Printer and toner cartridge environmental conditions

Item Operating Storage

Temperature 10° to 32° C (50 to 91° F) Toner cartridge:

0° to 35°C (32 to 95° F)

Printer:

-20 to 60°C (-4° to 140° F)

Relative humidity 20 to 80 percent relative

humidity (RH) (with no

condensation)

10 to 95 percent RH

Table 5. Operating sound power or pressure (Per ISO 9296)

Sound power level LWAd= 6.6 Bels (A) printing, LWAd= 4.1 Bels (A) idle

Operating position LpAm= 58 dB (A) printing, LpAm= 32 dB (A) idle

Bystander position LpAm= 52 dB (A) printing, LpAm= 26 dB (A) idle

EN Chapter 1 Printer description 25

Print media specifications

The following tables show print media specifications for the HP LaserJet 4100 series printer.

1. The printer supports a wide range of print media sizes. Check the printer software for

supported sizes. To print custom-size media, see the user guide.

2. Capacity can vary depending on media weight and thickness, and environmental conditions.

3. Custom media must be fed short-edge first (portrait).

Table 6. Print media specifications, tray 1

Supported

media Dimensions1Weight Capacity2

Minimum size

(custom3)76 by 127 mm

(3 by 5 inches) 60 to 199 g/m2

(16 to 53 lb) 100 sheets of 75 g/m2

(20 lb) paper

Maximum size

(custom3)216 by 356 mm

(8.5 by 14 inches)

Transparencies Same as minimum

and maximum paper

sizes listed above

Thickness:

0.10 to 0.11 mm

(0.0039 to

0.0043 inch)

50 transparencies

Labels Thickness:

0.13 to 0.18 mm

(0.005 to 0.007

inch)

50 labels

Envelopes 75 to 105 g/m2

(20 to 28 lb) 10 envelopes

26 Printer description EN

1. The printer supports a wide range of print media sizes. Check the printer software for

supported sizes. To print custom-size media, see the user guide.

2. Capacity can vary depending on media weight and thickness, and environmental conditions.

3. Custom media must be fed short-edge first (portrait).

1. Capacity can vary depending on media weight and thickness, and environmental conditions.

Table 7. Print media specifications, trays 2, 3, and 4

Supported

media Dimensions1Weight Capacity2

Letter 216 by 279 mm

(8.5 by 11 inches) 60 to 105 g/m2

(16 to 28 lb)

500 sheets of 75 g/m2

(20 lb) paper or

50 transparencies

A4 210 by 297 mm

(8.3 by 11.7 inches)

Executive 191 by 267 mm

(7.3 by 10.5 inches)

Executive (JIS)

(custom3)216 by 330 mm

(8.5 by 13 inches)

16K (custom3) 197 by 273 mm

(7.75 by 10.75

inches)

Legal 216 by 356 mm

(8.5 by 14 inches)

B5 (ISO)

(custom3)176 by 250 mm

(6.9 by 9.9 inches)

B5 (JIS) 182 by 257 mm

(7.2 by 10 inches)

A5 148 by 210 mm

(5.8 by 8.2 inches)

Custom3

148 by 210 mm

to 216 by 356 mm

(5.8 by 8.2 inches to

8.5 by 14 inches)

Table 8. Print media specifications, optional envelope feeder

Supported

envelope Dimensions Weight Capacity1

Monarch

(#7 3/4) 98.4 by 190.5 mm

(3.88 by 7.50 inches)

75 to 105 g/m2

(20 to 28 lb) 75 envelopes

Commercial 10

(#10) 104.9 by 241.3 mm

(4.13 by 9.5 inches)

DL ISO 110 by 220 mm

(4.33 by 8.66 inches)

C5 ISO 162 by 229 mm

(6.38 by 9.02 inches)

B5 ISO 176 by 250 mm

(6.93 by 9.84 inches)

EN Chapter 1 Printer description 27

Table 9. Print media specifications, optional duplexer

Supported

media Dimensions Weight

Letter 216 by 279 mm

(8.5 by 11 inches)

60 to 105 g/m2

(16 to 28 lb)

A4 210 by 297 mm

(8.3 by 11.7 inches)

Executive 184 by 267 mm

(7.3 by 10.5 inches)

Legal 216 by 356 mm

(8.5 by 14 inches)

B5 (JIS) 182 by 257 mm

(7.2 by 10 inches)

28 Printer description EN

Supported types of print media

The printer supports the following types of print media:

Note Transparencies and labels must be specified for use in laser printers.

!plain !preprinted

!letterhead !transparency (see page 32)

!prepunched !labels (see page 31)

!bond !recycled

!color !card stock

!rough

EN Chapter 1 Printer description 29

Types of print media to avoid

The following characteristics can affect the performance of the HP LaserJet printer unless the paper

or other print media used is specifically designed to work with the HP LaserJet printer.

!Print media that is very rough, highly textured, or heavily embossed.

!Print media with multipart forms.

!Print media that offsets materials or discolors.

!Print media that is damaged, curled, wrinkled, or irregularly shaped.

!Paper that is extremely shiny or glossy.

!Paper, labels, envelopes, or transparencies that produce undesirable emissions or melt when

exposed to a fusing temperature between 175° to 230° C (347° to 446° F) for 0.1 second.

!Media coatings, dyes, or inks that produce undesirable emissions or melt when exposed to a

fusing temperature between 175° to 230° C (347° to 446° F) for 0.1 second.

!Envelopes that have an open flap with the adhesive exposed so that closing the flap seals the

envelope.

!Envelopes with clasps, snaps, tie strings, windows, or synthetic materials. These materials can

severely damage the printer.

!Envelopes that are not square, straight, or constructed correctly (see "Envelope construction" on

page 33).

!Envelopes with a basis weight less than 60 g/m2 (16 lb) or greater than 105 g/m2 (28 lb).

!Envelopes with baggy construction or folds that are not sharply creased.

Note Some media types might not work in the printer because of differences in manufacturer specifications

or environmental conditions.

30 Printer description EN

Weight equivalence table

The following table shows equivalent weights for different grades of paper. A boldface type value

indicates a commonly available standard weight for that grade. Shaded boxes indicate a commonly

available standard weight for that grade.

Note Text and book grades marked with an asterisk (*) actually calculate to 51, 61, 71, and 81 but are

rounded to standard book or text weights of 50, 60, 70, and 80.

Table 10. Weight equivalence table

Bond

weight

(17 by 22

inches)

Book/text

weight

(25 by 38

inches)

Cover

weight

(20 by 26

inches)

Bristol

weight

(22.5 by 28.5

inches)

Index

weight

(25.5 by 30.5

inches)

Tag

weight

(24 by 36

inches)

Metric

weight

16# 41# 22# 27# 33# 37# 60 g/m2

17# 43# 24# 29# 35# 39# 64 g/m2

20# 50# * 28# 34# 42# 46# 75 g/m2

21# 54# 30# 36# 44# 49# 80 g/m2

24# 60# * 33# 41# 50# 55# 90 g/m2

27# 68# 37# 45# 55# 61# 100 g/m2

28# 70# * 39# 49# 58# 65# 105 g/m2

29# 74# 41# 50# 61# 68# 110 g/m2

32# 80# * 44# 55# 67# 74# 120 g/m2

36# 90# 50# 62# 75# 83# 135 g/m2

39# 100# 55# 67# 82# 91# 148 g/m2

40# 101# 55# 68# 83# 92# 150 g/m2

43# 110# 60# 74# 90# 100# 163 g/m2

45# 115# 63# 77# 94# 104# 170 g/m2

47# 119# 65# 80# 97# 108# 176 g/m2

51# 128# 70# 86# 105# 117# 190 g/m2

53# 134# 74# 90# 110# 122# 199 g/m2

54# 137# 75# 93# 113# 125# 203 g/m2

58# 146# 80# 98# 120# 133# 216 g/m2

65# 165# 90# 111# 135# 150# 244 g/m2

66# 169# 92# 114# 138# 154# 250 g/m2

67# 171# 94# 115# 140# 155# 253 g/m2

70# 178# 98# 120# 146# 162# 264 g/m2

72# 183# 100# 123# 150# 166# 271 g/m2

EN Chapter 1 Printer description 31

Adhesive labels

When printing on labels, use of tray 1 is recommended. Labels are multiple-layer media typically

consisting of a face sheet (the printable surface), pressure-sensitive adhesive, and a liner (a carrier

sheet coated with a release agent). Labels used in the HP LaserJet printer must be specifically

designed for laser printers. If labels other than those compatible with laser printers are used, there is

a significant risk of labels peeling or of adhesive contamination that can severely damage the printer.

All materials in laser label stock must be compatible with the heat and pressure of the fusing process.

The table below summarizes the adhesive label specifications that provide the best performance.

Table 11. Adhesive labels specifications

Property Specifications

Adhesive Must not be on any external surfaces of the label before,

during, or after printing. Label construction, adhesive

release strength, and die-cutting must not allow labels to

peel off during printing.

Caliper (thickness) Must not exceed 0.23 mm (9.0 mils).

Fusing compatibility All inks, adhesives, and other materials used in the label

construction must be compatible with the heat and

pressure of the fusing process. Materials must not scorch,

melt, ignite, offset materials, or release undesirable

emissions when heated to a temperature between

175° to 230° C (347° to 446° F) for 0.1 second.

Packaging Adhesive labels should be packaged in moisture-proof

wrap to preserve properties.

Shelf life One year maximum, stored at 23° C (73° F) and 50

percent RH.

32 Printer description EN

Overhead transparencies

When printing transparencies, use of tray 1 is recommended. Overhead transparency film must be

designed specifically for use with laser printers. Photocopy transparency film might not be

compatible with laser printers because of higher temperature and stiffness requirements.

Overhead transparency film is very smooth and must have a topcoat to provide the proper electrical

and toner adhesion properties. A transparency that is made of poor materials or that is too thin can

easily melt in the fuser and damage the printer.

Overhead transparency materials must be compatible with the heat and pressure of the fusing

process.

The table below summarizes the overhead transparency specifications that provide the best

performance.

Table 12. Overhead transparencies specifications

Property Specifications

Caliper (thickness) 0.10 mm to 0.11 mm (4.0 mils to 4.4 mils).

Electrical surface

resistivity 2.0 to 15 by 1010 ohms/square.

Fusing compatibility Overhead transparency materials must be compatible with

the heat and pressure of the fusing process. Materials

must not discolor, melt, offset materials, or release

undesirable emissions when heated to a temperature

between 175° to 230° C (347° to 446° F) for 0.1 second.

EN Chapter 1 Printer description 33

Envelopes

Envelope construction

Envelopes can only be printed from tray 1 or from the optional envelope feeder. Because of their

construction, some envelopes will not feed through the printer dependably. Observe the following

guidelines when purchasing and using envelopes:

!Make sure the envelope’s leading edge, which enters the printer first, is straight, with a sharp,

well-creased fold that has no more than two thicknesses of paper. Envelopes that exceed

105 g/m2 (28 lb) basis weight can cause jamming.

!Avoid using flimsy envelopes with thick or curved leading edges; they will not feed reliably.

!Envelopes should lie flat and should not be wrinkled, nicked, or otherwise damaged.

!Avoid envelopes with baggy construction; they might wrinkle while going through the printer’s

fuser assembly.

!Make sure that the adhesive labels used on envelopes will not scorch, melt, offset, or release

undesirable emissions when heated to a temperature between 175° to 230° C (347° to 446° F)

for 0.1 second.

!Avoid using envelopes with encapsulated adhesives that rely on pressure rather than moistening

to seal.

!Do not use envelopes with clasps, snaps, tie strings, transparent windows, holes, perforations, or

cutouts.

!Do not use envelopes that have any adhesive surfaces exposed to the printer.

!Woven or smooth finishes are recommended to ensure good toner adhesion on envelopes.

Many envelopes will feed through the HP LaserJet printer without problems. However, some

envelope constructions (as shown in the figure below) will not feed reliably. Problems can occur

when the envelopes are folded more tightly than normal, causing a thick leading edge near a corner.

Folding inconsistencies at the manufacturer can cause some envelopes to feed well and others to

jam.

Good construction Bad construction

34 Printer description EN

Envelope specifications

The table below summarizes the envelope specifications that provide the best performance.

Table 13. Envelope specifications

Property Specifications

Basis weight 64 g/m2 to 105 g/m2 (17 lb to 28 lb) typical.

See the user guide for specific printer and input limits.

Caliper (thickness) 0.09 mm to 0.14 mm (3.6 mil to 5.5 mil) typical single-layer

thickness.

Surface roughness 100 to 200 Sheffield.

Fusing compatibility All inks, adhesives, and other materials used in the

envelope construction must be compatible with the heat

and pressure of the fusing process. Materials must not

scorch, melt, ignite, offset materials, or release

undesirable emissions when heated to a temperature

between 175° to 230° C (347° to 446° F) for 0.1 second.

Dimensional accuracy

and construction quality

!Envelopes must be folded within ±1.0 mm (±0.04 inch)

of nominal size with no more than two thickness of

paper anywhere along the leading edge.

!All folds must be sharply creased and construction

must be tight (not baggy) to avoid wrinkling.

!Envelopes must not be stuck together from excess

seam adhesive (blocking).

!The flap must be flat within 1.5 mm (0.059 in) over the

width where adhesive is applied.

Curl Envelopes must lie flat, with no more than 6 mm (0.25

inch) curl across the entire surface.

Adhesive flap curl Envelope flap should be flat, with 1.5 mm (0.059 inch)

over the width where adhesive is applied.

Moisture content 4 percent to 6 percent by weight.

Grain Different envelope constructions might require different

grain orientations for best performance, which is left to the

discretion of the manufacturer.

Packaging Envelopes should be contained in a protective box to

prevent edge damage and maintain flatness.

EN Chapter 1 Printer description 35

Card stock and heavy paper

Many types of card stock and paper can be printed from tray 1, including index cards and postcards.

For optimum printer performance, do not use paper heavier than 199 g/m2 (53 lb) in tray 1 or

105 g/m2 (28 lb) in other trays. Paper that is too heavy might cause misfeeds, stacking problems,

jams, poor toner fusing, poor print quality, or excessive mechanical wear.

Note Before loading card stock, make sure it is regular in shape and not damaged or wrinkled. Also, make

sure the cards are not stuck together.

The table below summarizes the paper specifications that provide the best performance.

Table 14. Paper specifications

Property Specifications

Basis weight 64 g/m2 to 105 g/m2 (17 lb to 28 lb) typical.

See the user guide for specific printer and input limits.

Caliper (thickness) 0.09 mm to 0.17 mm (3.5 mil to 6.5 mil) typical.

See the user guide for specific printer and input limits.

Minimum stiffness 1.2 minimum (Taber) machine direction;

0.8 minimum (Taber) cross direction.

Grain Portrait feeding: short or long grain up to 36 lb.

Landscape feeding: long grain.

Electrical surface

resistivity 109 to 1013 ohms/square.

Electrical volume

resistivity 109 to 1014 ohms - cm.

Surface roughness 100 to 190 Sheffield optimal;

30 to 350 Sheffield extended (fusing or feeding

performance can be degraded at outer ranges).

Fusing compatibility Must not scorch, melt, ignite, offset materials, or release

undesirable emissions when heated to a temperature

between 175° to 230° C (347° to 446° F) for 0.1 second.

Furnish (composition) One hundred percent chemical pulp and/or cotton content;

recycled paper with up to 5 percent groundwood can be

used.

Dimensional accuracy Cut sheet within ±0.80 mm (±0.03 inch) of nominal.

Cut edge quality Cuts must be smooth and clean with no fray or edge roll.

Curl Must lie flat within 5 mm (0.2 inch).

Moisture content 4 percent to 6 percent by weight.

Packaging Card stock and heavy paper should be packaged in a

moisture-proof ream wrap.

Wax pick 12 minimum (Dennison).

36 Printer description EN

Safety information

Toner safety

Handling and storage

WARNING! Keep toner cartridges and toner particles away from excessive heat, sparks, and open flames.

If toner is spilled, avoid breathing in toner particles. Inhalation of toner particles can cause

respiratory tract irritation. Vacuum or sweep the material into a bag or other sealed container. If a

vacuum is used, the motor must be rated as dust-tight.

Dispose of waste toner in accordance with local requirements. Do not discharge toner particles in

drains.

First aid measures

!Ingestion. If toner is ingested, drink several glasses of water. Get medical attention if discomfort

persists.

!Inhalation. If toner particles are inhaled, move to fresh air immediately. If symptoms occur (such

as coughing, dizziness, or difficulty breathing), consult a physician.

!Eye contact. If toner comes in contact with the eyes, immediately flush with plenty of water for at

least 15 minutes. If irritation persists, consult a physician.

!Skin contact. If toner spills on skin, remove as much toner as possible with a dry tissue, and

then wash with cold water.

Clothing contact

Note Toner can stain clothing. Hot water or heat (from a clothes dryer) can cause toner to melt and

permanently fuse into clothing.

Clothing is best cleaned by removing as much toner as possible with a dry tissue, and then washing

with cold water. Air-dry clothing.

Additional information

The Toner Cartridge/Drum Material Safety Data Sheet (MSDS) can be obtained by contacting HP at

the following website:

http://www.ljsupplies.com

EN Chapter 1 Printer description 37

Laser safety

Do not open the laser scanner assembly. Avoid direct exposure to the laser beams.

WARNING! Using controls, making adjustments, bypassing safety switches, or performing procedures other than

those specified in this service manual can result in exposure to hazardous radiation.

Regulatory information

For regulatory information and requirements, please see the user guide.

38 Printer description EN

EN Chapter 2 Service approach 39

2Service approach

Chapter contents

Service approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Parts and supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Ordering information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Printer documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

HP direct ordering for genuine HP parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Exchange program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

World Wide Web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

HP service parts information compact disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

HP support assistant compact disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Toner cartridge information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Warranty statement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Printer warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Limited warranty for toner cartridge life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

40 Service approach EN

Service approach

Repair of the printer normally begins with use of the printer’s internal diagnostics in conjunction with

the troubleshooting procedures in chapter 7. When a faulty part is located, repair is generally

accomplished by assembly-level replacement of field-replaceable units (FRUs). Some mechanical

assemblies might be repaired at the subassembly level. Hewlett-Packard does not support

replacement of components on printed circuit boards.

Parts and supplies

Ordering information

Chapter 8 of this manual contains FRU and accessory part numbers. Replacement parts can be

ordered from the HP Customer Services and Support Organization.

Use only accessories specifically designed for this printer. Order accessories from an authorized

service or support provider. (See page 42.)

EN Chapter 2 Service approach 41

Printer documentation

The table below lists part numbers to use when ordering documentation. For information about

ordering, see page 42.

Note Some of the materials listed in table 15 are also available online at http://www.hp.com.

Table 15. Printer documentation

Item Description or use Part number

HP LaserJet Printer Family

Print Media Guide A guide to using paper and

other print media with

HP LaserJet printers

5963-7863

(English only)

PCL 5/PJL Technical

Reference Documentation

Package

A guide to using printer

commands with HP LaserJet

printers

5021-0330

(English only)

HP LaserJet Basics

CD-ROM A guide to using HP LaserJet

printer hardware H8789A

(English only);

online at: http://

software.hp.com

User Getting Started Guide,

HP LaserJet 4100 Series

Printers

An additional copy of the user

getting started guide C8049-90903

(English only)

HP LaserJet 4100 Series

Printers User Documentation

CD-ROM

An additional copy of the user

documentation CD-ROM C8049-60104

(English only)

HP LaserJet 4100 Series

Printers Software Technical

Reference

A guide to the printer software C8049-90921

(English only)

Service and Support CD-

ROM for the

HP LaserJet 4100 Series

Printers

An interactive training CD-

ROM for printer service

representatives and customer

care specialists

C8049-60116

(English only)

HP LaserJet 4100 Series

Printers Service Manual A service manual for the 4100

printer series. C8049-90920

(English only)

HP LaserJet 4100 Series

Printers Training Kit Includes service manual and

service and support CD-ROM C8049-67901

(English only)

42 Service approach EN

HP direct ordering for genuine HP parts

Customer Services and Support Organization (CSSO):

!(1) (800) 227-8164 (U.S. only)

!(49 7031) 142253 (Europe only)

!See chapter 8 for additional information.

Exchange program

HP offers remanufactured assemblies for some parts. These are identified in chapter 8 and can be

ordered through CSSO.

Consumables

Paper and toner cartridges can be ordered directly from Hewlett-Packard. See chapter 8 for ordering

information.

World Wide Web

Printer drivers, updated HP printer software, and product and support information can be obtained

from the following URL:

in the U.S., http://www.hp.com/support/lj4100

Printer drivers can be obtained from the following sites:

in China, ftp://www.hp.com.cn/support/lj4100

in Japan, ftp://www.jpn.hp.com/support/lj4100

in Korea, http://www.hp.co.kr/support/lj4100

in Taiwan, http://www.hp.com.tw/support/lj4100

or the local driver website, http://www.dds.com.tw

HP service parts information compact disc

This powerful, CD-ROM-based parts information tool is designed to give users fast, easy access to

parts information and recommended stocking lists for a wide range of HP products. To subscribe to

this quarterly service in the U.S. or Canada, call (1) (800) 336-5987. In Asia Pacific, call (65) 740-

4484. Parts identification and pricing information can also be found on the World Wide Web at: http:/

/www.hp.com/go/partsinfo

EN Chapter 2 Service approach 43

HP support assistant compact disc

This support tool offers a comprehensive online information system designed to provide technical

and product information about Hewlett-Packard products. To subscribe to this quarterly service in the

U.S. or Canada, call (1) (800) 457-1762. In Hong Kong, Indonesia, Malaysia, or Singapore, call

Mentor Media at (65) 740-4477.

Customer care reseller sales and service support center

The Customer Care Reseller Sales and Service Support Center is available to assist resellers and

service technicians. To reach this support center, call (1) (800) 544-9976.

HP authorized resellers and support

To locate authorized HP resellers and support, call

(1) (800) 243-9816 in the U.S. or (1) (800) 387-3867 in Canada.

HP service agreements

Call (1) (800) 743-8305 in the U.S. or (1) (800) 268-1221 in Canada.

Other areas

Outside of North America and Europe, contact the local HP sales office for assistance in obtaining

technical support for resellers and service technicians.

44 Service approach EN

Toner cartridge information

The toner cartridge is designed to simplify replacement of the major “consumable” parts. The toner

cartridge contains the printing mechanism and a supply of toner.

At five percent page coverage, a toner cartridge will print approximately 6,000 or 10,000 pages,

depending on the toner cartridge model installed. A toner cartridge might print fewer pages if

routinely printing with dense ink coverage, or more pages when routinely printing pages with less ink

coverage, such as short memos. If EconoMode or small media is always used, however, the toner

supply could outlast the mechanical parts in the toner cartridge.

Note For best results, always use a toner cartridge before the expiration date stamped on the toner cartridge

box.

Refilled toner cartridges

While Hewlett-Packard does not prohibit the use of refilled toner cartridges during the warranty

period or while the printer is under a maintenance contract, it is not recommended for the following

reasons:

!Repairs resulting from the use of refilled toner cartridges are not covered under Hewlett-Packard

warranty or maintenance contracts.

!Hewlett-Packard has no control or process to ensure that a refilled toner cartridge functions at

the high level of reliability of a new HP LaserJet toner cartridge. Hewlett-Packard also cannot

predict the long-term reliability effect on the printer from using different toner formulations found

in refilled cartridges.

!The print quality of HP LaserJet toner cartridges influences the customer’s perception of the

printer. Hewlett-Packard has no control over the actual print quality of a refilled toner cartridge.

Recycling toner cartridges

To reduce waste, Hewlett-Packard offers a recycling program for used toner cartridges. Cartridge

components that do not wear out are recycled. Plastics and other materials are recycled.

Hewlett-Packard pays the shipping costs from the user to the recycling plant. For each cartridge

returned, Hewlett-Packard donates one U.S. dollar to be shared by the Nature Conservancy and the

National Wildlife Federation. To join this recycling effort, follow the instructions inside the toner

cartridge box.

EN Chapter 2 Service approach 45

Warranty statement

The warranty for this product gives the customer specific legal rights. There might also be other

rights that vary from area to area.

Printer warranty

Hewlett-Packard warrants the HP LaserJet 4100 series printer for one year. For detailed information

about the printer warranty, see the limited warranty statement in the user guide.

Limited warranty for toner cartridge life

Note The warranty below applies to the toner cartridge that came with this printer. This warranty supersedes

all previous warranties (7/19/96).

The HP toner cartridge is warranted to be free from defects in materials and workmanship for the life

of the cartridge until the HP toner is depleted. The HP toner is depleted when the printer indicates a

toner-low message. Hewlett-Packard will, at its option, either replace products that prove to be

defective or refund the purchase price.

The warranty does not cover toner cartridges that have been refilled, or are emptied, abused,

misused, or tampered with in any way. This limited warranty gives the customer specific legal rights.

The customer might have other rights which vary from state to state, province to province, and

country to country.

To the extent allowed by applicable law, in no event shall Hewlett-Packard Company be liable for any

incidental, consequential, special, indirect, punitive, or exemplary damages or lost profits from any

break of this warranty or otherwise.

46 Service approach EN

EN Chapter 3 Printer operation 47

3Printer operation

Chapter contents

Using the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Control panel layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Control panel lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Control panel keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Settings and defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Control panel menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Quick copy jobs menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Private/stored jobs menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Information menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Paper-handling menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Printing menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Print quality menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Configuration menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

I/O menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

EIO menu (networked printers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Resets menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Page count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Maintenance count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Maintenance interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Cold reset paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Clear event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Top margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Tray 1 left margin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Trays 2 and 3 left margin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Testing the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Engine test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Resetting the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Cold reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Clearing NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Initialization of NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

48 Printer operation EN

Initialization of the hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

MS-DOS system configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Parallel DOS commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

EN Chapter 3 Printer operation 49

Using the control panel

Control panel layout

The printer control panel consists of a two-line display and lights and keys as shown below:

Figure 5. Control panel layout

Control panel lights

Ready

Data

Attention

Item

– Value +

Select

Cancel

Job

2-line

display

READY

Table 16. Control panel lights

Light Indication

Ready The printer is ready to print.

Data The printer is processing information.

Attention Action is required. See the control panel display.

50 Printer operation EN

Control panel keys

Table 17. Control panel keys

Key Function

GO!Places the printer either online or offline.

!Prints any data in the printer’s buffer.

!Allows the printer to resume printing after being offline.

Clears most printer messages and places the printer

online.

!Allows the printer to continue printing with an error

message such as TRAY X LOAD [TYPE] [SIZE] or

UNEXPECTED PAPER SIZE.

!Confirms a manual feed request if tray 1 is loaded and

TRAY 1 MODE=CASSETTE has been set from the paper-

handling menu on the printer control panel.

!Overrides a manual feed request from tray 1 by

selecting paper from the next available tray.

!Exits the control panel menus. (To save a selected

control panel setting, first press SELECT.)

CANCEL JOB Cancels the print job that the printer is processing. The time

and pages it takes to cancel depends on the size of the

print job and the number of pages in the buffer. (Press it

only once.)

MENU Cycles through the control panel menus. Press the right

end of the button to move forward or the left end of the

button to move backward.

ITEM Cycles through the selected menu’s items. Press the right

end of the button to move forward or the left end of the

button to move backward.

– VALUE + Cycles through the selected menu item’s values. Press + to

move forward or – to move backward.

SELECT !Saves the selected value for that item. An asterisk (*)

appears next to the selection to indicate that it is the

new default. Default settings remain when the printer is

switched off or reset.

!Prints any information pages shown in the control

panel.

[?] Provides instructions for resolving most printer errors.

Certain control panel error messages alternate with

instructions about gaining access to the online help system.

Press the right end of the ITEM button to scroll through help

messages.

EN Chapter 3 Printer operation 51

Settings and defaults

The printer makes most printing decisions based on either temporary settings or permanent defaults.

Note Settings sent from software applications override printer defaults.

Setting the display language

1Press and hold SELECT while turning on the printer. Hold SELECT until SELECT LANGUAGE appears

on the control panel display.

2Release SELECT.

3When LANGUAGE=ENGLISH appears on the display, press

– VALUE + until the language you want appears.

4Press SELECT to save your choice.

An asterisk (*) will appear beside the selected language.

5Press GO to exit the menu.

Table 18. Settings and defaults

Setting or default Explanation

Temporary setting A value set for the current print job by the software

application. For example, a request from the software to

print three copies instead of the control panel default value

of one copy is a temporary setting. The printer continues to

use the temporary setting until it receives another software

request or until it is reset.

Control panel default A value set at the control panel when you select a menu

item. An asterisk appears, indicating the default setting.

The printer retains this default when it is turned off.

Factory default The value set for each menu item at the factory. Factory

defaults are listed in the item column in the menu tables

starting on page 52.

52 Printer operation EN

Control panel menus

Press MENU for access to all control panel menus. When additional trays or other accessories are

installed in the printer, new menu items might automatically appear.

Changing a control panel setting

1Press MENU until the menu you want appears on the control panel display.

2Press ITEM until the item you want appears.

3Press – VALUE + until the setting you want appears.

4Press SELECT to save the selection.

An asterisk (*) appears next to the selection in the display, indicating that it is now the default.

5Press GO to exit the menu.

Note Settings in the printer driver and software application override control panel settings. Software

application settings override printer driver settings.

If you cannot get to a menu or item, it is either not an option for the printer, or the customer’s network

administrator has locked the function (the control panel reads ACCESS DENIED MENUS LOCKED). See the

customer’s network administrator.

Printing a control panel menu map

To see the current settings for all of the menus and menu items available on the control panel, print a

control panel menu map.

1Press MENU until INFORMATION MENU appears on the control panel display.

2Press ITEM until PRINT MENU MAP appears.

3Press SELECT to print the menu map.

EN Chapter 3 Printer operation 53

Quick copy jobs menu

This menu provides a list of the quick copy jobs stored on the printer. The user can print or delete

these jobs from the control panel.

Note This menu appears only if you have an optional hard-disk accessory or 32 MB of memory installed

and quick copy jobs are stored on it.

Table 19. Quick copy jobs menu

Item Value Explanation

[USERNAME]

[JOBNAME]

The name of the person who owns the

quick copy job and the job name.

COPIES=1 1 to 999

DELETE

The number of additional copies the user

wants to print.

1-999: Prints the requested number of

copies of the job.

DELETE: Deletes the job from the printer’s

hard disk.

After changing a setting, press SELECT.

54 Printer operation EN

Private/stored jobs menu

This menu provides a list of the stored jobs on the printer. The user can print or delete these jobs

from the control panel. See the user guide for more information.

Note This menu appears only if you have an optional hard-disk accessory or 32 MB of memory installed

and there are private or stored jobs on it.

Table 20. Private/stored jobs menu

Item Value Explanation

[USERNAME]

[JOBNAME]

The name of the person who owns the

quick copy job and the job name.

PIN:0000 To print the job, the user must enter the

personal identification number (PIN)

assigned to the job in the driver. See the

user guide for more information.

COPIES=1 1 to 999

DELETE

The number of copies the user wants to

print.

1-999: Prints the requested number of

copies of the job.

DELETE: Deletes the job from the printer.

After changing a setting, press SELECT.

EN Chapter 3 Printer operation 55

Information menu

This menu contains printer information pages that give details about the printer and its configuration.

To print an information page, use the ITEM key to scroll to the desired page and then press SELECT.

Table 21. Information menu

Item Explanation

MENU MAP

The menu map shows the layout and current settings of the

control panel menu items.

CONFIGURATION

The configuration page shows the printer’s current

configuration. If an HP JetDirect print server card is

installed (HP LaserJet 4100N/TN/DTN printers), a JetDirect

Configuration Page will also print.

PCL FONT LIST

The PCL font list shows all the PCL fonts currently available

to the printer.

PS FONT LIST

The PS font list shows all the PS fonts currently available to

the printer.

FILE DIRECTORY

This item appears only when a mass storage device (such

as an optional flash DIMM or hard disk) containing a

recognized file system is installed in the printer. The file

directory shows information for all installed mass storage

devices.

EVENT LOG

The event log lists the most current 20 printer events or

errors.

SHOW

EVENT LOG

This item allows you to view the most recent printer events

on the control panel display. Press – VALUE + to scroll

through the event log entries.

Note

The event log lists the error number (the first two digits), the

error code, and the associated page count.

PRINT USAGE PAGE The usage page shows the quantity of pages printed, as

well as the paper source used. It also reflects the number

of one-sided versus two-sided pages.

Note

This item will only show in the information menu if an

optional hard-disk accessory or 32 MB of memory is

installed in the printer. This item will generate a page

containing information that can be used for accounting

purposes.

PRINT SUPPLIES STATUS When used with an HP genuine toner cartridge, the

supplies status page shows toner cartridge information,

statistics about the total number of pages by size and jobs

processed, toner cartridge manufacture date and serial

number, page counts, and maintenance information.

56 Printer operation EN

PAPER PATH TEST

The paper-path test can be used to verify that the paper

path is working correctly, or to troubleshoot problems with a

type of paper. Choose the input tray, output bin, duplexer (if

available), and number of copies.

Table 21. Information menu (continued)

Item Explanation

EN Chapter 3 Printer operation 57

Paper-handling menu

When paper-handling settings are correctly configured through the control panel, you can print by

choosing the type and size of media from the printer driver or software application.

Some items in this menu (such as duplex and manual feed) are available from a software application,

or from the printer driver (if the appropriate driver is installed). Printer driver and software application

settings override control panel settings.

Table 22. Paper handling menu

Item/Default value Values Explanation

ENVELOPE FEEDER

SIZE=COM10

(110 V printers)

SIZE=DL

(220 V printers)

For supported print media

sizes, see page 28. This item appears only when the

optional envelope feeder is

installed. Set the value to

correspond with the envelope

size currently loaded in the

envelope feeder.

ENVELOPE FEEDER

TYPE=PLAIN

For supported print media

types, see page 28. This item appears only when the

optional envelope feeder is

installed. Set the value to

correspond with the envelope

type currently loaded in the

envelope feeder.

TRAY 1 MODE=

FIRST

CASSETTE

Determine how the printer will

use tray 1.

FIRST: If print media is loaded in

tray 1, the printer will pull media

from that tray first.

CASSETTE: A media size must be

assigned to tray 1 using the

TRAY 1 SIZE option (the next item

in this menu when TRAY 1

MODE=CASSETTE). This allows

tray 1 to be used as a reserved

tray.

TRAY 1 SIZE=

LETTER

(110 V printers)

(220 V printers)

For supported print media

sizes, see page 25

through page 27.

This item appears only when

TRAY 1 MODE= CASSETTE. Set the

value to correspond with the

media size currently loaded in

tray 1.

TRAY 1 TYPE=

PLAIN

For supported print media

types, see page 28. This item appears only when

TRAY 1 MODE= CASSETTE. Set the

value to correspond with the print

media type currently loaded in

tray 1.

TRAY 2 TYPE=

PLAIN

For supported print media

types, see page 28. Set the value to correspond with

the media type currently loaded in

tray 2.

58 Printer operation EN

TRAY 3 TYPE=

PLAIN

For supported print media

types, see page 28. This item appears only when a

third paper tray is installed. Set

the value to correspond with the

media type currently loaded in

tray 3.

TRAY 4 TYPE=

PLAIN

For supported print media

types, see page 28. This item appears only when a

fourth paper tray is installed. Set

the value to correspond with the

media type currently loaded in

tray 4.

SMALL PAPER

SPEED=NORMAL

NORMAL

SLOW

Select SLOW when alternating

printing envelopes (or small

media sizes) and standard media

sizes and print problems appear.

Be sure to return the speed to

NORMAL when finished.

When SLOW is selected, the printer

briefly pauses between pages to

reduce the possibility of a

repeating image.

MANUAL FEED=OFF OFF

Feed the print media manually

from tray 1, rather than

automatically from a tray. When

MANUAL FEED=ON and tray 1 is

empty, the printer goes offline

when it receives a print job and

displays MANUALLY FEED [PAPER

SIZE].

DUPLEX=OFF OFF

This item appears only when an

optional duplexer is installed. Set

the value to ON to print on both

sides (duplex) or OFF to print on

one side (simplex) of a sheet of

paper.

BINDING=

LONG EDGE

SHORT EDGE

This item appears only when an

optional duplexer is installed and

DUPLEX=ON. Choose the binding

edge when duplexing (printing on

both sides of paper).

Table 22. Paper handling menu (continued)

Item/Default value Values Explanation

EN Chapter 3 Printer operation 59

CONFIGURE FUSER

MODE MENU=NO

YES

Configure the fuser mode

associated with each print media

type. (This is only necessary if

you experience loose toner

problems, excessive curl, or other

print-quality issues when printing

on certain media types.)

NO: The fuser-mode menu items

are not available.

YES: Additional items appear (see

below).

Note

To see the default fuser mode for

each media type, select YES,

scroll back to the information

menu, and print a menu map.

[TYPE]=NORMAL NORMAL

HIGH1

LOW

HIGH2

This item appears only when

CONFIGURE FUSER MODE

MENU=YES. Most paper types are

set to NORMAL fuser mode by

default. The exceptions are as

follows:

ROUGH=HIGH1

TRANSPARENCY=LOW

NORMAL fuser mode provides a

fuser temperature for optimum

results on most typical papers.

HIGH1 fuser mode provides a

higher fuser temperature. HIGH1

should be used with rough-

textured or heavy paper if you

have trouble with toner adhering

to the page.

LOW fuser mode provides a lower

temperature, which can help

reduce curl on lightweight paper

and transparencies. However,

toner might not adhere as well to

the page.

HIGH2 fuser mode uses the same

higher temperature as HIGH1, but

it also slows printer throughput,

which creates the best fusing for

very rough paper.

Note

HIGH2 fuser mode only operates

for A4-, letter-, and legal-size

paper, and slows the throughput

to 16 pages per minute.

Table 22. Paper handling menu (continued)

Item/Default value Values Explanation

60 Printer operation EN

Printing menu

Some items in this menu can be used from a software application or from the printer driver (if the

appropriate driver is installed). Printer driver and software application settings override control panel

settings.

Table 23. Printing menu

Item Values Explanation

COPIES=1 1 TO 999 Set the default number of

copies by selecting any

number from 1 to 999.

Press –V

ALUE + once to

change the setting by

increments of 1, or hold

down – VALUE + to scroll by

increments of 10.

PAPER SIZE=LETTER

ENVELOPE=COM10

(110 V printers)

PAPER SIZE=A4

ENVELOPE=DL

(220 V printers)

For supported print media

sizes, see page 26 through

page 28.

Set the default size for print

media. (The item name

changes from paper to

envelope as you scroll

through the available sizes.)

CONFIGURE CUSTOM

PAPER=NO

YES

NO: The custom-paper

menu items are not

available.

YES: The custom-paper

menu items appear (see the

next item).

UNIT OF MEASURE=

INCHES

(110 V printers)

MILLIMETERS

(220 V printers)

INCHES

MILLIMETERS

This item appears only

when CONFIGURE CUSTOM

PAPER=YES. Select the unit

of measurement for the

custom paper size.

X DIMENSION=8.5 INCHES

(110 V printers)

216 MILLIMETERS

(220 V printers)

3.00 TO 8.5 INCHES

(110 V printers)

76 to 216 MILLIMETERS

(220 V printers)

This item appears only

when CONFIGURE CUSTOM

PAPER=YES. Select the

media width dimension to

be fed into the printer (short

edge).

Y DIMENSION=14.0 INCHES

(110 V printers)

356 MILLIMETERS

(220 V printers)

5.00 TO 14.0 INCHES

(110 V printers)

127 to 356 MILLIMETERS

(220 V printers)

This item appears only

when CONFIGURE CUSTOM

PAPER=YES. Select the

media length dimension

(long edge).

ORIENTATION=

PORTRAIT

LANDSCAPE

Determine the default

orientation of print on the

page.

EN Chapter 3 Printer operation 61

FORM LENGTH=60 LINES

(110 V printers)

64 LINES

(220 V printers)

5 to 128 Sets vertical spacing from 5

to 128 lines for default

paper size. Press – VALUE +

once to change the setting

by increments of 1, or hold

down – VALUE + to scroll by

increments of 10.

PCL FONT

SOURCE=INTERNAL

INTERNAL

SOFT

SLOT 1, 2, OR 3

(depends on location of

available fonts)

INTERNAL: Internal fonts.

SOFT: Permanent soft fonts.

SLOT 1, 2, or 3: Fonts

stored in one of the three

DIMM slots.

Note

Print a PCL font list

(page 55) to see the

available fonts.

PCL FONT

NUMBER=0

0 TO 999

(depends on location of

available fonts)

The printer assigns a

number to each font and

lists the numbers on the

PCL font list. The font

number appears in the font

# column of the printout.

Note

Print a PCL font list

(page 55) to see the

available fonts.

PCL FONT PITCH=

10.00

0.44 to 99.99 This item might not appear,

depending on the font

selected. Press – VALUE +

once to change setting by

increments of 0.01 for pitch,

or hold down – VALUE + to

scroll by increments of 1.

PCL SYMBOL

SET=PC-8

PC-8

many others Select any one of several

available symbol sets from

the printer control panel. A

symbol set is a unique

grouping of all the

characters in a font. A value

of PC-8 or PC-850 is

recommended for line

drawn characters.

Table 23. Printing menu (continued)

Item Values Explanation

62 Printer operation EN

COURIER FONT=REGULAR REGULAR

DARK

Select the version of

Courier font to use:

REGULAR: The internal

Courier font available on the

HP LaserJet 4 series

printers.

DARK: The internal Courier

font available since the HP

LaserJet III series printers.

Both fonts are not available

at the same time.

WIDE A4=NO NO

YES

The WIDE A4 setting

changes the number of

characters that can be

printed on a single line of

A4 paper.

NO: Up to 78 10-pitch

characters can be printed

on one line.

YES: Up to 80 10-pitch

characters can be printed

on one line.

OVERRIDE

A4/LETTER=NO

YES

Choose YES to print on

letter-size paper

automatically when an A4

job is sent, but no A4-size

paper is loaded in the

printer (or to print on A4-

size paper when a letter job

is sent, but no letter-size

paper is loaded in the

printer).

APPEND CR TO LF=

YES

Select YES to append a

carriage return to each line

feed encountered in

backward-compatible PCL

jobs (pure text, no job

control). Some

environments, such as

UNIX, indicate a new line

using only the line-feed

control code. This option

allows the user to append

the required carriage return

to each line feed.

Table 23. Printing menu (continued)

Item Values Explanation

EN Chapter 3 Printer operation 63

Print quality menu

Some items in this menu can be used from a software application, or from the printer driver (if the

appropriate driver is installed). Printer driver and software application settings override control panel

settings.

Table 24. Print quality menu

Item Values Explanation

RESOLUTION=

FASTRES 1200

300

600

FASTRES 1200

PRORES 1200

Select the resolution from the

following values:

300: Produces draft print quality

at the printer’s maximum speed;

300 dpi (dots per inch) is

recommended for some

bitmapped fonts and graphics,

and for compatibility with the

HP LaserJet III family of

printers.

600: Produces high print quality

at the printer’s maximum speed.

FASTRES 1200: Produces

optimum print quality

(comparable to 1200 dpi) at the

printer’s maximum speed.

PRORES 1200: Produces

optimum print quality (true 1200

dpi) at the printer’s maximum

speed.

When the resolution is

changed, any downloaded

resources (such as fonts or

macros) will need to be

downloaded again, unless they

are stored on an optional hard

disk or flash DIMM.

RET=MEDIUM OFF

LIGHT

MEDIUM

DARK

Use the printer’s Resolution

Enhancement technology

(REt) setting to produce print

with smooth angles, curves,

and edges.

The REt does not affect print

quality when the print

resolution is set to

ProRes 1200. All other print

resolutions, including

FastRes 1200, benefit from

REt.

64 Printer operation EN

ECONOMODE=OFF OFF

Turn EconoMode on (to save

toner) or off (for high quality).

EconoMode creates draft-

quality printing by reducing the

amount of toner on the printed

page by up to 50 percent.

Caution

Hewlett-Packard does not

recommend constant use of

EconoMode. If EconoMode is

always used, the toner supply

might outlast the mechanical

parts in the toner cartridge.

TONER DENSITY=3 1

Lighten or darken the print on

the page by changing the

toner density setting. The

settings range from 1 (light) to

5 (dark), but the default setting

of 3 usually produces the best

results.

Use a lower toner density

setting to save toner.

AUTO

CLEANING PAGE=OFF

OFF

Set AUTO CLEANING PAGE=ON to

have the printer automatically

create and process a cleaning

page (to remove debris from

the fuser) per the interval

specified in the next item.

AUTO CLEANING

FREQUENCY=2000

1000

2000

5000

10,000

20,000

This item appears when AUTO

CLEANING PAGE=ON.

Select the page interval for

automatically creating and

processing a cleaning page.

CLEANING PAGE SIZE=

LETTER

(110 V printers)

(220 V printers)

LETTER

This item appears when AUTO

CLEANING PAGE=ON.

This sets the media size upon

which the auto cleaning page

is processed. The default

media size corresponds with

the cold-reset media size.

Table 24. Print quality menu (continued)

Item Values Explanation

EN Chapter 3 Printer operation 65

CREATE

CLEANING PAGE

No value to select. Press SELECT to print a

cleaning page (for cleaning

excess toner from the fuser

assembly).

In order for the cleaning page

to work correctly, print the

page on copier-grade paper

(not bond or rough paper).

Follow the instructions on the

cleaning page.

PROCESS

CLEANING PAGE

No value to select. This item appears only after a

cleaning page has been

created (as described above).

Follow the instructions on the

cleaning page.

Note

It might take approximately two

minutes for the printer to finish

processing the cleaning page.

Table 24. Print quality menu (continued)

Item Values Explanation

66 Printer operation EN

Configuration menu

Items in this menu affect the printer’s behavior. Configure the printer according to printing needs.

Table 25. Configuration menu

Item Values Explanation

POWERSAVE TIME=

30 MINUTES

1 MINUTE

15 MINUTES

30 MINUTES

1 HOUR

2 HOURS

4 HOURS

Set the printer to enter PowerSave after

it has been idle for a specified amount

of time. Turning PowerSave off is not

recommended.

The PowerSave feature does the

following:

!Minimizes the amount of power

consumed by the printer when it is

idle.

!Reduces wear on the printer’s

electronic components by turning

off the backlight on the display.

When you send a print job, press a

control panel key, open a paper tray, or

open the top cover, the printer

automatically comes out of PowerSave

mode.

Note

PowerSave turns off the backlight on

the display, but the display is still

readable.

TONER LOW=

CONTINUE

STOP

Determine how the printer behaves

when toner is low. A toner-low message

first appears on the display when about

15 percent of the toner remains in the

cartridge (about 1,500 pages remaining

for the 10,000-page cartridge and

about 900 pages remaining for the

6,000-page cartridge at 5 percent page

coverage).

CONTINUE: The printer will continue to

print with the message displayed.

STOP: The printer will stop printing and

further action is required.

TONER OUT=

CONTINUE

STOP

Determine how the printer behaves

when toner is out. A toner-out message

appears on the display when the toner

cartridge is out of toner.

CONTINUE: The printer will continue to

print with the message displayed.

However, the print quality might be very

poor or difficult to see.

STOP: The printer will stop printing and

further action is required.

EN Chapter 3 Printer operation 67

CLEARABLE

WARNINGS=JOB

JOB

Set the length of time that a clearable

warning appears on the printer control

panel.

JOB: Warning messages appear on the

control panel until the end of the job

from which they were generated.

ON: Warning messages appear on the

control panel until GO is pressed.

AUTO CONTINUE=

OFF

Determine how the printer reacts to

errors.

ON: If a minor error occurs that prevents

printing, the message will appear, and

the printer will go offline for 10 seconds

before returning online.

OFF: If a minor error occurs that

prevents printing, the message will

remain on the display and the printer

will remain offline until GO is pressed.

If the printer is on a network, you will

probably want to turn AUTO CONTINUE to

ON.

JAM RECOVERY=

AUTO

OFF

Determine how the printer behaves

when a jam occurs.

AUTO: The printer automatically selects

the best mode for printer jam recovery

(usually ON).

ON: The printer automatically reprints

pages after a jam is cleared.

OFF: The printer does not reprint pages

following a jam. Printing performance

might be increased with this setting.

MAINTENANCE

MESSAGE=OFF

OFF This item appears only after the

PERFORM PRINTER MAINTENANCE

message appears on the display.

OFF: The PERFORM PRINTER

MAINTENANCE message will be

temporarily cleared but will return after

5 percent of the printer maintenance

interval (or after approximately 10,000

pages).

The message should be turned off only

while waiting for the printer

maintenance kit to be installed. If the

required maintenance is not performed,

the printer’s performance will degrade.

PRINT PS ERRORS=

OFF

Select ON to print the PS error page

when PS errors occur.

Table 25. Configuration menu (continued)

Item Values Explanation

68 Printer operation EN

RAM DISK=AUTO OFF

AUTO

Determine how the RAM disk is

configured. This item appears only if

there is no optional hard-disk

accessory installed and the printer has

at least 16 MB of memory.

OFF: The RAM disk is disabled.

Configure the amount of memory to be

used through the following item: RAM

DISK SIZE.

Note

If the setting is changed from OFF to

AUTO or from AUTO to OFF

, the printer will

automatically reinitialize.

QUICK COPY

JOBS=32

0 to 50 Specifies the number of quick copy jobs

that can be stored on the printer’s hard-

disk accessory.

HELD JOB

TIMEOUT=OFF

OFF

1 HOUR

4 HOURS

1 DAY

1 WEEK

Sets the amount of time that stored

jobs are kept before being

automatically deleted from the printer.

PERSONALITY=

AUTO

PCL

Select the default printer language

(personality). Possible values are

determined by which valid languages

are installed in the printer.

Normally, you should not change the

printer language (the default is AUTO). If

you change it to a specific printer

language, the printer will not

automatically switch from one language

to another unless specific software

commands are sent to the printer.

Table 25. Configuration menu (continued)

Item Values Explanation

EN Chapter 3 Printer operation 69

I/O menu

Items in the I/O (input/output) menu affect the communication between the printer and the computer.

Table 26. I/O menu

Item Values Explanation

PARALLEL ADV

COMMUNICATN=ON

OFF

Turn the bidirectional parallel

communication on or off. The default is set

for a bidirectional parallel port (IEEE-1284).

This setting allows the printer to send

status readback messages to the

computer. (Turning on the parallel

advanced functions might slow language

switching.)

PARALLEL HIGH

SPEED=YES

YES

Select the speed at which data is

transmitted to the printer.

YES: The printer accepts faster parallel

communications used for connections with

newer computers.

NO: The printer accepts slower parallel

communications used for connections with

older computers.

I/O TIMEOUT=15

SECONDS

5 to 300

SECONDS

Select the I/O timeout period in seconds.

(The I/O timeout refers to the time,

measured in seconds, that the printer waits

before ending a print job.)

This setting allows you to adjust timeout for

best performance. If data from other ports

appear in the middle of your print job,

increase the timeout value.

Press – VALUE + once to change settings by

increments of 1, or hold down – VALUE + to

scroll by increments of 10.

70 Printer operation EN

EIO menu (networked printers)

The EIO (enhanced input/output) menu appears only when an EIO device is installed in an EIO slot

on the printer (such as an HP JetDirect print server). The items in the menu depend on the particular

accessory product installed. If the printer contains an HP JetDirect print server EIO card, you can

configure basic networking parameters using the EIO menu. These and other parameters can also

be configured through HP Web JetAdmin.

Table 27. EIO menu

Item Values Explanation

CFG NETWORK=NO NO

YES

Select whether or not you want to use

the HP JetDirect menu.

NO: Bypass the HP JetDirect menu.

YES: Use the HP JetDirect menu. You

must change this to YES each time you

want to use the menu.

Note

You must select CFG NETWORK=YES to

display the following items.

IPX/SPX=ON ON

OFF

Select whether the IPX/SPX protocol

stack (in Novell NetWare networks, for

example) is enabled (ON) or disabled

(OFF).

DLC/LLC=ON ON

OFF

Select whether the DLC/LLC protocol

stack is enabled (ON) or disabled (OFF).

TCP/IP=ON ON

OFF

Select whether the TCP/IP protocol

stack is enabled (ON) or disabled (OFF).

ATALK=ON ON

OFF

Select whether the Apple EtherTalk

protocol stack is enabled (ON) or disabled

(OFF).

EN Chapter 3 Printer operation 71

CFG IPX/SPX=NO NO

YES

Select whether you want to use the IPX/

SPX menu and set IPX/SPX protocol

parameters.

NO: Bypass the IPX/SPX menu items.

YES: Use the IPX/SPX menu items.

In the IPX/SPX menu, you can specify

the frame-type parameter used on your

network.

The default is AUTO, to automatically set

and limit the frame type to the first one

detected.

For Ethernet cards, frame type

selections are EN_8023, EN_II,

EN_8022, EN_SNAP

For Token Ring cards, frame type

selections include TR_8022, TR_SNAP

In the IPX/SPX menu for Token Ring

cards, you can also specify NetWare

Source Routing parameters, which are

SRC RT=AUTO (default), OFF

, SINGLE R, or

ALL RT

CFG TCP/IP=NO NO

YES

Select whether you want to use the

TCP/IP menu and set TCP/IP protocol

parameters.

NO: Bypass the TCP/IP menu items.

YES: Use the TCP/IP menu items.

In the TCP/IP menu, you can specify

BOOTP=YES or DHCP=YES for TCP/IP

parameters to be automatically loaded

from a bootP or DHCP server when the

printer is turned on.

If you specify BOOTP=NO and DHCP=NO, you

can manually set the following TCP/IP

parameters from the control panel: each

byte of the IP address (IP), Subnet Mask

(SM), Syslog Server (LG), and Default

Gateway (GW). You can also manually

set the idle timeout period.

Print an HP JetDirect configuration page

to verify your settings. However, note that

the print server might overwrite selected

parameters with values that ensure

proper operation.

Table 27. EIO menu (continued)

Item Values Explanation

72 Printer operation EN

CFG LINK=NO NO

YES

Select whether you want to manually

configure the HP JetDirect 10/100Base-

TX print server’s network link speed and

communication mode. The HP JetDirect

settings must match the network.

NO: Bypass the link configuration menu

items.

YES: Use the link configuration menu

items. One of the following link

configurations can be set:

AUTO: The print server will automatically

configure itself to match the network’s

link speed and communication mode.

10T HALF: 10 Mbps, half-duplex

operation.

10T FULL: 10 Mbps, full-duplex

operation.

100T HALF: 100 Mbps, half-duplex

operation.

100T FULL: 100 Mbps, full-duplex

operation.

Table 27. EIO menu (continued)

Item Values Explanation

EN Chapter 3 Printer operation 73

Resets menu

Use the reset and restore options on this menu with caution. You can lose buffered page data or

printer configuration settings when you select these items. Only reset the printer under the following

circumstances:

!You want to restore the printer’s default settings.

!Communication between the printer and computer has been interrupted.

The items in the resets menu will clear all memory in the printer, while CANCEL JOB clears only the

current job.

Table 28. Resets menu

Item Values Explanation

NEW TONER

CARTRIDGE=NO

YES

Change the value to YES when you first install a non-HP

toner cartridge. YES allows the printer to recognize the new

cartridge, and the printer resets the toner gauge to full.

RESTORE

FACTORY

SETTINGS

Press SELECT to perform a simple reset and restores most of

the factory (default) settings. This item also clears the input

buffer for the active I/O.

POWERSAVE=

OFF

This item turns the PowerSave mode on or off.

POWERSAVE=ON mode does the following:

!Minimizes the amount of power consumed by the printer

when it is idle

!Reduces wear on the printer’s electronic components by

turning off the backlight on the display

When you send a print job, press a control panel key, open a

paper tray, or open the top cover, the printer automatically

comes out of PowerSave mode.

In the configuration menu, you can set how long the printer

remains idle before it enters PowerSave mode. Turning

PowerSave off is not recommended.

Note

PowerSave turns off the backlight on the display, but the

display is still readable.

74 Printer operation EN

Service mode

Service mode should be used only by authorized service personnel. The following can be done in

service mode:

!Verify and set the page count and serial number. These are shown on the configuration page.

!Set the cold reset paper size default. (This sets the factory default paper size to either Letter or

A4).

!Turn the diagnostic functions on or off (for software developers only).

!Clear the event log.

!Set the interval at which the PERFORM PRINTER MAINTENANCE message appears on the control

panel display.

To enter service mode:

1While turning on the printer, hold down SELECT and CANCEL JOB until all of the lights on the

control panel are lit.

2Press the right side of the MENU key, then press SELECT. The message SERVICE MODE

temporarily appears and will reappear when the printer completes the initialization process.

3To exit the service mode, press GO.

Note If READY appears in the control panel, the keys might have been released too soon, or the wrong keys

were pressed.

Note Before replacing the formatter or firmware DIMM, print a configuration page and a menu map to verify

the current printer settings. Use the information on these pages to reset the customer’s printer settings.

EN Chapter 3 Printer operation 75

Service menu

To enter the service menu, see “Service mode” on page 74.

Figure 6. Service menu

Changing settings

The item-count value is changed using a different method than is used for other control panel values.

Instead of increasing the entire value by increments, each digit can be selected and modified

individually. The following control panel keys are used to modify the page count value:

SELECT Enters any changes to the current digit and

advances the cursor one digit to the right. If the last

digit is currently selected, pressing the SELECT key

wraps the cursor around to the first digit.

VALUE - Increases the value of the currently selected digit by

one. Pressing VALUE + when 9 is the value of the

currently selected digit will change the value of the

digit to 0.

– VALUE Decreases the value of the currently selected digit by

one. Pressing – VALUE when 0 is the value of the

currently selected digit will change the value of the

digit to 9.

76 Printer operation EN

Table 29 shows the sequence of keystrokes used to change the page count from a value of 000000

to a value of 0010480.

Table 29. Changing the page count (example)

Key press Display Description

SERVICE MODE

MENU+SERVICE MENU Enter the SERVICE MENU.

ITEM+PAGES=0000000 * Advance to the first item in the SERVICE

MENU.

SELECT PAGES=0000000 * Advance the cursor one digit to the right.

VALUE + PAGES=0010000 * Increase the value of the third digit by

one.

SELECT PAGES=0010000 * Enter the change to the third digit and

advance the cursor one digit to the right.

SELECT PAGES=0010000 * Advance the cursor one digit to the right.

VALUE +

(4 presses)

PAGES=0010400 * Increase the value of the fifth digit by

four.

SELECT PAGES=0010400 * Enter the change to the fifth digit and

advance the cursor one digit to the right.

– VALUE

(2 presses)

PAGES=0010480 * Decrease the value of the sixth digit by

two.

SELECT

(2 presses)

PAGES=0010480 * Enter the change to the sixth digit and

advance the cursor one digit to the right

causing the cursor to wrap around to the

first digit.

GOExit.

EN Chapter 3 Printer operation 77

Page count

The page count that is stored in nonvolatile memory (NVRAM) and is shown on the configuration

page printout represents the number of pages the printer has printed (excluding engine test prints). If

it is necessary to install a new formatter in the printer, the page count must be reset so that it

represents the age of the printer engine rather than the age of the formatter.

Note Before replacing the formatter or firmware DIMM, print a configuration page and a menu map to verify

the current printer settings. Use the information on these pages to reset the customer’s printer settings.

Maintenance count

The maintenance count should be reset only after a maintenance kit has been installed. For more

information, see page 86.

Maintenance interval

The MAINTENANCE INTERVAL in the service-mode menu sets the page count interval at which the next

service is due for the printer. This is set initially at the factory to 200,000 pages. (For example, the

PERFORM PRINTER MAINTENANCE message appears at 200,000 pages. If the printer maintenance kit is

installed at 200,114 pages, the message reappears 200,000 pages later, at 400,114 pages.) The

procedure for editing this number is similar to editing the PAGES item.

Serial number

The printer serial number is stored in NVRAM. If a formatter is replaced, then the printer serial

number must be reentered. The procedure for editing this number is similar to editing the PAGES item.

Note Before replacing the formatter or firmware DIMM, print a configuration page and a menu map to verify

the current printer settings. Use the information on these pages to reset the customer’s printer settings.

Cold reset paper

The cold reset paper size is stored in NVRAM. When a printer cold reset is performed, the default

paper size (in the printing menu) is set to the value saved for the cold reset paper size. Possible

values are COLD RESET PAPER=LETTER and COLD RESET PAPER=A4. When replacing the formatter in

countries that use A4 rather than letter-size paper, set the cold reset paper size to A4.

Diagnostics

This menu item enables or disables the use of the firmware diagnostic features for software

development. Possible values are DIAGNOSTICS=OFF* and DIAGNOSTICS=ON. When enabled, the

diagnostic features are available when the printer is in the online READY state by pressing the SELECT

key.

Note The feature above is for software developers only.

78 Printer operation EN

Clear event log

This item deletes all items that have been recorded in the internal event log.

Top margin

This item can be used to adjust the margin between the top of the page and the top of the printed

image.

Note Adjust the top margin value in the software application first. This top margin value does not affect the

engine test top margin.

Before adjusting the top margin through the service menu, first ensure the engine test top margin

To set the top margin registration value:

1Press the ITEM key to scroll through the service menu until TOP MARGIN=07 appears.

2Press the VALUE key to increase or decrease the margin.

3Press the SELECT key to save the new margin adjustment.

Tray 1 left margin

This item can be used to adjust the margin between the left side of the pages from tray 1 and the left

side of the printed image.

1Press the ITEM key until TRAY 1 LEFT MARGIN=07 appears.

2Press the VALUE key to increase or decrease the margin.

3Press the SELECT key to save the new margin adjustment.

Trays 2 and 3 left margin

This item can be used to adjust the margin between the left side of the pages from trays 2 and 3 and

the left side of the printed image.

1Press the ITEM key until TRAYS 2 AND 3 LEFT MARGIN=07 appears.

2Press the VALUE key to increase or decrease the margin.

3Press the SELECT key to save the new margin adjustment.

Testing the printer

When you print a configuration page, the printer checks its internal controller and I/O interface, and

then prints a test page. You can review the configuration page printout to verify proper installation of

such options as paper trays or printer languages. For more information, see page 227.

Engine test

The engine test print can be used to verify that the print engine is functioning correctly. For more

information, see page 190.

EN Chapter 3 Printer operation 79

Resetting the printer

Cold reset

Cold reset clears all data from the printer memory and sets many of the defaults back to the factory

settings.

CAUTION Performing a cold reset resets the HP JetDirect configuration. To avoid making changes to your

configuration, remove the HP JetDirect card before performing a cold reset.

If possible, print a configuration page and a menu map to verify the current printer settings. Use the

information on these pages to reset the customer’s printer settings.

To perform a cold reset:

1Print a configuration page and a menu map.

2Turn on the printer while holding the GO key down.

3When COLD RESET appears on the control panel display, release the GO key.

Clearing NVRAM

This procedure will clean up the NVRAM by removing old areas that are not being used.

1Turn off the printer.

2Hold down the CANCEL JOB key, and then turn on the printer.

3When CLEANUP NVRAM appears on the control panel display, release the CANCEL JOB key.

Initialization of NVRAM

Initialization of NVRAM should always be executed immediately after replacing the formatter board.

This procedure aligns the firmware with the formatter. Not initializing NVRAM could result in

deterioration of print quality.

CAUTION Initializing NVRAM will erase several of the memory settings (including page count, printer serial

number, and the event log).

Note Before initializing NVRAM, print a configuration page and a menu map to verify the current printer

settings. Use the information on these pages to reset the customer’s printer settings.

To initialize NVRAM

1Print a configuration page and a menu map.

2Turn off the printer.

3Remove all formatter accessories (EIO cards, hard drive, DIMMs, etc.).

4While turning on the printer, hold down SELECT and CANCEL JOB until all of the lights on the

control panel are lit.

5Press CANCEL JOB, and then SELECT. The NVRAM INIT message appears on the control panel

display.

6After initializing the NVRAM, use service mode to reenter the settings from the configuration

page.

80 Printer operation EN

Initialization of the hard disk

To initialize the hard disk

1Print a configuration page and a menu map.

2Turn off the printer.

3While turning on the printer, hold down SELECT and CANCEL JOB until all of the lights on the

control panel are lit.

4Press MENU-, and then VALUE-.

5Press SELECT.

System configuration

MS-DOS system configuration

To communicate properly with the printer, the MS-DOS® environment requires the addition or

modification of mode commands in the AUTOEXEC.BAT file. Add or modify the mode command(s),

depending on the interface configuration, as follows:

Parallel DOS commands

Most IBM- and AT-compatible computers default to a parallel printer port. To ensure that information

is sent to the parallel printer port, type the following MS-DOS command at the MS-DOS prompt or

include it in the Autoexec.bat file:

MODE LPT1: , , P

For MS-DOS version 4.0 and above, type:

MODE LPT1: , , B

Note This example assumes that you are using parallel printer port LPT1. If you are using LPT2 or LPT3,

replace LPT1 in the example with the printer port that you are using.

Since the mode command is an external MS-DOS command (a program named mode.com is run

when the mode command is invoked), the program file must be contained in the root directory, or in

a directory specified in a preceding path command in the Autoexec.bat file.

After changing the Autoexec.bat file, restart the computer to initiate the changes.

EN Chapter 4 Printer maintenance 81

4Printer maintenance

Chapter contents

Cleaning the printer and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Using the printer cleaning page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Using the auto-cleaning page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Cleaning spilled toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Performing printer maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Reset maintenance count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Expected life of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

82 Printer maintenance EN

Cleaning the printer and accessories

To maintain superior print quality and performance, thoroughly clean the printer and the paper-

handling accessories:

!after printing approximately 10,000 pages.

!whenever print quality problems occur.

Also, run a cleaning page every time you change the toner cartridge.

Clean the outside surfaces of the printer and accessories with a water-dampened cloth. Clean the

inside parts as indicated in table 30 on page 83. Observe the warning and caution below.

WARNING! Before beginning these steps, turn the printer off and unplug all power cords to avoid shock hazard.

Be careful when cleaning around the fusing assembly area. It might be hot.

CAUTION To avoid permanent damage to the toner cartridge, do not use ammonia-based cleaners on or around

the printer.

Do not touch the transfer roller. Skin oils on the roller can cause print quality defects. If toner gets on

clothing, wipe it off with a dry cloth and wash the clothes in cold water. Hot water sets toner into fabric.

Figure 7. Location of the transfer roller – Do Not Touch!

EN Chapter 4 Printer maintenance 83

Table 30. Cleaning the printer

Component Cleaning method/notes

Outside covers Use a water-dampened cloth. Do not use solvents or

ammonia-based cleaners.

Inside With a dry, lint-free cloth, wipe any dust, spilled toner, and

paper particles from the paper path area, the registration

roller, and the toner cartridge cavity. Do not touch the

transfer roller with bare hands.

Paper pickup, feed, and

separation rollers Use a water-dampened, lint-free cloth.

Tray 1 separation pad Use a dry, lint-free cloth.

Registration roller Use a dry, lint-free cloth.

Transfer roller Use a dry, lint-free cloth. DO NOT TOUCH the transfer

roller.

Fuser Use a water-dampened, lint-free cloth.

84 Printer maintenance EN

Using the printer cleaning page

If toner specks appear on the front or back side of print jobs, follow the procedure below.

From the printer control panel, do the following:

1Press MENU until PRINT QUALITY MENU appears.

2Press ITEM until CREATE CLEANING PAGE appears.

3Press SELECT to create the cleaning page.

4Follow the instructions on the cleaning page to complete the cleaning process.

Note In order for the cleaning page to work correctly, print the page on copier-grade paper (not bond or

rough paper).

You might need to create and process a cleaning page more than once. When toner has been

cleaned from the fuser assembly, shiny black spots will appear on the page’s black strip. If white

spots appear on the black strip, create another cleaning page.

To ensure good print quality with certain types of paper, use the cleaning page every time the toner

cartridge is replaced. If the cleaning page is frequently needed, try a different type of paper.

Using the auto-cleaning page

The auto-cleaning page feature helps keep the fuser rollers clean, which maintains excellent output

quality. The auto-cleaning page feature is accessible through the control panel and is supported

through Web JetAdmin, as well. Once set up, the printer runs a cleaning page through the printer as

a separate job at the frequency requested with no further user intervention. The settings can be

changed or the feature can be turned off at any time.

Note Once the auto-cleaning page feature is enabled, the printer automatically pulls plain letter- or A4-sized

media from a tray. If the paper size or types are not available in the printer, a message appears in the

control panel display requesting the user to load media into the printer.

To override a paper load message, press GO, and then answer the questions on the control panel

display.

To set up the auto-cleaning page:

1Press MENU until PRINT QUALITY MENU appears.

2Press ITEM until AUTO CLEANING PAGE appears.

3Press VALUE+ until =ON appears, and then press SELECT.

4Press VALUE+ to select the auto cleaning frequency, and then press SELECT.

5Press ITEM until CLEANING PAGE SIZE=LETTER or A4, and then press VALUE+ to select the paper

size to be used for cleaning.

6Press SELECT to save the auto-cleaning settings.

Note The auto cleaning page takes about 2.5 minutes to process.

EN Chapter 4 Printer maintenance 85

Cleaning spilled toner

Defective or worn out toner cartridges can develop leaks. Also, after a jam has occurred, there might

be some toner remaining on the rollers and guides inside the printer. The pages that print

immediately after the jam might pick up this toner.

Clean spilled toner with a cloth dampened with cold water. Do not touch the transfer roller with the

damp cloth or with your fingers. Do not use a vacuum cleaner unless it is equipped with a micro-fine

particle filter.

86 Printer maintenance EN

Performing printer maintenance

The printer maintenance cycle for this printer is every 200,000 pages. The kit contains the following

replacement parts:

!one fuser

!one transfer roller

!one transfer roller tool

!one pickup roller (for tray 1)

!six feed and separation rollers (for trays 2, 3, and 4)

!one pair of disposable gloves

!instructions

See the instructions included in the kit for detailed replacement procedures.

The maintenance kit can be ordered from the Customer Services and Support Center. To order the

maintenance kit, see page 270.

Reset maintenance count

The maintenance page count should be reset only after a maintenance kit has been installed.

This resets the maintenance counter so that the message PERFORM PRINTER MAINTENANCE will

appear after another 200,000 pages (default).

1Hold down the - ITEM and - VALUE keys.

2Turn the printer on.

3Wait for RESET MAINTENANCE COUNT to appear and then release both keys.

Table 31. Maintenance kit part numbers

Description Exchange no. Product no.

Maintenance kit (110 V) C8057-69001 C8057A

Maintenance kit (220 V) C8058-69001 C8058A

EN Chapter 4 Printer maintenance 87

Expected life of components

The following table shows the expected life of certain components in the printer. To order parts, see

chapter 8.

Note If an HP LaserJet 4100 series printer component is not listed above, the component should last the

life of the printer.

Table 32. Life of components

No. Part name Part number Expected life

1 Tray 1 pickup roller RG5-3718-000CN 100,000 pages (for tray 1)

2 Tray 1 separation pad RF5-3086-000CN 200,000 pages (for tray 1)

3 Tray 1 pickup assembly RG5-5084-000CN 200,000 pages (for tray 1)

4 Feed and separation rollers

(trays 2, 3, and 4) RF5-3114-000CN 200,000 pages

5 Fuser

110 V

220 V RG5-5063-000CN RG5-

5064-000CN 200,000 pages

200,000 pages

6 Transfer roller RG5-5295-000CN 200,000 pages

7 Cooling fan RH7-1442-000CN 25,000 hours

8 Duplexer exhaust fan RH7-1443-000CN 25,000 hours

88 Printer maintenance EN

EN Chapter 5 Theory of operation 89

5Theory of operation

Chapter contents

Power supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

AC/DC power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Overcurrent/overvoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

High-voltage power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Toner-cartridge detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Cartridge memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Engine controller system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Engine controller board inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Laser/scanner drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Paper-motion monitoring and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Solenoids, sensors, clutches, and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Engine test print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Formatter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

PowerSave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Resolution Enhancement technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

EconoMode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Input/output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Printer memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

DIMM slots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

PJL overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

PML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Image formation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Toner cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Photosensitive drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Writing the image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Developing the image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Transferring the image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Image fusing/variable fusing temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Paper feed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Clutches and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

90 Theory of operation EN

Printing from tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

Printing from tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

Printing from the optional 500-sheet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

Envelope feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Duplexer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

Other controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

Environmental detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

Basic sequence of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

EN Chapter 5 Theory of operation 91

Power supply system

AC/DC power distribution

In this circuit, the AC power input from the power receptacle is converted into DC power. The DC

power is supplied to the loads.

The AC power is supplied to the low-voltage power supply circuit in the engine controller board when

the power switch (SW1) is turned on.

The AC power is converted into +24 VDC, +5 VDC, and +3.3 VDC in the circuit. The +24 VDC is

supplied to the main motor, scanner motor, solenoids, clutches, and to the high-voltage power supply

circuit. The +5 VDC is supplied to the laser and formatter, while +3.3 VDC is supplied to the sensors

and ICs on the engine controller board.

The +24 VDC is divided into +24 VA, which is constantly supplied from the low-voltage power supply

circuit, and +24 VB, which is interrupted when the interlock switch (SW101) is turned off by opening

the top cover. The +24 VB is supplied to the high-voltage power supply circuit on the engine

controller board and relay (RL102). It also functions as a door-open detection signal (/DOPEN), so

that the CPU detects an open door.

Figure 8. Low-voltage power supply circuit

92 Theory of operation EN

Overcurrent/overvoltage protection

If a short-circuit or other problem on the load side causes an excessive current flow or generates

abnormal voltage, the overcurrent/overvoltage protection systems automatically cut off the output

voltage to protect the power supply circuit.

If the overcurrent or overvoltage protection system are activated and the power supply circuit does

not generate DC voltage, it is necessary to turn the power off, correct the problem, and then turn the

printer on again.

The circuit has two fuses (FU1, FU2), which break and cut off the output voltage if overcurrent flows

through the AC line.

Fuser over-temperature protection

The fusing heater safety circuit is located on the engine controller board and constantly monitors the

fusing temperature.

To protect the fuser from excessive temperatures, the printer has the following three protective

functions:

!The CPU monitors the voltage of the FSRTH1 and FSRTH2 thermistor signals. If the fuser

temperature reaches 240° C (464° F), then the CPU turns off the relay (RL101) to interrupt the

power to the fusing heater.

!If the temperature of the fusing heater continues to rise abnormally and the temperature of the

thermal switch (TP101) exceeds about 250° C (482° F), TP101 opens up to cut off the power

supply to the fusing heater.

!The power supply on the coil side of RL101 and RL102 is connected to +24 VB. When the top

cover is opened, the power supply to RL101 and RL102 is cut off and the relay is turned off.

EN Chapter 5 Theory of operation 93

High-voltage power distribution

Figure 9. Engine controller board

In response to the instructions from the microprocessor (CPU:IC502) on the engine controller board,

the high-voltage power supply circuit applies high voltage to the primary charging roller, developing

cylinder, transfer roller, and the fuser film unit.

The circuit also detects the toner level and the presence or absence of the toner cartridge.

94 Theory of operation EN

Toner-cartridge detection

This printer has cartridge detection and toner-level detection.

For the cartridge detection, the CPU checks the voltage of the cartridge detection signal (CRGSNS),

which is a feedback signal for the primary charging. The CPU checks the voltage of the CRGSNS

signal several times while the primary charging AC bias is applied to the primary charging roller.

When the average of the voltage is 1 V or less, the CPU recognizes a "cartridge out" situation.

Cartridge memory

This memory is built-in EEPROM in the cartridge, so that the printer is capable of detecting the

cartridge conditions.

Read/write of the cartridge memory is performed by the memory controller board through the

antenna unit. The cartridge information read by the memory controller is updated by the engine

controller and written to the memory. The read/write of the memory is implemented when the

memory controller board receives a command from the engine controller board.

The engine controller instructs the memory controller to perform read/write at the following timing.

Reading timing

!When the power is turned on

!When the door is closed

!When the engine controller receives a command from the formatter

Writing timing

!When printing is completed

!When the engine controller receives a command from the formatter

The memory data sent from the memory controller also contains the error status that has occurred

during read/write operation. When error status is sent, the engine controller attempts to read the

operation four times. If the error status is not cleared after the operation, the engine controller

determines one of the following error conditions: sub-CPU failure, memory data abnormality, or

memory access abnormality.

CAUTION Do not remove the toner cartridge when the top cover interlock is overridden. Cartridge memory will

be disabled.

Figure 10. Cartridge memory

EN Chapter 5 Theory of operation 95

Engine controller system

The following systems and functions are controlled by the engine controller board:

!DC power distribution (+3.3 V DC, +5 V DC, +24 VA)

!Laser and scanner drive

!Paper-motion monitoring and control (photosensors and flags)

!Clutches (tray pickup and tray 1 feed)

!Engine test

!Motors (main drive, scanner, and fans)

Printer operations are controlled by the CPU on the engine controller board. When you press the

power button, the printer enters standby mode until it receives a print command or image data. The

CPU then sends the signals to drive internal components, such as laser diodes, motors, and

solenoids.

Figure 11. Engine controller board

96 Theory of operation EN

Engine controller board inputs and outputs

Figure 12. Engine controller board I/O (1 of 5)

EN Chapter 5 Theory of operation 97

Figure 13. Engine controller board I/O (2 of 5)

98 Theory of operation EN

Figure 14. Engine controller board I/O (3 of 5)

EN Chapter 5 Theory of operation 99

Figure 15. Engine controller board I/O (4 of 5)

100 Theory of operation EN

Figure 16. Engine controller board I/O (5 of 5)

EN Chapter 5 Theory of operation 101

Laser/scanner drive

The HP LaserJet 4100 series printer has two diodes in the laser/scanner assembly. The printer uses

a twin-beam method to scan two lines simultaneously. Based on information received from the

formatter, the engine controller board sends signals to the laser scanner assembly to modulate the

laser diodes on and off and to drive the laser scanner motor. See “Image formation system” on page

108 for more information.

Paper-motion monitoring and control

The engine controller board controls paper motion by continuously monitoring the various paper

sensors and coordinating paper movement with the other print processes. For more information, see

“Paper feed system” on page 117.

Solenoids, sensors, clutches, and switches

The engine controller board monitors the various sensors and switches in the printer and controls the

solenoids and clutches for paper movement. See "Engine controller board inputs and outputs" on

pages 96 through 100.

Engine test print

The engine controller board has a built-in engine test pattern that can be printed without using the

data from the formatter. See “Engine test” on page 190 in chapter 7.

Motors

See “Timing diagram” on page 131 for specific timing details for the printer motors.

This printer and optional input trays are driven by the main motor, which is controlled by commands

from the CPU.

102 Theory of operation EN

Figure 17. Main motor control

EN Chapter 5 Theory of operation 103

The main motor is a DC brushless motor with hall elements, and is unified with the motor drive

circuit.

The CPU (IC502) sets the main motor drive signal (/MON) to “L” and rotates the main motor. When

the main motor rotates and reaches the specified speed, the main motor sets the main motor ready

signal (/MRDY) to "L". When the /MRDY signal is "L," the CPU determines that the main motor is

rotating correctly.

Note When the printer is idle, the main motor comes on every seven hours for 500 milliseconds.

If the printer is in the following conditions, the CPU determines a main motor failure.

!The /MRDY signal does not go to "L" after 700 ms from the main motor rotation start.

!During normal rotation, the /MRDY signal goes to "H" continuously for 0.1 second after going to

"L".

The scanner motor is controlled and monitored by the engine controller board. It rotates the scanner

mirror during the initial rotation period and the print period.

The fan motor is controlled and monitored by the engine controller board. The fan operates at full

speed during the printing modes. During the wait period after the power is on, the fan motor prevents

the temperature from rising in the printer.

Note While in idle or PowerSave mode, the fan motor comes on every 14 minutes and stays on for 6 minutes

to cool the heat generated by the engine controller board and the power supply.

104 Theory of operation EN

Formatter system

The formatter is responsible for the following:

!Controlling the PowerSave mode

!Receiving and processing print data from the various printer I/Os

!Monitoring control panel inputs and relaying printer status information (through the control panel

and the bidirectional I/O)

!Developing and coordinating data placement and timing with the print engine

!Storing font information

!Communicating with the host computer through the bidirectional interface

The formatter receives a print job from the bidirectional interface and separates it into image

information and instructions that control the printing process. The engine controller board

synchronizes the image formation system with the paper input and output systems, and then signals

the formatter to send the print image data.

The formatter also provides the electrical interface and mounting locations for two EIO cards,

additional memory DIMMs, the hard-disk accessory, and the optional HP Fast Infrared Receiver.

PowerSave

This feature in the configuration menu conserves power after the printer has been idle for an

adjustable period of time. When the printer is in PowerSave mode, the control panel backlight is

turned off, but the printer retains all printer settings, downloaded fonts, and macros. The default

setting is POWERSAVE=ON, with a 30-minute idle time. PowerSave can also be turned OFF from the

resets menu on the control panel.

The printer exits PowerSave mode and enters the warm-up cycle when any of the following occurs:

!A print job, valid data, or a PML or PJL command is received at the parallel port, serial port, FIR

port, or EIO card.

!A control panel key is pressed.

!The top cover is opened.

!A paper tray is opened.

!The engine test button is pressed.

Note Printer error messages override the PowerSave message. The printer will enter PowerSave mode at

the appropriate time, but the error message will continue to appear.

Resolution Enhancement technology

The formatter contains circuitry for Resolution Enhancement technology (REt), which modifies the

standard video dot data on its way to the engine controller board to produce “smoothed” line edges.

The REt can be turned on or off from the control panel or from some software applications. The

default setting is medium.

Note The REt settings sent from software applications or printer drivers override the control panel settings.

EN Chapter 5 Theory of operation 105

EconoMode

The EconoMode setting uses up to 50 percent less toner than standard mode printing by reducing

the dot density. However, EconoMode does not extend toner cartridge component life. EconoMode,

which can be thought of as “draft mode,” can be selected from the control panel (print-quality menu)

and through some software applications and printer drivers. The default setting is OFF

CAUTION HP does not recommend full-time use of EconoMode. If EconoMode is used full-time, it is possible

that the toner supply will outlast the mechanical parts in the toner cartridge.

Note EconoMode does not affect print speed or memory usage, or extend the life of the toner cartridge.

Input/output

Parallel interface

The formatter receives incoming data through its bidirectional interface (IEEE-1284). The I/O

provides high speed and two way communication between the printer and the host, allowing the user

to change printer settings and monitor printer status from the host computer. The user can configure

the HIGH SPEED item in the control panel menu. The default setting, YES, allows the I/O to run at the

higher speeds supported by most newer computers. When set to NO, the parallel interface runs at the

slower mode that is compatible with older computers. The user can also configure the ADVANCED

FUNCTIONS item. The default setting, ON, allows for two-way parallel communications. The OFF mode

disables the advanced functionality. The I/O is compatible with the bidirectional parallel interface

standard.

Expanded I/O

The optional expanded I/O (EIO) card can be installed in the slots provided on the formatter. It

provides automatic I/O switching between multiple computers or networks connected to the printer.

HP Fast Infrared Receiver

The optional HP Fast Infrared Receiver enables wireless printing from any iRDA-compliant portable

device (such as a laptop computer) to the printer.

The printing connection is maintained by positioning the sending infrared port within operating range.

The connection can be blocked by objects such as a hand or paper, or by direct sunlight or any bright

light shining into either infrared port.

Flash

Optional flash is available in 2 MB and 4 MB flash memory DIMMs for storing forms, fonts, and

signatures.

Hard-disk accessory

The optional hard-disk accessory can be mounted in one of the EIO slots on the rear of the formatter.

The optional EIO-based hard disk is used for creating multiple original prints (mopies) and storing

forms, fonts, and signatures.

CPU

The HP LaserJet 4100 series printer formatter incorporates a 250 MHz RISC processor.

106 Theory of operation EN

Printer memory

If the printer encounters difficulty managing available memory, a clearable warning message will

appear on the control panel.

Some printer messages are affected by the auto-continue and clearable warning settings from the

configuration menu on the printer control panel. If CLEARABLE WARNING=JOB is set on the control

panel, warning messages appear on the control panel until the end of the job from which they were

generated. If CLEARABLE WARNING=ON is set, warning messages appear on the control panel until GO

is pressed. If an error occurs that prevents printing and AUTO CONTINUE=ON is set, the printer goes

offline for 10 seconds before it returns online. If AUTO CONTINUE=OFF is set, the message appears

until GO is pressed.

Read-only memory

Besides storing microprocessor control programs, the read-only memory (ROM) stores dot patterns

of internal character sets (fonts).

Random-access memory

The random-access memory (RAM) contains the page, I/O buffers, and the font storage area. It

stores printing and font information received from the host system, and can also serve to temporarily

store a full page of print-image data before the data is sent to the print engine. Memory capacity can

be increased by adding DIMMs to the formatter. Note that adding memory (DIMMs) might also

increase the print speed for complex graphics.

DIMM slots

The DIMM slots can be used to add memory, fonts, or firmware upgrades.

Firmware DIMM

To upgrade printer firmware, insert a new firmware DIMM in the lowest DIMM slot inside the formatter

assembly (see page 150).

Nonvolatile memory

The printer uses nonvolatile memory (NVRAM) to store I/O and information about the print

environment’s configuration. The contents of NVRAM are retained when the printer is turned off or

disconnected.

Memory Enhancement technology

The HP Memory Enhancement technology (MEt) effectively doubles the standard memory through a

variety of font- and data-compression methods.

Note The MEt is only available in PCL mode; it is not functional when printing in PS mode.

EN Chapter 5 Theory of operation 107

PJL overview

Printer job language (PJL) is an integral part of configuration, in addition to the standard printer

command language (PCL). With standard cabling, PJL allows the printer to perform functions such

as:

!Two-way communication with the host computer through a bidirectional parallel connection. The

printer can tell the host about such things as the control panel settings, and it allows the control

panel settings to be changed from the host.

!Dynamic I/O switching allows the printer to be configured with a host on each I/O. The printer can

receive data from more than one I/O simultaneously, until the I/O buffer is full. This can occur

even when the printer is offline.

!Context-sensitive switching allows the printer to automatically recognize the personality (PS or

PCL) of each job and configure itself to serve that personality.

!Isolation of print environment settings from one print job to the next. For example, if a print job is

sent to the printer in landscape mode, the subsequent print jobs print in landscape only if they

are formatted for landscape printing.

PML

The printer management language (PML) allows remote configuration and status readback through

the I/O ports.

Control panel

The formatter sends and receives printer status and command data to and from a control panel

board.

108 Theory of operation EN

Image formation system

The image formation system is the main system in the printer. It consists of five stages:

When the formatter board sends the print signal to the engine controller board, it drives the main

motor to rotate the photosensitive drum, the developing cylinder, the primary charging roller, the

transfer charging roller, and the fuser pressure roller.

The primary charging roller places a uniform negative charge on the surface of the photosensitive

drum. To form a latent image on the photosensitive drum, the laser beams modulated by the video

signals are illuminated on the photosensitive drum surface.

The latent image formed on the photosensitive drum is changed to a visual image by the toner on the

developing cylinder, then transferred to the paper by the transfer charging roller. Then the transferred

toner is fused with heat and pressure in the fuser to be a permanent image on the paper. After that,

the residual toner on the photosensitive drum surface is scraped off with the cleaning blade. Finally,

the charge on the drum is made uniform by the primary charging roller to prepare for a new latent

image.

The cartridge has a toner sensor that detects the remaining toner level and the presence of the

cartridge.

If the toner in the cartridge becomes lower than the specified level or if there is no cartridge in the

printer, it is reported to the formatter.

Figure 18. Image formation system

1. Conditioning 4. Fusing

2. Developing 5. Cleaning

3. Transferring

EN Chapter 5 Theory of operation 109

Toner cartridge

Figure 19. Toner cartridge

A major portion of the image formation system is contained in the cartridge as shown in figure 19.

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, primary

charging roller, developing roller, toner cavity, and cleaner blade. Including these components that

wear, degrade, or are consumed in the replaceable toner cartridge eliminates the need for a service

call when replacement is required.

110 Theory of operation EN

Photosensitive drum

The special properties of the photosensitive drum allow an image to be formed on the drum surface

and then transferred to paper. The drum is an aluminum cylinder coated with a layer of organic-

photoconductive material (OPC) which is non-toxic. The OPC material has properties similar to a

photoresistor. It becomes electrically conductive when exposed to light. (The negative charges

deposited on the drum are conducted to the ground potential of the drum base.) Areas not exposed

to light remain nonconductive and maintain their negative charge. The aluminum base of the

photosensitive drum is electrically connected to ground potential.

Figure 20. Photosensitive drum

Cleaning the drum

The cleaning blade is in contact with the surface of the drum at all times. As the drum rotates during

printing, excess toner is scraped off and stored in the waste toner receptacle.

Figure 21. Cleaning the drum

Photosensitive

Layer

Aluminum

Base

EN Chapter 5 Theory of operation 111

Conditioning the drum

The conditioning process consists of applying a uniform negative charge on the surface of the drum

with the primary charging roller. The primary charging roller is coated with conductive rubber with an

AC bias applied to erase any residual charges and maintain a constant drum surface charge. The

amount of DC voltage is modified by the print density setting.

Figure 22. Primary charging roller

112 Theory of operation EN

Writing the image

The laser/scanner of this printer has two diodes in the laser unit. During the writing process, the

modulated laser diodes project two beams onto the rotating six-sided scanning mirror. As the mirror

rotates, the beams reflect off the mirror, through a set of focusing lenses, through a slot in the top of

the toner cartridge, and onto the photosensitive drum. The beams sweep the drum from left to right,

discharging the negative potential wherever the beams strike the surface. This creates a latent

electrostatic image, which later is developed into a visible image.

Figure 23. Writing the image

Because the beams are sweeping the entire length of the drum and the drum is rotating, the entire

surface area of the drum can be covered. The speed of the scanner motor (which turns the scanning

mirror) and the speed of the main motor (which turns the drum) are synchronized, and each

successive sweep of a beam is offset by 1/1200th of an inch. The beams can be turned on and off to

place a dot of light every 1/1200th of an inch. This is how the printer achieves its true 1200 by 1200

dpi resolution. After the writing process, the drum surface has an invisible (latent) electrostatic image.

At the beginning of each sweep, the beams strike the beam detect mirror and PCB, generating the

beam detect signal (BD). The BD signal is sent to the engine controller board, where it is converted

to an electrical signal used to synchronize the output of video data for one sweep (two scan lines)

and to diagnose problems with the laser diode or scanner motor.

EN Chapter 5 Theory of operation 113

Developing the image

The developing process develops the latent electrostatic image into a visible image on the drum. The

developing unit consists of a metallic cylinder that rotates around a fixed magnetic core inside the

toner cavity. Toner is a powdery substance made of black plastic resin bound to iron particles, which

is uniformly attracted to the magnetic core of the cylinder.

The toner particles obtain a negative surface charge by rubbing against the developing cylinder

which is connected to a negative DC supply. The negatively charged toner is attracted to the

discharged (exposed, grounded) areas on the drum. An AC potential is applied to the developing

cylinder to decrease the attraction between the toner and the magnetic core of the cylinder, and to

increase the repelling action of the toner against the areas of the drum not exposed to laser light.

This AC potential improves density and contrast.

Figure 24. Developing the image

The print density control in the print quality menu adjusts the DC bias of the developing cylinder by

changing the force of attraction between the toner and drum. A change in the DC bias causes either

more or less toner to be attracted to the drum, which in turn either increases or decreases the print

density. Both the primary and developer DC bias voltages are changed in response to the density

setting.

114 Theory of operation EN

Transferring the image

During the transferring process the toner image on the drum surface is transferred to the paper. A

positive charge applied to the back of the paper by the transfer roller causes the negatively charged

toner on the drum surface to be attracted to the page.

The small diameter of the drum, combined with the stiffness of the paper, causes the paper to peel

away from the drum. The static eliminator teeth also help separate the paper from the drum. The

static eliminator teeth weaken the attractive forces between the negatively charged drum surface and

the paper. After separation, the drum is cleaned and conditioned for the next image.

Figure 25. Transferring the image

EN Chapter 5 Theory of operation 115

Image fusing/variable fusing temperature

During the fusing process, the toner is fused into the paper by heat and pressure to produce a

permanent image. The paper passes between a heated fusing roller and a soft pressure roller. This

melts the toner and presses it into the paper.

This printer utilizes an on-demand fusing method, which uses fusing film with small heat capacity.

This method has fast temperature-rising time. It is not necessary to supply power to the fuser heater

during the standby mode. Wait time is shortened and energy conservation is made possible by this

method.

The fusing roller contains a ceramic strip that contains three heating elements, providing heat for the

fusing process. Fusing temperature is monitored by the engine controller board using two

thermistors. The engine controller board maintains a temperature of about 195°C (383°F) during

print mode. If the fusing system overheats (about 240°C/464°F), a relay opens, interrupting power

to the fusing heater and causing a fuser error message (50.X FUSER ERROR). If the fusing system

exceeds 250°C (482°F), the thermal fuse will open, cutting off power to the fuser.

Figure 26. Image fusing

116 Theory of operation EN

Variable fusing temperature

Figure 27. Fusing temperature control

Variable fusing temperature is a feature that gives the user or service technician the ability to adjust

the fusing temperature based on the media being used in the printer. The default mode is normal and

should be optimal for most users. There are optional fuser-mode selections. If very heavy or rough

media is being used, then high fuser mode is beneficial. If transparencies or light media are being

used, then low fuser mode might be appropriate. CONFIGURE FUSER MODE is in the paper-handling

menu and when set to the default of NO, paper types are not displayed in the menu. When CONFIGURE

FUSER MODE is set to YES, the different paper types are displayed in the menu (see page 59).

Note High2 fusing mode only operates for A4-, letter-, and legal-size paper, and slows the throughput to 16

pages per minute.

EN Chapter 5 Theory of operation 117

Paper feed system

The printer in figure 29 on page 119 has two standard paper sources: the 100-sheet tray (tray 1) and

the 500-sheet tray (tray 2). Up to two additional optional paper trays can be included.

Both the size of the paper in the tray and the presence of a tray are detected by the three switches

(SW600, 601, 602) on the paper size detection circuit assembly.

All of the rollers on the paper path are driven by the main motor (M101). While the main motor

rotates, the tray pickup solenoid is turned on, the tray pickup roller rotates, and a sheet of print media

is fed into the printer. Then, the sheet passes the registration assembly, which compensates for the

skew of the sheet.

After the top of page sensor (PS103) detects the leading edge of the sheet, the vertical

synchronization signal (/TOP) is sent from the engine controller board to the formatter.

After the formatter receives the /TOP signal, the /VDO signal is sent; this synchronizes the leading

edge of the image on the drum with the leading edge of the sheet. The sheet of print media goes

through transfer, separation, and fusing stages; passes through the delivery unit; and is delivered to

the top output bin or rear output bin.

There are five photosensors (PS102, PS103, PS106, PS107, PS108) in the paper path that detect

the presence of media. If a sheet does not reach or pass these sensors within a prescribed time

interval, the microprocessor on the engine controller board detects a jam.

118 Theory of operation EN

Figure 28. Paper feed subsystem

EN Chapter 5 Theory of operation 119

Figure 29. Paper path

120 Theory of operation EN

Clutches and sensors

See chapter 7 for locations of switches, sensors, and clutches.

Printing from tray 1

The presence of paper in tray 1 is detected by the tray 1 paper sensor (PS105).

When the engine controller board receives the /PRNT signal from the formatter, the printer starts the

initial rotation phase. (This consists of main motor warm-up, scanner motor warm-up, high-voltage

control sequence and fuser warm-up.) When the initial rotation phase ends, the tray 1 pickup

solenoid (SL102) is activated.

The cam rotates, the paper tray lifter rises, and the media comes in contact with the tray 1 pickup

roller. At the same time, the tray 1 pickup roller rotates twice and a sheet of media in tray 1 is picked

up. The lifter plate prevents unnecessary sheets from feeding with the first sheet.

The sheet then reaches the registration assembly, where its skew is corrected. Then it goes through

transfer, separation, and fusing stages; passes through the delivery unit; and is delivered to the

output bin.

Note If paper is removed from tray 1 just before it is picked, the tray 1 pickup roller might continue to rotate

up to six times and a jam will be detected.

Figure 30. Tray 1 pickup timing

EN Chapter 5 Theory of operation 121

Figure 31. Tray 1 pickup

1Tray 1 pickup roller

2Tray 1 pickup solenoid

3Cam

4Lifter arm

5Lifter plate

122 Theory of operation EN

Printing from tray 2

When the formatter sends the /PRNT signal to the printer, the main motor (M101) and scanner motor

start rotation. When the main motor reaches its prescribed speed, the feed roller clutch (CL101) and

tray 2 pickup solenoid (SL101) are activated. (The tray 2 pickup roller, tray 2 feed roller, tray 2

separation roller, and paper feed rollers are driven by the main motor rotation.)

The tray 2 pickup roller, activated by the pickup solenoid, rotates once and picks up the media in the

tray. The unnecessary sheets are removed by the separation roller and the media is fed to the pre-

feed sensor (PS102).

The sheet then reaches the registration assembly, where its skew is corrected. Then it goes through

transfer, separation, and fusing stages; passes through the delivery unit; and is delivered to the

output bin.

Note If paper is removed from tray 1 just before it is picked, the tray 1 pickup roller might continue to rotate

up to six times and a jam will be detected.

Figure 32. Tray 2 pickup timing

EN Chapter 5 Theory of operation 123

Figure 33. Skew correction at registration assembly

124 Theory of operation EN

Multiple-feed prevention mechanism

The printer uses the separation roller in tray 2 to prevent multiple-feeding. Normally, the separation

roller rotates in the same direction as the feed roller. The separation roller is equipped with a torque

limiter, but because the force of the feed roller exceeds that of the torque limiter, the separation roller

is actually driven by the feed roller.

If multiple sheets of media are picked up, however, the low friction force between the sheets weakens

the rotational force from the feed roller to the separation roller. Consequently, the torque limiter takes

control of the separation roller, and rotates the separation roller in the reverse direction, which

removes the extra sheets.

Figure 34. Multiple-feed prevention mechanism

Printing from the optional 500-sheet tray

Note The HP LaserJet 4100 series printers support up to two optional 500-sheet feeders.

The operation sequences of the paper feeder are controlled by the paper-feeder driver. A 4-bit

microprocessor is used in the paper-feeder driver, which controls the paper feeder sequences and

the communication with the engine controller board. The engine controller board sends the pickup

command to the paper-feeder driver with the necessary timing.

The paper-feeder driver drives the solenoid in response to the pickup command. The paper-feeder

driver also returns the status of the paper feeder to the engine controller board.

A charge of +24 VDC is supplied to the paper feeder from the printer, and +3.3 V for the integrated

circuits is generated from +24 VDC inside the paper-feeder driver.

EN Chapter 5 Theory of operation 125

Figure 35. Paper-feeder driver I/O

Pickup and feeding

The media size and the presence of the 500-sheet tray are detected by three switches (SW1001,

1002, 1003) on the paper-feeder driver. The relationship between the switch combinations and the

paper sizes is the same as for the printer.

The paper feeder is driven by the main motor (M101) of the printer. When a print command is sent to

the paper feeder from the formatter, the main motor of the printer starts rotation. When the main

motor reaches its prescribed speed, the paper-feeder driver receives the pickup command from the

engine controller board, and the paper-feeder pickup solenoid (SL1001) is activated. (The pickup

roller, feed roller, and separation roller are driven by the main motor’s rotation.)

The pickup roller, activated by the solenoid, rotates once, picking up the media inside the 500-sheet

tray. Any unnecessary sheets are removed by the separation roller and the media is fed to the

prefeed sensor (PS102) of the printer.

The sheet then reaches the registration assembly, where its skew is corrected. Then it goes through

transfer, separation, and fusing stages; passes through the delivery unit; and is delivered to the

output bin. (For more information, see the graphic on page 252 in chapter 7.)

126 Theory of operation EN

Figure 36. Paper feed pickup

EN Chapter 5 Theory of operation 127

Envelope feeder

The operation sequences of the envelope feeder are controlled by the envelope-feeder driver. A 4-bit

microprocessor is used in the envelope feeder driver, which controls the envelope-feeder sequence

and the communication with the engine controller board of the printer.

The engine controller board sends the pickup command to the envelope-feeder driver with the

necessary timing. The envelope-feeder driver activates the solenoid in response to the command.

The envelope feeder driver also sends the envelope-feeder status to the engine controller board.

A charge of +24 VDC is supplied to the envelope feeder from the printer, and +3.3 V for the ICs is

generated from the +24 VDC inside the envelope-feeder driver.

Pickup and feeding

In the envelope feeder, the envelope sensor (PS901) detects the presence of envelopes and the

envelope-size sensor (PS903) detects if the envelope size is wide or narrow. All of the rollers in the

envelope feeder are driven by the envelope pickup motor (M901).

When a print command is sent to the printer from the formatter, the printer starts the main motor

(M101). When the initial rotation phase is completed, the scanner motor starts rotating. As the

scanner motor rotates, the envelope pick-up motor starts rotating to drive the pickup roller, feed roller,

and separation roller, and an envelope is picked up.

Then, any unnecessary envelopes are stopped by the separation roller, and the envelope is fed to

the printer. The envelope then reaches the registration assembly, where its skew is corrected. Then it

goes through transfer, separation, and fusing stages; passes through the delivery unit; and is

delivered to the output bin. See figure 104 on page 252.

Duplexer

The operation sequences of the duplexer are controlled by the duplexer driver. A 4-bit

microprocessor is used in the duplexer driver, which controls the duplexer sequence and the

communication with the engine controller board.

The duplexer driver drives the solenoid, motors, and fan according to commands sent from the

engine controller board to the duplexer and duplex pickup command via serial communication. The

duplexer also returns its status to the engine controller board.

A charge of +24 VDC is supplied to the duplexer from the printer, and +5 V for the ICs is generated

from the +24 VDC inside the duplexer driver.

Reversing and duplexer pickup

The duplexer has two stepping motors, the reversing motor (M701) and the duplex feed motor

(M702). Normal and reverse rotations are controlled by the duplexer driver.

Print media is fed to the duplexer from the face-up output tray divertor, which is controlled by the

duplexer solenoid.

Note If the face-up tray is open, the duplexer cannot be used.

When the trailing edge of the media passes the reverse sensor (PS703), the reversing motor

changes direction. The media is then transported by the oblique roller and feed roller so that its edge

makes contact with the left panel to correct its skew.

128 Theory of operation EN

Figure 37. Paper path for the duplexer

Jams

The following paper sensors are installed to detect whether or not the print media is present and

whether or not it is fed normally.

!Tray 2 paper sensor (PS101)

!Prefeed sensor (PS102)

!Top-of-page sensor (PS103)

!Face-down tray paper-full sensor (PS104)

!Tray 1 (multi-purpose tray) paper sensor (PS105)

!Paper width sensor (PS106)

!Fuser delivery sensor 1 (PS108)

!Fuser delivery sensor 2 (PS107)

The microprocessor (CPU) on the engine controller board detects a jam by checking for media

presence in the sensor unit at the check timing stored in the memory.

If the CPU detects that a jam has occurred, it stops print operation and signals the formatter.

EN Chapter 5 Theory of operation 129

Other controls

Environmental detection

This printer is capable of detecting the ambient environment using the environment temperature

sensor (TH3). The sensor, installed on the left side of the printer, measures the air temperature.

The CPU detects the air temperature with the voltage of ENVTMP signal and recognizes the ambient

environment as one of the following three conditions:

!Low temperature: air temperature is 17° C (63° F) or lower

!Normal temperature: air temperature is 17° to 31° C

(63° to 88° F)

!High temperature: air temperature is 31° C (88° F) or higher

This printer switches the temperature control for the fuser according to the ambient environment.

When the voltage of the ENVTMP signal becomes abnormally low-temperature (TH3 short) or

abnormally high-temperature (TH3 open), the CPU detects an environment temperature sensor

failure.

130 Theory of operation EN

Basic sequence of operation

The operation sequences of this printer are controlled by the microprocessor on the engine controller

board. The purposes of periods from power on until the main motor stops after the completion of

printing are described below.

Table 33. Printer timing

Period Timing Purpose

WAIT From power on until the main

motor completes the initial

rotation.

Clears the drum surface potential

and cleans the transfer roller.

During this period, the printer

checks the toner level and the

presence of the cartridge.

STBY

(standby) From the end of the WAIT or

the LSTR period until the input

of the PRNT signal from the

formatter. Or from the end of

the LSTR period until power

off.

Maintains the printer in ready state.

INTR

(initial rotation) From the input of the PRNT

signal from the formatter until

the engine controller sends

the TOP signal.

Stabilizes the photosensitive drum

sensitivity in preparation for printing.

Also cleans the transfer roller.

PRNT

(print) After the end of initial rotation

until the top of the page

sensor detects the trailing

edge of the print media.

Forms images on the photosensitive

drum based on the video signals

from the formatter and transfers the

image to the print media.

During this period, the printer

checks the toner level.

LSTR

(last rotation) After the primary voltage (DC)

turns off until the main motor

stops.

If another PRNT signal is sent

from the formatter, the printer

returns to the INTR period. If

not, it returns to the STBY

period.

Delivers the last sheet of print media

and cleans the transfer roller.

EN Chapter 5 Theory of operation 131

Figure 38. Timing diagram

132 Theory of operation EN

EN Chapter 6 Removing and replacing parts 133

6Removing and replacing parts

Chapter contents

Removal and replacement strategy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Other helpful tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Removing covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Rear right side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Top cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Left side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Front right side cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Rear cover/rear output bin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Removing internal assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Firmware DIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Formatter assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Output delivery assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Laser/scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Cartridge memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Main motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Transfer roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Tray 1 pickup roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Tray 1 pickup assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Right side toner cartridge guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Registration assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Paper feed assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Printer drive assembly (gear train). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Delivery drive assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Separating the engine module from the paper-feed module. . . . . . . . . . . . . . . . . . . . . . . . . . 171

Engine controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Paper-feed guide assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

134 Removing and replacing parts EN

Removing tray assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177

Paper-feed rollers for trays 2, 3, and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177

Separation rollers for trays 2, 3, and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178

Tray 2 paper-feed module disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179

Tray 3 and 4 paper-feed module disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180

EN Chapter 6 Removing and replacing parts 135

Removal and replacement strategy

This chapter describes how to remove and reassemble major assemblies.

Replacement is generally the reverse of removal. Occasionally, hints and notes are included to

provide direction for difficult or critical replacement procedures.

WARNING! Unplug the power cord from the power outlet before attempting to service the printer. If this warning

is not followed, severe injury can result.

Never operate or service the printer with the protective cover removed from the laser/scanner assembly.

The reflected beams, although invisible, can damage your eyes.

Some sheet metal edges, particularly around the formatter cage, are sharp. Be careful when working

in these areas to avoid cutting yourself.

CAUTION The printer contains parts that are sensitive to electrostatic-static discharge (ESD).

Always perform servicing at an ESD-protected workstation. The ESD symbol

appears in this chapter when the parts being serviced are especially susceptible

to ESD damage.

CAUTION If possible, print the configuration page and menu map before working on the product. Replacing the

formatter assembly clears the settings in memory. Clearing the settings can render the product

inoperable. The list of configuration settings can assist in restoring the settings.

CAUTION To install a self-tapping screw, first turn it counterclockwise to align it with the existing thread pattern,

then carefully turn clockwise to tighten. Do not overtighten. If a self-tapping screw-hole becomes

stripped, repair the screw-hole or replace the affected assembly.

Before performing service . . .

"Print a configuration page, menu map, and an event log.

"Remove all accessories.

"Remove all media from the printer.

"Turn off the printer, and then unplug all cables from the printer, beginning with the power cable.

"Place the printer on an ESD mat.

"Remove all trays.

"Remove the toner cartridge.

After completing service . . .

"Replace the toner cartridge.

"Reinstall all trays.

"Reconnect all cables to the printer.

"Load media.

"Replace all accessories.

"Make sure the latest firmware is installed on the printer.

"Restore customer configuration settings.

136 Removing and replacing parts EN

Required tools

Tools

!Phillips #2 magnetized screwdriver with 6-inch shaft

!Flat-blade screwdriver with 6-inch shaft

!Needle-nose pliers

!ESD mat

Other helpful tools

!A container (such as an ice cube tray) to hold printer screws

!Masking tape and pen to tag and identify connectors and screws

!Penlight

!Gloves (when removing or replacing the transfer roller)

Screws used in the printer

All screws used in the printer are Phillips head, which require a Phillips screwdriver. The following

figure shows the difference between a Phillips and a Posidriv screwdriver. Note that the Phillips tip

has more beveled surfaces.

CAUTION Using a Posidriv screwdriver will damage the screw heads. Use a Phillips #2 screwdriver only.

Figure 39. Comparing Phillips and Posidriv screwdrivers

Table 34 on page 137 describes the screws used in the printer and provides guidelines to help

determine where each type of screw is used. The screws can vary in length depending on the

thickness of the material being fastened.

Always note where each type of screw is located and replace each one into its original location.

CAUTION To install a self-tapping screw, first turn it counterclockwise to align it with the existing thread pattern,

then carefully turn clockwise to tighten. Do not overtighten. If a self-tapping screw-hole becomes

stripped, repair the screw-hole or replace the affected assembly.

Phillips Posidriv

EN Chapter 6 Removing and replacing parts 137

Table 34. Screws used in the printer

Drawing and description Purpose

Phillips machine screw with captive star washer

Used to fasten metal to metal

when good electrical contact is

needed

Self-tapping Phillips screw

Used to fasten metal or plastic

to plastic frames

Phillips machine screw with lock and flat washer

Used to fasten metal or plastic

to threaded plastic or metal

Long screw (116 mm/4.8 inches)

Used to anchor the tray 2 feed

module assembly to the

engine

Screw measurement guide

138 Removing and replacing parts EN

Removing covers

CAUTION Before removing covers, turn off the printer and unplug the power cord and any cables.

Hint Left and right are indicated as you face the front of the printer unless otherwise noted.

Rear right side cover

Figure 40. Removing the rear right side cover

The formatter assembly and dual inline memory modules (DIMMs) are located underneath the right

side cover.

1Grasp the cover by its rear lip and pull it firmly toward the rear of the printer until it stops.

2Remove the cover from the printer.

EN Chapter 6 Removing and replacing parts 139

Control panel

Control panel overlay

Figure 41. Removing the control panel overlay

1Using a flat-blade screwdriver, gently pry upward and outward on the right side of the control

panel overlay to loosen it.

2Remove the control panel overlay from the tabs on the left and lift it upward, off of the printer.

140 Removing and replacing parts EN

Control panel board

Figure 42. Removing the control panel board

1Remove the control panel overlay (page 139).

2Using a flat-blade screwdriver, release the claws on each side of the control panel board shown,

and then lift upward.

CAUTION To prevent damage to the control panel board, release the claws before prying upward.

3Remove the top of the control panel board from the top tab.

4Disconnect the ribbon cable from the control panel board.

Tab

EN Chapter 6 Removing and replacing parts 141

Top cover

CAUTION Do not remove the toner cartridge when the top cover interlock is overridden. Cartridge memory will

be damaged.

CAUTION To prevent damage to the toner cartridge, do not expose it to light for more than a few minutes.

1To remove the top cover:

a Open the top cover and remove the toner cartridge.

b Remove the rear right side cover (page 138).

c Remove the control panel (page 139).

Figure 43. Disconnecting the toner cartridge drive arm

2Disconnect the toner cartridge drive arm by using needle-nose pliers to pinch the pin from its

hinge on the top cover.

Hint Be sure to reconnect the toner cartridge drive arm when you replace the top cover, or the toner cartridge

will not seat properly.

142 Removing and replacing parts EN

Figure 44. Removing the top cover

3Open the rear output bin, and then remove two screws (callout 1) from the top cover, near the top

of the bin.

4Remove two more screws (callout 2) located under the top cover door.

Figure 45. Releasing tabs to lift the top cover

5Squeeze the frame below the tab to release the top cover. It might be necessary to use a small

flat-blade screwdriver to release the tab inside the small hole.

6Holding the output delivery assembly in place (located toward the rear of the printer), remove the

top cover.

EN Chapter 6 Removing and replacing parts 143

Left side cover

Figure 46. Removing the left side cover

1To remove the left side cover:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

2Open tray 1.

3Lift the left side cover upward off of the catch (callout 1), and then pull the cover away from the

printer.

144 Removing and replacing parts EN

Front right side cover

Figure 47. Removing the front right side cover

1To remove the front right side cover:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

2Open tray 1.

3Release the latch (callout 1) at the top center of the cover.

4Lift the cover straight up until it is free of the locating pins at the bottom and the power switch rod,

then pull it away from the printer.

Hint When you reinstall the front right side cover, be sure to reconnect the power switch rod.

EN Chapter 6 Removing and replacing parts 145

Rear cover/rear output bin

Figure 48. Removing the rear cover/rear output bin

1Remove the tray 2 dust cover if installed.

2Facing the rear of the printer, press the left side (formatter side) of the rear output bin and

release the hinge from the slot.

3Rotate the bin upward and slide it to the left to release the right hinge.

Hint Before reinstalling the dust cover, ensure the claws at the top of the dust cover are not damaged, and

then snap the claws into place.

146 Removing and replacing parts EN

Tray 1

Figure 49. Removing tray 1 from the front cover

1Open tray 1.

2Push outward on the two slot hinges (callout 1) to release the pins on tray 1.

3Slide the front cover to the right and remove it from the three hinges on the bottom.

Figure 50. Removing the tray 1 sensor arm cover

4Firmly pull both sides of the tray 1 sensor arm cover toward you until it releases from the shaft.

EN Chapter 6 Removing and replacing parts 147

Figure 51. Detail of the tray 1 sensor arm cover

Hint When you reinstall the tray 1 sensor arm cover, be sure the sensor arms move freely.

5Rotate tray 1 upward and release the hinge spring from the bottom of tray 1 located on the right

tray 1 hinge pin. Note the position of the hinge spring before proceeding.

Figure 52. Detail of hinge spring

148 Removing and replacing parts EN

6Rotate tray 1 downward completely and remove the tray from the left hinge.

7Slide tray 1 to the left to remove the tray from the right hinge.

Hint Tape the hinge spring to tray 1.

Hint When you reinstall the hinge spring, place the long side of the spring in the slot underneath tray 1, and

hook the short end of the spring in the small notch located directly below the pivot point.

EN Chapter 6 Removing and replacing parts 149

Removing internal assemblies

Fuser

WARNING! Let the fuser assembly cool before removal.

1If a duplexer is installed, remove it. If a duplexer is not installed, remove the tray 2 dust cover from

the rear of the printer by pulling from the bottom.

2Remove the rear cover/rear output bin (page 145).

Figure 53. Unlocking the fuser assembly

3Rotate the two blue levers on the fuser assembly up to the unlocked position.

4Pull the fuser assembly straight out of the printer.

CAUTION To prevent damage to the fuser assembly, do not grasp the fuser by the black plastic diverter.

Hint When reinstalling the fuser assembly, be sure the blue levers are initially in the unlocked position. Make

sure the fuser assembly is seated fully before rotating the blue levers down into the locked position.

150 Removing and replacing parts EN

Firmware DIMM

CAUTION Static electricity can damage dual inline memory modules (DIMMs). When handling DIMMs, either

wear an antistatic wrist strap or frequently touch the surface of the DIMM’s antistatic package, and

then touch bare metal on the printer.

1Print a configuration page, a menu map, and an event log. The information is necessary to

reconfigure the printer after you replace the firmware DIMM.

2Turn off the printer.

3Unplug the power cord and disconnect any other cables.

4Remove the rear right side cover (page 138). The formatter assembly is directly underneath.

5Open the formatter access door by pulling on the large metal tab (see figure 55 on page 151).

6Remove any installed accessories, EIO devices, memory DIMMs, or flash DIMMs.

Note Remove the old firmware DIMM installed in the lowest DIMM slot.

7Remove the new firmware DIMM from the antistatic bag and install the DIMM in the lowest DIMM

slot.

Figure 54. Installing a firmware DIMM

8Close the formatter access door.

9Plug the power cord into the printer.

10 Wait until READY appears.

11 Turn off the printer.

12 Reinstall all accessories, EIO devices, memory DIMMs, or flash DIMMs.

13 Turn on the printer.

14 Print a new configuration page and menu map, and compare the settings with the information

pages printed in step 1. Verify the installed options and menu settings are consistent.

EN Chapter 6 Removing and replacing parts 151

Formatter assembly

Figure 55. Removing the formatter assembly

1Print a configuration page and menu map. The information is necessary to reconfigure the

printer after you replace the formatter.

2Remove the rear right side cover (page 138). The formatter assembly is directly underneath.

3Pull outward on the large metal tab (callout 1) to open the DIMM access door. Remove and

transfer any DIMMs or EIO accessories to the new formatter assembly.

4Remove the two screws (callout 2) to the left of the formatter assembly.

5Slide the formatter assembly toward the rear of the printer and remove it.

Hint If a new formatter assembly is installed, perform a NVRAM initilization (see page 79).

Note Using the configuration page and menu map you printed in step 1 above, reconfigure the printer after

replacing the formatter assembly and initializing NVRAM. Be sure to reset the printer’s page count,

serial number, maintenance count, all configuration page features, and all control panel settings.

Hint When reinstalling the formatter assembly, ensure it is seated over the two stepped screws located

behind the formatter assembly.

152 Removing and replacing parts EN

Output delivery assembly

Figure 56. Removing the output delivery assembly

1To remove the output delivery assembly:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

Figure 57. Left end of output delivery assembly (brass arm)

2Facing the rear of the printer, rotate the brass arm up 90° located on the gear-end of the output

delivery assembly.

White

Brass

EN Chapter 6 Removing and replacing parts 153

Figure 58. Right end of output delivery assembly (white tab)

3Facing the rear of the printer, carefully release the white tab located on the right end of the output

delivery assembly.

CAUTION The white tab is fragile. Use minimum deflection when releasing the tab.

4Lift the assembly up and out of the printer.

CAUTION Lift the assembly carefully to avoid damaging the top output-bin-full sensor flag.

Hint When the assembly is replaced, the flag must be able to rotate freely.

154 Removing and replacing parts EN

Laser/scanner

Figure 59. Removing the laser/scanner

1To remove the laser/scanner:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

The laser/scanner is on top of the printer, tilted toward the rear.

2Unplug the three connectors (callout 1) as shown.

3Remove the screw to disconnect the grounding cable (callout 2).

4Remove the four recessed screws around the edges of the laser/scanner. Do not remove the

three small screws on the cover of the laser/scanner.

CAUTION Do not loosen the Allen screw on the rear of the scanner assembly.

5Lift the laser/scanner straight up.

Hint When you replace the laser/scanner, be sure the black shutter interlock arm (callout 3) is resting on

top of the metal shutter plate.

EN Chapter 6 Removing and replacing parts 155

Cartridge memory

Cartridge memory controller

1To remove the cartridge memory controller PCA:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

d Remove the laser/scanner assembly (page 154).

CAUTION Do not loosen the Allen screw on the rear of the laser/scanner assembly.

2Disconnect the two wires from the cartridge memory controller PCA.

3Remove the two self-tapping screws from the cartridge memory controller PCA.

Cartridge memory antenna

1To remove the cartridge memory antenna:

a Remove the toner cartridge.

b Remove the rear right side cover (page 138).

c Remove the control panel (page 139).

d Remove the top cover (page 141).

e Remove the laser/scanner assembly (page 154).

CAUTION Do not loosen the Allen screw on the rear of the laser/scanner assembly.

2Disengage the antenna clips from the printer frame (located under the scanner near the memory

controller PCA).

3Disconnect the wire from the cartridge memory antenna.

4Rotate the antenna (located inside the printer above the paper guide assembly) down to remove

it from the metal bracket.

156 Removing and replacing parts EN

Fan

Figure 60. Removing the fan

1To remove the fan:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

d Remove the left side cover (page 143).

2Unplug the fan’s connector (callout 1) to the engine controller board on the left side of the printer.

EN Chapter 6 Removing and replacing parts 157

Figure 61. Detail of the plastic fan clip

3Using a flat-blade screwdriver, press the retaining claw behind the left edge of plastic fan clip,

and then remove the clip from the fan.

4Slide the fan toward the rear of the printer and remove it.

Hint When replacing the fan, be sure the airflow arrow on the fan points inward.

158 Removing and replacing parts EN

Main motor

Figure 62. Removing the main motor

1To remove the main motor:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

d Remove the front right side cover (page 144).

2While holding the main motor board, unplug the main motor connector (callout 1) on the right

front side of the printer.

3Remove the three screws around the corners of the metal plate.

4Remove the main motor from the printer.

EN Chapter 6 Removing and replacing parts 159

Transfer roller

Figure 63. Removing the transfer roller

CAUTION Do not remove the toner cartridge when the top cover interlock is overridden. Cartridge memory will

be damaged.

CAUTION To prevent damage to the toner cartridge, do not expose it to light for more than a few minutes.

1Open the top cover and remove the toner cartridge. The transfer roller is underneath the toner

cartridge.

CAUTION Do not touch the black rubber part of the roller. Skin oils on the roller can cause problems with print

quality. Use of gloves is recommended.

2Using a flat-blade screwdriver, lift the left end of the metal shaft out of place near the blue gear.

Slide the transfer roller to the left to remove.

Hint When you install the transfer roller, make sure the black collar on the left side is oriented properly, with

the open end down.

160 Removing and replacing parts EN

Tray 1 pickup roller

Figure 64. Removing the pickup roller (shown with envelope entrance cover removed)

1Open tray 1. The tray 1 pickup roller is in the center of the tray 1 pickup assembly.

2Grasp the envelope entrance cover directly above the pickup roller and pull it straight away from

the printer.

3Use a flat-blade screwdriver to pry open the blue latch on the roller.

4Lift the roller out.

Hint To replace the roller, make sure the pin in the roller lines up with the hole in the shaft. Then, ensure

the blue latch snaps securely in place.

Figure 65. Installation of tray 1 pickup roller

EN Chapter 6 Removing and replacing parts 161

Tray 1 pickup assembly

1To remove the tray 1 pickup assembly:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

d Remove the left side cover (page 143).

e Remove the front right side cover (page 144).

f Remove tray 1 (page 146).

Figure 66. Removing the gear cover

2Remove the gear cover as follows:

a. Remove the self-tapping screw (callout 1) at the bottom of the gear cover.

b. Remove the long screw (116 mm/4.8 inches) on the right side of the tray 1 pickup assembly

(callout 2).

c. Remove the gear cover by pressing down on the claw.

162 Removing and replacing parts EN

Figure 67. Removing the tray 1 pickup assembly—right side

3Disconnect the three-pin solenoid connector (callout 1) on the right side of the tray 1 pickup

assembly and unroute the cable from the cable guide. (Note the way the cables are routed for

replacement.)

Note The solenoid connector is a three-part connector. Do not lose the gender-changer (center piece).

Figure 68. Removing the tray 1 pickup assembly—left side

4Unplug the connector (callout 1) to the engine controller board on the left side of the tray 1 pickup

assembly. (Note the way the cables are routed for replacement.)

5Remove the long screw (116 mm/4.8 inches) from the left side of the assembly.

EN Chapter 6 Removing and replacing parts 163

Figure 69. Removing the tray 1 pickup assembly—front side

6Remove the four screws (callout 1) shown, and carefully pull the tray 1 pickup assembly straight

out.

CAUTION Do not damage the solenoid cable on the right side of the tray 1 pickup assembly.

Note The left side toner cartridge might become dislodged while removing the tray 1 pickup assembly. Ensure

the left side toner cartridge guide is installed before reinstalling the four screws that secure the tray 1

pickup assembly.

164 Removing and replacing parts EN

Right side toner cartridge guide

Remove the right side toner cartridge guide to get to the printer drive assembly. Follow the steps

below:

1To remove the tray 1 pickup assembly:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

d Remove the front right side cover (page 144).

e Remove tray 1 (page 146).

f Remove the tray 1 pickup assembly (page 161).

Figure 70. Removing the right side toner cartridge guide

2Remove the small silver screw (callout 1) to disconnect the ground wire.

3Remove the self-tapping screw (callout 2) on the right front side of the printer.

4Lift the right side toner cartridge guide off the printer.

5Unplug the three connectors (callout 3).

EN Chapter 6 Removing and replacing parts 165

Registration assembly

Figure 71. Removing the registration assembly

1To remove the registration assembly:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

d Remove the left side cover (page 143).

e Remove the front right side cover (page 144).

f Remove tray 1 (page 146).

g Remove the tray 1 pickup assembly (page 161).

h Lift aside the right side toner cartridge guide (page 164). It is not necessary to unplug the

connectors.

2Remove the three self-tapping screws (callout 1) shown. (Lift the green handle on the right end of

the registration assembly to get to the screw on the left rear side.)

166 Removing and replacing parts EN

Figure 72. Detail of screws for the registration assembly

CAUTION Do not remove the silver, hex-headed screw (callout 1) closest to the registration assembly! It holds

the spring in place. Take out the silver screw farther from the registration assembly (the one that is

under the green handle).

3Lift the green handle. Remove the two self-tapping screws and the rearmost silver screw shown.

See the caution above.

4Lift the registration assembly from the printer.

EN Chapter 6 Removing and replacing parts 167

Paper feed assembly

1To remove the paper feed assembly:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

d Remove the left side cover (page 143).

e Remove the front right side cover (page 144).

f Remove tray 1 (page 146).

g Remove the tray 1 pickup assembly (page 161).

The paper feed assembly is on the front of the printer.

Figure 73. Unplugging the connector to the paper feed assembly

2Unplug and unroute the two-pin connector (callout 1) from the right side.

CAUTION For replacement of the paper feed assembly, note the way the wires are routed to the connector. If a

wire is routed improperly, it can be damaged.

Note wire routing

168 Removing and replacing parts EN

Figure 74. Removing the upper screws from the paper feed assembly

3Remove the two upper screws (callout 1), and then remove the paper feed assembly.

Hint After replacing the paper feed assembly, make sure to insert the two upper screws only. The two lower

screws are for holding the tray 1 pickup assembly in place. Ensure the lower sheet-metal guide hangs

down loosely.

Hint For replacement of the paper feed assembly, orient the clutch properly by inserting the tab into the

slot, as shown.

Figure 75. Detail of clutch orientation

EN Chapter 6 Removing and replacing parts 169

Printer drive assembly (gear train)

Figure 76. Removing the printer drive assembly

1To remove the printer drive assembly:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

d Remove the left side cover (page 143).

e Remove the front right side cover (page 144).

f Remove the rear cover/rear output bin (page 145).

g Remove the fuser assembly (page 149).

h Remove tray 1 (page 146).

i Remove the tray 1 pickup assembly (page 161).

j Remove the right side toner cartridge guide (page 164).

k Remove the registration assembly (page 165).

l Remove the formatter assembly (page 151).

2Remove the seven self-tapping screws and one machine screw.

3Pull the ribbon cable assembly upward to release it from the two tabs at the bottom. Then, pull

outward to release it from the retaining claw and pin (callout 1).

4Unplug the main motor, and remove all remaining wires from the white plastic cable guide.

Note It might be necessary to separate the engine module from the paper-feed module (see page 171).

5Slide out the printer drive assembly.

Note When you reinstall the printer drive assembly, slide the top in first and then push the bottom in.

170 Removing and replacing parts EN

Delivery drive assembly

Figure 77. Removing the delivery drive assembly

1To remove the delivery drive assembly:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

d Remove the rear cover/rear output bin (page 145).

e Remove the fuser assembly (page 149).

f Remove the output delivery assembly (page 152)

g Remove the formatter assembly (page 151).

2Remove the two screws (callout 1).

3Unplug the three-pin connector (callout 2) shown.

4Lift the delivery drive assembly upward, away from the printer.

EN Chapter 6 Removing and replacing parts 171

Separating the engine module from the paper-feed module

1To separate the engine module from the paper-feed module:

a Remove the tray 2 dust cover or the duplexer (if installed).

a Remove the rear right side cover (page 138).

b Remove the formatter assembly (page 151).

c Remove the two long screws from the tray 1 pickup assembly (page 161 and 162).

Figure 78. Unplugging the connector to the paper-feed module

2Unplug the connector (callout 1) to the paper-feed module on the right rear side of the printer

(under the formatter assembly). Remove the cable from its brackets.

3Remove the two screws (callout 2), or one screw, if the printer drive assembly has been

removed.

172 Removing and replacing parts EN

Figure 79. Separating the engine from the paper-feed module

4Remove the single, self-tapping screw (callout 1) from the left side of the printer, below the fan.

CAUTION Lift the engine carefully, being sure that all cables are disconnected.

5Lift the engine away from the paper-feed module.

EN Chapter 6 Removing and replacing parts 173

Engine controller board

Note After you replace the engine controller board, readjust the top margin as described on page 175.

1Remove the fuser assembly (page 149).

2Separate the engine from the paper-feed module (page 171). The engine controller board is on

the underside of the engine.

Figure 80. Removing the engine controller board

3Remove the seven screws shown.

•Four self-tapping M4 screws (three in front and one in the right rear)

•From the left rear, three M3 screws (two recessed)

4Disconnect the power switch rod.

174 Removing and replacing parts EN

Figure 81. Removing the engine controller board

5Disconnect the three connectors on the fan side.

6Lifting from the fan side, tip the board up.

Hint Use masking tape and a pen to identify all cables, if necessary.

7Unplug all connectors from the engine controller board.

Hint The black cable holder in the middle of the engine controller board can be folded aside with the cables

intact. When you replace the board, reconnect and route all cables before reconnecting the power

switch rod.

EN Chapter 6 Removing and replacing parts 175

Adjusting the top margin

When you replace the engine controller board, you must readjust the top margin as follows:

Figure 82. Location of VR501

1After setting the VR501 on the engine controller board to the center position (0), load letter or A4

paper in tray 2, 3, or 4. Press the engine test print button (located on the left side of the printer,

below the vent) to make several test prints.

Figure 83. Adjusting the top margin

2Measure the distance between the leading edge of the paper and the print pattern. Measure all

the test prints and calculate the average.

3Adjust VR501 so that the margin becomes 2 mm (.08 inch). Turn VR501 clockwise to increase

the margin or counter-clockwise to decrease the margin.

4Make several test prints again and perform step 2 above. If the top margin is still incorrect, repeat

the procedure.

Measure this distance

176 Removing and replacing parts EN

Paper-feed guide assembly

1To remove the paper-feed guide assembly:

a Remove the rear right side cover (page 138).

b Remove the control panel (page 139).

c Remove the top cover (page 141).

d Remove the left side cover (page 143).

e Remove the front right side cover (page 144).

f Remove the rear cover/rear output bin (page 145).

g Remove the fuser assembly (page 149).

h Remove tray 1 (page 146).

i Remove the tray 1 pickup assembly (page 161).

j Remove the right side toner cartridge guide (page 164).

k Remove the registration assembly (page 165).

l Remove the formatter assembly (page 151).

m Remove the printer drive assembly (page 169).

n Separate the engine module from the paper-feed module (page 171).

o Remove the engine controller board (page 173).

2Remove the plastic main gear cable guide by releasing the three tabs.

3Loosen the plastic formatter ribbon cable guide.

4Disconnect the paper-sensor cable.

5Remove the two self-tapping screws.

6Carefully remove the paper-feed guide assembly.

Note The engine controller board grounding spring might interfere with removal.

EN Chapter 6 Removing and replacing parts 177

Removing tray assemblies

Paper-feed rollers for trays 2, 3, and 4

Figure 84. Removing the paper feed roller

1Remove the paper tray(s) from the paper feeder(s). The paper-feed roller is inside the feeder, on

top of the paper feeder assembly.

2Pinch the release at the left side of the roller and slide it off the shaft.

Hint When reinstalling the feed roller, ensure it locks into place. Otherwise, repeated paper jams might occur.

178 Removing and replacing parts EN

Separation rollers for trays 2, 3, and 4

Figure 85. Removing the separation roller

The separation roller is inside the paper trays.

1Release the latch and lift the access cover inside the tray.

2Pinch the release at the left side of the roller and slide it off the shaft.

CAUTION To prevent damage to the printer, ensure the access cover is securely locked into position.

Note When reinstalling the separation roller, ensure it locks into place. Otherwise, repeated paper jams

might occur.

EN Chapter 6 Removing and replacing parts 179

Tray 2 paper-feed module disassembly

Remove the paper-feeder plate to gain access to the paper pickup drive assembly. It is not necessary

to separate the engine module from the paper-feed module to gain access to the paper-size

detection PCB, although it will provide easier access.

Figure 86. Removing the tray 2 paper-feeder plate

1Separate the engine module from the paper-feed module (page 171).

2Remove the tray from the paper-feed module.

3Remove the four self-tapping screws (one screw is recessed in front).

4Lift the paper-feeder plate to remove it.

5Release the two tabs on the paper-size detection PCB cover.

6Disconnect the three cables on the paper-size detection PCB.

7Press the two tabs to release the paper-size detection PCB. Note the cable routing.

8Slide the PCB from the paper-feeder frame.

9Remove the two machine screws from the paper pickup drive assembly.

180 Removing and replacing parts EN

Tray 3 and 4 paper-feed module disassembly

Remove the paper-feeder plate to gain access to the paper pickup drive assembly. It is not necessary

to remove the paper-feeder plate to access the feeder controller PCA, although it will provide easier

access.

Figure 87. Removing the paper-feeder plate

1Lift the printer from the optional feeder.

2Remove the tray from the paper feeder.

3Remove the four self-tapping screws from the side rails as shown, and then lift the side rails from

the paper feeder.

4Remove the six self-tapping screws around the paper-feeder plate (two on the left and four on

the right).

5Remove the two machine screws and one self-tapping screw from the paper-feeder plate and the

paper pickup assembly.

6Carefully lift the paper-feeder plate from the paper-feeder frame and the paper pickup assembly.

7Use a flat-blade screwdriver to release the two tabs on the feeder controller PCA cover.

8Disconnect the four connectors from the PCA. Note the cable routing.

9Remove the single self-tapping screw from the PCA.

10 Slide the PCA from the paper-feeder frame.

Note The clutch release lever (located near the tray number) might dislodge if not careful. figure 89 and

figure 90 show detail of the lever location for reassembly.

11 Remove the paper pickup assembly.

12 Ensure the clutch release (figure 88) functions properly after the paper-feeder plate is reinstalled.

EN Chapter 6 Removing and replacing parts 181

Figure 88. Detail of clutch release

Hint Pull the clutch release (callout 1) towards the front of the tray. Hold the clutch in place as you reinstall

the paper-feeder plate.

Figure 89. Detail of spring and lever

Note If the spring and lever dislodge when removing the paper-feeder plate, use needle-nose pliers to

reattach the spring before replacing the lever.

182 Removing and replacing parts EN

Figure 90. Location of spring and lever (the paper feeder is inverted)

EN Chapter 7 Troubleshooting 183

7Troubleshooting

Chapter contents

Troubleshooting process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Troubleshooting flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Troubleshooting the printing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Preliminary operating checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Power on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Engine test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Printer messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

General paper-path troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Information pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Image quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Image system troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Reference diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Engine controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

Paper-size detection switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Motors and fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

PCAs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Sensors, switches, and thermistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Solenoids and clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

184 Troubleshooting EN

Troubleshooting process

The troubleshooting process is a systematic approach that addresses the major problems first, and

then other problems, as you identify the causes for printer malfunctions and errors. The

troubleshooting flowchart on page 185 illustrates the major steps for troubleshooting the printing

system. Each heading depicts a major troubleshooting step.

The following list describes the basic questions for the customer and the corresponding

troubleshooting step to help you quickly define the problem(s).

Table 35. Major steps for troubleshooting

"Power on"

(page 188) Does the printer power up and display a message?

This section gives the procedures for correcting power

supply problems.

"Display"

(page 191) Does the control panel indicate READY

, OFFLINE, or

POWERSAVE ON?

This section gives the procedures for clearing control panel

error messages.

"Event log"

(page 191) Are there recurring problems in the event log?

This section gives information about printing the event log

and evaluating the error history.

"Printer messages"

(page 193) Does the printer control panel display an error message?

This section provides an alphabetical and numerical listing

of the printer control panel messages, and gives the

recommended actions to resolve the problem.

"General paper-path

troubleshooting"

(page 220)

Is there a jam in the printer?

This section gives information about solving problems in

the paper path.

"Information pages"

(page 222) Will the printer print information pages successfully?

This section gives the procedures for printing the

information pages and evaluating and correcting the

printer’s configuration.

"Image quality"

(page 227) Does the print quality meet the customer’s expectations?

This section gives toner cartridge checks, information about

EconoMode, image defect examples, and the repetitive

defect ruler.

EN Chapter 7 Troubleshooting 185

Troubleshooting flowchart

A “yes” answer to the questions below allows you to proceed to the next major step.

A “no” answer indicates that additional testing is needed. Proceed to the referenced location and

follow the directions for that area. After completing the additional testing, proceed to the next major

step.

Figure 91. Troubleshooting flowchart (1 of 2)

186 Troubleshooting EN

Troubleshooting flowchart (continued)

Figure 92. Troubleshooting flowchart, continued

EN Chapter 7 Troubleshooting 187

Troubleshooting the printing system

Preliminary operating checks

Before troubleshooting a specific printer problem, you should ensure that:

!The printer is being maintained on a regular basis as described in chapter 4.

!The customer is using acceptable print media as specified in the HP LaserJet Printer Family

Print Media Guide.

!The printer is positioned on a solid, level surface.

!The line voltage does not vary more than 10 percent from the nominal rated value as specified

on the power rating label.

!The operating environment for the printer and paper is within the temperature and humidity

specifications listed in chapter 1 of this manual.

!The printer is never exposed to ammonia fumes such as those produced by diazo copiers or

office cleaning materials.

!The printer is not exposed to direct sunlight.

!Non-HP components (such as refilled toner cartridges, EIO accessories, and DIMMS) are

removed from the printer.

Note When moving the printer into a warm room from a cold location such as a warehouse, various problems

can occur as a result of condensation in the printer. Additionally, if the photosensitive drum is cold, the

resistance of the photoconductive layer will be high. This will lead to incorrect contrast. Leave the

printer running for 10 to 20 minutes before its first job.

188 Troubleshooting EN

Power on

Note It is important to have the printer control panel functional as soon as possible in the troubleshooting

process so that the printer’s diagnostics can assist in locating printing errors.

Table 36. Power on defect or blank display

Problem Action

The power cord is not

plugged into the wall

outlet and the printer.

Make sure the power cord is firmly plugged into the printer

and the outlet.

Proper AC power is not

available. Measure the voltage at the outlet. If necessary, plug the

power cord into another AC circuit outlet.

The power switch is off. Set the switch to the on position. You should hear the

switch toggle. If the front right side cover has been

removed recently, be sure that the rod leading to the power

supply moves as the rocker switch is toggled.

If the printer still does not turn on, the power switch might

be defective.

1. Remove the engine controller board.

2. Measure the resistance between the two terminals of the

power switch (SW1) by applying the tester probes to the

terminals. The resistance must be low (under 1 KΩ) when

the power is turned on, and high (over 6 MΩ) when the

switch is turned off.

3. Replace the engine controller board, if necessary.

The overcurrent/

overvoltage detection

circuit is activated.

Wait for more than two minutes before turning the printer

back on.

A fuse is blown. 1. Check the fuses (FU1 and FU2) on the engine controller

board.

2. Replace the fuses if necessary.

EN Chapter 7 Troubleshooting 189

The fan does not turn on

when the printer is first

powered up.

Note

An operational fan indicates the following:

1. AC power is present in the printer.

2. DC power supply is functional (both 24 VDC and 3.5

VDC are being generated).

3. The engine controller board’s microprocessor is

functional.

If the fan is not working:

1. Turn the printer off and remove the formatter. Disconnect

the optional accessories.

2. Turn the printer on and check the fan again.

If the fan is still not working, perform the following steps:

1. Verify that the fan is connected to the engine controller

board.

2. Replace the fan.

3. Replace the engine controller board.

Note

The fan only operates during initial power on and while

printing, unless the temperature inside the printer is too

high. If the temperature is too high, the fan turns on to cool

the inside of the printer.

The fan works, but the

control panel display is

blank.

1. Print an engine test. See “Engine test” on page 190.

2. If the engine test is successful, perform the following

steps:

a. Reseat the control panel and formatter connector.

b. Replace the control panel assembly.

c. Replace the firmware DIMM.

d. Replace the cable from the control panel.

3. If the engine test is not successful, replace the engine

controller board.

Table 36. Power on defect or blank display (continued)

Problem Action

190 Troubleshooting EN

Engine test

The printer has a built-in test pattern (pairs of vertical lines). The test print can be made by pressing

the test print switch located on the left side of the printer (see figure 93 on page 190) once—after the

photosensitive drum has stopped and the printer has entered the standby mode. If the switch is held

down, the test pattern is printed continuously. The switch can be used when paper is loaded in any

tray other than tray 1.

The engine test:

!Verifies if the print engine is functioning correctly (the formatter is completely bypassed during an

engine test)

!Is used for isolating printer problems

!Is used for checking and adjusting registration

!Prints from tray 2, 3, or 4 only, not from tray 1

!Can be activated with the formatter removed

Note For the printer to perform an engine test, tray 2, 3, or 4 must be installed and loaded with paper, and

the toner cartridge must be installed in the printer.

Location of engine test button

The engine test button is located on the left side of the printer, below the fan vent, as shown figure 93

on page 190.

Figure 93. Location of the engine test button

EN Chapter 7 Troubleshooting 191

Display

The control panel should display READY

, OFFLINE, or POWERSAVE ON. If the display is blank, see page

188. If an error message is displayed, refer to the printer messages table starting on page 194 and

perform the necessary actions to correct the error condition.

Event log

Use the event log to diagnose and troubleshoot printer errors and intermittent failures. You can either

display or print the event log.

Access the event log from the control panel information menu. (Select PRINT EVENT LOG or SHOW

EVENT LOG.) The event log retains the printer’s last 20 error messages.

Figure 94. Sample event log

192 Troubleshooting EN

Print the event log

The printer’s internal event log stores the last 20 errors and can be printed at any time. To print the

event log:

1Press MENU until INFORMATION MENU appears.

2Press ITEM until PRINT EVENT LOG appears.

3Press SELECT to print the event log.

Display the event log

If the printer cannot print or move any media, follow these steps to display the event log.

1Press MENU until INFORMATION MENU appears.

2Press ITEM until SHOW EVENT LOG appears.

3Press SELECT to show the event log. The control panel will show the sequence, the error type,

and the page count at which it occurred.

4Press + to scroll through the event log.

5Write down the error messages.

6Check the event log for specific error trends in the last 10,000 printed pages.

7Ask the customer for any observed error trends. (For example, do jams tend to occur in a specific

area of the printer?)

8Record any specific error trends.

9If the control panel displays READY

, OFFLINE, or POWERSAVE ON, go to the next section. If it displays

any other message, refer to the printer messages table starting on page 194 and perform the

necessary corrective action.

Interpret the event log

The event log is the key tool in troubleshooting printer problems. Figure 94 on page 191 shows a

typical event log. The event log shows the current page count at the top left of the page with the

printer’s serial number directly to the right of the page count. The left column is the error sequence

number (the highest sequence number is the most recent error logged). The second column is the

error type. The next column is the page count at the time of the error, and the last column is the

personality (PCL or PostScript) column or the cause of the jam at the time of the error.

To interpret the event log:

!Each individual entry in the log is called an “error,” while all errors occurring at the same page

count are called an “event.” Read the recommended action for each error comprising an event to

gain a clear picture of what took place during that event.

!Use the printer messages table in this section to associate errors in the event log with the control

panel error message. Follow the recommended action listed in the table for each error or event.

EN Chapter 7 Troubleshooting 193

Printer messages

The following table explains messages that might appear on the printer control panel. Numerical and

alphabetical printer messages and their meanings are listed in the following table.

Hint If a message persists in requesting that you load a tray, or if a message indicates that a previous print

job is still in the printer memory, press GO to print or press CANCEL JOB to clear the job from the printer

memory.

Note Not all messages are described (many are self-explanatory).

Some printer messages are affected by the auto-continue and clearable warning settings from the

configuration menu in the printer control panel. If CLEARABLE WARNING=JOB is set on the control panel,

warning messages remain on the control panel until the end of the job from which they were generated.

If CLEARABLE WARNING=ON is set, warning messages appear on the control panel until GO is pressed.

If an error occurs that prevents printing and AUTO CONTINUE=ON is set, the printer goes offline for 10

seconds before it returns online. If AUTO CONTINUE=OFF is set, the message remains until GO is pressed.

194 Troubleshooting EN

Table 37. Printer messages

Control panel

message Explanation Recommended action

ACCESS DENIED

MENUS LOCKED

The control panel function

you are trying to use has

been locked by the

network administrator to

prevent unauthorized

access.

Ask the network administrator to

unlock the function.

BAD DUPLEXER

CONNECTION

The duplexer is not

correctly installed. 1. Ensure that the right-angle

power cord that shipped with the

printer is being used.

2. Turn the printer off.

3. Remove and reinstall the

duplexer.

4. Turn the printer off and back

on.

5. If the message persists, make

sure the duplexer is connected

and the connector is not

damaged.

6. Replace the duplexer.

BAD ENV FEEDER

CONNECTION

The envelope feeder is not

connected properly to the

printer.

1. Remove and reinstall the

envelope feeder.

2. Turn the printer off and back

on.

3. Replace the envelope feeder.

BAD OPT TRAY

CONNECTION

There is a problem with an

optional 500-sheet paper

tray connection with the

printer:

!The tray is not

connected properly.

!More than two optional

500-sheet paper trays

have been installed

(the printer cannot

support more than four

trays total).

!The electronics in the

paper tray are faulty.

1. Reinstall the optional tray.

2. Turn the printer off and back

on.

3. Make sure the optional tray is

connected and the connector is

not damaged.

4. Replace the optional-tray or

optional-feeder controller PCA.

CANNOT DUPLEX

CLOSE REAR BIN

The printer cannot duplex

because the rear output

bin is open.

1. Close the rear output bin.

2. If the message persists, check

sensor PS702 in the duplexer.

EN Chapter 7 Troubleshooting 195

CHECK INPUT DEVICE

alternates with

PAPER PATH OPEN

PLEASE CLOSE IT

The optional input tray

cannot feed print media to

the printer because a door

or paper guide is open.

1. Check the doors and paper

guides and close any that are

open.

2. If doors and trays are closed,

check tabs and sensor levers in

the tray for proper operation.

Replace any defective tabs or

sensors.

3. Replace the PCA controller in

the feeder.

CHECK OUTPUT DEVICE

alternates with

CLOSE OUTPUT

DELIVERY PATH

The optional output device

is not properly connected

to the printer.

1. Ensure the optional output

device is fully seated and

properly installed.

2. Check any doors on the output

device and verify they are closed.

CHECKING PAPER PATH The engine is checking for

possible jams or print

media that was not cleared

from the printer.

Wait for the printer to finish

checking (up to 30 seconds).

CLOSE TOP COVER The top cover is open and

must be closed for printing

to continue.

1. Close the top cover.

2. If the message persists, check

SW101 for proper operation.

(See page 263 for the sensor

location.) Make sure wires are

connected.

3. Replace SW101.

4. If the new switch does not

solve the error, the wiring or the

engine controller board might be

defective.

DISK DEVICE FAILURE The EIO disk had a critical

failure or fatal error. 1. Reseat the EIO disk.

2. Remove the EIO disk and

replace it with a new one.

DISK FILE OPERATION

FAILED

The requested operation

could not be performed (for

example, attempting to

download a file to a

nonexistent directory).

1. Check the file name and the

directory name.

2. Reseat the EIO disk.

3. Retry the operation.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

196 Troubleshooting EN

DISK FILE SYSTEM IS

FULL

The disk file system is full. 1. Delete all unnecessary files

from the EIO disk and then try

again. Use HP Resource

Manager to download or delete

files and fonts. (See the software

help for more information.)

2. Advise the customer to

increase the permanent storage

(use a larger EIO disk or add a

RAM DIMM).

DISK IS WRITE

PROTECTED

The EIO disk is protected,

and no new files can be

written to it.

Disable the write protection

through HP Resource Manager.

DUPLEX ERROR

CHECK DUPLEXER

There is a problem with the

duplexer. 1. Make sure the duplexer is

properly installed.

2. Make sure the right-angle

power cord is used for the printer

and the duplexer is making a

good connection.

3. Replace the duplexer PCA.

EIO DISK [x] NOT

FUNCTIONAL

The EIO disk is not

working correctly. 1. Reseat the EIO disk in slot [X].

2. Remove and replace the EIO

disk in slot [X].

EIO [x] NOT

FUNCTIONAL

The EIO disk is not

working correctly. 1. Reseat the EIO disk in slot [X].

2. Remove and replace the EIO

disk in slot [X].

EIO [x]

INITIALIZING

alternates with

DO NOT POWER OFF

The disk accessory in EIO

slot [x] is initializing. 1. Wait for the message to

disappear (up to five minutes). If

the printer EIO card is operating

correctly and communicating with

the network, this message

disappears after approximately

one minute and no action is

required.

2. If the EIO card is unable to

communicate with the network,

this message remains for five

minutes and then disappears.

The problem might be an

unseated EIO card, a bad EIO

card, a bad cable or connection

on the network, or a network

problem.

3. Contact the network

administrator.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

EN Chapter 7 Troubleshooting 197

ENV FEEDER LOAD

[TYPE] [SIZE]

A job has been sent to the

envelope feeder and the

feeder is empty, the wrong

size is loaded in the feeder,

or the type and size are set

incorrectly on the control

panel.

1. Load the requested envelope

type and size into the envelope

feeder.

2. Make sure the envelope size

and type are set correctly from

the paper-handling menu in the

printer control panel.

3. Press GO if the desired

envelope is already loaded in the

feeder.

4. Press -VALUE+ to scroll through

other available types and sizes.

5. Press SELECT to accept the

alternate type or size.

ENVELOPE FEEDER

SIZE = [xxxxx]

The printer is asking what

size envelopes have been

loaded in the envelope

feeder.

In response, you can take either

of the following actions:

1. Press SELECT to accept the

current envelope size.

2. Press -VALUE+ to change the

size and then press SELECT to

accept the new size.

If you do not press any buttons,

the message disappears in about

one minute.

Note

Changing the size here changes

the default for the envelope-

feeder size in the paper-handling

menu.

ENVELOPE FEEDER

TYPE = [xxxxx]

The printer has received a

job under the following

conditions:

!The envelope type the

job requested is not

available in the printer.

!Envelopes have been

placed in the envelope

feeder (thus triggering

the paper sensor).

You can take either of the

following actions:

1. Press SELECT to accept the

paper type and then press GO.

2. Press +VALUE- to change the

type, press SELECT to accept the

new type, and then press GO to

continue.

FLASH DEVICE

FAILURE

The flash DIMM had a

critical or fatal failure. 1. Reseat the flash DIMM and

ensure it is locked into place.

2. Remove the flash DIMM and

replace it with a new one.

FLASH FILE

OPERATION FAILED

The requested operation

could not be performed (for

example, attempting to

download a file to a

nonexistent directory).

1. Check the file name and the

directory name.

2. Reseat the flash DIMM.

3. Retry the operation.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

198 Troubleshooting EN

FLASH FILE SYSTEM

IS FULL

The flash file system is full. Delete unnecessary files from the

flash DIMM and try again.

Use HP Resource Manager to

download or delete files and

fonts. (See the software help for

more information.)

FLASH IS WRITE

PROTECTED

The flash DIMM is

protected and no new files

can be written to it.

Disable the write protection

through HP Resource Manager.

INPUT DEVICE

CONDITION [XX.YY]

An input paper-handling

device has a condition that

needs attention before

printing can resume.

1st X = Device number in

chain

2nd X= Device type

(three types):

1 = Input

2 = Output

3 = Stapler/stacker unit

YY = Device specific error

1. Turn the printer off.

2. Disconnect the cable to the

input paper handling devices and

then reconnect it.

3. Ensure the device is properly

connected and any doors or

paper guides are properly closed.

4. Turn the printer on.

5. See the documentation that

came with the paper-handling

device for assistance.

INSTALL DUPLEXER The printer is unable to

print the current job

because the duplexer is

not installed or not inserted

correctly.

1. Install or reinsert the duplexer

and ensure it is fully seated.

2. Ensure the right-angle power

cord is used for the printer.

INSTALL TONER

CARTRIDGE

The toner cartridge has

been removed and must

be reinstalled for printing to

continue.

Reinstall the toner cartridge and

ensure it is fully seated.

INSTALL TRAY [X] The printer is unable to

print the current job

because the specified tray

[X] is open or not inserted

correctly.

1. Reinsert the specified tray.

2. Check for damaged tabs on

the right side of the tray.

3. Check for damaged tray

sensor switches in the printer.

4. Replace the PCA controller in

the feeder.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

EN Chapter 7 Troubleshooting 199

LOADING PROGRAM

[NUMBER]

alternates with

DO NOT POWER OFF

Programs and fonts can be

stored on the printer’s file

system. At startup time,

these entities are loaded

into RAM. (These entities

can take a long time to

load into RAM depending

on the size and number of

entities being loaded.) The

<NUMBER> specifies a

sequence number

indicating the current

program being loaded.

Wait for the program to load.

MANUALLY FEED

[TYPE] [SIZE]

One of the following

occurred:

!A manual feed was

requested.

!There is no media in

tray 1.

!The wrong size of

media is loaded.

!The control panel is not

set for the size and

type of media loaded.

1. Load the requested paper into

tray 1.

2. Press GO if the desired paper

is already loaded in tray 1.

3. Press -VALUE+ to scroll through

other available types and sizes.

4. Press SELECT to accept the

alternate type or size.

MEMORY FULL STORED

DATA LOST

There is no available

memory in the printer. The

current job might not print

correctly and some

resources (such as

downloaded fonts or

macros) might have been

deleted.

Advise the customer to add more

memory to the printer or to

simplify the print job.

MEMORY SETTINGS

CHANGED

The printer changed its

memory settings because

it did not have enough

memory to use the

previous settings for I/O

buffering and resource

saving. This usually occurs

after removing memory

from the printer, adding a

duplexer, or adding a

printer language.

Advise the customer to add more

memory to the printer or to

simplify the print job.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

200 Troubleshooting EN

MEMORY SHORTAGE JOB

CLEARED

The printer did not have

enough free memory to

print the entire job. The

remainder of the job will

not print and will be

cleared from memory.

1. Press GO to continue.

2. Advise the customer to add

more memory to the printer or to

simplify the print job.

MEMORY SHORTAGE

PAGE SIMPLIFIED

The printer had to

compress the job to fit it in

available memory. Some

data loss might have

occurred.

1. Press GO to continue. (The

print quality of these pages might

not be acceptable.)

2. Advise the customer to add

more memory to the printer or to

simplify the print job.

NON HP TONER

DETECTED

alternates with

PRESS GO TO

CONTINUE

The printer has detected

that the toner cartridge is

not a genuine HP toner

cartridge because it does

not see or recognize the

toner cartridge’s

identification (model,

manufacturing date, and

serial number).

1. Make sure the toner cartridge

is a genuine HP toner cartridge.

A non-HP toner cartridge will

produce this error. Any printer

repair required as a result of

using non-HP toner is not

covered under the printer

warranty.

2. If the HP toner cartridge is

new, the Elabel (cartridge

memory) is missing or has been

tampered with. If you believe the

toner cartridge is a fraud, call the

HP fraud hotline at

(1) (877) 219-3183 (toll-free in

North America).

3. If the HP toner cartridge is

used, the printer will not

recognize the cartridge until 20

pages have been printed. After

20 pages have been printed, the

error message disappears.

4. If the HP toner cartridge is

used, and the error message

remains after 20 pages have

been printed, the cartridge has

previously run out of toner.

Replace the toner cartridge.

OFFLINE The printer is offline. Press GO to place the printer

online.

OUTPUT BIN FULL

alternates with

CLEAR PAPER FROM

[BINNAME]

The output bin is full and

needs to be emptied. Remove the sheets from the

output bin.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

EN Chapter 7 Troubleshooting 201

PAPER WRAPPED

AROUND FUSER

Print media is wrapped

around the fuser. 1. Turn the printer off to keep the

media from wrapping more firmly

around the fuser.

2. Open the top cover and

remove the toner cartridge.

3. Remove all the visible media.

4. Leave the printer turned off

and remove the fuser to remove

any remaining print media.

PERFORM PRINTER

MAINTENANCE

To ensure optimum print

quality, the printer prompts

the customer to have

routine maintenance

performed every 200,000

pages.

Install the printer maintenance

kit. You must reset the

maintenance page count after

performing printer maintenance

by pressing ITEM- and VALUE-

while turning the printer on.

Note

The printer maintenance kit is a

consumable item and is not

covered under warranty.

PROCESSING JOB The printer is processing a

job. Wait for the job to finish. This can

take several minutes for a

complex print job.

PROCESSING CLEANING

PAGE

The printer is conducting

the manual cleaning-page

process.

Wait for the job to finish. This can

take up to 2.5 minutes.

RAM DISK DEVICE

FAILURE

The RAM disk had a

critical or fatal failure. 1. Reseat the RAM disk.

2. Replace the RAM disk.

RAM DISK FILE

OPERATION FAILED

The requested operation

could not be performed (for

example, attempting to

download a file to a non-

existent directory).

1. Check the filename and

directory name.

2. Reseat the RAM disk.

3. Retry the operation.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

202 Troubleshooting EN

RAM DISK FILE

SYSTEM IS FULL

The RAM disk file system

is full. 1. Delete unnecessary files and

then try again, or turn the printer

off, and then turn the printer on to

delete all files on the device.

(Delete files using HP Resource

Manager or another software

utility. See the software online

help for more information.)

2. If the message persists,

increase the size of the RAM

disk. Change the RAM disk size

from the configuration menu on

the printer control panel. HP

Resource Manager can also be

used to increase or decrease the

RAM disk size.

RAM DISK IS WRITE

PROTECTED

The RAM disk is protected,

and no new files can be

written to it.

Disable the write protection

through HP JetAdmin.

TONER LOW The message first appears

when about 15 percent of

the toner is remaining in

the toner cartridge (about

1,500 pages remaining for

the 10,000-page cartridge

and about 900 pages

remaining for the 6,000-

page cartridge at five

percent coverage).

Depending on how the

printer has been

configured in the

configuration menu, it will

either continue to print or

stop.

1. If the printer has stopped, you

can resume printing by pressing

GO for each job.

2. Advise the customer to have a

replacement toner cartridge on

hand.

TONER OUT The toner cartridge has

run out of toner.

Depending on how the

printer has been

configured, it will either

continue to print or stop.

Due to the resolution of the

toner level sensor, it is

possible that a small

amount of toner (less than

one percent) might still be

present in the cartridge.

1. If the printer has stopped, you

can resume printing by pressing

GO for each job.

2. Replace the toner cartridge.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

EN Chapter 7 Troubleshooting 203

TRAY [X] EMPTY

[TYPE] [SIZE]

The specified tray is empty,

but the current job does

not need this tray in order

to print correctly.

If this message appears

and the tray contains print

media, a sensor could be

damaged.

PS105 detects paper in

tray 1.

PS101 detects paper in

tray 2.

PS1001 detects paper in

the optional 500-sheet

feeder.

See figure 113 on page

263 and figure 114 on

page 264 for sensor

locations.

1. Load the empty tray (x) to clear

the message.

If you do not load the specified

tray, the printer will continue

printing from the next available

tray, and the message remains.

2. If the message remains after

the specified tray is loaded, check

sensor arm flags for damage and

be sure they move freely.

4. Replace defective paper out

sensors.

TRAY [x] LOAD [TYPE]

[SIZE]

where x is tray 2, 3, or

This message occurs for

the following reasons:

!Tray 2, 3, or 4 was

requested, but the tray

is empty.

!Tray 2, 3, or 4 was

requested, but the

adjustments are not set

for the requested type

or size.

1. Make sure that all three paper

size adjustments have been

made (see the explanation of

adjustments in table 39 on page

220). Also make sure that the

type has been set at the control

panel.

2. Load the requested media into

an indicated tray. Ensure the tray

is fully seated.

3. If you are trying to print on A4-

or letter-size media and this

message appears, make sure the

default paper size is set correctly

from the printing menu in the

printer control panel and also in

the software program.

4. Press GO to print from the next

available tray.

5. Press -VALUE+ to scroll through

the available types and sizes.

6. Press SELECT to accept the

alternate type or size.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

204 Troubleshooting EN

TRAY 1 LOAD [TYPE]

[SIZE]

The print job has

requested a size and/or

type of media that is not

loaded.

1. Load the requested print

media into tray 1 (or any other

desired tray).

!Ensure that the trays are

correctly adjusted for size.

!The tray type settings (and

size for tray 1) must be set

from the paper-handling

menu.

2. If you are trying to print A4- or

letter-size media and this

message appears, make sure the

default paper size is set correctly

from the printing menu in the

printer control panel.

3. If this message appears and

the correct media is loaded:

!Ensure that all paper size

adjustments have been

properly performed (see page

220).

!Ensure the tray type setting is

correct in the paper-handling

menu.

!Check the size tabs on the

right side of the tray.

!Check the size switches and

paper sensors.

!Ensure the tray is fully seated.

4. To print on a different media

that is already loaded:

a. Press GO to print from the next

available tray.

b. Press -VALUE+ to scroll through

the available types and sizes.

c. Press SELECT to accept the

alternate type or size.

d. Inspect the switches in the tray.

e. Turn the printer on with the tray

removed and push the switches

by hand to see if they register.

See “Paper-size detection

switches” on page 255.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

EN Chapter 7 Troubleshooting 205

TRAY 1 SIZE = [xxxx] The printer is asking what

size of media has been

loaded in tray 1.

In response, you can take either

of the following actions:

1. Press SELECT to accept the

paper size.

2. Press -VALUE+ to change the

size and then press SELECT to

accept the new size.

The printer will first display the

TRAY 1 TYPE = XXXX message

(see the description of that

message). If you do not press

any buttons in the time-out period

(about one minute), it displays

this TRAY 1 SIZE = XXXX

message.

Changing the size here changes

the default for tray 1 paper size in

the paper-handling menu.

TRAY 1 TYPE = [xxxx] The printer has received a

job under the three

following conditions:

!The media type

requested by the job is

not available in the

printer.

!Tray 1 has been set for

CASSETTE.

!Media has been placed

in tray 1 (thus

triggering tray 1’s

paper sensor).

If you do not press any

buttons, the message

disappears in about one

minute).

You can take either of the

following actions:

1. Press SELECT to accept the

paper type.

2. Press -VALUE+ to change the

type and then press SELECT to

select the new type.

Note

Changing the type here changes

the default for tray 1 media type

in the paper-handling menu.

If you do not do anything during

the time-out period (about one

minute), the printer will print on

the media in tray 1.

UNABLE TO MOPY JOB Memory or file system

failures would not allow a

mopy job to occur. Only

one copy will be produced.

1. Reseat RAM DIMMs and/or

the EIO hard disk.

2. Install additional memory or an

EIO hard disk.

UNABLE TO STORE JOB Memory or file system

failures would not allow the

print to store the job.

1. Reseat RAM DIMMs and/or

the EIO hard disk.

2. Install additional memory or an

EIO hard disk.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

206 Troubleshooting EN

UNSUPPORTED SIZE IN

TRAY [yy]

An external paper-handling

device detected an

unsupported media size.

The printer will go offline

until the condition is

corrected.

Verify the media meets the

supported size specifications in

table 7 on page 26.

USE [TYPE]

[SIZE] INSTEAD?

If the requested media size

or type is not loaded, the

printer asks if it should use

another size or type

instead.

1. Press -VALUE+ to scroll through

the available types and sizes.

2. Press SELECT to accept the

alternate type or size.

WAIT FOR PRINTER TO

REINITIALIZE

The RAM disk setting has

been changed from the

printer control panel. This

change will not take effect

until the printer

reinitializes.

If you change the mode of the

external device, turn the printer

off, turn the printer on and wait for

the printer to reinitialize.

xx.yy PRINTER ERROR

PRESS GO TO

CONTINUE

A printer error has

occurred that can be

cleared by pressing GO on

the printer control panel.

Press GO on the printer control

panel.

13.XX PAPER JAM

[LOCATION]

Media is jammed at the

specified location (and

possibly at other

locations).

If the message persists

after all jams have been

cleared, a sensor or

sensor lever might be

stuck or broken.

For all jam messages, do the

following:

1. Remove jammed print media

from the specified location.

Check the entire paper path for

other pieces of media in the path.

2. Open and close the top cover

to clear the message.

3. If the jam reoccurs, see

“General paper-path

troubleshooting” on page 220.

4. Check sensors and flags in the

paper path for proper operation.

For sensor locations, see page

263.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

EN Chapter 7 Troubleshooting 207

13.0 PAPER JAM

[LOCATION]

A non-specific paper jam

occurred. 1. Remove jammed media from

the specified location.

2. Verify the paper tray is fully

closed.

3. Inspect and/or replace the feed

and separation rollers.

4. Ensure there is no obstruction

in the path, such as a torn piece

of paper.

5. Open and close the top cover

to clear the message.

6. Check sensors and flags for

proper operation (page 263).

13.1 PAPER JAM

OPEN INPUT TRAYS

Paper-delay jam at paper-

feed area. 1. Ensure that paper trays are

loaded and adjusted properly so

media can feed from the tray. It

might be necessary to reduce the

stack height of media in the tray.

2. Check the input area for

obstructions such as media in the

path. Also check to see if the

registration assembly damaged

or unseated.

3. Check PS102 and PS103 for

proper operation. Replace any

defective sensors or flags. For

sensor locations, see page 263.

4. Verify the media meets the

specifications in table 6 and

table 7 (page 25 and page 26).

5. Check the pickup feed and

separation rollers for unusual

wear. Replace as needed.

6. Rotate the media in the input

tray by 180° and/or turn it over.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

208 Troubleshooting EN

13.2 PAPER JAM

OPEN INPUT TRAYS

Paper-stopped jam at

paper-feed area. 1. Check the input area for

obstructions such as paper in the

path. Also check to see if the

registration assembly is damaged

or if the transfer roller is out of

place.

2. Check PS102 and PS103 for

proper operation. Replace any

defective sensors or flags. For

sensor locations, see page 263.

3. Ensure the media does not

exceed the maximum length

(356 mm/14 inches).

4. If multiple sheets are feeding, it

might be necessary to fan the

media and reduce the stack

height.

5. Verify that the fuser is properly

installed.

13.5 PAPER JAM

CHECK REAR DOOR

alternates with

OPEN AND CLOSE TOP

COVER

Paper-delay jam at fuser. 1. Check the transfer roller and

small media belt to ensure they

are operating and can feed print

media.

2. Check the paper path for

obstructions at the transfer roller,

toner cartridge, paper feed

assembly, and fuser.

3. Check PS107 and PS108 for

proper operation. Replace any

defective sensors or flags. For

sensor locations, see page 263.

4. Turn the media stack over and/

or rotate it by 180° in the input

tray.

13.6 PAPER JAM

CHECK REAR DOOR

alternates with

OPEN AND CLOSE TOP

COVER

Paper-stopped jam at

fuser. 1. Check the paper path for

obstructions at the fuser and

output/delivery area.

3. Check PS107 and PS108 for

proper operation. Replace any

defective sensors or flags. For

sensor locations, see page 263.

13.10 PAPER JAM

CHECK DUPLEXER

alternates with

OPEN AND CLOSE TOP

COVER

Jam at duplexer. 1. Check the duplexer and the

rear area of the printer for

obstructions or damage.

2. Check PS701 and PS703 in

the duplexer for proper operation.

Replace the duplexer if a sensor

is defective.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

EN Chapter 7 Troubleshooting 209

13.20 PAPER JAM

CHECK REAR DOOR

alternates with

OPEN AND CLOSE TOP

COVER

OPEN INPUT TRAYS

Media stopped in the

paper path during power-

on or when the top door

was closed.

1. Remove all media in the paper

path, and then open and close

the top cover.

2. If the message persists after all

media is removed:

!Check if media is jammed in

the prefeed area (PS102).

!Check PS102, PS103,

PS107, and PS108 for proper

operation. Replace any

defective sensors or flags

(see page 263).

13.21 DOOR OPEN JAM The top cover was open

while printing. 1. Clear the jam and close the top

door.

2. If the message persists, check

the top door switch (SW101) for

proper operation.

13.99 PAPER JAM

[LOCATION]

A non-specific paper jam

occurred. 1. Remove jammed media from

the specified location.

2. Verify the paper tray is fully

closed.

3. Inspect and/or replace the feed

and separation rollers.

4. Ensure there is no obstruction

in the path, such as a torn piece

of paper.

5. Open and close the top cover

to clear the message.

6. Check sensors and flags for

proper operation (page 263).

20 INSUFFICIENT

MEMORY

alternates with

PRESS GO TO

CONTINUE

The printer received more

data than can fit in

available memory. You

might have tried to transfer

too many macros, soft

fonts, or complex graphics.

Press GO to print the transferred

data (some data might be lost).

Advise the customer to simplify

the print job or install additional

memory.

21 PAGE TOO COMPLEX

alternates with

PRESS GO TO

CONTINUE

The data (dense text,

rules, raster or vector

graphics) sent to the

printer is too complex.

Press GO to print the transferred

data. (Some data might be lost.)

Advise the customer to simplify

the print job.

40 EIO x BAD

TRANSMISSION

alternates with

PRESS GO TO

CONTINUE

The connection has been

broken between the printer

and the EIO card in the

specified slot. (Data loss

might occur in this

situation.)

1. Press GO to clear the error

message and continue printing.

2. Reseat the EIO card in slot

[X].

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

210 Troubleshooting EN

41.x PRINTER ERROR

alternates with

PRESS GO TO

CONTINUE

A temporary printing error

has occurred. Press GO. The page containing

the error will automatically be

reprinted.

If the error persists:

1. Reseat the connections to the

laser scanner and then to the

engine controller board.

2. Replace the laser scanner.

3. Replace the engine controller

board.

41.3 UNEXPECTED

PAPER SIZE

alternates with

LOAD TRAY [X] TYPE

SIZE

The printer detected a

media size different from

what it was expecting. This

is typically caused if two or

more sheets stick together

in the printer or if the tray is

not properly adjusted.

1. Reload the tray with the correct

print media size.

2. Ensure that media in the tray is

loaded under the front and back

tabs. Check sensors PS103 and

PS106 for proper operation.

3. If you are printing from tray 1,

verify that the correct paper size

is selected in the control panel.

4. If you are printing from tray 2,

3, or 4, verify that the three

paper-size adjustments (length

guide, width guide, size-selector

switch) on the paper tray have

been made correctly. Make sure

the media is under the corner

tabs.

5. After performing the actions

above, press GO. The page

containing the error will

automatically be reprinted if jam

recovery is enabled. (Or, you

might want to press CANCEL JOB

to clear the job from the printer’s

memory.)

41.5 PRINTER ERROR The media reached the

PS102 or PS103 sensor

too early.

1. This error usually occurs with

smooth media, such as

transparencies or labels.

!If the problem persists when

using tray 1, load media one

sheet at a time.

!If the problem persists when

using trays 3 and 4, replace

the feed and separation

rollers.

2. Check sensors PS102 and

PS103 for proper operation.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

EN Chapter 7 Troubleshooting 211

49.XX PRINTER ERROR

alternates with

CYCLE POWER TO

CONTINUE

A firmware error occurred. 1. Press CANCEL JOB to clear the

print job from the printer memory.

2. Turn the printer off, and then

turn the printer on.

3. Try printing a job from a

different software application. If

the job prints, go back to the first

application and try printing a

different file. (If the message only

appears with a certain software

application or print job, contact

the software vendor for

assistance.)

4. If the message persists with

different software applications

and print jobs, disconnect all

cables to the printer that connect

it to the network or printer.

5. Turn the printer off.

6. Remove all memory DIMMs or

third-party DIMMs from the

printer. (Do not remove the

firmware DIMM in the lowest

DIMM slot.)

7. Remove all EIO devices from

the printer.

8. Turn the printer on.

9. If the error no longer exists,

install each DIMM and EIO

device one at a time, making sure

to turn the printer off and back on

as you install each device.

10. Replace a DIMM or EIO

device if you determine that it

causes the error.

11. Remember to reconnect all

cables that connect the printer to

the network or computer.

12. If the error persists, replace

the firmware DIMM.

13. Replace the formatter.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

212 Troubleshooting EN

50.X FUSER ERROR A fuser error has occurred.

X description:

1 = Low fuser

temperature

2 = Fuser warm-up

service

3 = High fuser

temperature

1. Turn the printer off, wait 20

minutes, and then turn the printer

on.

2. If the message persists, reseat

the fuser.

!If that does not work, replace

the fuser.

!To check the fuser, turn the

printer off and remove the

fuser. Measure the resistance

between the fuser connectors

J132-1 and J132-2. If it is not

within the range of 200 kΩ to

500 kΩ, replace the fuser.

!If there is not continuity

between the fuser connectors

J143F (neutral) and J142F

(hot) with the fuser removed,

replace the fuser.

!If the problem is not related to

the fuser, replace the engine

controller board.

50.4 PRINTER ERROR

alternates with

CYCLE POWER TO

CONTINUE

A problem exists with the

customer’s line voltage. 1. Remove the printer from any

UPS supplies, additional power

supplies, or power strips.

2. Plug the printer into a wall

outlet and see if this resolves the

problem.

3. If the printer is already plugged

into a wall outlet, try another

power source in the building that

is independent of the one

currently being used.

4. The line voltage and current

source at the printer location

might need to be inspected to

ensure that it meets the printer’s

electrical specifications.

51.X PRINTER ERROR

alternates with

CYCLE POWER TO

CONTINUE

A loss of beam-detect

occurred.

X description:

1 = Beam-detect error

2 = Laser error

1. Press GO. The page containing

the error will automatically be

reprinted.

2. Turn the printer off and then

on.

3. Reseat cables to the laser/

scanner and engine controller.

4. Replace the laser/scanner.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

EN Chapter 7 Troubleshooting 213

52.X PRINTER ERROR

alternates with

CYCLE POWER TO

CONTINUE

The laser scanner speed is

incorrect.

X description:

1 = Scanner startup error

2 = Scanner rotation error

1. Press GO. The page containing

the error will automatically be

reprinted.

2. Turn the printer off and then

on.

3. Reseat cables to the laser/

scanner and engine controller.

4. Replace the laser/scanner.

53.XY.ZZ PRINTER

ERROR

There is a memory error

with an accessory. The

DIMM that caused the

error will not be used.

Values of X, Y

, and ZZ are

as follows:

X = DIMM type

0 = ROM

1 = RAM

Y = Device location

0 = internal memory

(ROM or RAM)

1 to 4 = DIMM slots

1, 2, 3, or 4

ZZ = Error number

0, 1, 2 = Unsupported o

unrecognized memory

3 = Failed RAM test

4, 5 = Exceeded

maximum RAM or ROM

size

6 = Invalid DIMM speed

7 = DIMM reporting

information incorrectly

8 = DIMM RAM parity

error

9 = ROM needs to be

mapped to an

unsupported address

10 = DIMM address

conflict

11 = PDC XROM out of

bounds

12 = Unable to make a

temporary mapping

1. Turn the printer off, and reseat

or replace the specified DIMM.

2. Try the DIMM in another slot.

(The firmware DIMM must remain

in slot #4—the lowest DIMM slot.)

3. Replace the DIMM that caused

the error.

54.1 REMOVE SEALING

TAPE

alternates with

FROM TONER

CARTRIDGE

The toner cartridge has

been installed without

removing the sealing tape.

1. Open the top cover and

remove the toner cartridge.

2. Pull the sealing tape tab to

remove the strip.

3. Reinstall the toner cartridge

and close the top cover.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

214 Troubleshooting EN

54.4 PRINTER ERROR

alternates with

CYCLE POWER TO

CONTINUE

A problem exists with the

customer’s line voltage. 1. Remove the printer from any

UPS supplies, additional power

supplies, or power strips.

2. Plug the printer into a wall

outlet and see if this resolves the

problem.

3. If the printer is already plugged

into a wall outlet, try another

power source in the building that

is independent of the one

currently being used.

4. The line voltage and current

source at the printer location

might need to be inspected to

ensure that it meets the printer’s

electrical specifications.

55.xx PRINTER ERROR

alternates with

CYCLE POWER TO

CONTINUE

An internal

communications error

occurred.

The page containing the error will

automatically be reprinted.

1. Check the power at the

customer’s location.

2. Replace the formatter and/or

firmware DIMM.

4. Replace the engine controller

board.

56.X PRINTER ERROR

alternates with

CYCLE POWER TO

CONTINUE

An incompatible

combination of input/

output bins was selected.

X = description:

1 = Illegal input or bad

accessory connector

2 - Illegal output

The page containing the error will

automatically be reprinted.

1. Turn the printer off, and then

turn the printer on.

2. Check the printer’s

configuration.

3. Verify accessory connection.

57.X PRINTER ERROR

alternates with

CYCLE POWER TO

CONTINUE

A fan failure was detected.

X description:

4 = Printer fan

7 = Duplex fan

1. Check the fan’s connector and

make sure the fan is not blocked.

2. Replace the fan.

58.2 PRINTER ERROR

alternates with

CYCLE POWER TO

CONTINUE

An environmental

thermistor (TH3) failure

occurred.

1. Turn the printer off, and then

turn the printer on.

2. Verify the environmental

thermistor cable is securely

connected.

3. Replace the environmental

thermistor.

4. If the error persists, replace the

engine controller board.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

EN Chapter 7 Troubleshooting 215

59.X PRINTER ERROR

alternates with

CYCLE POWER TO

CONTINUE

A main motor error

occurred.

X description:

0 = Motor error

1 = Motor startup error

2 = Motor rotation error

1. Turn the printer off, and then

turn the printer on.

2. Check and reseat the fuser

and toner cartridge to make sure

they are not hindering gear

movement in the drive train.

3. Check the main motor’s cable

to ensure that it is seated

properly.

4. If the error persists, replace the

main motor.

62.X PRINTER ERROR There is a problem with the

printer memory. The X

value refers to the location

of the problem:

0 = Internal memory

1 to 4 = DIMM slots 1, 2,

3, or 4

1. Reseat the specified DIMM.

2. Replace the specified DIMM.

64 PRINTER ERROR

alternates with

CYCLE POWER

A scan buffer error

occurred. 1. Turn the printer off, and then

turn the printer on.

2. Perform a cold reset.

3. If the message persists,

replace the formatter or firmware

DIMM.

66.XX.YY [TYPE]

FAILURE

alternates with

CHECK CABLES AND

CYCLE POWER

An error occurred in an

external paper-handling

device.

1st X = Device number in

chain

2nd X = Device type

1 Input

2 Output

3 Stapler/stacker unit

YY = Device specific error

Press GO to clear the message. If

the message will not clear:

1. Turn the printer off, and then

turn the printer on.

3. Check and reseat all cables

between the printer and the

specified device.

4. Reseat the external paper-

handling device.

68 NVRAM ERROR

CHECK SETTINGS

An error occurred in the

printer non-volatile

memory (NVRAM) and

one or more printer

settings has been reset to

its factory default.

1. Print a configuration page and

check the printer settings to

determine which values have

changed.

2. Hold down CANCEL JOB while

turning the printer on. This will

clean up the NVRAM by

removing old areas that are not

being used.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

216 Troubleshooting EN

68 NVRAM FULL

CHECK SETTINGS

An error occurred in the

printer’s NVRAM and one

or more printer settings

has been reset to its

factory default.

1. Print a configuration page and

check the printer settings to

determine which values have

changed.

2. Hold down CANCEL JOB while

turning the printer on. This will

clean up the NVRAM by

removing old areas that are not

being used.

68.X PERMANENT

STORAGE ERROR

alternates with

CHECK SETTINGS

An error occurred in the

printer’s permanent

storage and one or more

printer settings has been

reset to its factory default.

Print a configuration page and

check the printer settings to

determine which values have

changed.

68.X PERMANENT

STORAGE FULL

The printer’s permanent

storage is full. Some

settings might have been

reset to the factory

defaults.

1. Print a configuration page and

check the printer settings to

determine which values have

changed.

2. Hold down CANCEL JOB while

turning the printer on. This will

clean up the permanent storage

by removing old areas that are

not being used.

69.X PRINTER ERROR

alternates with

CYCLE POWER TO

CONTINUE

A temporary printing error

occurred.

X description:

0 = The duplex mechanism

has failed

1. Turn the printer off, and then

turn the printer on.

2. Reseat the duplexer.

3. Replace the duplexer.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

EN Chapter 7 Troubleshooting 217

79 SERVICE [XXXX] The printer detected an

error. 1. Press CANCEL JOB to clear the

print job from the printer memory.

2. Turn the printer off, and then

turn the printer on.

3. Try printing a job from a

different software application. If

the job prints, go back to the first

application and try printing a

different file. (If the message only

appears with a certain software

application or print job, contact

the software vendor for

assistance.)

4. If the message persists with

different software applications

and print jobs, disconnect all

cables to the printer that connect

it to the network or printer.

5. Turn the printer off.

6. Remove all memory DIMMs or

third-party DIMMs from the

printer. (Do not remove the

firmware DIMM in the lowest

DIMM slot.)

7. Remove all EIO devices from

the printer.

8. Turn the printer on.

9. If the error no longer exists,

install each DIMM and EIO

device one at a time, making sure

to turn the printer off and back on

as you install each device.

10. Replace a DIMM or EIO

device if you determine that it

causes the error.

11. Remember to reconnect all

cables that connect the printer to

the network or computer.

12. If the error persists, replace

the firmware DIMM.

13. Replace the formatter.

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

218 Troubleshooting EN

The following table lists the disk-error numbers reported on either the printer collation or job storage

disk-error page, which is printed when an error exists.

8X.YYYY EIO [Z]

ERROR

The EIO accessory in slot

[z] has encountered a

critical error.

[z] description:

1 = EIO slot 1—The

printer detected an error

with the EIO accessory.

2 = EIO slot 2—The

printer detected an error

with the EIO accessory.

6 = EIO slot 1—The EIO

accessory detected an

error.

7 = EIO slot 2—The EIO

accessory detected an

error.

1. Turn the printer off, and then

turn the printer on.

2. Turn the printer off, reseat the

EIO accessory in slot [z], and

then turn the printer on.

3. Turn the printer off, remove the

EIO accessory from slot [z],

install it in a different EIO slot,

and turn the printer on.

4. Replace the EIO accessory in

slot [z].

Table 37. Printer messages (continued)

Control panel

message Explanation Recommended action

Table 38. Mopy disk error messages

Disk error

number Error description Solution

1 Disk volume not present–it

might be uninitialized Hard disk: Initialize the hard disk. If the

problem persists, replace the hard disk.

RAM disk: Turn the printer off, and then

turn the printer on.

3 A requested file or directory

could not be found The data might be corrupted. Delete the

job that prompted the error.

5 Invalid number of bytes given

in a read/write request The data might be corrupted. Delete the

job that prompted the error.

6 Attempt to create a file or

directory that already exists The user has sent a username that is the

same as an existing directory. Change the

username in the driver and resend the job.

15 Bad disk Hard disk: Initialize the hard disk. If the

problem persists, replace the hard disk.

16 No volume label Hard disk: Initialize the hard disk. If the

problem persists, replace the hard disk.

23 Bad seek request–the

resulting offset would be

negative

The data might be corrupted. Delete the

job that prompted the error.

EN Chapter 7 Troubleshooting 219

24 Unexpected internal error The data might be corrupted. Delete the

job that prompted the error.

Disk-media problem: Initialize the hard

disk or restart the printer to reinitialize the

RAM disk.

If the problem persists on a hard disk,

replace the hard disk.

55 Bad file system Data might be corrupted. Delete the job

that prompted the error.

Disk-media problem: Initialize the hard

disk or restart the printer to reinitialize the

RAM disk.

If the problem persists on a hard disk,

replace the hard disk.

56 Hardware failure Replace the hard disk.

59 The maximum number of

directories has been

reached

A maximum number of directories can be

put on a disk. Stored jobs are stored in

directories created for each user. To solve

this problem:

1. Delete all jobs stored for a user. The

firmware will automatically delete the

directory for a user with no stored jobs.

2. Delete other directories on the disk.

70 Disk error 1. Reseat the disk.

2. Replace the disk.

Table 38. Mopy disk error messages

Disk error

number Error description Solution

220 Troubleshooting EN

General paper-path troubleshooting

Jams occur in the printer when print media does not either reach or clear a photosensor along the

printer paper path in a specific amount of time. If a jam occurs, a 13.XX PAPER JAM message appears

on the printer control panel. The following table contains general questions you might ask and topics

to explore before troubleshooting.

Table 39. General paper-path troubleshooting questions

Troubleshooting check Action

What is the frequency of the jams (for

example: continuous, one jam per 100

pages, one jam per 1000 pages)?

Verify with the customer. Print the event

log to determine the jam history. See

figure 94, “Sample event log,” on page

191. to evaluate the event log.

Do jams only occur when the print media

is fed from a particular paper input source

(such as tray 1 or tray 2)?

Use the paper path test to isolate the

problem. See “Paper-path test” on page

222.

Do jams only occur when print media is

output to a specific output bin (either the

top output bin or rear output bin)?

Use the paper-path test to isolate the

problem. See “Paper-path test” on page

222.

Do jams occur with a specific type of

paper? Try different media. See the HP LaserJet

Printer Family Print Media Guide. The

guide is bundled with this service manual.

Where does the leading edge of the first

sheet of paper in the printer paper path

stop when a jam occurs? Are any sheets

of media damaged or torn?

Attempt to duplicate. Use the paper-path

test to isolate the problem. Inspect the

paper path and all paper-path mechanical

assemblies up to the location where the

jams occur.

Is the customer loading the paper trays

correctly? Observe the customer loading print

media. Do not fan paper. See proper

media handling procedures in the HP

LaserJet Printer Family Print Media Guide.

Is the customer overfilling the paper trays? Ensure that print media is not over the

maximum fill marks in the paper trays.

Heavy media, such as transparencies,

labels, and card stock, might feed better if

only a few sheets are loaded at a time.

Observe the customer loading paper in

the trays.

EN Chapter 7 Troubleshooting 221

There are five photosensors (PS102, PS103, PS106, PS107, and PS108) in the paper path for

detecting arrival or passing of the paper. Additional sensors are located in the optional duplexer.

If the sheet does not reach or pass these sensors within the prescribed time, the microprocessor on

the engine controller board assesses a jam. See page 263 for the location and function of sensors.

Are the paper tray guides set correctly? For tray 1, ensure the guides are adjusted

correctly with the sides of the media. Make

sure the media fits under the tabs on the

guides and not above the load-level

indicators.

For trays 2, 3, and 4:

1. Squeeze the lever on the left guide and

slide the guides into place to match the

width of the paper.

2. Squeeze the lever on the rear paper

guide and slide it to the desired size until it

clicks into place.

3. To make the third adjustment, squeeze

the blue tab located on the right side of the

tray and move it to the correct position

based on the media size required.

4. Make sure the print media is flat in the

tray at all four corners and below the front

and back tabs.

Does the printer need to be cleaned? Inspect the paper path and paper path

rollers. See the cleaning procedures in

chapter 4.

When was maintenance last performed on

the printer? Determine from the configuration page the

number of pages since the last

maintenance. (See “Maintenance interval”

on page 77.) The printer maintenance kit

should be installed every 200,000 images.

Table 39. General paper-path troubleshooting questions (continued)

Troubleshooting check Action

222 Troubleshooting EN

Paper-path test

To perform a paper-path test:

1Press MENU until INFORMATION MENU appears.

2Press ITEM until PRINT PAPER PATH TEST appears.

3Press SELECT. INPUT=TRAY 1 is displayed

4Press VALUE+ to cycle selections until the desired paper tray appears.

5Press SELECT. OUTPUT=TOP BIN is displayed.

6Press VALUE+ until the desired output bin appears (open the rear output bin to print to it).

7Press SELECT. DUPLEX=ON is displayed. This selection only appears when a duplexer is installed.

8Press VALUE+ until the desired duplex mode (ON or OFF) appears.

9Press SELECT. COPIES=1 appears.

10 Press VALUE+ to cycle selections until the desired number of copies appears. Choose 1, 10, 50,

100, or 500 copies.

11 Press SELECT to perform the paper-path test.

Information pages

From the printer control panel you can print pages that give details about the printer and its current

configuration. The following information pages are described here:

!Menu map

!Configuration page

For a complete list of the printer information pages, print a menu map and see the information menu.

Menu map

To see the current settings for the menus and items available on the control panel, print a control

panel menu map:

1Press MENU until INFORMATION MENU appears.

2Press ITEM until PRINT MENU MAP appears.

3Press SELECT to print the menu map.

The content of the menu map varies, depending on the options currently installed in the printer. The

printer driver or software application can override many of these values.

EN Chapter 7 Troubleshooting 223

Figure 95. Sample menu map (1 of 2)

Figure 96. Sample menu map (2 of 2)

224 Troubleshooting EN

Embedded Web server

The embedded Web server allows you to view printer and network status and to manage printing

functions from your computer instead of from the printer control panel. This service is designed for

offices using an IP network and a standard Web browser. Below are examples of what you can do

using the embedded Web server:

!View printer control panel messages.

!Determine the remaining life of all consumables.

!Order consumables.

!View and change tray configurations.

!View and change the printer control panel menu configuration.

!View and print internal pages.

!Receive notification of printer events.

!View and change network configuration.

To use the embedded Web server, you must have an IP-based network and a Web browser. The

embedded Web server can be used with Microsoft® Internet Explorer 4 or above, and with Netscape™

Navigator 4 and above. IPX-based printer connections are not supported by the embedded Web

server.

To use the embedded Web server

1Open your Web browser.

2Type the IP address assigned to the printer into the Address or Location field.

The IP address for the printer is listed on the printer configuration page. For more information about

printing a configuration page, see page 226.

Embedded Web server page sets

The embedded Web server has three sets of internal Web pages for collecting information about the

printer and for changing configuration options. These sets are:

!Home pages

!Device pages

!Networking pages

When the embedded Web server is active, each set of pages is listed on the browser screen. Click

the set that you want to view, and the selection expands to display a list of frequently used Web links.

Note Each page in the embedded Web server connects to online Help. For more information regarding a

particular page, click the Help button.

EN Chapter 7 Troubleshooting 225

Home page set

The home pages of the embedded Web server are the informational pages for the printer. These

include:

!Printer status page

This page displays printer capabilities, control panel messages, and status lights that currently

appear on the printer control panel. From here, you can set the frequency at which the

embedded Web server will check the printer status. This page also displays consumable life

levels and the input tray configurations.

!Configuration page

This page displays the printer configuration page. For more information about interpreting and

printing the configuration page, see page 226.

!Supplies status page

This page displays the levels of the consumables for the printer.

!Usage page

This page displays the amount of each media type that has been used by the printer.

!Event log page

This page displays the printer event log. For more information about displaying and printing the

event log, page 192.

!Device identification page

This page displays the name, asset number, network address, model number, and serial number

for this printer.

!Device page set

The device pages of the embedded Web server allow you to configure the printer from your

computer. The device pages can be password protected. Always consult with your network

administrator before changing the printer’s configuration.

!Configure printer page

Configure all printer settings from this page.

!Alerts page

Input a list of recipients for electronic notification of various printer events.

!E-mail page

Configure the incoming and outgoing mail servers.

!Security page

Set a password for the embedded Web server. Passwords and features configuration should

only be determined by the network administrator. If a password is set, users will require a

password for entry into the device sections of the embedded Web server.

!Other links page

Add or customize links to other websites. These links are displayed on the navigational bar

throughout the embedded Web server pages.

There are two permanent links: “Ask a question” where the user can get help with the printer,

and “Order Supplies” where you can order printer supplies. “Order Supplies” is only available

from the device page set.

226 Troubleshooting EN

!Language page

Determine the language in which to display the embedded Web server information.

!Device Identification page

Name the printer and assign an asset number to it. Input the name and e-mail address of the

primary point of contact for information about the printer. This page also shows the printer’s

network names, addresses, and printer model information.

Configuration page

Use the configuration page to view current printer settings, to help troubleshoot printer problems, or

to verify installation of optional accessories, such as memory (DIMMs), paper trays, and printer

languages.

Note If an HP JetDirect print server EIO card is installed, a JetDirect configuration page will print out as well.

To print a configuration page:

1Press MENU until INFORMATION MENU appears.

2Press ITEM until PRINT CONFIGURATION appears.

3Press SELECT to print the configuration page.

Figure 97 on page 227 is a sample configuration page. The content of the configuration page varies,

depending on the options currently installed in the printer.

EN Chapter 7 Troubleshooting 227

Figure 97. Sample configuration page (HP LaserJet 4100 series printer)

Verify installed options

Under “Installed Personalities and Options” on the configuration page, look for options such as hard

disk or DIMM types and sizes.

Verify that the options installed in the printer are reflected on the configuration page. If an installed

device is not shown, reseat the device and print a new configuration page.

Image quality

When you are working with customers, obtain a print sample before you begin troubleshooting the

printer. Ask the customer to explain the quality expected from the printer. The print sample will also

help clarify the customer’s explanation.

4100 Series printers

Printer Information

Lists the serial number, HP JetSend IP

addresses, page counts, and other

information for the printer.

Memory

Lists printer memory, PCL driver work

space (DWS), and I/O buffering and

resource-saving information.

Event Log

Lists the

number of

entries in the

log, the

maximum

number of

entries

viewable, and

the last three

entries.

Security

Lists the

status of

the printer

control

panel lock,

control

panel

password,

and disk

drive.

Installed

Personalities

and Options

Lists all

printer

languages

that are

installed

(such as PCL

and PS) and

lists options

that are

installed in

each DIMM

slot and EIO

slot.

Paper

Trays and

Options

Lists the

size

settings for

all trays and

lists

optional

paper-

handling

accessories

that are

installed.

228 Troubleshooting EN

Check the toner cartridge

Image formation defects are often the result of problems with the toner cartridge. If there is any

doubt, always replace the toner cartridge before troubleshooting image defects.

Use the following checklist to ensure that the toner cartridge is still operable.

!Ensure that the toner cartridge has toner. Weight is one indication of the presence of toner, as

shown in table 41.

1. Depending on the exact pages printed, the toner cartridge might be empty and weigh more

than these values.

!Check the expiration date of the toner cartridge (stamped on the box).

!Check the toner cartridge to see if it has been disassembled or refilled.

!Ensure that the toner cartridge is seated properly in the printer.

!Inspect the cartridge for toner leaking through worn seals. (If the drum has been manually

rotated, the rotation might have caused internal damage and toner might spill.)

Table 40. Image quality checks

Image quality checks Action

Does the problem repeat on

the page? Use the repetitive defect ruler on page 243.

Is the toner cartridge full and

is it manufactured by HP? Check the toner cartridge using the checklist on page 228.

Is the customer using print

media that meets all HP

paper specification

standards?

For more information about HP’s paper specification standards,

see chapter 1 of this manual and the HP LaserJet Printer Family

Print Media Guide.

Is the print sample similar to

those in the print-quality

tables see page 1-22?

Compare and perform the actions recommended in the print-

quality tables.

Is the problem on the toner

cartridge drum or the

transfer roller?

Perform the half self-test functional check (page 244) to determine

where the defect is.

If a dark and distinct toner image is preset on the drum’s surface,

assume that the first four functions of the electrophotographic

process are functioning (cleaning, conditioning, writing, and

developing–see chapter 5), and troubleshoot the failure as a

transfer or fusing problem.

Table 41. Weights of toner cartridges

Toner Cartridge

Capacity Full

Weight Typical Empty

Weight1

6,000 pages 1343 grams

(47.4 ounces) 1105 grams

(39 ounces)

10,000 pages 1490 grams

(52.59 ounces) 1110 grams

(39.18 ounces)

EN Chapter 7 Troubleshooting 229

Note Toner cartridges are rated for 6,000 or 10,000 images at 5 percent coverage (depending on the model).

It is possible to wear out the gears and the cartridge seals before TONER LOW appears if the number of

images exceeds 6,000 or 10,000 (depending on the model). See “EconoMode” below. A depleted

cartridge will often create print defects.

!Check the surface of the photosensitive drum in the cartridge to see if it has been damaged or

scratched. Touching the drum will contaminate the photosensitive surface and can cause

spotting and defects during printing.

!White areas on the page might indicate that the drum has been exposed to light for too long. If

white areas appear, stop the printer and wait a few minutes. This should eliminate most defective

images. If not, place the toner cartridge in a dark environment for several days. This can restore

some life to the drum.

EconoMode

EconoMode creates draft-quality printing by reducing the amount of toner on the printed page by up

to 50 percent. Advise the customer to turn EconoMode on or off from the printer driver or software

application, because those settings override the control panel settings. EconoMode settings can also

be changed from the print quality menu.

CAUTION HP does not recommend full-time use of EconoMode. If EconoMode is used frequently, it is possible

that the toner supply will outlast the mechanical parts in the toner cartridge.

230 Troubleshooting EN

Image defects

The quality of the printer output is subject to the judgment of the user. This section of the manual

helps you define print quality defects and understand what factors affect print quality.

The print samples shown in the following tables illustrate some print quality defects. For future

reference, retain copies of print quality defects encountered in the field with an explanation of their

causes.

The image defects listed below are covered in the following tables.

!Black page (page 231)

!Blank spots (page 233)

!Creases (page 233)

!Curl (page 234)

!Contamination on back (page 234)

!Distorted image (page 235)

!Dropouts (page 235)

!Faded print/bubbles (page 235)

!Gray background (page 236)

!Horizontal black lines (page 236)

!Horizontal smudges (page 237)

!Horizontal white lines (page 237)

!Light print, dark print, or fade (page 238)

!Loose toner (page 239)

!Repetitive defects (page 239)

!Skew (page 239)

!Toner smear (page 240)

!Toner specks (page 240)

!Vertical black lines (page 241)

!Vertical dots (page 241)

!Vertical white lines (page 241)

!Repeating image (page 242)

!Misformed characters (page 242)

!Tire tracks (page 242)

!White spots on black (page 243)

Hint If you find a defect that is not depicted, record the probable cause along with the conditions in the

printing environment and save a copy of the defect for future reference.

EN Chapter 7 Troubleshooting 231

Table 42. Image defects

Problem Cause Solution

Black page The high-voltage power supply

connections are contaminated. Clean the high-voltage power

supply terminals. (See “Engine

controller board layout,” figure

105 on page 254.) Also clean the

high-voltage springs where they

contact the toner cartridge.

The high-voltage power supply is

installed improperly.

If the high-voltage power supply

has been removed and replaced,

it might not be seated properly.

Remove the engine controller

board and check the connectors

for damage. Reseat the engine

controller board, being certain to

fully seat the connectors.

Defective primary charging roller. Replace the toner cartridge.

The laser drive circuitry is

damaged on the engine controller

board so that the laser is always

on.

Replace the laser scanner

assembly and engine controller

board, followed by the formatter, if

necessary.

232 Troubleshooting EN

White page No toner is available for print. Remove sealing tape or replace

the toner cartridge.

Defective laser shutter. Check the laser shutter for free

operation when inserting the

toner cartridge.

Toner cartridge guide damaged,

improperly positioned, or missing. Make sure the guide is installed

properly above the toner

cartridge.

No transfer roller voltage. Without transfer roller voltage,

toner cannot be attracted from

the surface of the drum to the

print media. Perform the half

self-test functional check (page

244) to check all other

electrophotographic processes.

Replace the transfer roller if

necessary.

No developing bias. 1. Clean the high-voltage power

supply contacts. With no

developing bias charge, toner is

not attracted to the drum.

2. Replace the engine controller

board.

No drum ground path. With no ground path, the drum

cannot discharge. The negative

charge on the drum repels toner,

and leaves a white page with

bubble print.

1. Check the drum ground spring

and reconnect it, if necessary.

2. Replace the engine controller

board.

Defective laser scanner cable

assembly. Low-level signals exchanged

between the laser/scanner

assembly and the engine

controller board might be

affecting laser output. Replace

the laser/scanner cable assembly.

Table 42. Image defects

Problem Cause Solution

EN Chapter 7 Troubleshooting 233

Blank spots Print media does not meet printer

specifications or is stored

improperly.

1. Print a few more pages to see

if the problem corrects itself.

2. Turn over the stack of media in

the tray. Also try rotating the

media 180°.

3. If the print media does not

meet HP specifications, replace

the paper, and advise the

customer to use the

recommended print media and

store it properly.

Contaminated or deformed

transfer roller. Replace the transfer roller.

Defective toner cartridge. Replace the toner cartridge.

Grizzsm LJ4100_SM LJ4100 SM

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